Removable Flow Control Insert for Low-Downtime Solution Applicators
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Solution Overview
Problem
Existing solution applicator assemblies face issues with clogging due to hard water deposits, dried chemical residue, and pressure fluctuations, leading to performance degradation and prolonged downtime during maintenance, especially in venturi-based systems.
Innovation Solution
A solution applicator assembly with a removable flow control insert that allows for easy detachment and replacement of the flow control insert without disrupting other connections, enabling quick cleaning and maintenance, and accommodating varying fluid pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire assembly is disassembled for maintenance of the flow control unit, then the flow control unit can be cleaned of mineral deposits, but the assembly requires prolonged downtime and pipe fittings must be disconnected requiring resealing
Solution Approach 1:
The assembly is divided into separable components: the flow control unit with its jet can be removed as a separate assembly from the main body. This segmentation allows the flow control unit to be accessed and cleaned independently without disassembling the entire assembly or disconnecting pipe fittings, thereby reducing maintenance downtime and eliminating the need for resealing operations.
2Ease of repair
If the flow control unit is cleaned by acid bath, then mineral deposits are removed, but the assembly is rendered inoperable for a prolonged period
Solution Approach 1:
By separating the flow control unit from the main assembly, the invention enables the flow control unit to be removed and cleaned independently. This allows other parts of the assembly to remain operational during maintenance, reducing the overall downtime associated with acid bath cleaning operations.
Solution Approach 2:
The flow control unit can be removed and prepared for cleaning before the acid bath process begins. This preliminary separation action allows the cleaning to be performed more efficiently and reduces the time the entire assembly needs to be taken offline, as the flow control unit can be replaced or reinstalled once cleaning is complete.
3Adaptability or versatility
If venturi-based flow control unit is used, then chemical mixing is achieved, but pressure fluctuations cause performance degradation
Solution Approach 1:
The invention introduces an adjustable flow control mechanism that allows dynamic adaptation to pressure fluctuations. The flow control unit can be adjusted to maintain optimal performance across varying pressure conditions, enabling the system to adapt to pressure changes without degrading chemical mixing performance.
Solution Approach 2:
The flow control unit incorporates adjustable parameters that can be modified to compensate for pressure fluctuations. By changing flow control parameters such as orifice size or flow restriction settings, the system can maintain stable chemical mixing performance despite variations in water pressure caused by other equipment demands.
4Reliability
If the flow control unit is replaced instead of cleaned, then performance is restored, but complete disassembly and replacement of many components is required
Solution Approach 1:
The flow control unit is designed as a separable, modular component that can be removed independently from the main assembly. This segmentation reduces the number of components that need to be disassembled and replaced during maintenance, as only the flow control unit itself needs to be removed rather than complete disassembly of the entire assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates efficient and time-saving maintenance by allowing the flow control insert to be swapped or serviced without disrupting other connections, ensuring consistent performance and reducing downtime.
Implementation Method 1
A flow control insert is removeably receivable in the central channel for receiving and accelerating the solution from the upper channel and releasing it into the lower channel
Implementation Method 2
Venturi-based chemical injector assemblies utilize a flow control unit for mixing a water stream with a chemical. The flow control unit is configured to draw in the chemical via a reduced pressure of the water passing through a neck portion of the flow control unit near the jet
Data Source
AI summary
A solution applicator assembly comprises an upper body defining an upper channel. The upper body further includes a primary inlet fluidly connected to the upper channel. A lower body defines a lower channel being fluidly connectable to the upper channel to define a central channel. The lower body further defines a primary outlet fluidly connected to the lower channel. A flow control insert is removeably receivable in the central channel for receiving a chemical solution from the upper channel and releasing the solution into the lower channel. The upper body and the lower body are removeably connectable to one another to selectively allow the flow control insert to be removed and positioned in the central channel.