Resonance Chamber Tone Generator for Acoustic Deposit Cleaning
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Solution Overview
Problem
Existing methods for removing deposits from industrial process components, such as utility boilers, are inefficient, costly, and disruptive due to the use of shock cleaning systems, steam sootblowing, and acoustic horns, which incur high operational costs and require frequent maintenance of moving parts.
Innovation Solution
A tone generator assembly that utilizes a resonance chamber and nozzle to produce a high-intensity, narrow frequency band tone noise by directing a high-pressure fluid jet into a closed-end cavity, creating compressive and expansion waves to generate a tone with frequencies less than two kilohertz for effective cleaning without moving parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If shock cleaning systems are used to remove deposits, then cleaning effectiveness is improved, but operation costs increase due to fuel combustion requirements
Solution Approach 1:
The patent replaces mechanical shock cleaning systems with an acoustic field-based cleaning mechanism. Instead of using combustion-generated shock waves, the system uses a tone generator to produce focused acoustic energy that cleans surfaces through vibratory effects, eliminating the need for fuel combustion and associated operation costs.
Solution Approach 2:
The patent employs pneumatic principles by using compressed air as the medium to transmit acoustic energy. The tone generator creates pressure variations in the air that propagate as sound waves, which then interact with the surface to be cleaned, replacing the need for mechanical shock generators.
2Productivity
If steam soot blowing is used to remove deposits, then cleaning capability is improved, but surface erosion increases
Solution Approach 1:
The patent substitutes mechanical/thermal cleaning methods with acoustic field interaction. The tone generator produces sound waves that create vibratory effects on the surface, allowing deposit removal through resonant vibration rather than direct mechanical impact or thermal stress, thereby eliminating surface erosion.
Solution Approach 2:
The patent relies on mechanical vibration principles where the tone generator creates acoustic waves that induce vibratory motion in the surface and deposited materials. This vibration allows deposits to loosen and detach without applying direct mechanical force or thermal shock that would cause erosion.
3Power
If acoustic horns are used to generate cleaning tones, then tone generation is achieved, but frequency spectrum becomes wide and includes non-contributing frequencies
Solution Approach 1:
The patent uses a tone generator with variable frequency capability that can be dynamically adjusted to match the resonant frequency of the target surface or deposit type. This dynamic frequency adjustment allows the system to optimize cleaning effectiveness while maintaining a narrow frequency band, unlike fixed-frequency acoustic horns.
Solution Approach 2:
The patent employs parameter changes by allowing the tone generator to vary its output frequency based on specific cleaning requirements. The system can adjust frequency, amplitude, and duration parameters to optimize cleaning performance for different materials and deposit types, achieving precise frequency control rather than a wide fixed spectrum.
4Productivity
If moving parts are used in cleaning systems, then initial effectiveness is achieved, but maintenance requirements increase
Solution Approach 1:
The patent replaces mechanical moving parts with a stationary tone generator that produces acoustic fields. The cleaning action is performed by sound waves rather than mechanical components, eliminating wear and the need for maintenance while maintaining cleaning effectiveness.
Solution Approach 2:
The tone generator system is designed to be self-sustaining without moving parts that require maintenance. The acoustic field is generated continuously from the same energy source, and the cleaning action occurs automatically without requiring replacement or adjustment of mechanical components.
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
This solution provides a cost-effective, non-destructive, and efficient cleaning method that maintains process availability by using compressed air, reducing maintenance needs, and producing a purer tone with higher dB output, allowing for online cleaning of industrial components.
Implementation Method 1
directing the jet of fluid into a closed end cavity, alternately forming compressive waves and expansion waves in the cavity
Implementation Method 2
The dimensions of the resonance chamber and nozzle are selected to facilitate emitting a tone having a frequency less than two kilohertz and tuned to a frequency determined to provide cleaning vibratory energy
Data Source
AI summary
A method and system for a tone generator assembly are provided. The tone generator assembly includes a resonance chamber that includes a first end and a second end and a body extending therebetween. The body surrounds a cavity therein, wherein the first end includes a resonance chamber opening in flow communication with the cavity. The tone generator assembly also includes a nozzle having a bore therethrough. The bore includes an inlet opening configured to receive a flow of relatively high pressure fluid and an outlet opening coupled in flow communication with the inlet opening and configured to discharge an underexpanded jet of fluid when the flow of relatively high pressure fluid is received at the inlet opening. The resonance chamber and the nozzle are positioned relatively and sized to facilitate emitting a tone from the tone generator assembly having a frequency less than two kilohertz.