Rotary Nozzle Cleaning With Airflow Feedback for Particle Removal
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Solution Overview
Problem
Existing cleaning systems fail to ensure complete removal of particles and contaminants from workpieces, leading to reduced cleaning quality and potential functional defects, particularly in critical applications like battery modules, due to inadequate monitoring and management of the cleaning process.
Innovation Solution
A system comprising an inlet module, cleaning module with controllable nozzles, and outlet module, along with sensors and a higher-level control unit, regulates airflow and monitors system parameters to ensure consistent cleanliness, using centrifugally controlled rotary nozzles and ionization electrodes to neutralize static charges, with data recording for process documentation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rotary nozzles are used for cleaning workpieces, then cleaning efficiency is improved, but particle removal completeness deteriorates due to filter clogging
Solution Approach 1:
The system continuously monitors extraction airflow parameters (velocity, volume flow rate) and provides feedback to the control unit. When filter clogging is detected through parameter degradation, the system can trigger filter replacement or adjust operating parameters to maintain cleaning quality, thus resolving the contradiction between maintaining high cleaning efficiency and ensuring complete particle removal.
Solution Approach 2:
The system performs preliminary monitoring of extraction airflow parameters before complete filter clogging occurs. By detecting gradual parameter degradation in advance, the system can take preventive actions (filter replacement, parameter adjustment) to maintain both cleaning efficiency and particle removal completeness, preventing the deterioration before it happens.
2Reliability
If extraction velocity is increased to improve particle removal, then particle removal completeness is improved, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts extraction airflow parameters based on real-time monitoring and process requirements. Rather than maintaining constantly high extraction velocity, the system optimizes airflow parameters to achieve sufficient particle removal while minimizing energy consumption, resolving the contradiction between complete particle removal and energy efficiency.
Solution Approach 2:
The system changes extraction airflow parameters (velocity, volume flow rate) based on monitored conditions and process requirements. By optimizing these parameters rather than maintaining fixed high values, the system achieves complete particle removal while reducing unnecessary energy consumption, resolving the contradiction between reliability and energy use.
3Reliability
If multiple monitoring parameters are implemented to ensure cleaning quality, then cleaning quality is improved, but system complexity increases
Solution Approach 1:
The control unit serves multiple functions: it monitors extraction airflow parameters, controls cleaning nozzle operation, manages filter replacement timing, and optimizes energy consumption. By consolidating these functions into a single control system, the patent achieves high cleaning quality through comprehensive monitoring while minimizing the increase in system complexity through functional integration.
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
Ensures high-quality, consistent cleaning by maintaining specified target values, preventing static charging and ensuring complete removal of particles, thereby guaranteeing the functionality of workpieces like battery modules.
Implementation Method 1
an extraction device (9) for removing the exhaust air laden with contaminated particles from the cleaning module (3)
Implementation Method 2
an ionization electrode/discharge electrode (10) arranged downstream of the sensor detecting the static charge in the direction of travel of the conveyor (5). This electrode is positioned to neutralize electrical charges on the workpieces or tools (6)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a system for the quality-assured cleaning of workpieces and/or tools, comprising an inlet module (2), a cleaning module (3) with several air-operated, centrifugal force-controlled rotary nozzles (16), an outlet module (4), and a higher-level control unit (8). A conveying device (5) is provided on which the workpieces (6) or tools (6) are successively moved through the modules (2, 3, 4) of the modular system (1). The higher-level control unit (8) controls the speed of the conveying device (5) such that the workpieces (6) or tools (6) are cleaned of contaminating particles located on the surface of the workpiece (6) or tool (6) during their passage through the cleaning module (3). A suction device (9) is assigned to the cleaning module (3), and the higher-level control unit (8) controls the suction device (9) in such a way that...that the particles removed from the surface of the workpieces (6) or tools (6) are removed with the extracted airflow from the cleaning module (3).