Sensor Holder Assembly for Automated In-Situ Cleaning
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Solution Overview
Problem
Current sensor cleaning and calibration methods in water processing facilities are inadequate, as they often require manual removal of sensors for cleaning and calibration, are ineffective when submerged, and lack comprehensive cleaning functions, leading to inaccurate measurements and increased labor and safety risks.
Innovation Solution
A sensor holder assembly made from acid-resistant plastic, equipped with a programmable logic controller, LEDs for visual inspection, and multiple cleaning options like ultrasonic cleaning, allowing for automated cleaning and calibration without sensor removal, enabling bypass of the aqueous analyte stream and safe handling of chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual retrieval and cleaning of sensors is performed, then cleaning effectiveness is improved, but labor requirements and safety risks increase
Solution Approach 1:
The sensor holder assembly enables automated cleaning functions where the system cleans itself without manual intervention. The assembly includes integrated cleaning mechanisms such as air spargers, water jets, and chemical injection systems that automatically remove contaminants from the sensor surface, eliminating the need for manual retrieval and cleaning while maintaining cleaning effectiveness.
Solution Approach 2:
Manual mechanical cleaning operations are replaced with automated systems including pneumatic air spargers, hydraulic water jets, and electronically controlled chemical injection systems. These automated mechanisms substitute human labor with mechanical and electronic systems that perform cleaning functions remotely and safely.
2Productivity
If sensors are cleaned while submerged in aqueous analyte stream, then continuous monitoring is maintained, but cleaning effectiveness decreases
Solution Approach 1:
The sensor holder assembly acts as an intermediary structure that provides a controlled cleaning environment around the sensor while it remains in the aqueous analyte stream. The assembly includes isolated chambers and flow paths that allow cleaning agents (air, water, chemicals) to be directed at the sensor surface without requiring the sensor to be removed from its monitoring position, thus maintaining both continuous monitoring and cleaning effectiveness.
3Reliability
If multiple cleaning functions are implemented, then comprehensive contaminant removal is achieved, but device complexity increases
Solution Approach 1:
The sensor holder assembly is designed as a multi-functional integrated unit that combines several cleaning mechanisms (air sparging, water jetting, chemical injection) within a single structure. This universal design allows the same assembly to handle multiple types of contaminants using different cleaning methods, achieving comprehensive contaminant removal without requiring separate complex systems for each cleaning function.
4Measurement precision
If sensors are frequently retrieved for cleaning, then measurement accuracy is maintained, but downtime increases
Solution Approach 1:
The automated cleaning system enables continuous operation by performing cleaning functions in-situ without requiring sensor retrieval or system shutdown. The sensor remains continuously mounted and functional while automated mechanisms periodically clean its surface, eliminating downtime associated with manual cleaning operations and maintaining uninterrupted measurement capability.
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
The system reduces labor, improves safety, and ensures accurate sensor measurements by enabling comprehensive automated cleaning and calibration of sensors in situ, accommodating various water quality conditions and types of contaminants.
Implementation Method 1
Ultrasonic cleaning is likewise ineffective when the sensor is positioned in water, as sonic waves generated by a transducer dissipate through the aqueous stream and away from the targeted sensor.
Implementation Method 2
such devices are generally configured to employ only a single cleaning function, or in some cases dual cleaning functions, which is typically inadequate to prevent accumulation of the full array of foulants that may be encountered.
Implementation Method 3
many such methods and systems employ only an air burst or water jet (or in some cases both) to maintain the cleanliness of the electrode and/or sensor surface
Implementation Method 4
many such methods and systems employ only an air burst or water jet (or in some cases both) to maintain the cleanliness of the electrode and/or sensor surface
Data Source
AI summary
An electrode cleaning and calibration system generally comprises a sensor holder assembly machined from a block of solid acrylic or similar plastic material, which can accommodate a variety of types and sizes of sensors for use in monitoring and measurement of water processing and treatment processes. Examples of sensors suitable for use in the system include pH sensors, dissolved oxygen sensors, chlorine sensors, ozone sensors, total suspended solid sensors, mixed liquor suspended solid sensors, ammonia sensors, monochloramine sensors, and ultraviolent transmittance sensors.