Separator Device with Fixed Filter and Capacitance Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing water-oil separators in compressed air plants face issues with the movement of filtering elements and incomplete saturation signaling, leading to inefficient operation and environmental concerns due to the need to dispose of entire mixtures during maintenance.
Innovation Solution
A separator device with a fixed filtering element and integrated electric sensors or electrodes within a niche on the container wall, allowing for reliable saturation detection and replacement without removing the entire mixture, ensuring constant operation and prompt signaling of saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the filtering element is made movable to indicate saturation by position change, then the saturation state can be signaled, but the filtering element's operational stability deteriorates and movement reliability worsens
Solution Approach 1:
The detection function is segmented from the filtering element. Electric sensors are placed in separate niches on the container wall, while the filtering element remains fixed. This segmentation allows independent optimization: the filter maintains stability while sensors provide reliable saturation detection through electrical capacity measurements.
Solution Approach 2:
Electric sensors act as intermediaries between the filtering element and the saturation detection system. Instead of moving the filter itself, the sensors measure electrical capacity variations caused by oil accumulation on the fixed filtering element, providing indirect but reliable saturation indication.
2Measurement precision
If electric sensors are integrated inside the filter or on a downstream plate, then saturation can be detected, but maintenance complexity increases and mixture disposal is required
Solution Approach 1:
The electric sensors are extracted from the filtering element structure and placed in separate niches on the container wall. This extraction allows sensors to be accessed, maintained, or replaced independently without disturbing the filtering element or requiring mixture disposal, significantly improving ease of repair.
Solution Approach 2:
The filtering element continues to perform its primary function of separating oil from water while simultaneously serving as the sensing medium for the electric sensors. The oil accumulation on the filter directly affects electrical capacity, allowing the filter to 'self-report' its saturation state without additional moving parts or complex mechanisms.
3Ease of operation
If the filtering element moves to indicate saturation, then a simple signaling mechanism is provided, but the operational efficiency deteriorates due to movement interruptions
Solution Approach 1:
The mechanical movement-based signaling system is replaced with an electrical detection system. Electric sensors measure electrical capacity variations caused by oil accumulation on the fixed filtering element, providing saturation signals without any mechanical movement. This substitution maintains continuous filtering operation and improves productivity while preserving ease of operation through reliable electrical signaling.
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
Enables reliable and efficient saturation detection of the filtering element, allowing for timely replacement without disposing of the entire mixture, reducing environmental impact and maintenance costs.
Implementation Method 1
The sensors are suitable to detect a variation in the electric capacity following the increase in the quantity of oil, or other impurity to be removed, absorbed by the filter
Implementation Method 2
at least one filtering element, preferably of the adsorbent type, suitable to remove from the liquid mixture the component to be filtered, for example particles of oil
Data Source
AI summary
Separator device for a liquid mixture containing impurities to be removed, the device comprising a container (11), equipped with an inlet (12) for the mixture to be filtered and an outlet (13) for the purified liquid to be discharged, and at least a filtering element (16, 25) disposed inside the container (11) and able to remove said impurities from the liquid mixture. The filtering element (16, 19) has a fixed position inside the container (11) and is associated with means that detect the progress of its saturated condition, in order to signal to the user, when said saturated condition is reached, the need for replacement or an intervention of another type, of said filtering element (16). The detection means comprises one or more electric sensors (22, 23) disposed over the length of the filtering element (16, 19), and suitable to detect a variation in the electric capacity due to the increase in the quantity of impurities to be removed, absorbed by the filtering element (16, 19), and an electronic card (30) that signals to the user when the electric capacity detected corresponds to a saturated condition of the filtering element (16, 19).