Wastewater Separator Pump Control by Layer Thickness Sensing
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Solution Overview
Problem
Existing wastewater treatment systems rely on floats that react to liquid density and are prone to errors due to varying liquid densities and impurities, leading to premature shut-downs or failure to shut-down during heavy inflows, causing operational disruptions.
Innovation Solution
A system using a layer thickness sensor to measure the thickness of a separating layer between lighter and heavier liquids, coupled with a control unit to activate or deactivate a pumping station based on the layer thickness, ensuring reliable shut-off and operation only when within predefined parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If floats are used to detect light liquid levels, then automatic shut-off is achieved, but reliability deteriorates due to density variations and impurities causing premature or failed shut-downs
Solution Approach 1:
The patent replaces the mechanical float-based detection system with an electronic sensor system that measures electrical parameters (capacitance, resistance, or impedance) to detect the presence and thickness of light liquid layers. This substitution eliminates the reliability issues associated with float density calibration and sensitivity to liquid density variations, while maintaining automatic shut-off functionality through electronic control of the inlet valve.
Solution Approach 2:
The patent introduces an intermediary evaluation unit that processes sensor signals and determines when shut-off should occur. This intermediary layer between the sensor and the inlet valve provides intelligent decision-making based on measured parameters, allowing for more reliable and adaptable automatic shut-off compared to direct mechanical float valve coupling.
2Ease of operation
If inlet barriers or floats are used for shut-off, then automatic flow control is achieved, but operational continuity worsens due to premature shut-downs during heavy rainfall or blocked separators
Solution Approach 1:
The patent implements a dynamic detection system using multiple sensors at different heights that can adapt to varying operating conditions. The evaluation unit dynamically determines shut-off timing based on real-time sensor readings, allowing the system to maintain operational continuity during heavy rainfall by distinguishing between normal high flow conditions and actual separator blockage, thereby preventing premature shut-downs while maintaining automatic flow control.
3Measurement precision
If floats calibrated to one light liquid density are used, then specific light liquid detection is achieved, but adaptability worsens when multiple liquids with different densities are present
Solution Approach 1:
The patent implements a universal detection system using electrical sensors (capacitive, resistive, or impedance-based) that can detect multiple types of light liquids regardless of their density. The sensors measure electrical parameters that change when light liquid contacts them, providing a density-independent detection method that maintains high measurement precision while being adaptable to various liquid types including oil, grease, and other hydrocarbons.
Solution Approach 2:
The patent changes the detection parameter from mechanical density-based float calibration to electrical parameter measurement (capacitance, resistance, or impedance). This parameter change allows the system to detect light liquids through their electrical properties rather than density, enabling precise detection that is universally applicable to multiple liquid types with different densities.
4Extent of automation
If float density is altered by impurities, then float calibration shifts, but shut-off reliability deteriorates causing premature closure or failure to close
Solution Approach 1:
The patent replaces the mechanical float system susceptible to impurity contamination and density changes with an electronic sensor system that measures electrical parameters. This substitution eliminates the problem of float calibration shifts due to impurities, as the electrical sensors are not affected by liquid contamination in the same way mechanical floats are, maintaining reliable shut-off timing accuracy.
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 reliable separation and pumping of treated wastewater by preventing premature shut-downs and allowing for electronic reactivation, reducing operational disruptions and enhancing system reliability.
Implementation Method 1
The sensor is designed as a capacitive sensor and has at least one evaluation unit for evaluating the sensor signal and, in particular, for determining the thickness of the separating layer
Implementation Method 2
separating light liquids and/or fats from the supplied liquid in the separation volume and collecting the separated light liquids and/or fats in the separation volume
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a cleaning system (10), in particular for wastewater, for separating light liquids and/or fats, with one or more separation tanks (12) forming at least one separation volume (16) and a storage volume (18), wherein the separation volume (16) has at least one inlet (28) for liquids to be cleaned, in particular wastewater, and the separation volume (16) and the storage volume (18) are fluidically connected via a separator (20) for separating light liquids and/or fats, wherein a lifting system (24) is provided for pumping liquid from the storage volume (18).The invention is characterized in that at least one layer thickness sensor is arranged in the separation volume (16) for measuring the layer thickness of at least one separating layer and a control unit is designed to release or lock the lifting system (24) for conveying liquids from the storage volume (18) depending on the detected layer thickness.