Sludge Viscosity Sensing Ring for Precise Tank Release Control

Solution Overview

Problem

Existing methods for controlling sludge release from tanks, such as using timers or reactive pump control, are unsophisticated and lead to inefficiencies, causing either tank overflow or excessive water release due to inadequate viscosity sensing.

Innovation Solution

A viscosity-sensing apparatus comprising a ring with sensors connected to a pipe, which measures sludge viscosity at various depths and communicates with a controller to adjust the valve's operation, ensuring precise control of sludge release.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a timer is used to control the pump, then the pump operation is automated, but the control precision is insufficient leading to either tank overflow or excessive water release

Engineering Contradiction:

Improvepump operation automationVSAvoidsludge thickness measurement precision

Core Design Contradiction:

Extent of automationVSMeasurement precision

Solution Approach 1:

The patent replaces mechanical torque measurement with electromagnetic sensing. The viscosity sensor uses electromagnetic fields to detect sludge viscosity directly, eliminating the need for mechanical torque measurement systems and providing more precise, reliable measurements without mechanical wear or friction interference.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a viscosity sensor as an intermediary device between the control system and the sludge flow. This sensor acts as a mediator that provides accurate real-time viscosity data to the controller, enabling precise pump control based on actual sludge conditions rather than rough torque estimates.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If torque measurement is used to determine sludge thickness, then pump control can be adjusted, but the measurement is affected by mechanical problems with the motor

Engineering Contradiction:

Improvesludge thickness determination reliabilityVSAvoidmechanical problems with motor

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical torque measurement with electromagnetic sensing. The viscosity sensor uses electromagnetic fields to detect sludge viscosity directly, eliminating the need for mechanical torque measurement systems and providing more precise, reliable measurements without mechanical wear or friction interference.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If the valve is inadequately opened, then sludge release is controlled, but the tank fills with sludge affecting effluent quality

Engineering Contradiction:

Improvevalve controlVSAvoideffluent quality control precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent implements a feedback control system where the viscosity sensor continuously monitors sludge viscosity and provides real-time data to the controller. The controller adjusts the valve opening based on this feedback, creating a closed-loop system that maintains effluent quality within specified ranges by dynamically responding to changing sludge conditions.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces mechanical torque measurement with electromagnetic sensing. The viscosity sensor uses electromagnetic fields to detect sludge viscosity directly, eliminating the need for mechanical torque measurement systems and providing more precise, reliable measurements without mechanical wear or friction interference.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If the valve is excessively opened, then sludge release is accelerated, but thin sludge with too much water is released causing depression cones and increased handling costs

Engineering Contradiction:

Improvesludge release rateVSAvoidsludge concentration control precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements a feedback control system where the viscosity sensor continuously monitors sludge viscosity and provides real-time data to the controller. The controller adjusts the valve opening based on this feedback, creating a closed-loop system that maintains effluent quality within specified ranges by dynamically responding to changing sludge conditions.

Inventive Principle:

Principle #23Feedback

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 apparatus provides precise control over sludge release, preventing tank overflow and minimizing water loss by accurately detecting changes in sludge viscosity and adjusting the valve accordingly.

Implementation Method 1

The sensors are impedance sensing in nature and sense values of viscosity of the sludge at various depths in the ring

Methodology Applied

Scientific EffectImpedance sensing: Electrical Resistance

Data Source

PatentUS11977013B2Viscosity-sensing apparatus

Publication Date: 2024.05.07 TAIWAN WATER & SOIL INSTR

AI summary

A viscosity-sensing apparatus includes a ring and sensors. The ring is connected to a pipe of a tank. The sensors are connected to an internal face of the ring at various heights. Sludge travels into the ring from the tank through the pipe. The sensors sense values of viscosity of the sludge at various depths in the ring.