Self-Powered Spray Nozzle Sensor for Drying Hotspot Detection
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Solution Overview
Problem
Existing spray drying technologies face challenges in achieving homogeneous drying processes due to inhomogeneous spraying, leading to potential flame hotspots and increased fire and explosion risks, particularly when organic components are involved, and existing monitoring methods using infrared cameras are limited in detecting local temperature increases and alignment issues.
Innovation Solution
A spray nozzle with a groove on its outer wall housing a self-sufficient temperature measuring sensor, powered by a piezoelectric element, allowing for direct temperature measurement and early detection of encrustations and potential flame formation, with wireless signal transmission to prevent cable interference and enhance operational safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature measuring sensor is installed on the spray nozzle, then temperature detection capability is improved, but device complexity increases due to cable routing requirements
Solution Approach 1:
The measuring sensor is equipped with an independent power supply in the form of a piezoelectric element that generates electrical energy through mechanical deformation when clamped in the groove. This self-powered design eliminates the need for external cable-based power supply, resolving the contradiction between measurement capability and device complexity.
Solution Approach 2:
The power supply function is extracted from the external system and integrated directly into the measuring sensor itself through the piezoelectric element. This extraction eliminates the need for cable routing to external power sources while maintaining continuous power supply for temperature measurement.
2Measurement precision
If infrared cameras are used to monitor temperature in the drying chamber, then temperature monitoring capability is improved, but detection reliability deteriorates due to limited field of view and alignment difficulties
Solution Approach 1:
Instead of using a single infrared camera with limited field of view to monitor the entire drying chamber, temperature measurement is localized to each spray nozzle individually. Each nozzle has its own measuring sensor that directly detects temperature at its specific location, ensuring reliable detection of local hotspots without alignment issues.
Solution Approach 2:
The optical measurement system (infrared camera requiring line of sight and alignment) is replaced with a direct contact mechanical measurement system. The measuring sensor is physically coupled to the spray nozzle, eliminating the need for optical alignment and ensuring reliable temperature detection regardless of viewing angle or distance.
3Reliability
If external cable-based power supply is used for the measuring sensor, then power supply reliability is improved, but operational safety deteriorates due to cable tangling and interference with spray nozzle operation
Solution Approach 1:
The measuring sensor generates its own electrical energy through the piezoelectric element, which converts mechanical deformation into electrical energy. This self-powered design completely eliminates external cables and their associated interference, tangling risks, and safety hazards while maintaining continuous power supply for temperature measurement.
Solution Approach 2:
The electrical power transmission through mechanical cables is replaced with direct mechanical coupling of the piezoelectric element to the spray nozzle structure. The mechanical vibrations and deformations of the nozzle during operation directly generate electrical energy, eliminating the need for flexible cable connections and their associated safety risks.
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 early detection of temperature increases and potential flame formation directly on the spray nozzle, reducing the risk of fire and explosion, and allows for a more homogeneous drying process, ensuring high-quality dried products and extended service life of the spray nozzle and dryer.
Implementation Method 1
the independent power supply, in particular by means of a piezoelectric element, is arranged in the groove
Data Source
Figure 1~2
AI summary
The invention relates to a spray nozzle (101) for spraying an article to be dried, wherein the spray nozzle has a groove (103) on an outer wall, and a measurement sensor (105) for measuring a measurement variable is arranged in the groove. The measurement sensor (105) is paired with an autonomous energy supply and/or the autonomous energy supply is arranged in the groove, in particular by means of a piezo element (107), such that the measurement sensor can be operated free from an external cable-based energy supply. The invention further relates to a spray dryer (119) for drying an article to be dried and to a method for monitoring and/or controlling and/or regulating a temperature during the spraying process of an article to be dried.