Submersible Control Panel Epoxy Sealing Design
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Solution Overview
Problem
Existing submersible control panels for storm and lift stations are not reliable in harsh environmental conditions, such as high winds and flooding, due to complex sealing mechanisms that can fail and allow water ingress, necessitating a flood-proof construction that maintains water-tightness for extended periods.
Innovation Solution
A submersible control panel system with a stainless steel frame, water-tight doors, and epoxy-sealed conduits containing a porous material damper, such as a sponge, to prevent epoxy flow and ensure electrical wiring is sealed, allowing the panel to remain water-tight for at least 24 hours submerged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If complex lifting devices are provided to lift control panels during flooding, then the control panels can be elevated above flood levels, but the device complexity increases and reliability decreases due to potential failure of the lifting mechanism
Solution Approach 1:
The invention removes the complex lifting mechanism entirely and instead focuses on making the control panel itself flood-proof through waterproof construction. The control panel is designed to withstand submersion directly without requiring active lifting devices, thereby eliminating the reliability issues associated with mechanical lifting systems while still achieving the goal of protecting the control panel during flooding events.
Solution Approach 2:
Instead of actively lifting the control panel above water level using complex mechanisms, the invention inverts the approach by designing the control panel to passively resist water ingress and function while submerged. This is achieved through waterproof seals, gaskets, and enclosed designs that prevent water from entering the control panel interior, eliminating the need for unreliable lifting devices.
2Reliability
If thick-film elastomeric coating is applied to seal the cabinet, then environmental contamination is prevented from penetrating, but the coating is subject to damage during installation or from flying debris compromising water-tightness
Solution Approach 1:
The invention employs multiple layers of protection including gaskets, seals, and waterproof coatings in combination with the cabinet structure. This multi-layer composite approach ensures that even if one layer is damaged, other layers continue to provide water-tight protection. The combination of mechanical seals and protective coatings creates a redundant sealing system that is more resilient to damage than a single thick coating alone.
Solution Approach 2:
The invention incorporates gaskets and seals that provide a cushioning protective layer between the external environment and the cabinet interior. These elastomeric gaskets are designed to absorb impact and deformation, protecting the primary sealing surfaces from damage by debris or installation stresses, thereby maintaining water-tightness even when subjected to harsh conditions.
3Reliability
If the control panel is designed to be submersible with water-tight construction, then flood proof capability is achieved, but the device complexity increases to ensure water-tightness for extended periods
Solution Approach 1:
The invention divides the control panel into sealed modular sections with gaskets and seals at the joints. This segmentation approach allows each section to be independently sealed and tested, simplifying the overall water-tight construction. The modular design with standardized sealing interfaces reduces complexity compared to attempting to seal a monolithic structure, while still achieving comprehensive flood-proof 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 solution provides a reliable, water-tight submersible control panel that withstands harsh conditions, including 175 mph winds and 6+ feet of water, maintaining functionality and preventing water ingress, ensuring operational integrity during severe weather events.
Implementation Method 1
A conduit is sealed in a water-tight manner with respect to the connection opening. The conduit is filled with an epoxy to seal an interior of the conduit in a water-tight manner with respect to electrical wiring passing through the conduit into the frame.
Implementation Method 2
a porous material is disposed in said conduit at a bottom end of said conduit. The porous material defines a damper for preventing said epoxy from flowing out of said conduit during filling of said epoxy into said conduit.
Data Source
AI summary
A submersible control system with a control panel. The control panel has a frame to house electronic components. The frame has a connection opening for wiring required for an electrical connection to the electrical components. An outer door is attached to the frame to be water-tight to the frame in a closed position thereof. A conduit is sealed to be water-tight with respect to the connection opening. The conduit is filled with an epoxy for water-tight sealing an interior of the conduit to the wiring fed through the conduit. The control panel will remain water-tight for at least 24 hours after being submerged.