Submersible Mixer Reverse Cleaning to Prevent Solid Buildup
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Solution Overview
Problem
Existing submersible flow generators in wastewater and digester applications face issues with clogging due to solid waste accumulation, leading to reduced performance, increased power consumption, and difficulty in hoisting, which can trigger safety modes and require frequent unplanned services.
Innovation Solution
A method for monitoring and controlling the operation of flow generators that includes a cleaning sequence where the propeller reverses direction to remove solid matter from the main body, triggered by time-based or temperature-based conditions, maintaining bulk flow and ensuring safe hoisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flow generator operates continuously in wastewater with solid matter, then productivity is maintained, but solid waste accumulates on the main body and propeller, leading to clogging and reduced performance
Solution Approach 1:
The patent implements periodic reverse rotation of the propeller at predetermined time intervals during normal forward operation. This periodic action prevents solid waste accumulation by periodically flushing the main body and propeller surfaces, thereby maintaining reliability without interrupting overall productivity.
Solution Approach 2:
The cleaning function is integrated into the continuous operation by utilizing brief reverse rotation phases within the ongoing forward operation cycle. This ensures that cleaning action occurs continuously over time without requiring separate maintenance interruptions, maintaining both productivity and reliability.
2Reliability
If the propeller rotates in reverse direction to clean the main body, then solid matter is removed improving reliability, but the bulk flow of liquid in the tank is temporarily affected
Solution Approach 1:
The reverse rotation is applied partially - only for brief predetermined time intervals rather than continuous operation. This partial action is sufficient to remove solid matter accumulation while minimizing disruption to the bulk flow, thereby balancing reliability improvement with productivity maintenance.
Solution Approach 2:
The cleaning sequence operates periodically rather than continuously, with the propeller alternating between forward operation (maintaining bulk flow) and brief reverse rotation (cleaning). This periodic approach ensures bulk flow is maintained most of the time while still achieving effective cleaning periodically.
3Reliability
If cleaning sequence is performed frequently to prevent clogging, then reliability is improved, but energy consumption increases due to repeated reverse operations
Solution Approach 1:
The cleaning sequence is executed periodically at predetermined time intervals rather than continuously or too frequently. This periodic timing optimizes the balance between preventing clogging (maintaining reliability) and minimizing energy consumption from repeated reverse operations.
Solution Approach 2:
The system monitors operational parameters such as power consumption and cleaning effectiveness to optimize the timing and duration of reverse rotation sequences. By adjusting these parameters, the system maintains reliable clogging prevention while minimizing energy expenditure on cleaning operations.
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 method effectively prevents clogging, reduces the risk of safety mode triggers, prolongs service intervals, and maintains efficient operation by keeping the flow generator clean and cool, thus enhancing reliability and reducing maintenance needs.
Implementation Method 1
driving the propeller in a reverse direction of rotation in order to generate a local flow of liquid from the downstream side of the propeller towards the upstream side of the propeller and along the main body
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for monitoring and controlling the operation of a liquid flow generator (1) configured for operation in a tank (18) housing in a liquid comprising solid matter. The flow generator (1) comprises a propeller (3) and a main body (7) having a drive unit (4), wherein a control unit (4) is operatively connected to the flow generator (1) in order to monitor and control the operation of the flow generator (1), the method comprises the steps of: a) driving the propeller (3) in a normal direction of rotation, wherein the liquid flow is directed from an upstream side of the propeller (3) towards a downstream side of the propeller (3), wherein the main body (7) is located at the upstream side of the propeller (3), b) performing a cleaning sequence in response to a main body cleaning signal, wherein the cleaning sequence comprises the steps of: i) stopping the propeller (3) from rotating in the normal direction of rotation, ii) driving the propeller (3) in a reverse direction of rotation, wherein the liquid flow is directed from the downstream side of the propeller (3) towards the upstream side of the propeller (3) and along the main body (7) in order to remove any solid matter accumulated on the main body (7), and iii) stopping the propeller (3) from rotating in the reverse direction of rotation, c) resume driving of the propeller (3) in the normal direction of rotation.