Tank Flow Generator Speed Control for Variable Liquid Levels
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Solution Overview
Problem
Existing flow generators in tanks with varying liquid levels consume excessive power due to constant high operational speeds, leading to inefficient mixing and reduced operational life, especially in buffer tanks with fluctuating liquid volumes.
Innovation Solution
A method and system for controlling flow generators with variable operational speeds based on liquid level detection, using a control unit to adjust speed according to the liquid level, minimizing power consumption and extending the generator's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flow generator is operated at constant high speed to prevent sedimentation, then mixing effectiveness is improved, but power consumption increases excessively
Solution Approach 1:
The flow generator's operational speed is changed from constant to variable, dynamically adjusted according to liquid level measurements. The control unit receives liquid level data and automatically modifies the rotational speed of the impeller to match actual mixing requirements, eliminating unnecessary high-speed operation when liquid levels are low.
Solution Approach 2:
The operational parameter (rotational speed) of the flow generator is changed based on the liquid level parameter. By establishing a relationship between liquid level height and required mixing speed, the system optimizes power consumption while maintaining adequate mixing effectiveness through parameter adaptation.
2Reliability
If the flow generator operates at maximum speed continuously, then sedimentation is prevented, but the operational life of the generator is reduced
Solution Approach 1:
The system dynamically adjusts the flow generator speed based on actual liquid levels, reducing mechanical stress and wear on the generator components during periods when maximum mixing intensity is not required. This extends the operational life while maintaining sedimentation prevention capability when needed.
Solution Approach 2:
The control system continuously monitors liquid level and uses this feedback to adjust generator speed accordingly. This closed-loop control prevents unnecessary high-speed operation that would accelerate wear, while ensuring adequate mixing to prevent sedimentation when liquid levels require it.
3Use of energy by moving object
If the flow generator speed is reduced to save energy, then power consumption decreases, but mixing effectiveness and sedimentation prevention are compromised
Solution Approach 1:
The system changes the operational speed parameter based on liquid level conditions, ensuring that speed reduction for energy savings does not compromise mixing effectiveness. The control algorithm maintains the minimum necessary speed to prevent sedimentation while optimizing energy consumption.
Solution Approach 2:
Different operational speeds are applied to different liquid level conditions. The system provides high mixing intensity only when and where needed (high liquid levels), and reduces speed when liquid levels are low, matching the local mixing requirements to energy input.
4Productivity
If parallel buffer tanks are used to enable cleaning during operation, then continuous operation is maintained, but the system complexity and space requirements increase
Solution Approach 1:
The flow generator is designed to be self-cleaning through its variable speed operation. By maintaining adequate mixing even at reduced speeds, the system prevents sedimentation that would require external cleaning operations, eliminating the need for parallel tanks and complex cleaning infrastructure.
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
Reduces power consumption and extends the operational life of flow generators by optimizing mixing efficiency based on liquid volume changes, ensuring uniform mixing without unnecessary energy use.
Implementation Method 1
The flow generator (1) comprises an impeller (3) and a stationary body (2) having a drive unit, wherein the impeller (3) is connected to and driven in rotation by said drive unit
Implementation Method 2
the flow generator (1) is configured to be operated at a variable operational speed (n) and in that the control unit (4) is configured to set a present operational speed (n-present) of the flow generator (1) equal to a demand of operational speed (n-demand)
Data Source
AI summary
The invention relates to a method for controlling a flow generator (1) in a tank (20) configured for housing a liquid comprising solid matter, the flow generator (1) comprising an impeller and being located at a height (h-mixer) in the tank (20) and the tank (20) having a predetermined maximum filling height (h-max), wherein the flow generator (1) is configured to be operated at a variable operational speed (n) and the demand of operational speed (n-demand) is dependent on the present liquid level height (h-present) in the tank (20), wherein a max operational speed (n-max) of the flow generator (1) is the operational speed required when the liquid level in the tank (20) is equal to the maximum filling height (h-max), the present operational speed (n-present) being set equal to the demand of operational speed (n-demand) of the flow generator (1) that is determined using the formula:(n-present)=(n-demand)=(n-max)[(h-max)/(h-present)]^aat least when [(h-mixer)+X]≤(h-present)≤(h-max), wherein a≥(¼) and a<1, X=radius of the impeller of the flow generator+1, and all heights and measures are given in meter.