Ultrasonic Separator Energy Optimization

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Solution Overview

Problem

Existing ultrasonic separation methods consume more energy than necessary for removing particulates from fluids, as they often apply large amplitude ultrasonic fields for extended durations, leading to inefficiencies.

Innovation Solution

Measuring a reference portion of a fluid to determine an energy-efficient ultrasonic exposure, selecting the ultrasonic power and duration based on the energy-efficient range for particulate separation, and using an ultrasonic generator controller to apply the selected power and duration, thereby reducing energy consumption while maintaining effective particulate removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If large amplitude ultrasonic fields are applied for long durations, then particulate removal effectiveness is improved, but energy consumption increases

Engineering Contradiction:

Improveparticulate removal effectivenessVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The system dynamically adjusts ultrasonic power and exposure duration based on real-time monitoring of particulate concentration and removal rate. The controller modulates the ultrasonic field parameters to maintain optimal separation effectiveness while minimizing energy consumption, transitioning from static high-power operation to adaptive dynamic control.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements feedback control by monitoring the rate of particulate mass removal and using this information to adjust ultrasonic exposure parameters. When the removal rate decreases below a threshold, the system modifies power and duration settings, creating a closed-loop control system that optimizes energy efficiency while maintaining separation effectiveness.

Inventive Principle:

Principle #23Feedback

2Use of energy by moving object

If ultrasonic power and exposure duration are reduced to save energy, then energy consumption decreases, but particulate separation effectiveness may be compromised

Engineering Contradiction:

Improveenergy consumptionVSAvoidparticulate separation effectiveness

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The system applies partial ultrasonic action by delivering reduced power and shortened exposure durations compared to conventional full-power operation. This partial action is sufficient to achieve the required separation effectiveness for many applications, eliminating the need for excessive energy input while maintaining adequate particulate removal performance.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system changes operating parameters (power level and exposure duration) based on the specific characteristics of the particulate-fluid mixture being processed. By adapting parameters to match the actual separation requirements rather than using fixed high settings, the system achieves effective separation with reduced energy consumption.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If fixed high ultrasonic power is applied, then separation effectiveness is maintained, but energy efficiency deteriorates

Engineering Contradiction:

Improveseparation effectivenessVSAvoidenergy efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The system transitions from fixed static power application to dynamic power modulation. The ultrasonic generator controller continuously adjusts power levels during the exposure duration based on monitored separation progress, ensuring that energy is delivered only when and where needed to maintain separation effectiveness, thereby improving overall energy efficiency.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system employs periodic ultrasonic exposure with variable intervals and durations rather than continuous fixed-power operation. By applying ultrasonic energy in optimized periods and allowing intervals for particulate aggregation and separation, the system maintains separation effectiveness while reducing total energy input and improving energy efficiency.

Inventive Principle:

Principle #19Periodic action

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

This approach allows for efficient removal of particulates from fluids with reduced energy usage, achieving low energy per unit mass ratios by optimizing ultrasonic exposure times and powers, thereby enhancing the energy efficiency of the separation process.

Implementation Method 1

particulate matter in fluids can be removed using ultrasonic separators in which particles aggregate in response to an ultrasonic field

Methodology Applied

Scientific EffectAcoustic radiation pressure: Acoustic Radiation Pressure

Implementation Method 2

applying the selected ultrasonic power corresponds to selecting an electrical drive power to an ultrasonic transducer

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS11395982B1Ultra low power acoustic separation

Publication Date: 2022.07.26 SONOSEP TECH INC

AI summary

Energy-efficient separation of particulates from fluids is based on determining particulate mass removal as a function of applied energy. Energy-efficient ultrasonic field powers and exposure durations are applied to a particulate containing fluid, and particles removed. In some cases, ultrasonic exposures are selected that provide the maximum particulate removal per applied energy.