Vacuum-Purge Liquid Sampling Without Filtration for Textile Washers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Commercial textile washers face challenges in processing high volumes of heavily soiled textiles, leading to inconsistent chemical dosing, which can result in excessive chemical usage or inadequate cleaning and sanitization due to varying soil levels, and existing liquid sampling systems are prone to plugging from solid materials.
Innovation Solution
A liquid sampling system that uses a sensor housing and a liquid conveyance device with a motive element to draw and expel liquid samples without passing through a screen, employing bidirectional flow to purge solid materials and prevent fouling, allowing for continuous operation without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screen is placed between the source of liquid being sampled and the sample extraction device, then the liquid sample can be filtered to remove solid material, but the pores of the screen may plug with solid material over time, rendering the sample extraction device inoperable
Solution Approach 1:
The patent removes the screen filtration component from the sampling system entirely. The liquid conveyance device draws liquid samples directly from the source without passing through a screen, eliminating the plugging problem while maintaining sample extraction functionality through alternative means.
Solution Approach 2:
The patent introduces a liquid conveyance device as an intermediary between the liquid source and the sampling point. This device uses vacuum pressure and positive pressure to move liquid without requiring filtration, serving as a mediator that eliminates the need for screens while maintaining system functionality.
2Reliability
If the amount of chemical additive preprogrammed to be introduced into the washer is too great to cover the most soiled articles possible, then all articles will be treated, but most wash cycles will overdose on chemical additive, resulting in excessive cleaning cost
Solution Approach 1:
The patent implements a feedback system where liquid samples are continuously drawn from the washer, analyzed by sensors to determine soil level and chemical concentration, and used to dynamically adjust chemical dosing. This closed-loop control ensures optimal chemical usage based on actual conditions rather than fixed preprogramming.
Solution Approach 2:
The system dynamically changes chemical dosing parameters based on real-time analysis of liquid samples. Sensors measure soil concentration and chemical levels, and the system adjusts additive introduction rates accordingly, transitioning from static preprogrammed dosing to dynamic parameter adjustment.
3Loss of substance
If the amount of chemical additive preprogrammed to be introduced into the washer is too little for the soil demands of the article being washed, then chemical cost is reduced, but the article may not be properly cleaned and sanitized/disinfected
Solution Approach 1:
The feedback system continuously monitors liquid samples for soil concentration and chemical effectiveness, adjusting dosing in real-time to ensure minimum cleaning standards are met while avoiding excessive chemical use. This dynamic adjustment prevents both under-dosing and over-dosing scenarios.
Solution Approach 2:
The system transitions from static preprogrammed chemical dosing to dynamic adjustment based on real-time conditions. The chemical additive introduction rate is continuously modified according to measured soil levels and cleaning effectiveness, allowing optimal dosing for each specific wash cycle.
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 system effectively extracts and analyzes liquid samples from textile washers, ensuring accurate chemical dosing and maintaining system functionality by preventing plugging and fouling, thus optimizing cleaning and sanitization processes.
Implementation Method 1
The liquid conveyance device may generate a vacuum pressure to draw liquid from the larger source to the liquid conveyance device
Implementation Method 2
The liquid conveyance device may also generate a positive pressure to expel the liquid drawn toward the conveyance device back away from the conveyance device
Data Source
AI summary
A filtration-free liquid sampling system may be used to extract particulate or debris-containing liquid samples that may otherwise plug a filter over its service life. For example, such a system may be used to extract liquid sample from an industrial textile washer to monitor and/or validate the quality of wash conditions within the washer. In some examples, the system includes a pump that creates a vacuum on a backstroke, drawing liquid into a sensor housing positioned between the pump and the washer. After holding the liquid in the sensor housing long enough to measure its properties, the pump can be driven in a reverse stroke to pressurize the contents in the sensor housing and force the liquid back into the washer. This vacuum fill/pressure purge can keep the sensor housing free of debris.