WO2014057163A1 - System and method for the purification of flowing fluid - Google Patents

System and method for the purification of flowing fluid Download PDF

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Publication number
WO2014057163A1
WO2014057163A1 PCT/FI2013/050868 FI2013050868W WO2014057163A1 WO 2014057163 A1 WO2014057163 A1 WO 2014057163A1 FI 2013050868 W FI2013050868 W FI 2013050868W WO 2014057163 A1 WO2014057163 A1 WO 2014057163A1
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WO
WIPO (PCT)
Prior art keywords
fluid
detection unit
control valve
purification system
filter
Prior art date
Application number
PCT/FI2013/050868
Other languages
French (fr)
Inventor
Aslak Siimes
Ville RAUHALA
Original Assignee
Aslak Siimes
Rauhala Ville
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aslak Siimes, Rauhala Ville filed Critical Aslak Siimes
Publication of WO2014057163A1 publication Critical patent/WO2014057163A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16N—LUBRICATING
    • F16N39/00—Arrangements for conditioning of lubricants in the lubricating system
    • F16N39/06—Arrangements for conditioning of lubricants in the lubricating system by filtration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D27/00—Cartridge filters of the throw-away type
    • B01D27/10—Safety devices, e.g. by-passes
    • B01D27/103—Bypass or safety valves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D37/00—Processes of filtration
    • B01D37/04—Controlling the filtration
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
    • G01N33/26—Oils; viscous liquids; paints; inks
    • G01N33/28—Oils, i.e. hydrocarbon liquids
    • G01N33/2888—Lubricating oil characteristics, e.g. deterioration

Definitions

  • the present invention provides a system and method for the purification of flowing fluid. Especially, the invention provides a purification system and purification method, which detects and removes particular material from the flowing fluid in a real-time fashion.
  • a mechanical device naturally causes erosion of the machine parts, which in turn results to the ablation of small particles, which get mixed into the fluid flowing through the systems.
  • Many machine tools use perfusing fluid as a lubricant to minimize friction between machine parts and to prevent erosion, thus prolonging working life of the device.
  • Flowing fluid can also be used for other purposes, like in hydraulic systems, wherein the main purpose of the fluid is to serve as a force mediator.
  • Particular materials mixed into flowing fluid have an ef- feet on the quality of the flowing fluid as well as on the erosion of the machine, and they can indicate a machine breakdown.
  • Filtering systems comprise different amounts and types of filters, which are intended to arrest impurities flowing in the fluid.
  • the said filtering systems include some drawbacks. The more dense the structure is, the more smaller particles it will catch, but simultaneously it will impair the fluid flow. Over time, the filters will also be corroded and obstructed, which means that their operational function will be declined and that they have to be changed or purified at regular intervals. Due to the difficulty to assess the operational function of the filters, they are not alone a feasible solution for maintaining the purity of the flowing fluid.
  • Present sampling methods are based on the fact, that a small sample will be tak- en at predetermined intervals from the flowing fluid, which is then analyzed e.g. by laboratory methods or in industry plants by their own particle counters. Depending on the method, this process takes few days to several months, during which the machines can already have built up serious damages. Thus, by using present sampling methods, proactive welfare measures for the machines are ab- solutely impossible to implement. In addition to the long delay, also the small quantity of samples used in analysis weakens its reliability. As a result, this will not necessarily give a correct view of impurities present in the flowing fluid.
  • particle counters used in industrial environment detect only small par- tides. Further, in laboratory analyses only the purity of the oil are analysed, and the condition of the machine itself is not considered. These analyses do not consider large particles, which indicate machine breakdown. So, with presently used systems and methods it is difficult to execute a vehicle-based maintenance control.
  • the object of the present invention is to solve the above-described problems or at least to diminish their consequences.
  • the present invention aims to provide a system, which can be easily installed to several sites of applications, and which is able to detect and remove particles of different sizes, forms and quantities from the flowing fluid in a real-time fashion.
  • the characteristics of the purification system of the present invention are defined in the characterizing part of the independent claim 1.
  • the characteristics of the purification system of the present invention are defined in the characterizing part of the independent claim 6.
  • the purification system of the invention comprises - a detection unit for the detection of a particle in the flowing fluid
  • control valve which comprises at least one inlet and two outlets for the conduction of the fluid to the site of application or into the by-pass channel,
  • control system - a control system, wherein the detection unit, control valve, by-pass channel, filter and control system cooperate functionally so, that the control system switches the control valve based on the measures provided by the detection unit in such way, that once a removable particle is detected, an adequate volume of fluid containing the said removable particle will flow into the by-pass channel, via the detection unit and back to the control valve, whereby the filter between the control valve and detection unit will separate the particle from the fluid.
  • the system is connected to the site of application by pipelines and/or flexible tubes and appropriate interfaces.
  • the site of application comprises the flowing fluid to be purified, e.g. a lubricant flowing through machine tools.
  • the fluid leaving the site of application flows via the detection unit to the control valve. From the control valve, either the fluid enters back to the site of application or it will be conducted into the by-pass channel, via the detection unit and back to the control valve. In between the control valve and detection unit there is at least one filter, through which the fluid flows when entering back to the control valve via the detection unit. Thereafter, either the fluid flows again from the control valve to the site of application or it will be conducted into the by-pass channel. The flowing fluid can be recycled till all removable particles have been separated from the said fluid.
  • the guidance of the control valve is provided by an automatic control system. Based on the measures provided by the detection unit, the control system will guide the valve. According to one embodiment, the valve is switched in such way, that the fluid will by default flow back to the site of application, but in case the detection unit observes a removable particle, the control system will turn the flow into the by-pass channel by the aid of the control valve.
  • the guidance can be provided e.g. by using auto- matic control system, wherein, based on the flow rate of the fluid and the dis- tance between the detection unit and control valve, and alternatively after a certain delay, the fluid is conducted for a certain time into the by-pass channel. Based on the flow rate and the distance between the detection unit and control valve, a timespan, and in addition alternatively a certain delay, will be preset, which are needed to conduct the particle/particles into the by-pass channel.
  • particles in the flowing fluid can be determined e.g. based on their form, size and/or quantity.
  • the particles can be determined/calibrated according to needs of the site of application. As and when necessary, and based on the detection method used, even particles having a size of 3 ⁇ can be observed.
  • the system can detect smaller particles, which are preferably 3 - 100 ⁇ in size.
  • Maintenance control of a device, e.g. machine tool can be carried out by adjusting the system to detect larger particles of over 100 ⁇ , and also even larger, over 150 ⁇ parti- cles, which are indicative of more serious machine breakdowns.
  • the system can be adjusted to detect particles of all sizes, from small 3 ⁇ particles to particles of over 100 ⁇ and also particles over 150 ⁇ .
  • the detection unit used in the system preferably comprises an imaging technique based on machine vision, but additionally or alternatively other detection technique ⁇ ) can be used, like Hall-sensors, optical fiber sensors and/or magnetic field.
  • the machine vision comprises a light source, a (video)camera and a computer.
  • the said computer is generally equipped with an image-processing program, which can interprete images automatically.
  • Present high-speed cameras enable a very fast and accurate imaging.
  • the record rate in convalveional applications is appr. 1000 frames/s, in more advanced applications even over million frames/s, if necessary.
  • the system comprises in addition sampling.
  • the fluid leaving the site of application flows via the first detection unit of the present system to the first control valve.
  • the first control valve either the fluid is conducted into the sampling bottles or it will go on through the filter and via the second detection unit to the second control valve.
  • Sampling can be carried out e.g. based on the measures provided by the detection unit, by a preset and/or manual fashion.
  • the embodiments, wherein the sampling is carried out only by a preset and/or manual fashion can alternatively be executed without the first detection unit.
  • From the sec- ond control valve either the fluid enters back to the site of application or it will be conducted into the by-pass channel via the second detection unit and back to the second control valve.
  • the second control valve and detection unit there is at least one filter, through which the fluid flows when it enters back to the second control valve via the detection unit. Thereafter, either the fluid flows from the second control valve to the site of application or it will be conducted into the by-pass channel. The fluid can be recycled till all removable particles have been separated from the said fluid.
  • the system comprises an alarm system.
  • the alert can be executed e.g. by a sound and/or visual signal.
  • the alert can be initiated e.g. based on the measures provided by the detection unit using predetermined size, form and/or quantity of the particles.
  • the alert can be executed, when the system has completed sampling.
  • the alert can also be indicative of a failure in the system and/or site of application.
  • the flowing fluid to be purified is oil or water.
  • the flowing fluid can also be e.g. a lubricant, which consists at least partly of oil.
  • valves which comprise at least one inlet and at least two outlets.
  • One feasible solution is to use 3-way valves, which allow the flow of the fluid from one inlet to one outlet all at once. In cases, where a removable particle is detected and/or during the sampling, the fluid is conducted to the second outlet, whereby the flow into the first outlet is prevented.
  • the valve is automatically controlled by connecting therein an actuator, which executes the inlet-outlet-switching of the valve according to the guidance of the control system.
  • the actuator of the valve can be e.g. an electric motor or a solenoid.
  • This system provides automatic high- speed reactive valve applications, which enable a real-time conduction of the fluid into the purification system of the present invention.
  • a valve including multiple inlets and outlets like a 4-way valve, can be used, if necessary.
  • the method for the purifica- tion of flowing fluid comprises at least steps of:
  • the usefulness of the purification system of the present invention is based on several facts. This system enables the detection of particles having a wide scale of sizes, quantities and/or forms. This system can be automatized to detect and remove particles from the flowing fluid in a real-time fashion.
  • the present system provides means to monitor the state of an operating unit, like a machine tool, in a real-time fashion. This makes it possible to intervene in failures and problems immediately they become apparent.
  • the system is easy to be installed and can be applied in several sites of applications.
  • a pipe-to-pipe installation is very simple to integrate to several sites of applications.
  • the term "site of application” denotes a device, machine and/or system, which comprises flowing fluid to be purified, e.g. a machine tool and its lubricant.
  • Figure 1 shows a purification system according to one embodiment of the present invention
  • Figure 2 shows a purification system according to another embodiment of the present invention
  • Figure 3 is a flow chart of one embodiment, which shows the method of the present invention for removing a particle from the flowing fluid
  • Figure 4 is a flow chart of another embodiment, which shows the method of the present invention for removing a particle from the flowing fluid.
  • FIG. 1 shows one embodiment of the purification system according to the present invention.
  • the system 102 for the purification of flowing fluid comprises detection unit 106, control valve 108, at least one filter 110a, 110b, and means 112, e.g. pipes and/or tubes, for transferring the flowing fluid.
  • the system 102 is pro- vided in the site of application 104 in such way, that the fluid to be purified used in the site of applicationl04 is able to flow into the purification system 102 in the direction of V shown in figure 1.
  • the purification system 102 is provided by appropriate direct pipe-to-pipe-installations to the site of application 104.
  • the filters 110a, 110b shown in figure 1 reflect the two appropriate locations for the filters.
  • the location of the filter 110a is beneficial, because when the flowing fluid leaves the site of application 104, it will always flow through the filter 110a, whereby impurities can possible be separated from the fluid, before it enters to the detection unit 106 or control valve 108. Thus, it may be possible to minimize the guidance of the control valve 108 so, that the fluid is able to flow directly back to the site of application 104, i.e. in the direction A.
  • the filter 110a is preferentially located in front of the site of application 114.
  • the detection unit 106 observes a removable particle in the fluid and the fluid is con- ducted into the site of application 114, it will flow through the filter 110a and the particle could be separated from the fluid before it flows through the detection unit 106 and control valve 108.
  • the filter 110b into the by-pass channel 114, the filter will not affect per se to the flow of the fluid, when the fluid leaves the site of application 104. Thus, the flow will stay constant and if a removable particle is detected, the fluid can still be conducted from the valve 108 into the by-pass channel 114, wherein the filter 110b is located. Then, by the aid of the said filter 110b, the particle can be separated from the fluid.
  • the purification system 102 of the present invention shows only two appropriate locations for the filters 110a, 110b.
  • the filters 110a, 110b can be used together in different applications and, in addition, multiple filters can be installed into the system illustrated in figure 1 to support the function of the said two filters 110a, 110b. This enables an effective filtering system for the purification system 102.
  • the installation of the filters 110a, 110b, and application of alternative solutions to provide an efficient filtering in the purification system 102, is readily apparent to a person skilled in the art from reading the appended examples of the present disclosure.
  • the detection unit 106 is preferably provided in the front side of the control valve 108.
  • the control valve 108 can be switched either in the direction A or B.
  • the control valve 108 like e.g. a 3-way valve, is preferably equipped with an actuator, which enables an automatic and remote control.
  • the control valve 108 is in principle switched in the direction A, and in case the detection unit 106 observes a removable particle in the fluid, the valve 108 will be switched in the direction B, whereby the fluid will be conducted into the by-pass channel 114.
  • the conduction of the fluid into the by-pass channel 114 is preset so, that an adequate volume of the fluid containing the detected removable particle will be conducted into the by-pass channel 114.
  • the switching time of the control valve 108 in the direction B can be preset e.g. on the basis of the flow rate of the fluid and the distance between the detection unit 106 and control valve 108.
  • a delay can be preset into the control system, which is activated before the switch of the control valve 108 in the direction B is initiated. By this delay, an extra flow of the fluid into the by-pass channel 114 can be prevented.
  • the guidance of the control valve 108 can be fully automatic.
  • the purification system 102 can be equipped with e.g. flow sensors, which transmit information about the flow rate to the control system. Using flow sensors in the purification system is especially preferred, if the flow rate of the fluid varies.
  • the distance between the detection unit 106 and control valve 108 can be verified also by using appropriate measuring and/or localization means.
  • Different embodiments can also be provided, which include multiple detection units 106, control valves 108, filters 110a, 110b, and/or by-pass channel 114 in a series and/or parallel fashion such, that the particle is possible to be detected several times and that the fluid can be recycled several times via the by-pass channel 114 and through the filters 110a and 110b, as shown in figure 1.
  • the detection unit used in the purification system is preferably equipped with a machine vision, which can detect small 3 ⁇ particles, larger particles of over 100 ⁇ , which are indicative of a machine breakdown, and even larger, over 150 ⁇ particles, which are indicative of more serious machine breakdown.
  • the machine vision comprises a light source, a (video)camera and a com-puter, which is additionally equipped with an image-processing program.
  • Present high- speed cameras can record over 1000 frames/s, in more advanced applications even over million frames/s, if necessary. These applications can detect particles of appropriate sizes, forms and quantities.
  • detection technique(s) like Hall-sensors, optical fiber sensors and/or magnetic field, can be used in the detection unit of the purification system.
  • FIG. 2 shows another embodiment of the purification system according to the present invention.
  • a sampling unit 216 is provided with the purification system 202.
  • the purification system 202 comprises the first detection unit 206a. Based on the measures provided by the first detection unit 206a, the fluid is conducted from the valve 208a in the direction B for sampling 216.
  • the detection unit 206a can also be omitted in some applications, and the sampling can be carried out e.g. in a preset and/or manual fashion in such way, that the guidance of the valve 208a, e.g. 3-way valve, is carried out in a preset and/or manual fashion.
  • a small aliquot of fluid is taken for the sampling 216.
  • the sampling 216 can com- prise e.g. one or more sampling bottle(s).
  • the purification system 202 can comprise its own means for the analysis of the fluid, or the sample can be send e.g. into a laboratory for further studies.
  • the filters 210a, 210b shown in figure 2 reflect the two appropriate locations for the filters.
  • the location of the filter 210a is beneficial, because when the flowing fluid leaves the first control valve 208a, it will always flow through the filter 210a, whereby impurities can possible be separated from the fluid, before it enters to the second detection unit 206b or the second control valve 208b.
  • the second control valve 208b e.g. a 3-way valve so, that the fluid is able to flow directly back to the site of application 204, i.e. in the direction A.
  • the filter 210a is preferentially located in front of the by-pass channel 214.
  • the second detection unit 206b observes a removable particle in the fluid and the fluid is conducted into the bypass channel 214, it will flow through the filter 210a and the particle could be separated from the fluid before it enters the second detection unit 206b and control valve 208b.
  • the filter 210b will not affect per se to the flow of the fluid, when the fluid leaves from the first valve 208a.
  • the flow will stay constant and if a removable particle is detected, the fluid can still be conducted from the second valve 208b into the by-pass channel 214, wherein the filter 210b is located. Then, by the aid of the said filter 210b, the particle can be separated from the fluid.
  • the purification system 202 of the present invention shows only two appropriate locations for the filters 210a, 210b.
  • the filters 210a, 210b can be used together in different applications and, in addition, multiple filters can be installed into the system illustrated in figure 2 to support the function of the said two filters 210a, 210b. This enables an effective filtering system for the purification system 202. Installation of the filters 210a, 210b, and application of alternative solutions to pro- vide an efficient filtering in the purification system 202, is readily apparent to a person skilled in the art from reading the appended examples of the present disclosure.
  • the second detection unit 206b is preferably pro- vided in the front side of the control valve 208b.
  • the control valve 208b can be switched either in the direction A or B.
  • the control valve 208b is preferably equipped with an actuator, which enables an automatic and remote control.
  • the control valve 208b is in principle switched in the direction A, and in case the detection unit 206b observes a removable particle in the fluid, the control valve 208b will be switched in the direction B, whereby the fluid will be conducted into the by-pass channel 214.
  • the conduction of the fluid into the by-pass channel 214 is preset so, that an adequate volume of the fluid containing the detected remov- able particle will be conducted into the by-pass channel 214.
  • the switching time of the control valve 208b in the direction B can be preset e.g. on the basis of the flow rate of the fluid and the distance between the detection unit 206b and control valve 208b.
  • a delay can be preset to the control system, which is activated before the switch of the control valve 208b in the direction B is initiat- ed. By this delay, an extra flow of the fluid into the by-pass channel 214 can be prevented.
  • Different embodiments can also be provided, which include multiple detection units 206a, 206b, valves 208a, 208b, filters 210a, 210b, and/or by-pass channels 214 connected in a series and/or parallel fashion such, that the particle is possible to be detected several times and that the fluid can be recycled several times via the by-pass channel 214 and through the filters 210a and 210b, as shown in figure 2.
  • purification system 202 can be provided with flow sensors to detect the flow rate, and the control system is preferably able to automatically control the switching time of the valve 208b in the direction B, and also the possi- ble delay before the switch in such way, that an appropriate volume of the fluid including the removable particle is conducted into the by-pass channel 214.
  • the purification system comprises an alarm system.
  • an alert can be executed, e.g. when the system has completed sampling, and/or when the detection unit has observed particles having predetermined size, form and/or quantity.
  • the alert can be carried out by a visual and/or sound signal.
  • Figure 3 shows a flow chart according to one embodiment of the system of the present invention for the purification of flowing fluid.
  • the purification system will be connected to the site of application by using appropriate methods.
  • the purification system is connected by interfaces to the pipeline of the site of application.
  • step 304 the flowing fluid leaves the site of application and flows into the purification system.
  • the fluid flows into the purification system e.g. via the pipes and/or tubes provided.
  • step 306 the fluid flows at least through one filter.
  • filters are installed so, that the fluid does not straightaway flow through them upon coming from the site of application.
  • the purpose of the fil- ters is to separate foreign particles from the fluid and thus to prevent their flow onwards in the system.
  • step 308 the fluid flows through the detection unit.
  • the said detection unit monitors the flowing fluid and transmits information to the control system, if the fluid comprises particles not belonging thereto.
  • the detectable particles to be removed can vary e.g. according to their size, form and quantity.
  • step 310 if the fluid includes any removable particles, the control system switches the control valve of the present purification system in such way, that the fluid is conducted into the by-pass channel.
  • the fluid recycles to step 306 and during the circulation, it will pass through at least one filter. If no removable particles exist, the fluid will flow from the control valve onwards to the site of application.
  • step 312 the fluid leaves the purification system and enters back to the site of application.
  • Step 314 illustrates the end of the circulation of the flowing fluid in the purification system according to the present invention.
  • Figure 4 shows a flow chart according to another embodiment of the system of the present invention for the purification of flowing fluid.
  • the purification system will be connected to the site of application by using appropriate methods.
  • the purification system is connected by interfaces to the pipeline of the site of application.
  • step 404 the flowing fluid leaves the site of application and flows into the purification system.
  • the fluid flows into the purification system e.g. via the pipes and/or tubes provided.
  • step 406 the fluid flows through the detection unit.
  • the said detection unit monitors the flowing fluid and transmits information to the control system, if the fluid comprises particles not belonging thereto.
  • the detectable particles can vary e.g. according to their size, form and quantity.
  • This step is optional, since based on the information transmitted via the detection unit, a sample can be taken at steps 408, 410, but the sampling can also be carried out in a manual or preset fashion, whereby the detection unit and step 406 are not necessary.
  • step 408 if the fluid is sampled, an aliquot of the fluid will be conducted from the valve to the sampling step 410. For sampling, only an appropriate volume of fluid is taken, where after the valve is switched back and the fluid will flow to step 412.
  • the fluid Without sampling the fluid flows directly from the valve to step 412.
  • the fluid optionally flows at least through one filter.
  • filters are installed so, that the fluid does not straightaway flow through them upon coming from step 410.
  • the purpose of the filters is to separate foreign particles from the fluid and thus prevent their flow onwards in the system.
  • the fluid flows through the detection unit.
  • the said detection unit monitors the flowing fluid and transmits information to the control system, if the fluid comprises particles not belonging thereto.
  • the detectable particles can vary e.g. according to their size, form and quantity.
  • step 416 if the fluid includes any removable particles, the control system switches the control valve of the present purification system in such way, that the fluid is conducted into the by-pass channel.
  • the fluid recycles to step 306 and during the circulation, it will pass through at least one filter. If no removable particles exist, the fluid will flow from the control valve onwards to the site of application.
  • step 418 the fluid leaves the purification system and enters back to the site of application.
  • Step 420 illustrates the end of the circulation of the flowing fluid in the purification system according to the present invention.

Abstract

The present invention provides a purification system (102) for the purification of flowing fluid. The present invention enables detection and removing of particles from flowing fluid in a real-time fashion. The purification system according to the present invention comprises means for transferring the fluid, detection unit (106) for detecting particles in the fluid, control valve (108) for conducting the fluid into the by-pass channel (1 14) or to the site of application (104), at least one filter (1 10a, b) for separating particles from the fluid, and control system. The detection unit (106), control valve (108), filter (1 10a, b) and control system of the purification system cooperate functionally so, that the control system, based on the measures provided by the detection unit (106), guides the control valve (108) in such way, that once the removable particle is observed, an adequate volume of fluid containing the removable particle, will be conducted to the circulation (B) via the detection unit (106) and back to the control valve (108). The circulation includes at least one filter (1 10b) for separating the said particle from the fluid.

Description

SYSTEM AND METHOD FOR THE PURIFICATION OF FLOWING FLUID
Technical Field The present invention provides a system and method for the purification of flowing fluid. Especially, the invention provides a purification system and purification method, which detects and removes particular material from the flowing fluid in a real-time fashion. Background of the Invention
Several applications have been designed to purify flowing fluids. Especially in manufacturing field, a need for the purification of particular lubricants used in machine tools has been widely noticed, and as a consequent, several systems to maintain the purity of lubricants have been developed. However, there are some drawbacks in the systems used at present.
The use of a mechanical device naturally causes erosion of the machine parts, which in turn results to the ablation of small particles, which get mixed into the fluid flowing through the systems. Many machine tools use perfusing fluid as a lubricant to minimize friction between machine parts and to prevent erosion, thus prolonging working life of the device. Flowing fluid can also be used for other purposes, like in hydraulic systems, wherein the main purpose of the fluid is to serve as a force mediator. Particular materials mixed into flowing fluid have an ef- feet on the quality of the flowing fluid as well as on the erosion of the machine, and they can indicate a machine breakdown. Studies show, that the smallest particles (less than 100 μηι) have an effect on the quality of the fluid, and in turn larger particles (over 100 μιτι) will wear out machine parts, and their existence can be indicative of a machine breakdown. A longer-lasting increase of the impu- rities in flowing fluid causes serious problems within the machine and eventually leads to its breakdown.
Methods of the prior art for maintaining fluid purity are based mainly on particular filtering systems and sampling methods. Filtering systems comprise different amounts and types of filters, which are intended to arrest impurities flowing in the fluid. However, the said filtering systems include some drawbacks. The more dense the structure is, the more smaller particles it will catch, but simultaneously it will impair the fluid flow. Over time, the filters will also be corroded and obstructed, which means that their operational function will be declined and that they have to be changed or purified at regular intervals. Due to the difficulty to assess the operational function of the filters, they are not alone a feasible solution for maintaining the purity of the flowing fluid.
Present sampling methods are based on the fact, that a small sample will be tak- en at predetermined intervals from the flowing fluid, which is then analyzed e.g. by laboratory methods or in industry plants by their own particle counters. Depending on the method, this process takes few days to several months, during which the machines can already have built up serious damages. Thus, by using present sampling methods, proactive welfare measures for the machines are ab- solutely impossible to implement. In addition to the long delay, also the small quantity of samples used in analysis weakens its reliability. As a result, this will not necessarily give a correct view of impurities present in the flowing fluid.
Moreover, particle counters used in industrial environment detect only small par- tides. Further, in laboratory analyses only the purity of the oil are analysed, and the condition of the machine itself is not considered. These analyses do not consider large particles, which indicate machine breakdown. So, with presently used systems and methods it is difficult to execute a vehicle-based maintenance control.
Summary of the Invention
The object of the present invention is to solve the above-described problems or at least to diminish their consequences. Particularly, the present invention aims to provide a system, which can be easily installed to several sites of applications, and which is able to detect and remove particles of different sizes, forms and quantities from the flowing fluid in a real-time fashion.
The objectives of the invention will be accomplished as defined in the independ- ent claims.
The characteristics of the purification system of the present invention are defined in the characterizing part of the independent claim 1. The characteristics of the purification system of the present invention are defined in the characterizing part of the independent claim 6.
Some preferred embodiments of the invention are defined in dependent claims.
According to one embodiment, the purification system of the invention comprises - a detection unit for the detection of a particle in the flowing fluid,
- a control valve, which comprises at least one inlet and two outlets for the conduction of the fluid to the site of application or into the by-pass channel,
- a by-pass channel for the conduction of the fluid through at least one filter, - at least one filter for the separation of the particle from the flowing fluid, and
- a control system, wherein the detection unit, control valve, by-pass channel, filter and control system cooperate functionally so, that the control system switches the control valve based on the measures provided by the detection unit in such way, that once a removable particle is detected, an adequate volume of fluid containing the said removable particle will flow into the by-pass channel, via the detection unit and back to the control valve, whereby the filter between the control valve and detection unit will separate the particle from the fluid.
According to one embodiment of the invention, the system is connected to the site of application by pipelines and/or flexible tubes and appropriate interfaces. The site of application comprises the flowing fluid to be purified, e.g. a lubricant flowing through machine tools.
According to one embodiment of the invention, the fluid leaving the site of application flows via the detection unit to the control valve. From the control valve, either the fluid enters back to the site of application or it will be conducted into the by-pass channel, via the detection unit and back to the control valve. In between the control valve and detection unit there is at least one filter, through which the fluid flows when entering back to the control valve via the detection unit. Thereafter, either the fluid flows again from the control valve to the site of application or it will be conducted into the by-pass channel. The flowing fluid can be recycled till all removable particles have been separated from the said fluid.
According to one embodiment of the invention, the guidance of the control valve is provided by an automatic control system. Based on the measures provided by the detection unit, the control system will guide the valve. According to one embodiment, the valve is switched in such way, that the fluid will by default flow back to the site of application, but in case the detection unit observes a removable particle, the control system will turn the flow into the by-pass channel by the aid of the control valve.
According to one embodiment, the guidance can be provided e.g. by using auto- matic control system, wherein, based on the flow rate of the fluid and the dis- tance between the detection unit and control valve, and alternatively after a certain delay, the fluid is conducted for a certain time into the by-pass channel. Based on the flow rate and the distance between the detection unit and control valve, a timespan, and in addition alternatively a certain delay, will be preset, which are needed to conduct the particle/particles into the by-pass channel.
According to one embodiment of the invention, particles in the flowing fluid can be determined e.g. based on their form, size and/or quantity. The particles can be determined/calibrated according to needs of the site of application. As and when necessary, and based on the detection method used, even particles having a size of 3 μητι can be observed. To maintain the quality of the flowing fluid, the system can detect smaller particles, which are preferably 3 - 100 μητι in size. Maintenance control of a device, e.g. machine tool, can be carried out by adjusting the system to detect larger particles of over 100 μητι, and also even larger, over 150 μηι parti- cles, which are indicative of more serious machine breakdowns. According to the site of application, the system can be adjusted to detect particles of all sizes, from small 3 μηη particles to particles of over 100 μιτι and also particles over 150 μιη.
The detection unit used in the system preferably comprises an imaging technique based on machine vision, but additionally or alternatively other detection technique^) can be used, like Hall-sensors, optical fiber sensors and/or magnetic field. In general, the machine vision comprises a light source, a (video)camera and a computer. The said computer is generally equipped with an image-processing program, which can interprete images automatically. Present high-speed cameras enable a very fast and accurate imaging. The record rate in convalveional applications is appr. 1000 frames/s, in more advanced applications even over million frames/s, if necessary.
According to one embodiment of the invention, the system comprises in addition sampling.
According to one embodiment of the invention, the fluid leaving the site of application flows via the first detection unit of the present system to the first control valve. From the first control valve, either the fluid is conducted into the sampling bottles or it will go on through the filter and via the second detection unit to the second control valve. Sampling can be carried out e.g. based on the measures provided by the detection unit, by a preset and/or manual fashion. The embodiments, wherein the sampling is carried out only by a preset and/or manual fashion, can alternatively be executed without the first detection unit. From the sec- ond control valve, either the fluid enters back to the site of application or it will be conducted into the by-pass channel via the second detection unit and back to the second control valve. In between the second control valve and detection unit there is at least one filter, through which the fluid flows when it enters back to the second control valve via the detection unit. Thereafter, either the fluid flows from the second control valve to the site of application or it will be conducted into the by-pass channel. The fluid can be recycled till all removable particles have been separated from the said fluid.
According to one embodiment of the invention, the system comprises an alarm system. In this alarm system, the alert can be executed e.g. by a sound and/or visual signal. The alert can be initiated e.g. based on the measures provided by the detection unit using predetermined size, form and/or quantity of the particles. In addition, or alternatively, the alert can be executed, when the system has completed sampling. The alert can also be indicative of a failure in the system and/or site of application.
According to one embodiment of the invention, the flowing fluid to be purified is oil or water. The flowing fluid can also be e.g. a lubricant, which consists at least partly of oil.
In general, feasible valve applications appropriate for the present system are valves, which comprise at least one inlet and at least two outlets. One feasible solution is to use 3-way valves, which allow the flow of the fluid from one inlet to one outlet all at once. In cases, where a removable particle is detected and/or during the sampling, the fluid is conducted to the second outlet, whereby the flow into the first outlet is prevented. The valve is automatically controlled by connecting therein an actuator, which executes the inlet-outlet-switching of the valve according to the guidance of the control system. The actuator of the valve can be e.g. an electric motor or a solenoid. This system provides automatic high- speed reactive valve applications, which enable a real-time conduction of the fluid into the purification system of the present invention. Also, a valve including multiple inlets and outlets, like a 4-way valve, can be used, if necessary.
According to another embodiment of the invention, the method for the purifica- tion of flowing fluid comprises at least steps of:
- transferring the fluid to be purified from the site of application into the purification system,
- transferring the fluid through the detection unit,
- detecting particles possible existing in the fluid by the detection unit, - transferring the fluid to the control valve, wherein the fluid is, based on the observation of particles, either conducted to the site of application or into the bypass channel at least through one filter, via the detection unit and back into the control valve.
The usefulness of the purification system of the present invention is based on several facts. This system enables the detection of particles having a wide scale of sizes, quantities and/or forms. This system can be automatized to detect and remove particles from the flowing fluid in a real-time fashion.
The present system provides means to monitor the state of an operating unit, like a machine tool, in a real-time fashion. This makes it possible to intervene in failures and problems immediately they become apparent. In addition, the system is easy to be installed and can be applied in several sites of applications. According to one embodiment, a pipe-to-pipe installation is very simple to integrate to several sites of applications.
In addition, the flexibility of the system with respect to single components and sub-assemblies enables economical production, and further contributes its use and installation in several sites of applications.
In this application, the term "site of application" denotes a device, machine and/or system, which comprises flowing fluid to be purified, e.g. a machine tool and its lubricant.
Brief Description of the Drawings
Next, the preferred embodiments of the invention are described in more detail with reference to the accompanying drawings, wherein:
Figure 1 shows a purification system according to one embodiment of the present invention, Figure 2 shows a purification system according to another embodiment of the present invention,
Figure 3 is a flow chart of one embodiment, which shows the method of the present invention for removing a particle from the flowing fluid, and Figure 4 is a flow chart of another embodiment, which shows the method of the present invention for removing a particle from the flowing fluid.
Detailed Description of the Preferred Embodiments
Figure 1 shows one embodiment of the purification system according to the present invention. The system 102 for the purification of flowing fluid comprises detection unit 106, control valve 108, at least one filter 110a, 110b, and means 112, e.g. pipes and/or tubes, for transferring the flowing fluid. The system 102 is pro- vided in the site of application 104 in such way, that the fluid to be purified used in the site of applicationl04 is able to flow into the purification system 102 in the direction of V shown in figure 1. In different embodiments, the purification system 102 is provided by appropriate direct pipe-to-pipe-installations to the site of application 104.
The filters 110a, 110b shown in figure 1 reflect the two appropriate locations for the filters. The location of the filter 110a is beneficial, because when the flowing fluid leaves the site of application 104, it will always flow through the filter 110a, whereby impurities can possible be separated from the fluid, before it enters to the detection unit 106 or control valve 108. Thus, it may be possible to minimize the guidance of the control valve 108 so, that the fluid is able to flow directly back to the site of application 104, i.e. in the direction A. Additionally, the filter 110a is preferentially located in front of the site of application 114. This means, that if the detection unit 106 observes a removable particle in the fluid and the fluid is con- ducted into the site of application 114, it will flow through the filter 110a and the particle could be separated from the fluid before it flows through the detection unit 106 and control valve 108. On the other hand, by installing the filter 110b into the by-pass channel 114, the filter will not affect per se to the flow of the fluid, when the fluid leaves the site of application 104. Thus, the flow will stay constant and if a removable particle is detected, the fluid can still be conducted from the valve 108 into the by-pass channel 114, wherein the filter 110b is located. Then, by the aid of the said filter 110b, the particle can be separated from the fluid.
The purification system 102 of the present invention shows only two appropriate locations for the filters 110a, 110b. The filters 110a, 110b can be used together in different applications and, in addition, multiple filters can be installed into the system illustrated in figure 1 to support the function of the said two filters 110a, 110b. This enables an effective filtering system for the purification system 102. The installation of the filters 110a, 110b, and application of alternative solutions to provide an efficient filtering in the purification system 102, is readily apparent to a person skilled in the art from reading the appended examples of the present disclosure.
In the purification system 102, the detection unit 106 is preferably provided in the front side of the control valve 108. When the fluid flows through the detection unit 106, information is transmitted to the control system provided in the system. By the aid of the control system, the control valve 108 can be switched either in the direction A or B. The control valve 108, like e.g. a 3-way valve, is preferably equipped with an actuator, which enables an automatic and remote control. The control valve 108 is in principle switched in the direction A, and in case the detection unit 106 observes a removable particle in the fluid, the valve 108 will be switched in the direction B, whereby the fluid will be conducted into the by-pass channel 114. The conduction of the fluid into the by-pass channel 114 is preset so, that an adequate volume of the fluid containing the detected removable particle will be conducted into the by-pass channel 114. The switching time of the control valve 108 in the direction B can be preset e.g. on the basis of the flow rate of the fluid and the distance between the detection unit 106 and control valve 108. In addition, a delay can be preset into the control system, which is activated before the switch of the control valve 108 in the direction B is initiated. By this delay, an extra flow of the fluid into the by-pass channel 114 can be prevented. The guidance of the control valve 108 can be fully automatic. The purification system 102 can be equipped with e.g. flow sensors, which transmit information about the flow rate to the control system. Using flow sensors in the purification system is especially preferred, if the flow rate of the fluid varies. The distance between the detection unit 106 and control valve 108 can be verified also by using appropriate measuring and/or localization means.
Different embodiments can also be provided, which include multiple detection units 106, control valves 108, filters 110a, 110b, and/or by-pass channel 114 in a series and/or parallel fashion such, that the particle is possible to be detected several times and that the fluid can be recycled several times via the by-pass channel 114 and through the filters 110a and 110b, as shown in figure 1.
The detection unit used in the purification system is preferably equipped with a machine vision, which can detect small 3 μητι particles, larger particles of over 100 μητι, which are indicative of a machine breakdown, and even larger, over 150 μιη particles, which are indicative of more serious machine breakdown. In gen-eral, the machine vision comprises a light source, a (video)camera and a com-puter, which is additionally equipped with an image-processing program. Present high- speed cameras can record over 1000 frames/s, in more advanced applications even over million frames/s, if necessary. These applications can detect particles of appropriate sizes, forms and quantities.
Additionally or alternatively, also other detection technique(s), like Hall-sensors, optical fiber sensors and/or magnetic field, can be used in the detection unit of the purification system.
Figure 2 shows another embodiment of the purification system according to the present invention. Therein, a sampling unit 216 is provided with the purification system 202.
The fluid leaves the site of application 204 in the direction V. In one application, the purification system 202 comprises the first detection unit 206a. Based on the measures provided by the first detection unit 206a, the fluid is conducted from the valve 208a in the direction B for sampling 216. The detection unit 206a can also be omitted in some applications, and the sampling can be carried out e.g. in a preset and/or manual fashion in such way, that the guidance of the valve 208a, e.g. 3-way valve, is carried out in a preset and/or manual fashion. Preferably, a small aliquot of fluid is taken for the sampling 216. The sampling 216 can com- prise e.g. one or more sampling bottle(s). During the sampling 216 the purification system 202 can comprise its own means for the analysis of the fluid, or the sample can be send e.g. into a laboratory for further studies.
The filters 210a, 210b shown in figure 2 reflect the two appropriate locations for the filters. The location of the filter 210a is beneficial, because when the flowing fluid leaves the first control valve 208a, it will always flow through the filter 210a, whereby impurities can possible be separated from the fluid, before it enters to the second detection unit 206b or the second control valve 208b. Thus, it may be possible to minimize the guidance of the second control valve 208b, e.g. a 3-way valve so, that the fluid is able to flow directly back to the site of application 204, i.e. in the direction A. Additionally, the filter 210a is preferentially located in front of the by-pass channel 214. This means, that if the second detection unit 206b observes a removable particle in the fluid and the fluid is conducted into the bypass channel 214, it will flow through the filter 210a and the particle could be separated from the fluid before it enters the second detection unit 206b and control valve 208b. On the other hand, by installing the filter 210b into the by-pass channel 214, the filter 210b will not affect per se to the flow of the fluid, when the fluid leaves from the first valve 208a. Thus, the flow will stay constant and if a removable particle is detected, the fluid can still be conducted from the second valve 208b into the by-pass channel 214, wherein the filter 210b is located. Then, by the aid of the said filter 210b, the particle can be separated from the fluid.
The purification system 202 of the present invention shows only two appropriate locations for the filters 210a, 210b. The filters 210a, 210b can be used together in different applications and, in addition, multiple filters can be installed into the system illustrated in figure 2 to support the function of the said two filters 210a, 210b. This enables an effective filtering system for the purification system 202. Installation of the filters 210a, 210b, and application of alternative solutions to pro- vide an efficient filtering in the purification system 202, is readily apparent to a person skilled in the art from reading the appended examples of the present disclosure.
In the purification system 202, the second detection unit 206b is preferably pro- vided in the front side of the control valve 208b. When the fluid flows through the detection unit 206b, information is transmitted to the control system provided in the system. By the aid of the control system, the control valve 208b can be switched either in the direction A or B. The control valve 208b is preferably equipped with an actuator, which enables an automatic and remote control. The control valve 208b is in principle switched in the direction A, and in case the detection unit 206b observes a removable particle in the fluid, the control valve 208b will be switched in the direction B, whereby the fluid will be conducted into the by-pass channel 214. The conduction of the fluid into the by-pass channel 214 is preset so, that an adequate volume of the fluid containing the detected remov- able particle will be conducted into the by-pass channel 214. The switching time of the control valve 208b in the direction B can be preset e.g. on the basis of the flow rate of the fluid and the distance between the detection unit 206b and control valve 208b. In addition, a delay can be preset to the control system, which is activated before the switch of the control valve 208b in the direction B is initiat- ed. By this delay, an extra flow of the fluid into the by-pass channel 214 can be prevented.
Different embodiments can also be provided, which include multiple detection units 206a, 206b, valves 208a, 208b, filters 210a, 210b, and/or by-pass channels 214 connected in a series and/or parallel fashion such, that the particle is possible to be detected several times and that the fluid can be recycled several times via the by-pass channel 214 and through the filters 210a and 210b, as shown in figure 2. Additionally, purification system 202 can be provided with flow sensors to detect the flow rate, and the control system is preferably able to automatically control the switching time of the valve 208b in the direction B, and also the possi- ble delay before the switch in such way, that an appropriate volume of the fluid including the removable particle is conducted into the by-pass channel 214.
The detection units 206a, 206b and valves 208a, 208b preferably used in the puri- fication system 202, are presented above. Different applications may use the same or alternatively a different detection technique in units 206a and 206b. With respect to the valves 208a and 208b, it is also possible to use the same or alternatively divergent solutions, which still are feasible for the purification system. According to one embodiment, the purification system comprises an alarm system. In this alarm system an alert can be executed, e.g. when the system has completed sampling, and/or when the detection unit has observed particles having predetermined size, form and/or quantity. The alert can be carried out by a visual and/or sound signal.
Figure 3 shows a flow chart according to one embodiment of the system of the present invention for the purification of flowing fluid.
In step 302, the purification system will be connected to the site of application by using appropriate methods. In one feasible application, the purification system is connected by interfaces to the pipeline of the site of application.
In step 304, the flowing fluid leaves the site of application and flows into the purification system. The fluid flows into the purification system e.g. via the pipes and/or tubes provided.
In step 306, the fluid flows at least through one filter. However, in some applications filters are installed so, that the fluid does not straightaway flow through them upon coming from the site of application. In general, the purpose of the fil- ters is to separate foreign particles from the fluid and thus to prevent their flow onwards in the system.
In step 308, the fluid flows through the detection unit. The said detection unit monitors the flowing fluid and transmits information to the control system, if the fluid comprises particles not belonging thereto. The detectable particles to be removed can vary e.g. according to their size, form and quantity.
In step 310, if the fluid includes any removable particles, the control system switches the control valve of the present purification system in such way, that the fluid is conducted into the by-pass channel. Thus, the fluid recycles to step 306 and during the circulation, it will pass through at least one filter. If no removable particles exist, the fluid will flow from the control valve onwards to the site of application. In step 312, the fluid leaves the purification system and enters back to the site of application.
Step 314 illustrates the end of the circulation of the flowing fluid in the purification system according to the present invention.
Figure 4 shows a flow chart according to another embodiment of the system of the present invention for the purification of flowing fluid.
In step 402, the purification system will be connected to the site of application by using appropriate methods. In one feasible application, the purification system is connected by interfaces to the pipeline of the site of application.
In step 404, the flowing fluid leaves the site of application and flows into the purification system. The fluid flows into the purification system e.g. via the pipes and/or tubes provided.
In step 406, the fluid flows through the detection unit. The said detection unit monitors the flowing fluid and transmits information to the control system, if the fluid comprises particles not belonging thereto. The detectable particles can vary e.g. according to their size, form and quantity. This step is optional, since based on the information transmitted via the detection unit, a sample can be taken at steps 408, 410, but the sampling can also be carried out in a manual or preset fashion, whereby the detection unit and step 406 are not necessary. In step 408, if the fluid is sampled, an aliquot of the fluid will be conducted from the valve to the sampling step 410. For sampling, only an appropriate volume of fluid is taken, where after the valve is switched back and the fluid will flow to step 412. Without sampling the fluid flows directly from the valve to step 412. In step 412, the fluid optionally flows at least through one filter. However, in some applications filters are installed so, that the fluid does not straightaway flow through them upon coming from step 410. In general, the purpose of the filters is to separate foreign particles from the fluid and thus prevent their flow onwards in the system. In step 414, the fluid flows through the detection unit. The said detection unit monitors the flowing fluid and transmits information to the control system, if the fluid comprises particles not belonging thereto. The detectable particles can vary e.g. according to their size, form and quantity.
In step 416, if the fluid includes any removable particles, the control system switches the control valve of the present purification system in such way, that the fluid is conducted into the by-pass channel. Thus, the fluid recycles to step 306 and during the circulation, it will pass through at least one filter. If no removable particles exist, the fluid will flow from the control valve onwards to the site of application.
In step 418, the fluid leaves the purification system and enters back to the site of application.
Step 420 illustrates the end of the circulation of the flowing fluid in the purification system according to the present invention.
Only some embodiments of the discoveries according to the present invention are set forth above. It will, however, be readily apparent to a skilled artisan, that the principle of the disclosed invention can be varied within the scope of the appended claims, e.g. with respect to different particulars and applications.

Claims

Claims
1. A purification system (102) for removing a particle from flowing fluid, wherein the purification system (102) comprises
- a detection unit (106) for the detection of a particle in flowing fluid,
- a control valve (108), wherein the control valve (108) comprises at least one inlet and two outlets (A, B), for the conduction of the fluid to a site of application (104) or into a by-pass channel (114),
- a by-pass channel (114) for the conduction of the fluid through at least one filter (110a, 110b),
- at least one filter (110a, 110b) for the separation of the particle from the flowing fluid, and
- a control system, wherein the detection unit (106), control valve (108), by-pass channel (114), filter (110a, 110b) and control system cooperate functionally so, that the control system, based on the measures provided by the detection unit (106), switches the control valve (108) in such way, that once the removable particle is detected, an adequate volume of fluid containing the removable particle, will flow into the by- pass channel (114), via the detection unit (106) and back to the control valve (108), wherein the filter (110a, 110b) has been installed between the control valve (108) and detection unit (106) to separate the particle from the fluid.
2. The purification system according to claim 1, wherein the purification system comprises at least one flow sensor for measuring the fluid flow rate, and which flow sensor transmits the measured information to the control system to guide the control valve.
3. The purification system of any of the preceding claims, wherein the puri- fication system comprises an alarm system, which indicates an actualized event, like a sampling in the purification system, detection of particles of certain sizes, forms and/or quantities observed by the detection unit, and/or a failure detected in the purification system, e.g. by a visual or sound signal.
4. The purification system of any of the preceding claims, wherein a machine vision is used in the detection unit.
5. The purification system of any of the preceding claims, wherein the purification system comprises another control valve, which can conduct the flowing fluid into the sampling unit.
6. A method for the purification of flowing fluid, comprising at least the steps of:
- transferring the fluid to be purified from the site of application into the purification system,
- transferring the fluid through the detection unit,
- detecting particles possibly existing in the fluid by the detection unit,
- transferring the fluid to the control valve, wherein the fluid is, based on the observation of particles, either conducted to the site of application or into the bypass channel at least through one filter, via the detection unit and back into the control valve.
PCT/FI2013/050868 2012-10-10 2013-09-09 System and method for the purification of flowing fluid WO2014057163A1 (en)

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