DETECTION DEVICE FOR A CLEANING SYSYTEM

Abstract

The present disclosure describes embodiments of a detection device for a cleaning system used in heat exchange systems which comprise a plurality of tubes. The detection device comprises a mounting plate defining a plurality of perforations and a plurality of sensors. Each sensor is being coupled to at least one perforation. In many embodiments of this disclosure, each of the plurality of tubes is operable with a corresponding one of the sensors and during a cleaning process where cleaning balls passage through the plurality of tubes, the cleaning balls are detected by a corresponding one of the sensors.

Description

FIELD OF INVENTION

The present invention relates generally to a detection device for a cleaning system for use with heat exchangers for cleaning thereof.

BACKGROUND

Heat exchange systems are used in various industries for a wide variety of applications such as for heating ventilation and air-conditioning (HVAC) installations. A heat exchange system is an apparatus for facilitating heat transfer from one medium to another. A tubular heat exchange system is an example of a heat exchange system involving a series of tubes for the heat exchange process and for such installations, fluid is circulated through the heat exchange system for heat exchange to occur at a bundle of tubes. To achieve optimal heat exchange efficiency, any debris and fouling deposits accumulated at the bundle of tubes must be totally or substantially removed. Taking the heat exchange system off-line for physical flushing is not only ineffective but also disallow use of the heat exchange system for the duration it remains off-line.

As such, new cleaning systems for use in conjunction with the heat exchange systems use cleaning balls transported by fluid to be fed and circulated in the heat exchange system. When the cleaning balls passage through the bundle of tubes during circulation in the heat exchange system, any debris or fouling deposits in the bundle of tubes are pushed out. The cleaning balls are then subsequently retrieved by the cleaning system. An example of such cleaning system for use with a plurality of tubes of a heat exchange system comprises a displacement system having a first port and a second port, a manifold defining a first chamber and a second chamber, a flow diverting system and at least one cleaning ball. The at least one cleaning ball is configured to passage through the plurality of tubes of the heat exchange system for cleaning thereof.

However, the cleaning systems described above have no means for ensuring and tracking which particular tubes of the plurality of tubes have been cleaned. This may result in some tubes not being cleaned and some tubes being cleaned for unnecessary number of times and thus, compromising on the efficiency of the cleaning system.

Therefore, there is a need for a device or apparatus for addressing the foregoing problems.

SUMMARY

One of the objects of certain exemplary aspects of the present disclosure is to address the aforementioned exemplary problems and/or to overcome the exemplary deficiencies commonly associated with the prior art as described herein. Accordingly, for example, provided and described herein are certain exemplary embodiments of exemplary apparatus, system and method according to the present disclosure which can be used for detecting cleaning balls.

According to one aspect of the invention, there is provided a detection device for use with a heat exchanger having a plurality of tubes. The device comprises a mounting plate couplable to the plurality of tubes. The mounting plate defining a plurality of perforations and the plurality of perforations aligned with the plurality of tubes. The plurality of perforations being shaped and dimensioned to facilitate passage of at least one of a plurality of cleaning balls therethrough. The device further comprises a plurality of sensors and each sensor of the plurality of sensors being coupled to at least one of the plurality of perforations. Each of the plurality of tubes is operable with a corresponding one of the plurality of sensors and when the plurality of cleaning balls is introduced into a portion of the heat exchanger for passage through the plurality of tubes for cleaning thereof, each cleaning ball passaging through one of the plurality of tubes is detectable by the corresponding one of the plurality of sensors.

The plurality of tubes of the detecting device defines two extremities. The plurality of tubes defines a plurality of inlets at one of and a plurality of outlets at the other of the extremities.

Further, the mounting plate is being shaped and dimensioned for disposing onto one of the extremities of the plurality of tubes.

In another aspect of the invention, there is provided a detection device for use with a heat exchanger having a plurality of tubes. The plurality of tubes being demarcated into a plurality of regions, each of the plurality of regions includes at least one tube. The device comprises a mounting plate couplable to the plurality of tubes. The mounting plate defines a plurality of perforations where each of the plurality of perforations is shaped and dimensioned to facilitate fluid communication with at least one tube of each region. The plurality of perforations shaped and dimensioned to facilitate passage of at least one of a plurality of cleaning balls therethrough. The device further comprises a plurality of sensors and each sensor of the plurality of sensors is being coupled to at least one of the plurality of perforations. Each of the plurality of perforations is operable with a corresponding one of the plurality of sensors and when the plurality of cleaning balls is introduced into a portion of the heat exchanger for passage through the plurality of tubes for cleaning thereof, each cleaning ball passaging through a tube of the plurality of tubes is detectable by the corresponding sensor of the perforation.

The mounting plate of the detection device is formed from at least one of plastic, graphene, rubber and polytetrafluroethylene (PTFE).

The plurality of sensors being coupled to the at least one of the plurality of perforations includes at least one sensor.

The detection device further comprises a manifold. The manifold is couplable to the plurality of sensors for one of receiving detection signals and electronically communicating with the plurality of sensors.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure are described hereinafter with reference to the following drawings, in which:

FIG. 1 is an example of a heat exchanger comprising a plurality of tubes.

FIG. 2A is a detection device comprising a mounting plate defining a plurality of perforations and a plurality of sensors according to some embodiments of the disclosure.

FIG. 2B is a side view of a detection device for use with a heat exchanger according to some embodiments of the disclosure.

FIG. 2C is a detection device being coupled or couplable to a plurality of tubes according to some embodiments of this disclosure.

FIG. 3A is a top view of a detection device for detecting cleaning balls regionally according to some embodiments of the disclosure.

FIG. 3B is a first perforation of a detection device for detecting cleaning balls regionally according to some embodiments of this disclosure.

FIG. 4A is a top view of a detection device which depicts the coupling and positioning of a plurality of sensors according to some embodiments of this disclosure.

FIG. 4B is a side view of a detection device which depicts the coupling and positioning of a plurality of sensors according to some embodiments of this disclosure.

FIG. 5A is a top view of a detection device where a plurality of sensors is coupled on a top side of the mounting plate according to some embodiments of this disclosure.

FIG. 5B is a side view of a detection device where a plurality of sensors is coupled on a top side of the mounting plate according to some embodiments of this disclosure.

FIG. 6 shows a configuration of devices for processing of detection signals.

FIG. 7 is an example of a detection device in operation based upon FTIR according to some embodiments of this disclosure.

DETAILED DESCRIPTION

Representative embodiments of the disclosure for addressing one or more of the foregoing problems associated with conventional cleaning systems for heat exchangers are described hereafter with reference to FIGS. 1 to 7. For purposes of brevity and clarity, the description herein is primarily directed to systems, devices, and techniques for detecting or sensing cleaning balls for cleaning heat exchangers. This, however, does not preclude various embodiments of the disclosure from other applications where fundamental principles prevalent among the various embodiments of the disclosure such as operational, functional, or performance characteristics are required. In the description that follows, like or analogous reference numerals indicate like or analogous elements.

Reference will now be made in detail to an exemplary embodiment of the present invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the embodiment, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of embodiments of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be recognized by one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the embodiments of the present invention

Embodiments of this disclosure are directed to sensing or detection devices which enable, allow or facilitate detection of cleaning balls for cleaning a plurality of tubes of heat exchangers during a cleaning cycle or process. The sensing or detection devices of this disclosure include a mounting plate defining a plurality of perforations and a plurality of sensors couplable to the plurality of perforations. The plurality of sensors being one of coupled to and disposed on the periphery of the plurality of perforations and by doing so, any cleaning balls passaging a tube of the heat exchanger therethrough will be detected by a corresponding sensor. By detecting the presence or passage of the cleaning balls, more efficient methodologies for cleaning the heat exchanger can be implemented, resulting in reduced operating cost. For instance, by knowing the number of cleaning balls passaging through the plurality of tubes, any upcoming maintenance will concentrate on the tubes where the plurality of cleaning balls passages less frequent and hence operational, time and cost efficiencies can be improved. The ability to detect passage of cleaning balls will enable a user to know how many tubes and which particular tubes are stuck with debris. Such real time information is useful for a maintenance team to plan and strategize their tube cleaning schedule, resulting in time efficiency. Further, this ability to detect passage of cleaning balls can result in significant cost savings in the sense that the maintenance team can perform the cleaning of the tubes as and when required. This is distinct from current practices where cleaning of the tubes is performed on a scheduled basis regardless whether the cleaning is necessary or not. In summary, the detecting devices according to embodiments of this disclosure provide efficient cleaning methodologies with significant cost and time savings.

The mounting plate is disposed at one extremity of the plurality of tubes for detecting the cleaning balls and resultantly, any unnecessary disruptions to the cleaning process for detecting the cleaning balls is eliminated. Additionally, by detecting the presence of cleaning balls, the efficiency in cleaning the heat exchangers can be improved by adopting a targeted or selected cleaning process where the less clean tubes of the heat exchanger can be targeted or selected for cleaning on a more frequent basis. This also ensures that cleaning time and resources are not wasted on the relatively clean exchangers.

As used herein, the detecting or sensing function and any embodiment of a detecting function in a ‘sensor’ is intended to be construed in its broadest context as the capability, for example, but not limited to, sense, detect, measure, indicate, report, feedback or collect, or any combination thereof, information, presence, status, state or data relating to cleaning balls and in particular, presence of the cleaning balls.

For purposes of brevity and clarity, descriptions of embodiments of the present invention are limited hereinafter to detection devices for use with heat exchange cleaning systems. This however does not preclude embodiments of the invention where fundamental principles prevalent among the various embodiments of the invention such as operational, functional or performance characteristics are required.

Description of a Heat Exchanger Operation

An example of a heat exchanger 10 comprising a plurality of tubes 12 is shown in FIG. 1. Depending upon the configuration of the heat exchanger 10, the plurality of tubes 12 can include at least three or more individual or singular tubes. In such a heat exchanger 10, fluid or refrigerant is circulated through the heat exchanger 10 by way of each of the plurality of tubes 12 for heat exchange to occur.

The fluid or refrigerant from a source (not shown) for circulation through the plurality of tubes 12 can be fed or channelled through a plurality of inlets 14. The fluid or refrigerant can exit from the plurality of tubes 12 by a plurality of outlets 16. The plurality of inlets 14 defines a first plurality of openings and the plurality of outlets 16 defines a second plurality of openings. Cleaning systems for use in conjunction with the heat exchanger 10 uses cleaning balls 18 transported by fluid to be fed and circulated in the heat exchanger 10. The plurality of cleaning balls 18 is introduced through the plurality of inlets 14 and can exit from the plurality of tubes 12 by a plurality of outlets 16.

Detection Device According to Some Embodiments of this Disclosure

FIG. 2A show a detection device 20 according to an embodiment of this disclosure. FIG. 2B shows a side view of the detection device 20. The detection device 20 facilitates, allows or enables the plurality of cleaning balls 18 to be detected as the plurality of cleaning balls 18 travel through one or more of the plurality of tubes 12. By detecting the presence or movement of the plurality of balls 18 through one or more of the plurality of tubes 12, the cleaning system for cleaning the heat exchanger 10 can be made more efficient.

The detection device 20 comprises a mounting plate 22 defining a plurality of perforations 28 and a plurality of sensors 30. The mounting plate 22 includes a first planar surface or a top side 24 and a second planar surface or a bottom side 26 outwardly opposing the first planar surface 24. The top side 24 is substantially parallel to the bottom side 26.

Additionally, the plurality of perforations 28 are defined from the top side 24 through the bottom side 26 of the mounting plate 22. The mounting plate 22 is being formed from at least one of plastic, graphene and rubber. In many embodiments, the mounting plate 22 is being formed from a weather and/or heat resistant material such as polytetrafluroethylene (PTFE). As will be understood by a person of ordinary skill in the related art, the mounting plate 22 can be shaped and dimensioned by way of laser cutting or precision water jet cutting technologies. Similarly, the plurality of perforations 28 can be defined by way of laser cutting or precision water jet cutting technologies. The mounting plate 22 can be of varying thickness, for example, between approximately 5 and 120 mm. In some embodiments, the mounting plate 22 is between approximately 20 and 80 mm.

In many embodiments, the mounting plate 22 is couplable to the plurality of tubes 12. Depending on embodiment details, the mounting plate 22 can be coupled to the plurality of tubes 12 by one or more mechanically attached connections. The term ‘mechanically attached connections’ means any connection that involves at least one connection that is held in place by mechanically applied force, stress, pressure, torque, or the like, such as a threaded connection, a clamped connection, a bolted or screwed connection. In some embodiments, the mounting plate 22 can be welded, soldered or adhered to the plurality of tubes 12.

FIG. 2C shows the detection device 20 being coupled or couplable to the plurality of tubes 12. The plurality of tubes 12 defines two extremities with the plurality of inlets 14 defining a first extremity and the plurality of outlets 16 defining a second extremity. The plurality of inlets 14 defines a first plurality of openings and the plurality of outlets 16 defines a second plurality of openings. In many embodiments, the mounting plate 22 is being shaped and dimensioned to be disposed on one extremity of the plurality of tubes 12. In many embodiments, the mounting plate 22 is disposed such that the bottom side 26 of the mounting plate 22 faces the plurality of inlets 14 and is spatially aligned with at least a portion of the first plurality of openings of the plurality of inlets 14. As will be appreciated by a person of ordinary skill in the art, disposing the mounting plate 22 at the first extremity of the plurality of tubes 12 provides the advantage that when fluid or refrigerant displaces through the plurality of tubes 12, the force or momentum of the fluid or refrigerant will push the mounting plate 22 against the plurality of tubes 12. This prevents the mounting plate 22 from being displaced away from the plurality of tubes 12 when a cleaning operation is in process.

In many embodiments of this disclosure, the plurality of perforations 28 is aligned with the plurality of tubes 12. The alignment is such that when fluid or refrigerant with the plurality of cleaning balls 18 are circulated through the plurality of tubes 12, the plurality of perforations 28 does not impede, obstruct or block the passage of the fluid, refrigerant and/or the plurality of cleaning balls 18 through the plurality of perforations 28. The plurality of perforations 28 is shaped and dimensioned to facilitate passage of at least one of a plurality of cleaning balls 18 therethrough. Each of the plurality of perforations 28 can be of any size and shape, including circle, square, rectangle and triangle. In some embodiments, each one of the plurality of perforations 28 is of the same shape and size. In some other embodiments, the plurality of perforations 28 can be of varying sizes and/or different shapes. The plurality of perforations 28 can include at least three perforations.

In many embodiments, each of the plurality of sensors 30 is being coupled to at least one of the plurality of perforations 28. Particularly, each of the plurality of sensors 30 being one of coupled to and disposed on or adjacent to the periphery of a corresponding perforation of the plurality of perforations 28. Depending upon implementation details, at least a portion of the plurality of sensors 30 can be embedded within the mounting plate 22. In some embodiments, the at least a portion of the plurality of sensors 30 are embedded along the periphery of the corresponding perforation of the plurality of perforations 28. For such embedded systems, the at least a portion of the plurality of sensors 30 may not be visible from the exterior of the perforations. Subsequently, any reference to coupling of the plurality of sensors 30 to the periphery of a corresponding perforation of the plurality of perforations 28 or of the plurality of sensors 30 being coupled to the periphery of a corresponding perforation of the plurality of perforations 28 includes embedding at least a portion of the plurality of sensors 30 within the mounting plate 22.

Each sensor of the plurality of sensors 30 plays a role in detecting the presence of the cleaning balls. By coupling or attaching each of the plurality of sensors 30 to at least one of the plurality of perforations 28, any cleaning balls entering or exiting a tube of the plurality of tubes 12 can be detected by at least one of the plurality of sensors 30. In many embodiments, each of the plurality of sensors 30 is coupled or attached to at least one of the plurality of perforations 28. Accordingly, each of the plurality of tubes 12 is operable with a corresponding one of the plurality of sensors 30. Upon detection of the cleaning balls 18, the detection signals will be further processed.

From FIG. 2C, it can be seen that a first perforation 28a is aligned with a first tube 12a, a second perforation 28b is aligned with a second tube 12b and a third perforation 28c is aligned with a third tube 12c. Correspondingly, a first sensor 30a is coupled to the first perforation 28a, a second sensor 30b is coupled to the second perforation 28b and a third sensor 30c is coupled to the third perforation 28c. By having this configuration, when a plurality of cleaning balls 18 is introduced into a portion of the heat exchanger 10 for passage through the plurality of tubes 12 for cleaning thereof, each cleaning ball passaging through one of the plurality of tubes is detectable by the corresponding one of the plurality of sensors 30. For example, a cleaning ball 18a travelling along tube 12a can passage through the first perforation 28a and as it comes into contact with or is in the proximity of the first sensor 30a, it will be detected by the first sensor 30a. For clarity, the plurality of perforations 28 comprises the first perforation 28a, the second perforation 28b and the third perforation 28c. The plurality of tubes comprises the first tube 12a, the second tube 12b and the third tube 12c.

Some embodiments of this disclosure have the capability to detect the presence of the cleaning balls regionally. This is discussed in the following section.

Detecting Cleaning Balls Regionally

FIG. 3A shows a top view of a detection device 20 being disposed on one extremity of the plurality of tubes 12 to detect cleaning balls regionally according to a representative embodiment of this disclosure. The plurality of tubes 12 can be demarcated into a plurality of regions. Each region can include one or more tubes. For example, Region A can include the first tube 12d, the second tube 12e and the third tube 12f and Region B includes a fourth tube 12g, a fifth tube 12h and a sixth tube 12i.

The detection device 20 comprises a mounting plate 22 defining a plurality of perforations 28, namely a first perforation 28d and a second perforation 28e and a plurality of sensors 30, namely a first sensor 30d and a second sensor 30e. Each of the plurality of perforations 28 is shaped and dimensioned to facilitate fluid communication with at least one tube of a region. The plurality of perforations 28 can be shaped and dimensioned to facilitate passage of at least one of a plurality of cleaning balls therethrough. Depending upon embodiment details, the perforation 28d and/or 28e can be of any size and shape including square, circle, rectangle and triangle shapes. The first sensor 30d is coupled to the first perforation 28d and the first perforation 28d is shaped and dimensioned for fluid communication with the first tube 12d, the second tube 12e and the third tube 12f. In a similar fashion, the second sensor 30e is coupled to the second perforation 28e and the second perforation 28e is shaped and dimensioned for fluid communication with the fourth tube 12g, the fifth tube 12h and the sixth tube 12i. In many embodiments, each sensor being one of coupled to and disposed on or adjacent to the periphery of each perforation. Depending upon implementation details, at least a portion of the plurality of sensors 30 can be embedded within the mounting plate 22. In some embodiments, the at least a portion of the plurality of sensors 30 are embedded along the periphery of each perforation of the plurality of perforations 28. For such embedded systems, the at least a portion of the plurality of sensors 30 may not be visible from the exterior of the perforations. Subsequently, any reference to coupling of each of the plurality of sensors 30 to the periphery of each perforation of the plurality of perforations 28 or of each of the plurality of sensors 30 being coupled to the periphery of each perforation of the plurality of perforations 28 includes embedding at least a portion of the plurality of sensors 30 within the mounting plate 22.

Although FIG. 3A illustrates that each region includes three tubes, it should be understood that a Region can include less than or more than three tubes, for example, two or five tubes. In some embodiments, each perforation is being coupled with more than one sensor, for example two or more sensors.

By shaping and dimensioning each perforation, for example, the first perforation 28d to enable, allow or facilitate fluid communication with the first tube 12d, the second tube 12e and the third tube 12f, the presence of cleaning balls can be detected regionally. During a cleaning process, cleaning balls (not shown) passaging through at least one of the first tube 12d, the second tube 12e and the third tube 12f can be detected by a corresponding one of the plurality of sensors 30 (i.e. sensor 30d). Similarly, cleaning balls passaging through at least one of the fourth tube 12g, the fifth tube 12h and the sixth tube 12i can be detected by the second sensor 30e. The configuration of FIG. 3A provides a method of detecting the cleaning balls regionally and it serves to notify and/or provide information relating to the passage of balls in a particular region (i.e Region A or B).

FIG. 3B shows a first perforation 28f of a detection device 20 according to an embodiment of this disclosure. The first perforation 28f is shaped and dimensioned to enable, facilitate or allow fluid communication with a plurality of tubes, for example, the first tube 12j, the second tube 12k and the third tube 12l. The first perforation 28f is aligned such that any cleaning balls or liquid flowing through the first tube 12j, the second tube 12k and the third tube 12l will be able to flow or passage therethrough without being impeded or blocked by the first perforation 28f. As such, during a heat exchange or cleaning operation, the fluid or cleaning ball is able to passage through the first tube 12j, the second tube 12k and the third tube 12l and perforation 28f to other parts of the heat exchanger 10.

The first perforation 28f has a plurality of sensors, namely, a first sensor 30f, a second sensor 30g and a third sensor 30h. Each of these sensors, 30f, 30g and 30h is one of coupled to and disposed on the periphery of the first perforation 28f. Each of the sensors, 30f, 30g and 30h is aligned and/or positioned with respect to a tube, for example, the first sensor 30f is positioned on the periphery of perforation 28f in close proximity to the first tube 12j, the second sensor 30g is positioned on the periphery of the first perforation 28f in close proximity to the second tube 12k and the third sensor 30h is positioned on the periphery of the first perforation 28f in close proximity to the third tube 12l. The positioning of each of the sensors 30f, 30g and 30h is such that when a cleaning ball passages through a tube, for example, the first tube 12j, the corresponding first sensor, 30f detects the presence of the cleaning ball.

As will be appreciated by a person of ordinary skill in the art, the first perforation 28f can be shaped and dimensioned to enable, facilitate or allow fluid communication with more than three tubes, for example, four or more tubes.

In the foregoing embodiments, the plurality of sensors 30 is being one of coupled to, is couplable to and disposed on the periphery of the plurality of perforations 28. The coupling and/or positioning of the plurality of sensors 30 to the plurality of perforations 28 is described in greater detail in the following sections.

Coupling and/or Positioning of the Plurality of Sensors

FIGS. 4A and 4B show a top view and a side view of a detecting device 20, respectively according to various embodiments of this disclosure. As shown, the plurality of sensors 30 is one of coupled to and disposed on the periphery of a corresponding perforation of the plurality of perforations 28. Particularly, the plurality of sensors 30 is one of coupled to and disposed on at least a portion of the perimeter or circumference of the plurality of perforations 28. In some embodiments, the plurality of sensors 30 is one of coupled to and disposed on at least a portion of an inner surface of each perforation and the plurality of sensors 30 is substantially flushed with the top side 24 of the mounting plate 22.

FIGS. 5A and 5B show a top view and a side view of a detecting device 20, respectively according to various embodiments of this disclosure. As can be seen in FIG. 5A, the plurality of sensors 30 are one of being coupled to and disposed on the periphery of the plurality of perforations 28. In some embodiments, the plurality of sensors 30 is coupled to or disposed on the top side 24 of the mounting plate 22. Depending upon embodiment details, the plurality of sensors 30 may protrude from a surface of the top side 24 of the mounting plate 22.

In some other embodiments, at least one of the plurality of sensors 30 is formed with the mounting plate 22. For example, a recess can be formed on the mounting plate 22 to embed at least one of the plurality of sensors 30.

Each of the plurality of sensors 30 being one of couplable to and formed with the corresponding at least one of the perforations by way of adhesive, embedding, sputtering, metal injection moulding, casting, compressing, printing and etching.

Sensor Characteristics and Operation

Each of the plurality of sensors 30 is being detectable in many different ways, including but not limited to at least one of electromagnetic, acoustic-magnetic, magnetic resonance, inductive coupling including antenna, infrared, eddy current, ultrasonic and piezoelectric. The theory of Frustrated Total Internal Reflection (FTIR) can also be adopted for the plurality of sensors 30 and this will be explained in detail later. Upon detection of the cleaning balls, the detection signals will be further processed.

FIG. 6 shows a configuration of devices for processing of detection signals. The detecting device 20 can further comprise a manifold 32. Each sensor of the plurality of sensors 30 is electrically couplable to the manifold 32, which in turn is electrically coupled to a processing unit 34 for processing of the sensed data or information. The manifold 32 can be operable for one of receiving detection signals and electronically communicating with the plurality of sensors 30. The signal coupling between each sensor and the manifold 32 is by way of wired or wireless technology. The processing unit 34 can include a single processing device or a plurality of processing devices. Such a processing unit 34 can be a microprocessor, micro-controller, digital signal processor, microcomputer, field programmable gate array, programmable logic device, logic circuitry, digital circuitry, analogue circuitry and/or any other devices that is capable of manipulating signals. Memory (not shown) coupled to and/or embedded in the processor unit 34 may be a single memory device or a plurality of memory devices. Such a memory device can be a read-only memory, random access memory, volatile memory, static memory, dynamic memory, cache memory and/or any device that stores digital information. Depending upon embodiment details, the plurality of sensors 30 can communicate with the processing unit 34 in a wired or wireless manner with the latter adopting technologies such as BLUETOOTH, Wi-Fi, 2G, 3G, RFID, acoustic, infrared and optical. In some embodiments, any processed detecting signals are displayed on a monitor 36. This enables a user of the detecting device 20 to manipulate the processed detecting signals through the processing unit 34 by external or peripheral devices such as a computer keyboard and a computer mouse.

Frustrated Total Internal Reflection

Frustrated Total Internal Reflection (FTIR) is a technology that can be implemented with the sensors of this disclosure. When light encounters an interface to a medium with a lower index of refraction, such as glass to air, the light becomes refracted to an extent that depends on its angle of incidence. Beyond a critical angle, the light undergoes total internal reflection (TIR). If another material is placed at the interface, total internal reflection must be frustrated thereby causing light to escape the waveguide. This area of technology is well known and is readily understood by a person of ordinary skill in the art.

FIG. 7 shows an example of a detection device 10 in operation based upon FTIR according to some embodiments of this disclosure. The sensor 30i can include a waveguide 38 and a detector 40. Light 42 emitted from a light source (not shown) undergoes total internal reflection, causing the light 42 to be trapped within the waveguide 38. A cleaning ball 18 travels along or through a tube 12. When the cleaning ball 18 comes into contact with, touches or impacts the waveguide 38, light 42 that was totally internally reflected is frustrated thus causing some light to escape from the waveguide 38. The frustrated or scattered light 44 escapes from the optical waveguide 38 and is being detected by the detector 40. In some embodiments, the detector 40 can be equipped with a band pass filter (not shown) to minimize optical noise. The detector 40 is based upon one of charged-coupled device (CCD), complementary metal-oxide-semiconductor (CMOS) technology and opto-electro transducer.

In some embodiments, the detector 40 can be wired to a computer or any other electronic device capable of handling various well-known detection processing.

Thus, there has been shown and discussed various embodiments of a detecting device for use with a heat exchanger which fulfils the objectives and advantages sought thereof. Many changes, modifications, variations, and other uses and applications of the subject disclosure will, however, become apparent to those skilled in the art after considering this specification together with the accompanying figures and claims. The same detection device, together with ensuing benefits are also applicable to similar equipment in unrelated industries where objects must be detected so as to improve operating efficiencies. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the detecting device of this disclosure are deemed to be covered by embodiments of this disclosure which is limited only by the claims which follows.

In the foregoing manner, various embodiments of the disclosure are described for addressing at least one of the foregoing disadvantages. Such embodiments are intended to be encompassed by the following claims, and are not to be limited to specific forms or arrangements of parts so described and it will be apparent to one skilled in the art in view of this disclosure that numerous changes and/or modification can be made, which are also intended to be encompassed by the following claims.

Claims

1. A detection device for use with a heat exchanger having a plurality of tubes, the device comprising:

a mounting plate couplable to the plurality of tubes, the mounting plate defining a plurality of perforations, the plurality of perforations aligned with the plurality of tubes, the plurality of perforations being shaped and dimensioned to facilitate passage of at least one of a plurality of cleaning balls therethrough; and

a plurality of sensors, each sensor of the plurality of sensors being coupled to at least one of the plurality of perforations;

wherein each of the plurality of tubes is operable with a corresponding one of the plurality of sensors and when the plurality of cleaning balls is introduced into a portion of the heat exchanger for passage through the plurality of tubes for cleaning thereof, each cleaning ball passaging through one of the plurality of tubes is detectable by the corresponding one of the plurality of sensors.

2. The detection device of claim 1, the plurality of tubes defining two extremities, the plurality of tubes defining a plurality of inlets at one of and a plurality of outlets at the other of the extremities.

3. The detection device of claim 2, the mounting plate being shaped and dimensioned for disposing onto one of the extremities of the plurality of tubes.

4. The detection device of claim 1, the mounting plate being formed from at least one of plastic, graphene, rubber and polytetrafluroethylene (PTFE).

5. The detection device of claim 1, the mounting plate having a thickness of between approximately 20 and 80 mm.

6. The detection device of claim 1, wherein the plurality of perforations include at least 3 perforations.

7. The detection device of claim 1, each of the plurality of perforations being of any shape.

8. The detection device of claim 1, each of the plurality of sensors being one of couplable to and formed with the corresponding at least one of the perforations by way of adhesive, embedding, sputtering, metal injection moulding, casting, compressing, printing and etching.

9. The detection device of claim 1, further comprising a manifold, the manifold couplable to the plurality of sensors for one of receiving detection signals and electronically communicating with the plurality of sensors.

10. The detection device of claim 1, each of the plurality of balls being detectable by the plurality of sensors by way of at least one of frustrated total internal reflection (FTIR), electromagnetic, acoustic-magnetic, magnetic resonance, inductive coupling including antenna, infrared, eddy current, ultrasonic and piezoelectric.

11. The detection device of claim 1, each of the plurality of sensors being one of coupled to and disposed on the periphery of a corresponding perforation of the plurality of perforations.

12. The detection device of claim 1, at least one of the plurality of sensors being embedded within the mounting plate.

13. The detection device of claim 1, the mounting plate having a first planar surface and a second planar surface outwardly opposing the first planar surface.

14. The detection device of claim 10, at least one of the plurality of sensors being disposed on the first planar surface.

15. A detection device for use with a heat exchanger having a plurality of tubes, the plurality of tubes being demarcated into a plurality of regions, each of the plurality of regions includes at least one tube, the device comprising:

a mounting plate couplable to the plurality of tubes, the mounting plate defining a plurality of perforations, each of the plurality of perforations shaped and dimensioned to facilitate fluid communication with at least one tube of each region, the plurality of perforations shaped and dimensioned to facilitate passage of at least one of a plurality of cleaning balls therethrough; and

a plurality of sensors, each sensor of the plurality of sensors being coupled to at least one of the plurality of perforations;

wherein each of the plurality of perforations is operable with a corresponding one of the plurality of sensors and when the plurality of cleaning balls is introduced into a portion of the heat exchanger for passage through the plurality of tubes for cleaning thereof, each cleaning ball passaging through a tube of the plurality of tubes is detectable by the corresponding sensor of the perforation.

16. The detection device of claim 15, the mounting plate being formed from at least one of plastic, graphene, rubber and polytetrafluroethylene (PTFE).

17. The detection device of claim 15, wherein the plurality of sensors being coupled to the at least one of the plurality of perforations includes at least one sensor.

18. The detection device of claim 15, further comprising a manifold, the manifold couplable to the plurality of sensors for one of receiving detection signals and electronically communicating with the plurality of sensors.

19. The detection device of claim 15, each of the plurality of balls being detectable by the plurality of sensors is by way of at least one of frustrated total internal reflection (FTIR), electromagnetic, acoustic-magnetic, magnetic resonance, inductive coupling including antenna, infrared, eddy current, ultrasonic and piezoelectric.

20. The detection device of claim 15, wherein each of the plurality of sensors being one of coupled to and disposed on the periphery of a perforation of the plurality of perforations.