Patent ID: 12226808

DETAILED DESCRIPTION

Disclosed herein are embodiments of an apparatus, a system, and a method to provide cleaning maintenance to barriers such as louvers of factory-assembled or field-erected cooling towers. Such cooling towers are those towers used, for example, for building heating, ventilation, and air conditioning (HVAC) systems. These louvers may become clogged with contaminants over time due to the continuous operation of the cooling towers. In induced-draft cooling towers, a fan draws ambient air into the cooling tower through the louvers. During operation contaminants such as debris and scale accumulate in the louvers and restrict air flow.

Embodiments disclosed herein describe a system and method to clean the louvers in place while the cooling tower is in service and remove accumulated debris automatically. In accordance with one or more embodiments, the system may be automated. A pumping system coupled to a cleaning head may be attached to a carriage frame to automatically clean the louvers in place. In accordance with one or more embodiments, the pumping system may operate in accordance with an industry standard such as, for example, medium pressure per ASME B31.3 Process Piping, chapter IX. The cleaning head may automatically move vertically, horizontally, and all around the cooling tower while spraying water or other cleaning fluid on the louvers. In accordance with one or more embodiments, the apparatus may include a control system. The motion of the cleaning head, both in speed and direction, as well as the pump parameters, may be preselected and/or controlled by the control system. The motion may be controlled by a switch, a controller, and/or a control panel. The control panel may be coupled to the control system. In accordance with one or more embodiments, cleaning fluid, such as water, may be provided to the pump system by a cleaning fluid supply hose. Electric power may also be provided to operate the pump and the controller, and to energize one or more actuators for moving the cleaning head.

FIGS.1A-3Bshow variations of induced draft cooling towers. As can be seen, a fan15is located at the top of the cooling tower. For crossflow cooling towers, typically configured in a square or rectangular shape as viewed from above, the fan15draws air typically from only two sides (e.g., a first air inlet13and a second air inlet14). For counterflow cooling towers the fan15draws air typically from all four sides of square or rectangular-configured cooling towers, and along the entire circumference of round or oval counterflow cooling towers. The air is drawn in through the louvers (e.g., in an air flow direction18) and then across one or more of a heat transfer fill or filling (e.g., a fill19), as is known in the art, and then out of an outlet (e.g., an air outlet17). Common fill types include film fill and splash fill.

Shown inFIG.1A,FIG.1B, andFIG.1Cis an example of an induced-draft, crossflow cooling tower (e.g., a cooling tower102) arranged in a generally rectangular shape as viewed from above.FIG.1Bshows a top view andFIG.1Cshows an isometric view of the cooling tower. The crossflow filling is arranged at a slight angle off of horizontal with respect to the base of the cooling tower. Cooling water enters at a first water inlet11and/or a second water inlet12. The cooling water then falls in a water flow direction20onto a top surface at an edge of the filling that faces the interior of the cooling tower. Air flows generally sideways against the water falling down on the filling and across the water on the filling. The water exits the cooling tower102at a water outlet16.

FIG.2A,FIG.2B, andFIG.2Cshow an example of an induced-draft, counterflow cooling tower.FIG.2Bshows a top view andFIG.2Cshows an isometric view of the cooling tower.FIG.3Ashows a cross section andFIG.3Bshows a top view of a round cooling tower. Air is drawn from a portion or all of the circumference of round and/or oval cooling towers. The air is drawn through the louvers and then across the filling. The counterflow filling is arranged horizontally with respect to the base of the cooling tower and cooling water falls onto a top side of the filling. Air flows generally upward against the water falling down on the filling and, therefore, counter to the direction of the water on the filling.

FIG.4shows examples of louver variations (e.g., a louver104). Each louver may have an outwardly facing generally planar surface (e.g., a planar surface106). Cooling tower air inlet louvers may be known in the art by several names and/or styles such as labyrinth, eggcrate, and slat. An example louver is made from a plastic material such as a PVC (polyvinyl chloride) and has dimensions of 1640 mm×810 mm×65 mm (64″ (inches)×32″×2.6″). Cooling towers may be equipped with barriers such as grates, guards, or screens. Embodiments disclosed herein may apply to one or more of these various barriers, collectively known hereafter as “louvers.” Clogging of louvers restricts air passage through the louvers and thus may reduce or minimize efficiency of the cooling tower. Contaminant build up and risk of clogging results in a need for periodic maintenance. Cleaning the louvers may be a manual process and that process may require removal of the louvers from the cooling tower. The removal may, in turn, require the use of scaffolding or other equipment for access at height. Furthermore, the periodic cleaning may occur at such time intervals that cause significant contaminant build-up and, therefore, prolonged and/or more complex cleaning cycle activities. Frequent periodic cleaning may prevent the contaminant build up, reduce the duration of or eliminate the manual cleaning, and reduce the complexity of the cleaning cycle.

FIG.5shows a system (e.g., a system100) in accordance with one or more embodiments. One or more of the modules and/or elements shown inFIG.5may be omitted, repeated, combined, and/or substituted. Accordingly, embodiments disclosed herein should not be considered limited to the specific arrangements of modules and/or elements shown inFIG.5. System100shows an apparatus101and an example of cooling tower102. System100may include a remote pump, external power supply, uninterruptible power supply (UPS), internal power supply, utility air, and other components. The power supply may receive an input voltage of, for example, 110 or 220 VAC (volts alternating current) at 60 Hz (Hertz) of utility power. The cooling tower has at least one of louver104.

The apparatus101includes a cleaning head120with a spray head122. Cleaning head120is shown coupled to a heavy-duty sliding rails sub-system (e.g., a carriage frame180). Cleaning head120is coupled to a pump140and a drive150. Pump140draws cleaning fluid110through a conduit170coupled to a fluid supply112. Pump140pressurizes cleaning fluid110and directs it out of spray head122onto the louver104. Drive150moves cleaning head120along carriage frame180to direct the cleaning fluid110to sections of the cooling tower102.

A control panel192may be coupled to the control system190to receive from a user a set of operational parameters and to monitor and to control the operational parameters of the apparatus101. The user may enter target values as part of the set of operational parameters. The user may prepare a workflow that includes the set of operational parameters. The control system190may mathematically seek the target values associated with variables of the apparatus in response to feedback from a workflow in cooperation with the apparatus, the systems, and the method. For example, the workflow may include a pressurization cycle comprising a pressure and a duration of time. The workflow may also include a movement of the movable mount, and therefore the cleaning head, along the preselected route. The control system may use feedback from a sensor system and mathematically seek a target distance, a target pressure, and/or a target time duration.

Processor196may be used to perform a comparing of operational parameters. Processor196may be used to determine pressure of the fluid supply112and/or the pressurized fluid114. Processor196may be used to determine position of the cleaning head120on the carriage frame180. Processor196may work with one or more of a sensor804described below inFIG.8and the accompanying description. Processor196may be the same as or similar to that of computer processor1218described below inFIG.12and the accompanying description.

The carriage frame180may be installed around a perimeter of cooling tower102such as along each of four sides of cooling tower102. The carriage frame may be supported, for example, at four corners of the carriage frame. The carriage frame180and the spray head122may be arranged proximate the louvers of cooling tower102and the spray head122may direct a cleaning medium such as the cleaning fluid110onto the planar surface106of the louver104.

FIG.6shows that apparatus101in accordance with one or more embodiments. Apparatus101may have hydraulic and/or pneumatic lines such as pipes, tubes, hoses, etc., connecting the components. Pump140may be a low-pressure, medium-pressure, or high-pressure pump such as positive displacement pump or a centrifugal pump. A low pressure pump may operate with a Example pressure ranges may include fifty to eighty psi (pounds per square inch) for low-pressure, eighty to one thousand psi for a medium-pressure, and over one thousand psi for high-pressure.

The positive displacement pump may be a reciprocating plunger pump, a piston pump, or diaphragm pump. The positive displacement pump may be single-acting or double-acting. The piston pump and the plunger pump may be one cylinder or may have more than one cylinder. The pump driver may be an electric motor, an engine, or a linear motion electromagnetic driver. Pump140conveys the cleaning fluid110from the fluid supply112and may incorporate one or more valves, fittings, and regulators in a manifold to regulate the cleaning fluid110pressure and flowrate.

FIG.6shows that carriage frame180may have provision to support movement of cleaning head120using a movable mount136in one, two, and/or three orthogonal directions. For example, carriage frame180may have a series of rails oriented in three dimensions such as left and right (horizontally), up and down (vertically), and fore and aft (in and out) relative to a fixed position. Carriage frame180may be dimensioned to encompass the perimeter of some, part, or all of the cooling tower. In accordance with one or more embodiments the carriage frame180may have at least two orthogonal directions along the planar surface of the louver.

FIG.6shows that carriage frame180may include a drive150for driving the cleaning head120in each orthogonal direction. The drive150may be configured for movable mount136to move in each orthogonal direction individually or simultaneously. In accordance with one or more embodiments a rail182may be oriented to support movement of movable mount136in a first orthogonal direction183such as left and right. A trolley184may be oriented in a second orthogonal direction185such as up and down and may couple with the first orthogonal direction183.

FIG.6shows that a third orthogonal direction187may be oriented in a direction such as fore and aft. A connector rail188may couple the rail182with trolley184and/or with third orthogonal direction187. Connector rail188may be curved to form a curved connector rail to achieve the transition. In accordance with one or more embodiments the carriage frame180may be in a square shape, a rectangular shape, a circular shape, an oval shape, or any appropriate shape to accommodate the cooling tower shape. The square shape may comprise equal length rails in the first orthogonal direction and in the third orthogonal direction. The rectangular shape may comprise a rail with a first rail length oriented in the first orthogonal direction and a rail with a second rail length oriented in the third orthogonal direction187. The circular shape may comprise a rail formed with a circumference of a magnitude large enough to encircle, either in part or in whole, the cooling tower. The oval shape may have two or more curved rails and one or more straight rails in combination to encompass the cooling tower.

The carriage frame may have one or more of the rails182. The carriage frame may comprise an upper and lower rail. The upper rail may be positioned at a first proximity with respect to the cooling tower and the lower rail may be positioned at a second proximity with respect to the cooling tower.

The carriage frame may have one or more trolleys. A first trolley may be disposed at a first portion of the cooling tower and a second trolley may be disposed at a second portion of the cooling tower. The first trolley may be spaced from the second trolley around the perimeter of cooling tower. The first trolley may be spaced above or below the second trolley.

FIG.7shows an example setup of system100and apparatus101. System100may include safety and surveillance accessories (e.g., accessories700) such as one or more of each of a personnel exclusion barrier702, a motion detector704, a proximity sensor706, and/or a camera708. One or more of the safety and surveillance accessories may be operatively coupled to the control system190.

FIG.8shows the cleaning head120in accordance with one or more embodiments. The cleaning head120may include the spray head122and the movable mount136for movably coupling the spray head122to the carriage frame180. Cleaning head120may have one or more reservoirs130. Each of the implementations of the reservoir130may have a reservoir inlet132and a reservoir outlet134and may hold cleaning fluid110or other substance.FIG.8shows that the spray head122, the pump140, a manifold806, and the drive150may be enclosed within the cleaning head120coupled to the carriage frame180. Pump140may have one or more of a pump inlet142and one or more of a pump outlet144. Pump outlet144may be configured to couple to the conduit first end172and a spray head inlet (a head inlet124) may be configured for a hydraulic connection to the conduit second end174. Pump140may be disposed within, on, or outside of cleaning head120. Pump140may be disposed between the fluid supply112and/or the reservoir outlet134and a spray head outlet (a head outlet126). Pump140may be configured to receive the cleaning fluid110from the fluid supply112and/or the reservoir130.

FIG.8shows the pump140in accordance with one or more embodiments. The pump140may be in hydraulic communication with the fluid supply112and/or the reservoir130and may draw the cleaning fluid110from fluid supply112and/or from reservoir130and pressurize the cleaning fluid110to a preselected pressure such as a target pressure to form a pressurized fluid114at the preselected pressure. Pump140may pressurize cleaning fluid110at a preselected flowrate such as a target flowrate. Spray head122may deliver cleaning fluid110to head outlet126and may direct the pressurized fluid114onto planar surface106of louver104. Reservoir130may be filled at reservoir inlet132and/or reservoir inlet132may be hydraulically coupled to fluid supply112. Pump140may be configured to draw cleaning fluid110from fluid supply112and reservoir130simultaneously and/or intermittently. The type of cleaning fluid110from fluid supply112and from reservoir130may differ. For example, cleaning fluid110from fluid supply112may be utility water and cleaning fluid110from reservoir130may comprise a water at a second temperature and/or it may comprise a solvent, surfactant, detergent, and/or acid. Apparatus101may have a second pump to draw cleaning fluid110from reservoir130and deliver cleaning fluid110to head outlet126.

FIG.8shows that the control panel192may be coupled to control system190. Control system190may include a monitoring subsystem800, a communication module802, a power supply194, a processor196, and a control memory198coupled to processor196. Control panel192may be used as the interface between a user and the apparatus101. Control panel192may be configured for user commands and user inputs. Control panel192may use power supply194in combination with the monitoring subsystem to control operation of apparatus101through the control system190. Control panel192may include a power switch, a controller, and/or a control switch. Control panel192may be coupled to the apparatus101and or to the control system190using a wired or a wireless connection. Control panel192may include an input interface used, for example to input cleaning cycles, pressure settings, flow rates, durations, travel speeds, positions, etc.

Drive150may be controlled by an electrical circuit coupled to the first actuator154and the second actuator160. The pump140and/or the drive150may be operated by the control system190with signals received from a user such as a user providing commands from the controller, such as control panel192. Apparatus101may incorporate a wide range of speeds, loads, and conditions and may all be controlled by a controller switch, such as control panel192.

The monitoring subsystem may include one or more of the sensor804(e.g., pressure transmitter, timer, flow meter, linear transducers, proximity sensors etc.) configured to measure, for example, pump output pressure, cleaning fluid flowrate, etc. The monitoring subsystem191may include a display showing all system parameters, monitored parameters, and the set of operational parameters, such as pressure, temperature, and flowrate parameters, including a protection system to provide limit alarm trips and one or more program interlocks. The set of operational parameters may include those entered by a user in the workflow through the control panel192.

Control system190may integrate readiness states from the monitoring subsystem800. Readiness states may include confirming function of the personnel exclusion barrier(s), the motion detector(s), the proximity sensor(s), and/or the camera(s). Readiness states may include confirming function of interlocks such as a closing latch1104described below inFIG.11and the accompanying description. The user may enter into the control system the data required to define the preselected path of the cleaning head. The control system may receive from the monitored subsystem readiness states from which the control system may determine operational state of the apparatus. For example, the control system may receive a readiness state of the motion detectors and of the fluid supply112pressure prior to commencing a pressurization cycle on the preselected route.

In accordance with one or more embodiments the conduit170, such as a water supply hose, may deliver cleaning fluid110from fluid supply112. Fluid supply112may incorporate a stop valve, a regulating valve, and/or a choke in manifold806to control and regulate the incoming flow of cleaning fluid110. The cleaning fluid110may then flow through manifold806and into pump inlet142of pump140. The pressurized fluid114continues flowing out of pump outlet144and into head inlet124of the spray head122. Pressurized fluid114flows through spray head122and out of head outlet126. The hydraulic path from fluid supply112to the pump140may not use manifold806. The hydraulic path from fluid supply112to the pump140may use a reservoir in the hydraulic path between the fluid supply112and the manifold806. The fluid supply112may be the reservoir130containing cleaning fluid110. The cleaning fluid110may flow from the reservoir130through the manifold806into pump140. The cleaning fluid110may flow from the reservoir130directly into pump140.

FIG.9AandFIG.9Bshow the drive, the rail rack, and the trolley rack in accordance with one or more embodiments. Drive150may move along first orthogonal direction183and second orthogonal direction185. In like manner, the drive150may be applied to the third orthogonal direction187. Drive150may be configured with a rack and pinion drive system. In accordance with one or more embodiments a gear rack may comprise gear teeth configured to cooperate with corresponding gear teeth on a pinion gear.

FIG.9Ashows a rail rack in accordance with one or more embodiments. A gear rack (a rail rack152) fixed to the rail182may cooperate with a first pinion (a first driver156) coupled to a first actuator154such that the first actuator154, fixed to the movable mount136, which in turn is fixed to the cleaning head120, rotates first driver156against rail rack152thereby causing the cleaning head120to move along the length of rail182.FIG.9Aalso shows an embodiment of the bearings coupling the trolley184to the rail182.

FIG.9Bshows a trolley rack in accordance with one or more embodiments. A gear rack (a trolley rack158) fixed to the trolley184may cooperate with a second pinion (a second driver162) coupled to a second actuator160such that the second actuator160, fixed to the movable mount136, which in turn is fixed to the cleaning head120, rotates second driver162against trolley rack158, fixed to trolley184, thereby causing the cleaning head120to move along the length of trolley184. First actuator154and/or second actuator160may be hydraulically, pneumatically, or electrically operable without limitation.FIG.9Balso shows an embodiment of the bearings coupling the movable mount136to the trolley184.

The movable mount136and/or the trolley184may be actuated by a spline gear operating on a splined-profile shaft. The following discloses an implementation of motion control using the spline gear operating on a splined-profile shaft to move the trolley184along the rail182. The splined-profile shaft may be rotatably coupled to the movable mount136. The splined-profile shaft may be coupled to one or more rack gears (first driver156). At least one of the rack gears may engage a rail rack152such that rotating the splined-profile shaft coupled to the movable mount136rotates the first driver156and thereby propels the movable mount136in a direction parallel to that of the rail rack152.

The first actuator154may be coupled to a gear such as a worm gear (first driver156) configured to engage a mating gear with a splined internal diameter (the spline gear) disposed on the splined-profile shaft. Torque output of the first actuator154transfers to the first driver156which in turn transfers the torque to the spline gear mating with the first driver156and disposed on the splined-profile shaft thereby rotating the first driver156engaged on the rail rack152. In this manner the trolley184travels along the rail rack152. In this implementation the first actuator154and the second actuator160may operate simultaneously. When the movable mount136moves, the spline gear slides along the splined-profile shaft thereby unencumbering the motion of the movable mount136.

In accordance with one or more embodiments the movable mount136and/or the trolley184may be actuated by a worm screw (a worm driver) and a geared-profile shaft. The following discloses an implementation of motion control using the worm driver and geared-profile shaft to move the trolley184along the rail182. The geared-profile shaft may be rotatably coupled to the movable mount136. The geared-profile shaft may be coupled to one or more rack gears (first driver156). At least one of the rack gears may engage the rail rack152such that rotating the geared-profile shaft coupled to the movable mount136rotates the first driver156and, thereby, propels the movable mount136in a direction parallel to that of the rail rack152.

The first actuator154may be coupled to a gear such as a worm gear (first driver156) configured to engage the geared-profile shaft. Torque output of the first actuator154transfers to the first driver156which in turn transfers the torque to the geared-profile shaft thereby rotating the first driver156engaged on the rail rack152. In this manner the trolley184travels along the rail rack152. The worm gear may bind if the first actuator154and the second actuator160are activated simultaneously unless the following design parameters are met to allow the worm gear to back spin or back drive, as it is known in the art (hereafter back drive.) The back drive is analogous to a steering wheel of an automobile rotating by itself due to steering forces exerted on the automotive tires. The back drive of the first actuator154thereby unencumbers the motion of the movable mount136. The first actuator154may be designed to have, when not activated, a torque that is lower than the torque of the first driver156on rail rack152to move the trolley184. For example, a pneumatic motor may rotate relatively freely when not activated.

The design parameters to enable back drive are known in the art to be that the worm gear profile between the worm driver on the first actuator154and the geared-profile shaft has a static friction coefficient (μs) that is less than the tangent of the lead angle of the worm gear. I.e., the friction angle between the worm and the geared-profile shaft must be smaller than the lead angle of the worm. In this manner when the second actuator160operates, the first actuator154will back drive.

Although embodiments disclosed herein describe use of a rack and pinion style of drive, this is not intended to be limiting. Any suitable drive providing similar functionality to that described may also be implemented without departing from the scope of the present disclosure. For example, the gear rack(s) may be replaced by a roller chain and a roller chain sprocket. The gear rack(s) may be replaced by a toothed belt and a toothed belt sprocket.

The following discloses an implementation of motion control using the roller chain and the roller chain sprocket to move the trolley184along the rail182. A toothed belt and a toothed belt sprocket may replace the roller chain and the roller chain sprocket. The movable mount136may be coupled to first actuator154via trolley184. First actuator154may be coupled to a roller chain sprocket on the output shaft of first actuator154and engaged with a rail roller chain coupled to rail182such that when first actuator154rotates, the movable mount136moves via trolley184and, thereby, moves the cleaning head120along the length of rail182. Likewise, the movable mount136may be coupled to second actuator160. Second actuator160may be coupled to a roller chain sprocket on the output shaft of second actuator160and engaged with a trolley roller chain coupled to trolley184such that when second actuator160rotates, the movable mount136moves and thereby moves the cleaning head120along the length of trolley184.

The movable mount136may be coupled, via trolley184, to a link of a rail roller chain and the first actuator154may be coupled to a roller chain sprocket on the shaft of first actuator154and engaged on the rail roller chain. First actuator154may be coupled to the rail182, such that when first actuator154rotates, the chain moves along the rail and pulls the movable mount136. The first actuator154may be disposed on connector rail188. The first actuator154may be disposed on rail182. Similarly, movable mount136may be coupled to a link of a trolley roller chain and the second actuator160may be coupled to a roller chain sprocket on the shaft of second actuator160and engaged on the trolley roller chain. Second actuator160may be coupled to trolley184such that when second actuator160rotates, the chain moves along the trolley and pulls the movable mount136along trolley184.

The first driver156may comprise a friction driver such as a rubber wheel configured to cooperate with a contact surface for first driver156disposed on rail rack152to move trolley184along rail182. Likewise, the second driver162may comprise a friction driver such as rubber wheel configured to cooperate with a contact surface for second driver162disposed on trolley rack158to move movable mount136along trolley184.

The trolley184may be coupled to the rail182(FIG.9A) and/or the movable mount136may be coupled to the trolley184(FIG.9B) using any combination of bearings, slots, rails, bushings, wheels, pins, studs, nuts, screws, and bolts. Bearings may include linear bearings, sliding bearings such as ball bearings, cylindrical roller bearings, spherical roller bearings, tapered roller bearings, and/or journal bearings on one or both of the movable mount136and/or the rail182and/or the trolley184. Any suitable coupler providing similar functionality to that described may also be implemented without departing from the scope of the present disclosure. The components of apparatus101including carriage frame180may be constructed of high-strength, corrosion-resistant material to minimize corrosion when in its intended outdoor wet environment. The control panel may be connected to the apparatus using a suitable means such as screws, bolts, welds, etc. and using suitable materials such as angle iron, cold-rolled steel, hot-rolled steel, aluminum, etc. In one or more embodiments, an electrical cable harness may be used to connect some or all of the electrical components of system100. The electrical cable harness is also configured to transmit current, keep control over the system, and provide connection to the monitoring subsystem.

The first actuator154may comprise a motion controller such as a pneumatic cylinder, a hydraulic cylinder, an in-line motor, and/or an electromagnetic linear actuator. First actuator154may be horizontally-oriented. First actuator154may be coupled at a horizontal cylinder static end to a carriage frame cylinder point on the carriage frame180. First actuator154may be fastened at a horizontal cylinder dynamic end to a trolley184cylinder point. In this implementation the first actuator154may move trolley184as first actuator154extends and retracts. Likewise, second actuator160may comprise a motion controller. Second actuator160may be vertically-oriented. Second actuator160may be coupled at a vertical cylinder static end to a trolley cylinder point on the trolley184. Second actuator160may be fastened at a vertical cylinder dynamic end to a movable mount136cylinder point. In this implementation, the second actuator160may move movable mount136as the second actuator160extends and retracts.

The first actuator154may comprise one or more of a bell-crank or one or more of a crankshaft with a linkage for moving the trolley184along the rail182and/or the movable mount136along the trolley184.

The movable mount136and/or the trolley184may be actuated by a jack screw that cooperates with a jack nut. The following illustration discloses application of the jack screw motion control to the movable mount136. The jack screw may be coupled at a jack screw trolley end to a trolley jack first point of the trolley184such that the trolley184prevents the jack screw from rotating and trolley184receives thrust along an axis of the jack screw. The jack nut comprises a jack nut internal thread that engages an external thread on the jack screw. The jack screw extends through the jack nut. A jack screw second end may be coupled to a trolley jack second point of the trolley184or the jack screw second end may remain uncoupled. The jack screw thread may be, for example, a square thread, a trapezoidal thread such as an acme thread, or any other appropriate thread profile. The jack nut may comprise a jack nut external gear profile. The jack nut may be rotatably supported by the movable mount136along an axis of the jack nut and the jack screw. The jack nut may rotate along the length of the jack screw and the jack nut may react against the movable mount136. In this manner, axial displacement between the jack nut and the jack screw reacts between the movable mount136and the trolley184thereby displacing the movable mount136along the length of trolley184.

The second actuator160may be coupled to a vertical motion gear (second driver162). The vertical motion gear may have a vertical motion external gear profile. The vertical motion external gear profile may engage the jack nut external gear profile. The second driver162rotates the jack nut using torque from the second actuator160thereby transferring torque from second actuator160into axial displacement between movable mount136and trolley184along the length of trolley184. The jack nut gear and the second driver162corresponding to the jack nut gear may be, for example, a worm gear or a pinion gear. The jack nut gear and the second driver162may be a straight-cut gear, a spiral bevel gear, a helical-cut gear, a hypoid gear, or any other appropriate gear style. This arrangement may be applied in like manner to motion of the trolley for displacement of trolley184along the length of rail182.

FIG.10,FIG.10A, andFIG.10Bshow the cleaning head120in accordance with one or more embodiments. The cleaning head120may include more than one of the spray head122.FIG.10Balso shows another embodiment of the bearing details of the movable mount136coupled to the trolley184as shown inFIG.9A. In accordance with one or more embodiments the apparatus101may implement any combination of gears, sprockets, wheels, cylinders, motors, shafts, bearings, motion control, etc. providing similar functionality to that described without departing from the scope of the present disclosure.

FIG.11shows that the cleaning head120may include a cover1100configured to provide protection to the components of the cleaning head120. Cover1100may include a hinge1102. Protection may include protection against intrusion of objects, water, rain, sun, dust, and debris, and may provide protection to users and bystanders from accidental contact. The cleaning head120may include a water ingress protection (IP) rating such as IP66 and the IP rating may be certified by a certification authority. The IP rating may meet or exceed an international standard such as International Electrotechnical Commission code IEC 60529 and corresponding with Euronorm 60529. The cleaning head120may include a closing latch1104equipped with an interlock switch1106to apply or remove power to the washing mechanism such as the cleaning head120, the pump140, and/or the control system190. The closing latch prevents the system from operating by interrupting the flow of electricity to the system when a specific condition is met or not met. The closing latch may be used in cases such as during preventive maintenance, repair work, or any other reason. The closing latch may be triggered by activating an emergency shut down such as an emergency push button. Upon activation of the emergency shut down, the closing latch cuts off the power supply thereby preventing the automated mechanism from moving.

Apparatus101may include interlock switches disposed in or on the apparatus101to provide interlocks, via control system190, to the starting point and to the ending point of the travel of the cleaning head120along the carriage frame180. In addition to the travel interlock switches, the apparatus may include mechanical end stops to limit travel. The end stops may be disposed on the carriage frame. The end stops provide a positive means of stopping the cleaning head and/or the trolley travel in the event that the control system and/or the drive do not operate as intended. In this manner the end stops will not be used during normal operation as a means to stop travel. The end stops may include bumpers disposed on the end stops and/or the carriage frame. The end stops may be configured to absorb impacts if the movement of the cleaning head and/or the trolley contacts the end stops. The system may include sensors such as the accessories700including one or more of a motion detector704, surveillance camera (the camera708), and/or proximity sensor706in proximity to the apparatus and/or the cooling tower.

One or more computer-readable media associated with the control system190may also include computer-executable instructions (a program) configured to collect, store, parse, and analyze the operational data of the apparatus. The program may be configured to perform operations consistent with embodiments of the present disclosure, for example, determine current state variables of apparatus, adjust various operating characteristics based on determined values, etc. The program may further arithmetically calculate revised state variables that seek output state goals, such as for example, mathematically seeking target values associated with variables of the apparatus in response to feedback from a workflow in cooperation with the apparatus, the systems, and the methods of the present disclosure. While the apparatus may correspond to the single pump, in some embodiments, the system may correspond to multiple pumps.

The control system may also include a computer system that is the same as or similar to that of computer1202described below inFIG.12and the accompanying description.

FIG.12is a block diagram of a computer1202used to provide computational functionalities associated with described algorithms, methods, functions, processes, flows, and procedures as described in the instant disclosure, according to an implementation. Computer1202is intended to encompass any computing device such as a server, desktop computer, laptop/notebook computer, wireless data port, smart phone, personal data assistant (PDA), tablet computing device, one or more processors within these devices, or any other suitable processing device, including both physical or virtual instances (or both) of the computing device. Additionally, the computer1202may include a computer that includes an input device, such as a keypad, keyboard, touch screen, or other device that can accept user information, and an output device that conveys information associated with the operation of the computer1202, including digital data, visual, or audio information (or a combination of information), or a graphical user interface (GUI.)

The computer1202can serve in a role as a client, a network component, a server, a database or other persistency, or any other component (or a combination of roles) of a computer for performing the subject matter described in the instant disclosure. The computer1202is communicably coupled with a network1216. In some implementations, one or more components of the computer1202may be configured to operate within environments, including cloud-computing-based, local, global, or other environment (or a combination of environments).

At a high level, the computer1202is an electronic computing device operable to receive, transmit, process, store, or manage data and information associated with the described subject matter. According to some implementations, the computer1202may also include or be communicably coupled with an application server, e-mail server, web server, caching server, streaming data server, business intelligence (BI) server, or other server (or a combination of servers).

The computer1202can receive requests over network1216from a client application (for example, executing on another computer1202) and responding to the received requests by processing the said requests in an appropriate software application. In addition, requests may also be sent to the computer1202from internal users (for example, from a command console or by other appropriate access method), external or third-parties, other automated applications, as well as any other appropriate entities, individuals, systems, or computers.

Each of the components of the computer1202can communicate using a system bus1204. In some implementations, any or all of the components of the computer1202, both hardware or software (or a combination of hardware and software), may interface with each other or the interface1206(or a combination of both) over the system bus1204using an application programming interface (API1212) or a service layer1214(or a combination of the API1212and service layer1214. The API1212may include specifications for routines, data structures, and object classes. The API1212may be either computer-language independent or dependent and refer to a complete interface, a single function, or even a set of APIs. The service layer1214provides software services to the computer1202or other components (whether or not illustrated) that are communicably coupled to the computer1202.

The functionality of the computer1202may be accessible for all service consumers using this service layer. Software services, such as those provided by the service layer1214, provide reusable, defined business functionalities through a defined interface. For example, the interface may be software written in JAVA, C++, or other suitable language providing data in extensible markup language (XML) format or another suitable format. While illustrated as an integrated component of the computer1202, alternative implementations may illustrate the API1212or the service layer1214as stand-alone components in relation to other components of the computer1202or other components (whether or not illustrated) that are communicably coupled to the computer1202. Moreover, any or all parts of the API1212or the service layer1214may be implemented as child or sub-modules of another software module, enterprise application, or hardware module without departing from the scope of this disclosure.

The computer1202includes an interface1206. Although illustrated as a single one of the interface1206, more than one of the interface1206may be used according to particular desires or implementations of the computer1202. The interface1206is used by the computer1202for communicating with other systems in a distributed environment that are connected to the network1216. Generally, the interface1206includes logic encoded in software or hardware (or a combination of software and hardware) and operable to communicate with the network1216. More specifically, the interface1206may include software supporting one or more communication protocols associated with communications such that the network1216or interface's hardware is operable to communicate physical signals within and outside of the computer1202.

The computer1202includes at least one of a computer processor1218. Although illustrated as a single one of the computer processor1218, two or more processors may be used according to particular desires or particular implementations of the computer1202. Generally, the computer processor1218executes instructions and manipulates data to perform the operations of the computer1202and any algorithms, methods, functions, processes, flows, and procedures as described in the instant disclosure.

The computer1202also includes a memory1208that holds data for the computer1202or other components (or a combination of both) that can be connected to the network1216. For example, the memory1208may include a database storing data and/or processing instructions consistent with this disclosure. According to further embodiments, memory1208may correspond, for example, to control memory198where a computer1202has been implemented as a controller for apparatus101. Although illustrated as a single one of the memory1208, two or more memories may be used according to particular desires and/or implementations of the computer1202and the described functionality. While memory1208is illustrated as an integral component of the computer1202, in alternative implementations, memory1208can be external to the computer1202.

The application1210is an algorithmic software engine providing functionality according to particular desires and/or particular implementations of the computer1202, particularly with respect to functionality described in this disclosure. For example, application1210can serve as one or more components, modules, applications, etc. Further, although illustrated as a single one of application1210, the application1210may be implemented as more than one of the application1210on the computer1202. In addition, although illustrated as integral to the computer1202, in alternative implementations, the application1210can be external to the computer1202.

There may be any number of the computer1202associated with, or external to, a computer system containing computer1202, each one of the computer1202communicating over network1216. Further, the term “client,” “user,” and other appropriate terminology may be used interchangeably as appropriate without departing from the scope of this disclosure. Moreover, this disclosure contemplates that many users may use one of the computer1202, or that one user may use more than one of the computer1202.

FIG.13illustrates a method (Block1300) for automatically and continuously controlling and monitoring an apparatus for cooling tower cleaning. Further, one or more steps inFIG.13may be performed by one or more components as described inFIGS.1A-12(e.g., apparatus101). While the various steps inFIG.13are presented and described sequentially, one of ordinary skill in the art will appreciate that some or all of the steps may be executed in different orders, may be combined or omitted, and some or all of the steps may be executed in parallel. Furthermore, the steps may be performed actively or passively. Users may launch an automated software for operating the apparatus101. The user may acknowledge various steps of the method by clicking on, in the input interface, text descriptions of the steps.

Referring toFIG.13, initially apparatus101is provided (Block1310) for spraying the cleaning fluid. An operator or user may then set up the apparatus101(Block1320) by disposing the apparatus101in proximity to the louver104of the cooling tower102. The control system may have a feature for integrating motion sensors and cameras and for checking they are functioning correctly and may include an interlock for an occasion when they are not. The user may install motion detection sensors, surveillance cameras, and/or proximity sensors in proximity to the cooling tower102and apparatus101. The control system may therefore require the user to confirm or override the interlock.

Continuing with setting up the apparatus101, the user may connect the fluid supply112to the pump inlet142and connect any external power source, such as power supply194, to the apparatus101. The user may fill the reservoir130at the reservoir inlet132.

Continuing with setting up the apparatus101, the user may utilize a cleaning program and may input the program criteria into the control panel192of control system190. The data that the user inputs into the control panel may be the user commands and/or the user inputs. User commands may be, for example, start, stop, and emergency shutdown. The user inputs may comprise the program data to meet the program criteria. Program data may cause the cleaning fluid to be sprayed at preselected portions of the louver at preselected times. The cleaning head120may operate through a preset cycle or cycles or it can be operated anytime as needed.

The cleaning program begins by the control system receiving from a user a command to spray the cleaning fluid, i.e., by the user sending a command to actuate the apparatus101. (Block2230). The control system may in turn send the command to the apparatus and upon receipt of the command, the pump140may turn on (Block2240). The pump may then draw cleaning fluid110from fluid supply112and/or from reservoir outlet134of reservoir130. The cleaning fluid110is drawn into the pump inlet142and through the pump140to pressurize the cleaning fluid110to form the pressurized fluid114. Cleaning fluid110from fluid supply112may flow to the pump inlet142through conduit170. The monitoring subsystem may monitor the pressure of the pressurized fluid114at the pump outlet144and adjust the pump140, as necessary. The pressurized fluid114flows from the pump outlet144to the head inlet124of spray head122.

The method continues by directing the pressurized fluid114of the cleaning fluid110out of the head outlet126of spray head122of the cleaning head120at the planar surface106of the louver104, e.g., spraying the pressurized fluid114onto the planar surface106of the louver104(Block1350).

The cleaning program continues by sending a command to the first actuator154and/or the second actuator160to begin cleaning preselected portions of the louver104by traveling along the preselected path of carriage frame180(Block1360). The control system190, the power supply194, the processor196, and the control memory198may cooperate with the monitoring subsystem to direct the cleaning head120along the preselected cleaning path. The control memory may comprise a set of instructions configured to obtain a command to spray the pressurized fluid114, turn on the pump140to pressurize the cleaning fluid110to the preselected pressure, direct the pressurized fluid114at the planar surface106of the louver104, and to move the spray head122in the cleaning head120on a preselected path using the movable mount136and the first actuator154and/or the second actuator160. The path may include any one or all of the one orthogonal direction, two orthogonal directions, or three orthogonal directions. The path may include moving the cleaning head120using the movable mount136along the rail182, the trolley184, and/or the third orthogonal direction187. The movable mount136may direct the cleaning head120along the path using connector rail188to transition between any one or all of the orthogonal directions.

Upon completion of the cleaning program, the cleaning program begins a shutdown sequence. The shutdown sequence may include disengaging the pump and/or returning the cleaning head120to a start point and/or to an end point.

Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.