Automated Acid Mixing System with pH Feedback Control
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Solution Overview
Problem
Current acid solution mixing systems in the medical field require significant labor and are prone to errors in pH and concentration, which can lead to catastrophic results, especially in applications like hemodialysis, due to manual handling and lack of efficient quality control.
Innovation Solution
A system for automatically mixing and testing acid solutions using a hopper, mix tank, and controller with sensors and RFID technology to ensure accurate pH and concentration, minimizing user labor and preventing mismatched batch transfers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual handling and mixing methods are used, then device complexity is reduced, but manufacturing precision and reliability deteriorate due to errors in pH and concentration
Solution Approach 1:
The patent replaces manual mechanical mixing operations with an automated system that uses a recirculation pump to circulate the solution through a mixing chamber where dry powder is added. The system automatically controls the mixing process, eliminating manual handling errors and ensuring consistent pH and concentration accuracy.
Solution Approach 2:
The system incorporates automatic pH sensing and control capabilities where the pH sensor continuously monitors the solution and the system self-adjusts by adding dry powder or water as needed to maintain the target pH, reducing the need for complex manual intervention while maintaining high precision.
2Productivity
If automated mixing systems are implemented, then productivity is improved, but device complexity increases due to additional components and controls
Solution Approach 1:
The recirculation pump serves multiple functions: it circulates the solution through the mixing chamber, transports the solution to the storage tank, and enables continuous mixing by recirculating the solution. This multi-functionality reduces the need for separate components, improving productivity while limiting the increase in device complexity.
Solution Approach 2:
The patent combines the mixing chamber, pH sensor, and powder addition mechanism into an integrated assembly that works together as a unified system. The recirculation loop merges the functions of mixing, transportation, and storage preparation into a single continuous process, enhancing productivity without proportionally increasing complexity.
3Measurement precision
If manual pH testing and adjustment are performed, then measurement precision may be sufficient, but loss of time increases due to repeated testing and re-mixing
Solution Approach 1:
The pH sensor continuously monitors the solution pH during the mixing process rather than requiring periodic manual sampling and testing. The recirculation system continuously circulates the solution through the mixing chamber, ensuring constant mixing and continuous pH measurement, which eliminates the time loss associated with stopping to test and re-mix batches.
Solution Approach 2:
The system incorporates real-time pH feedback where the sensor continuously measures the solution pH and the controller automatically adjusts the mixing process by controlling powder addition or water addition to maintain the target pH, eliminating the need for repeated manual testing and re-mixing while maintaining measurement precision.
4Productivity
If batch transfer operations are performed without verification, then productivity is improved, but reliability deteriorates due to mismatched batch transfers
Solution Approach 1:
The system performs preliminary verification of batch identity using RFID tags before the transfer operation. The RFID reader scans the tag on the storage tank to verify that the batch to be transferred matches the intended batch, preventing mismatched transfers before they occur and maintaining both productivity and reliability.
Data Source
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AI summary
A system for mixing a liquid with a powder into a solution batch includes a hopper (20) into which said powder is deposited, the hopper (20) having a powder outlet (22) therein. A mix tank (60) is also provided having a liquid supply inlet (62), a recirculation inlet (64), and a solution outlet (66). A mix pump (40) that is in fluid communication with the solution outlet (66), the powder outlet (22), and the recirculation inlet (64) operates to mix and transfer the solution.