Air Operated Diaphragm Pump Control System Using Pressure Feedback

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Solution Overview

Problem

Air-operated diaphragm pumps face inefficiencies due to inherent reaction and delay times in their operation, which affect the speed and accuracy of fluid movement, particularly in pumping harsh materials like concrete.

Innovation Solution

A control system is implemented using a pressure sensor and controller to detect the position of diaphragms and adjust the supply of pressurized air, compensating for delays by anticipating the movement of pump components and optimizing the air supply timing to reduce delays and increase pump speed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If pressurized air is supplied continuously to the pump chamber, then the pump member can maintain continuous movement, but the pump member cannot be precisely controlled to stop at the second position, causing energy waste and reduced efficiency

Engineering Contradiction:

Improvepump speedVSAvoidenergy waste

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The controller activates the air supply valve before the pump member reaches the second position, anticipating the movement and ensuring the valve closes at the optimal moment to prevent energy waste while maintaining pump speed

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses pressure sensor feedback to detect the pump member's position and controls the air supply timing accordingly, creating a closed-loop system that optimizes energy efficiency while maintaining productivity

Inventive Principle:

Principle #23Feedback

2Loss of energy

If the air supply valve closes exactly when the pump member reaches the second position, then energy efficiency is maximized, but reaction and delay times prevent precise timing, reducing pump speed

Engineering Contradiction:

Improveenergy efficiencyVSAvoidpump speed

Core Design Contradiction:

Loss of energyVSSpeed

Solution Approach 1:

The controller activates the air supply valve before the pump member reaches the second position, compensating for reaction and delay times. This preliminary activation ensures the valve closes at the optimal moment, simultaneously achieving energy efficiency and high pump speed

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Pressure sensor feedback enables precise timing of the air supply valve closure by detecting the pump member's actual position, allowing the system to compensate for delays and optimize both energy efficiency and pump speed

Inventive Principle:

Principle #23Feedback

3Speed

If the pump member is moved quickly to the second position, then pump speed increases, but the pressurized fluid may flow into the pumping chamber before the pump member stops, causing loss of pressure and reduced efficiency

Engineering Contradiction:

Improvepump speedVSAvoidpressure loss

Core Design Contradiction:

SpeedVSStress or pressure

Solution Approach 1:

The controller activates the air supply valve before the pump member reaches the second position, creating a timing advantage that prevents pressurized fluid from flowing into the pumping chamber during the transition, thereby maintaining pressure while achieving high pump speed

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Pressure sensor feedback allows the controller to precisely timing the air supply valve closure to prevent pressure loss, while the preliminary activation ensures the valve closes before the pump member stops, maintaining both speed and pressure

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The control system enhances the operating speed and efficiency of air-operated diaphragm pumps by minimizing delays and optimizing air supply, leading to improved fluid discharge rates and reduced energy consumption.

Implementation Method 1

The pressure sensor is positioned to detect a pressure in at least one of the first and second diaphragm chambers and to output a signal indicative thereof

Methodology Applied

Scientific EffectPressure detection: