Brushless DC Pump System Ratio Control via Inter-Controller Communication
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Solution Overview
Problem
Plural component systems face challenges in maintaining accurate ratios of liquid components, which are crucial for reactions that are time and temperature dependent, especially in applications like coating and insulation, where precise delivery is essential.
Innovation Solution
A plural component pump system utilizing two brushless DC motors to drive reciprocating piston pumps, with a communication interface between controllers to ensure accurate delivery of liquid components at user-selected ratios, allowing for independent or linked operation of pump units to achieve precise ratio control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If independent pump operation is used, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The system dynamically switches between independent pump operation mode and linked operation mode. In independent mode, each pump operates autonomously for ease of use. In linked mode, the second pump's operation is synchronized with the first pump via communication interface to achieve precise delivery ratios. This dynamic switching resolves the contradiction by allowing the system to adapt its control strategy based on operational requirements.
2Manufacturing precision
If linked pump operation is used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
A communication interface acts as an intermediary between the two pump controllers. This intermediary enables synchronized operation and precise ratio control by transmitting control signals between pumps, while keeping each pump's internal structure relatively simple. The communication interface handles the complexity of coordination, allowing precise delivery ratios without significantly increasing the complexity of individual pump units.
3Device complexity
If traditional pump control is used, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The system implements feedback control where the communication interface continuously monitors and adjusts the operation of the second pump based on the first pump's performance. This feedback mechanism ensures accurate delivery ratios by making real-time adjustments to maintain the desired component ratio, achieving high measurement precision without requiring overly complex pump hardware.
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 system ensures accurate and precise delivery of liquid components at desired ratios, maintaining pump speeds within a few percent of set values, enabling reliable chemical reactions and improved performance in applications such as coating and insulation.
Implementation Method 1
a first brushless DC motor configured to drive a first pump and a second brushless DC motor configured to drive a second pump
Data Source
AI summary
A plural component pump system is provided for delivering plural liquid components at a selected ratio. The pump system includes a first brushless DC motor configured to drive a first pump that pumps a first liquid component to an output and a second brushless DC motor configured to drive a second pump that pumps a second liquid component to the output. The pump system includes a first controller configured to control the first motor and a second controller configured to control the second motor. The pump system also includes a communication interface between the first controller and the second controller. The first controller is configured to send a signal to the second controller using the communication interface and the second controller is configured to control the second motor based on the signal to deliver the first and second liquid components to the output at the selected ratio.