Automated Chemical Usage Calculation via Electronic Scale Integration
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Solution Overview
Problem
Municipal water and wastewater treatment plants face challenges in accurately tracking and documenting chemical usage for regulatory compliance, as traditional methods like weighing scales are not automated and can lead to inaccuracies in recording feed rates and remaining chemical quantities.
Innovation Solution
A system comprising a chemical tank mounted on an electronic scale, connected to a system controller that calculates chemical usage by monitoring weight changes and fill times, allowing for automated and accurate tracking of chemical usage during refilling processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional weighing scales are used to track chemical usage, then the system is simple, but the measurement precision and automation are insufficient
Solution Approach 1:
The patent replaces manual weighing scale operations with an automated electronic scale system that integrates with a controller. The electronic scale automatically detects weight changes, and the controller processes this data to calculate chemical usage, eliminating manual intervention while improving measurement precision through automated data processing and electronic sensing.
Solution Approach 2:
The system performs self-service by automatically monitoring its own chemical usage through integrated sensors and controllers. The electronic scale continuously weighs the tank, the controller automatically calculates usage based on weight changes and fill times, and the system self-reports data without requiring external manual measurement or recording operations.
2Productivity
If manual tracking methods are used, then the device complexity is low, but the productivity and automation level are reduced
Solution Approach 1:
The patent implements continuous monitoring where the electronic scale continuously weighs the chemical tank during filling operations. The controller continuously processes weight change data, calculates chemical usage in real-time, and maintains continuous records without interruption. This continuous automated action eliminates manual tracking gaps and significantly improves documentation efficiency.
Solution Approach 2:
The system replaces manual tracking mechanisms with an automated electronic control system that handles all chemical usage calculations and documentation. The controller automatically processes data from the electronic scale, computes feed rates and remaining quantities, and maintains digital records, thereby achieving high productivity with full automation.
3Extent of automation
If automated electronic scales are used, then the extent of automation is improved, but the device complexity increases
Solution Approach 1:
The patent merges the electronic scale, controller, and chemical tank monitoring into an integrated system. These components work together as a unified automated assembly where the scale connects directly to the controller which then processes all data. This merging reduces overall system complexity compared to having separate manual tracking systems, while maintaining high automation levels.
Solution Approach 2:
The controller serves multiple functions: it processes data from the electronic scale, calculates chemical usage, determines feed rates, computes remaining quantities, and maintains documentation records. This multi-functionality consolidates what would otherwise require separate devices or manual processes, thereby improving automation without proportionally increasing system complexity.
4Measurement precision
If accurate chemical usage calculations are performed, then the measurement precision is improved, but the loss of time in calculation and processing increases
Solution Approach 1:
The controller continuously calculates chemical usage in real-time as the electronic scale monitors weight changes during filling operations. Rather than performing calculations after the fact, the system continuously processes data streams, immediately determining feed rates and remaining quantities. This continuous calculation approach maintains high precision while minimizing time delays.
Solution Approach 2:
The patent replaces time-consuming manual calculations with automated electronic computation. The controller uses electronic data processing to instantly calculate chemical usage based on weight changes, eliminating the need for manual measurement and computation. This electronic substitution provides accurate real-time results without the time loss associated with manual methods.
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 provides accurate and automated calculations of chemical usage, ensuring compliance with regulations and enhancing safety by maintaining precise records of feed rates and remaining chemical quantities, applicable to various chemicals and treatment processes.
Implementation Method 1
a first supply tank of known capacity, the tank mounted upon an electronic scale, the scale being capable of generating a series of signals related to the weight of the tank
Data Source
AI summary
A system and method of calculating chemical usage during a refilling of a supply tank, which includes the steps of providing a chemical system having a first supply tank of known capacity, wherein the tank is mounted upon an electronic scale. A system controller receives a series of signals from the scale relating to the weight of the tank when empty and at various levels of fill. The first supply tank is filled from a source of chemical feed and the fill time for the filling of the first supply tank is obtained. The system controller inputs the series of signals from the scale relating to the weight of the tank when empty and at various levels of fill and calculates a usage during refilling based on a feed rate times the fill time.