Diaphragm Pump Assembly for Consistent Frozen Dessert Overrun
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Solution Overview
Problem
Existing frozen dessert machines struggle with inconsistent air and liquid mix delivery to the freezing chamber, leading to undesirable foam formation or air pockets due to variable dispense rates, which traditional pumps cannot handle effectively.
Innovation Solution
A pump assembly comprising a diaphragm pump, overrun unit, and control unit that maintains constant air pressure and volume delivery to the freezing chamber, adjusting speed to match dispense rates without the need for pressure sensors or relief valves, using a diaphragm assembly with a reciprocating mechanism and adjustable overrun chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional pump runs at a fixed speed, then the pump structure is simple, but the air and liquid mix delivery becomes inconsistent leading to foam formation or air pockets
Solution Approach 1:
The pump system transitions from fixed-speed operation to variable-speed operation, allowing the pump to dynamically adjust its speed according to the dispense rate requirements. This enables consistent air-to-liquid mix ratios regardless of whether the operator is dispensing slowly or quickly, eliminating foam formation and air pockets while maintaining product quality.
Solution Approach 2:
The system changes the operational parameters of the pump by varying its speed rather than maintaining a constant speed. This parameter adjustment allows the pump to deliver the precise amount of air and liquid mix needed at different dispense rates, ensuring consistent product quality without requiring complex additional components.
2Productivity
If the pump delivers more liquid mix than required, then the pump can maintain high productivity, but excess liquid is dumped back creating foam
Solution Approach 1:
The system incorporates feedback control where the pump speed is continuously adjusted based on the actual dispense rate. This feedback mechanism ensures that the pump delivers exactly the amount of liquid mix needed without over-delivery, preventing excess liquid from being dumped back into the hopper and creating foam, while still maintaining high productivity when needed.
3Ease of operation
If the pump delivers less liquid mix than required, then the pump can maintain simple operation, but air pockets form due to insufficient delivery
Solution Approach 1:
The pump system automatically adjusts its own operation to meet the dispense requirements without requiring manual intervention or complex external control. The variable-speed capability allows the pump to self-regulate its delivery rate to match the operator's dispense pace, ensuring adequate liquid mix delivery while maintaining ease of operation through automatic adaptation.
4Speed
If the pump speed is increased to match fast dispense rates, then the liquid mix delivery improves, but the pump cannot keep up with very fast dispense rates
Solution Approach 1:
The pump system employs dynamic speed adjustment capabilities that allow it to respond in real-time to varying dispense rate demands. By continuously adapting its speed rather than operating at a fixed maximum, the pump can keep up with even very fast dispense rates, ensuring adequate liquid mix and air delivery throughout the entire range of operational speeds.
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
Ensures consistent air and liquid mix delivery to the freezing chamber, preventing foam formation and air pockets, thereby maintaining optimal dessert quality and efficiency across varying dispense rates.
Implementation Method 1
a reciprocating diaphragm assembly including a diaphragm extending across the internal chamber. The diaphragm divides the internal chamber into a gas chamber on a first side of the diaphragm and a liquid mix receiving chamber on a second, opposite side of the diaphragm
Implementation Method 2
Upstream, the pump assembly is connected to an air pressure source. Downstream, the pump assembly is connected to the freezing chamber
Data Source
AI summary
A pump assembly for delivering liquid dessert to the freezing chamber of a soft serve machine where it is formed into frozen dessert. The pump includes a reciprocating diaphragm pump, an overrun unit, pressure chamber and control unit. The overrun unit is charged with pressurized air from an external pressure source. The pressure chamber receives liquid dessert from the pump, combines the liquid dessert with pressurized air from the overrun unit, and delivers the liquid dessert to the freezing chamber of an ice cream machine. The pump assembly is configured so that the pressure and of the air, and the volume of air delivered by the overrun unit to the pressure chamber per stroke of the pump is constant over the operating range of dispense rates of frozen dessert from an associated freezing chamber.