Diaphragm Pump Flow Rate Detection Using Optical Sensor
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Solution Overview
Problem
Existing diaphragm pumps require either a brushless motor or a custom-designed brushed motor to detect discharge flow rate, which are more expensive than ready-made motors, making it costly to implement flow rate detection.
Innovation Solution
A diaphragm pump design that uses a ready-made brushed motor and incorporates a counting sensor to detect the reciprocal motion of the driving mechanism's arm portion, allowing for flow rate calculation without the need for motor speed detection functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a brushless motor or custom-designed brushed motor with rotation speed detection function is used, then discharge flow rate detection is enabled, but motor cost increases
Solution Approach 1:
A light-shielding plate is introduced as an intermediary component attached to the crank. This plate periodically blocks the light sensor's detection target, creating detection signals that correspond to the crank's rotational position. This intermediary mechanism enables flow rate detection using a simple, inexpensive brushed motor without requiring complex motor control boards or custom motor designs.
Solution Approach 2:
The patent replaces the need for complex motor speed detection mechanisms (Hall devices, current waveform analysis, or integrated impeller sensors) with a simple optical detection system. The light sensor and light-shielding plate combination substitutes for expensive motor control electronics, achieving the same flow rate detection function through a much simpler and cheaper mechanical-optical system.
2Measurement precision
If rotation speed detection function is integrated into the motor, then discharge flow rate can be detected, but device complexity increases
Solution Approach 1:
The detection function is segmented from the motor itself and placed in the pump housing. The light sensor and light-shielding plate are separate components that work together to provide detection signals. This segmentation allows the motor to remain a simple, standard brushed motor while the detection function is implemented through separate, simple components in the pump assembly.
Solution Approach 2:
The light-shielding plate acts as a mediator between the crank's mechanical motion and the light sensor's detection. By attaching this simple plate to the crank, the system converts mechanical rotation into periodic light blockage events that the sensor can easily detect, without requiring any complexity within the motor itself.
3Ease of manufacture
If a ready-made brushed motor is used without rotation speed detection, then cost is reduced, but discharge flow rate detection becomes impossible
Solution Approach 1:
The light-shielding plate attached to the crank serves as an intermediary that enables detection functionality without modifying the motor. As the crank rotates, the plate periodically blocks the light sensor's view, creating detection signals that correspond to each rotation cycle. This allows a simple brushed motor to provide both drive and detection functions through the addition of this single, simple component.
Solution Approach 2:
The crank serves dual functions: it converts motor rotation into reciprocating motion for pumping, and simultaneously carries the light-shielding plate that enables flow rate detection. This multi-functionality allows the same mechanical component to serve both the pumping action and the detection reference, eliminating the need for separate detection mechanisms.
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
Enables accurate detection of discharge flow rate using an inexpensive ready-made motor, reducing costs and maintaining high detection accuracy.
Implementation Method 1
a sensor configured to use the reciprocal motion portion as a detection target and alternately switch between a detection state and a non-detection state as the reciprocal motion portion makes a reciprocal motion
Data Source
AI summary
A diaphragm pump includes a driving mechanism and a counting sensor. The driving mechanism includes an arm portion attached to a deformed portion that forms a pump chamber, and a crank that rotates integrally with the rotating shaft of a motor, in which the rotation of the crank is converted into a reciprocal motion to make the arm portion reciprocally move. The counting sensor is configured to use the arm portion as a detection target and alternately switch between a detection state and a non-detection state as the arm portion makes the reciprocal motion. It is therefore possible to provide a diaphragm pump capable of detecting a discharge flow rate using an inexpensive ready-made motor.