Automatic Dilution System Overflow Protection
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Solution Overview
Problem
Existing systems fail to provide a controlled method for dissolving solid chemical cakes and delivering the resulting solution based on the level of the holding tank, lacking automatic pressure regulation and overflow prevention.
Innovation Solution
A chemical solution dispensing apparatus using a dissolving tank with a gravity-fed system, equipped with a liquid level sensor and pressure regulator, which controls water flow into the dissolving tank based on the holding tank's liquid level, preventing overflow and ensuring consistent solution delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid chemical cake is dissolved in a tank and fed to a downstream application, then the chemical solution can be delivered, but the system lacks automatic pressure regulation and overflow prevention capabilities
Solution Approach 1:
The patent implements automatic level control using float sensors that detect liquid levels and provide feedback to control valves. When the liquid level reaches a predetermined high level, the float sensor activates a valve to stop inflow, preventing overflow. This closed-loop feedback mechanism ensures reliable overflow prevention without requiring complex manual monitoring systems.
Solution Approach 2:
The system employs self-regulating pressure reduction valves that automatically maintain constant pressure downstream without external control. The valve inherently responds to pressure changes and self-adjusts to maintain the set pressure, eliminating the need for complex external pressure regulation systems while ensuring reliable operation.
2Reliability
If manual monitoring of chemical solution levels is used, then the system structure can be simple, but overflow and depletion cannot be prevented
Solution Approach 1:
Float sensors are positioned at critical levels (high and low points) to continuously monitor liquid levels and provide automatic feedback control. When the liquid level reaches the high point, the float-actuated valve closes to prevent overflow. When the level drops to the low point, another float triggers replenishment. This automatic feedback eliminates the need for manual monitoring while maintaining simple system architecture.
Solution Approach 2:
The patent replaces manual visual monitoring and manual valve operation with automatic float-actuated mechanical valves. The float mechanism translates liquid level position into automatic valve actuation, eliminating the need for human operators to continuously monitor and respond to level changes, thereby improving reliability without significantly increasing complexity.
3Reliability
If pressure regulation is not implemented, then the system can be simpler, but consistent solution delivery cannot be ensured
Solution Approach 1:
The patent employs self-regulating pressure reduction valves that automatically maintain constant downstream pressure without external control systems. These valves inherently respond to pressure fluctuations and self-adjust to maintain the predetermined pressure setting, ensuring consistent solution delivery to downstream applications while keeping the pressure control mechanism simple and reliable.
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 controlled and automatic delivery of chemical solutions, maintaining adequate levels in the holding tank while preventing overflows, ensuring consistent and efficient operation.
Implementation Method 1
A liquid level sensor in the holding tank senses the liquid level of the solution
Implementation Method 2
A pressure regulator and controller enable the conduit line to be properly pressurized by an inlet source of water
Implementation Method 3
The dissolving tank receives water forming a chemical solution and then delivers the chemical solution into a holding tank by gravitational flow
Data Source
AI summary
A chemical solution dispensing apparatus uses a dissolving tank to hold a solid chemical cake. The dissolving tank delivers the chemical solution into a holding tank by gravitational flow and then to a receiving system. A liquid level sensor in the holding tank senses the liquid level of the solution and calls for water delivery through a conduit into the dissolving tank. When the level reaches a low point a circuit opens a inlet flow valve to deliver water into the dissolving tank. When the level reaches a high point, the circuit closes a safety shutoff valve in the conduit line. A pressure regulator and control relay enable the conduit line to be properly pressurized by an inlet source of water through a shutoff valve that is normally open. When the level in the holding tank rises above the high point, an alarm signal is released to initiate an audible alarm.