Dosing Pump Calibration Using Container Level and Pressure Data
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Solution Overview
Problem
Car wash systems face challenges with manual calibration of metering pumps, which becomes less precise as settings become smaller due to manufacturing tolerances, and require costly measurement activities, while also being limited by fixed container sizes and varying chemical consumption based on vehicle size and washing programs.
Innovation Solution
A computer-implemented method determines the actual delivery volume of a metering pump using digital level and pressure values, allowing for automatic calibration and flexible operation with variable container sizes, eliminating the need for electronic controls and enabling precise substance delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration of dosing pump is performed, then dosing precision can be determined, but the process becomes time-consuming and costly
Solution Approach 1:
The patent replaces the manual mechanical calibration process with an automated electronic system. A control unit automatically controls the dosing pump to deliver a test amount of substance, while a weighing device automatically measures the actual amount delivered. The system then automatically calculates calibration parameters and adjusts dosing settings, eliminating the need for manual calibration operations.
Solution Approach 2:
The dosing system performs self-calibration through automated feedback control. The control unit uses measurements from the weighing device to automatically adjust dosing parameters, enabling the system to calibrate itself without external manual intervention. This self-service capability continuously maintains dosing precision while minimizing time loss.
2Device complexity
If fixed container sizes are used, then dosing system structure is simplified, but adaptability to different chemical consumption requirements is reduced
Solution Approach 1:
The patent implements dynamic adaptability by enabling the dosing system to work with containers of various sizes through electronic control. The control unit can be configured with different container volume parameters, allowing the system to dynamically adjust dosing calculations and operations based on the specific container being used, without requiring structural modifications.
Solution Approach 2:
The system adapts to different container sizes by changing operational parameters rather than physical structure. The control unit accepts container volume as an input parameter and automatically adjusts dosing rates, timing, and delivery calculations to match the specific container configuration, maintaining versatility while keeping the physical structure simple.
3Device complexity
If manual stroke adjustment is used, then device complexity is reduced, but manufacturing tolerances cause increasing inaccuracy at smaller dosing settings
Solution Approach 1:
The patent implements a feedback control mechanism where the actual delivered amount (measured by the weighing device) is compared with the target dosing amount. The control unit uses this feedback information to calculate and apply correction factors, compensating for manufacturing tolerances and ensuring accurate dosing even at small settings while maintaining simple manual stroke adjustment 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
This solution improves the precision and efficiency of chemical delivery, reduces costs, and allows for flexible operation with different container sizes, enhancing the quality of the washing process and optimizing chemical consumption.
Implementation Method 1
a digital pressure value representing a pressure difference measured in the container between two points in time by at least one analog pressure sensor
Implementation Method 2
The actual delivery volume can alternatively or cumulatively be determined based on the digital pressure value, a density value for the substance to be pumped by the dosing pump, and the container data set
Data Source
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AI summary
The present invention relates to a computer-implemented method for determining an actual delivery volume for a metering pump (DP) intended for conveying a substance from a container (B), and which is further equipped with an adjustment means for manually setting a target delivery volume for use in a vehicle washing system (WA).The procedure comprises the following steps: reading a container data set (bds) for the container (B) from which the substance is to be pumped by the metering pump (DP); reading a digital level value (fs) representing a level measured in the container (B) by means of at least one analog level sensor (FSS) or reading a digital pressure value (p) representing a pressure measured in the container (B) by means of at least one analog pressure sensor (DS) and reading a digital density value (ϕ) for the substance to be pumped by the metering pump (DP); determining and outputting the actual delivery volume (ist-fv) that has actually been pumped by the metering pump (DP) in a measurement time interval, based on the read digital level value (fs) or the read digital pressure value (p) and the read density value (ϕ) and on the basis of the read container data set (bds).The quality of the washing process will be improved and the consumption of substances to be added will be reduced.