Dosing Pump Volume Calibration Using Container Level and Pressure
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Solution Overview
Problem
Existing dosing pumps in vehicle washing systems suffer from inaccuracies due to manufacturing tolerances, requiring time-consuming manual recalibration, and are limited by fixed container sizes, leading to inefficient chemical consumption and operational costs.
Innovation Solution
A computer-implemented method determines the actual delivery volume of a dosing pump using digital level and pressure values, enabling automatic calibration and accurate substance delivery without electronic controls, allowing for variable container sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual stroke adjustment is used on dosing pumps, then the dosing setting can be changed, but manufacturing tolerances cause increasing inaccuracy as the dosing setting becomes smaller
Solution Approach 1:
The system continuously measures the actual delivery volume using level sensors and pressure sensors, compares it with the target delivery volume, and automatically adjusts the pump stroke to compensate for manufacturing tolerances and maintain precise dosing across all setting ranges
Solution Approach 2:
The patent replaces manual mechanical stroke adjustment with an automated control system that uses electronic sensors and actuators to precisely control the pump stroke, eliminating the inaccuracy inherent in manual mechanical systems
2Measurement precision
If manual re-measuring process with measuring cylinder is used for calibration, then reference value for actual delivery rate can be obtained, but the procedure is time-consuming and causes cost-intensive measuring activities
Solution Approach 1:
The dosing system performs self-calibration by automatically measuring its own delivery volume using integrated level sensors and pressure sensors, eliminating the need for external manual calibration with measuring cylinders and reducing both time and cost
Solution Approach 2:
The patent replaces manual mechanical calibration procedures with an automated electronic measurement and control system that continuously monitors and adjusts delivery volume, eliminating time-consuming manual intervention
3Ease of manufacture
If fixed container sizes and shapes are used, then the dosing system structure is simplified, but the car wash operator is tied to fixed container sizes and structural adjustments are required when changing chemical suppliers
Solution Approach 1:
The system uses level sensors and pressure sensors that can adapt to different container geometries, making the dosing system universal and compatible with various container sizes and shapes from different chemical suppliers without requiring structural modifications
Solution Approach 2:
The patent changes the measurement parameters from fixed geometric assumptions to dynamic sensor-based measurements of level and pressure, allowing the system to adapt to different container configurations by measuring actual substance volume rather than relying on fixed container dimensions
4Device complexity
If dosing pumps are not electrically open or closed loop controlled, then the pump structure is simpler, but accurate determination of actual delivery rate cannot be achieved
Solution Approach 1:
The system uses level sensors and pressure sensors to continuously measure the actual delivery volume and provides feedback to the control system, enabling accurate determination of delivery rate while maintaining relatively simple pump structure
Solution Approach 2:
The patent introduces sensor-based measurement systems as intermediaries between the mechanical dosing pump and the control system, allowing accurate measurement and control without requiring complex electronic integration into the pump itself
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 precise substance delivery, reduces chemical consumption, and enhances operational efficiency by allowing flexible use of different containers, improving the quality and cost-effectiveness of vehicle washing processes.
Implementation Method 1
a digital pressure value which represents a pressure difference between two points in time measured in the container by means of at least one analog pressure sensor
Data Source
AI summary
A computer-implemented method for determining a delivery volume for use in a vehicle washing system. The method includes reading in a container data record for the container from which the substance is to be delivered by means of the dosing pump; reading in a digital level value representing a level measured in the container by means of at least one analog level sensor or reading in a digital pressure value representing a pressure measured in the container by means of at least one analog pressure sensor and reading in a digital density value for the substance to be delivered by the dosing pump, determining and outputting the delivery volume delivered by the dosing pump in a measuring time interval, based on the read-in digital level value or the read-in digital pressure value and the read-in density value and on the basis of the read-in vessel data record.