Electric Dual-Pump Drive for Precise Plural Spray Metering
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Solution Overview
Problem
Existing plural component dispensing systems face challenges in efficiently mixing and dispensing separate inert material components, such as epoxies and polyurethanes, which require immediate mixing to prevent premature curing, and existing drive systems lack precision in controlling the ratio and pressure of component materials.
Innovation Solution
A pumping system utilizing an electric motor with a stator and rotor, coupled with a drive mechanism that converts rotational output to linear input, to reciprocate pistons in both pumps, ensuring simultaneous and precise pumping of first and second component materials, with a controller managing speed profiles for optimal mixing and application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate inert material components are pumped and mixed immediately, then premature curing is prevented, but precise control over mixing ratio and pressure becomes difficult
Solution Approach 1:
The system divides the material handling into separate segments: component A and component B are pumped through separate pathways with independent positive displacement pumps, allowing precise control of each component's flow rate and pressure independently before mixing occurs at the dispensing device
Solution Approach 2:
The controller receives feedback from sensors monitoring pressure and flow rates of both components, and adjusts the pump operations in real-time to maintain precise mixing ratios and pressures, ensuring consistent mixing quality while preventing premature curing
2Device complexity
If a single motor drives multiple pumps, then system complexity is reduced, but precise simultaneous control of multiple pistons becomes challenging
Solution Approach 1:
A single electric motor is combined with a differential mechanism that distributes the motor's rotational output to drive multiple pistons simultaneously. The differential mechanism ensures that each piston receives precisely controlled rotational input, maintaining synchronization and precise reciprocation control while reducing the overall number of motors in the system
Solution Approach 2:
The differential mechanism acts as an intermediary between the single motor and multiple pistons, translating the motor's single rotational input into multiple synchronized rotational outputs that drive the pistons in precise unison, solving the synchronization challenge without requiring multiple independent motors
3Manufacturing precision
If positive displacement pumps are used for each component, then precise metering is achieved, but system complexity and space requirements increase
Solution Approach 1:
Multiple positive displacement pump functions are merged into a single integrated pump unit with a differential mechanism, allowing precise metering of multiple components while reducing the total number of separate pump systems and minimizing space requirements
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 precise control over the ratio and pressure of component materials, preventing premature curing and achieving consistent dispensing of plural component materials with desired properties, such as spray foam, by maintaining segregation of components until mixing occurs.
Implementation Method 1
an electric motor including a stator and a rotor configured to rotate about a pump axis
Implementation Method 2
a drive mechanism directly connected to the rotor and configured to convert a rotational output from the rotor to a linear input
Implementation Method 3
A dispensing device, such as a sprayer or other device, receives each component after it is pumped separately
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
An electrically operated pumping assembly for a plural component spray system includes an electric motor (14) having a stator (88) and a rotor (90). The rotor is disposed coaxially with first and second pumps (26a, 26b) and is configured to cause pumping by each of the first and second pumps. The first and second pumps are configured to pump different component materials to an applicator (34) for forming a plural component spray material. A drive mechanism (86) is disposed between and connected to each of the rotor and the fluid displacement members (70a, 70b) of the first and second pumps. The drive mechanism receives a rotational output from the rotor and provides a linear input to the first and second pumps to cause pumping.