Flow Meter FIFO Control for Small-Volume Process Sequencing
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Solution Overview
Problem
Traditional sequential control methods for processes like washing in food handling facilities are complex, time-consuming, and difficult to manage, especially when handling small volumes or dealing with deviations, making them inaccurate and inflexible.
Innovation Solution
A method utilizing a FIFO register and flow meters to simplify and accurately control processes by tracking the sequence of events in real-time, reducing the number of sequence steps and enabling precise control of small volumes through a dynamic product memory that synchronizes the process with a predetermined cycle of events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional sequential control methods are used to control washing processes, then the control can be implemented, but the programming becomes complex and time-consuming
Solution Approach 1:
The patent segments the washing process into discrete, standardized steps that can be independently defined and reused. Each washing step (pre-rinse, wash, rinse, etc.) is broken down into separate controllable units with specific volume requirements, allowing complex washing programs to be constructed by combining these basic segments rather than programming entire sequences from scratch.
Solution Approach 2:
The system dynamically adjusts the washing process by continuously monitoring actual volumes processed and automatically calculating required volumes for subsequent steps. The control method adapts to variations in product volume, flow rates, and process conditions in real-time, making the control sequence flexible rather than rigidly predetermined.
2Adaptability or versatility
If sequential control is used to handle various washing programs, then different washing processes can be controlled, but major reworking of sequences is required for changes
Solution Approach 1:
The patent creates a universal control framework that can handle multiple types of washing processes (pre-rinse, wash, rinse, sanitize, etc.) through a single standardized methodology. The system uses generic volume tracking and step-based control that applies to all washing programs, eliminating the need to create separate control sequences for different washing scenarios.
Solution Approach 2:
The system pre-defines standardized washing steps with typical volume ranges and characteristics before actual washing begins. These pre-configured steps serve as templates that can be quickly selected and adjusted for different washing programs, avoiding the need to program entire sequences from scratch when adapting to new requirements.
3Reliability
If sequential control with many steps is used for complex processes, then comprehensive control is achieved, but the control becomes difficult to overview and manage
Solution Approach 1:
The patent extracts the essential control element from complex sequential processes - the volume parameter. By focusing control decisions primarily on volume tracking and comparison rather than managing numerous sequential steps, the system simplifies the control overview while maintaining comprehensive process control. The complex volume calculations are handled automatically by the system rather than requiring manual oversight of each step.
4Measurement precision
If traditional sequential control is used, then process control can be implemented, but accuracy in handling small volumes is difficult
Solution Approach 1:
The patent changes the control parameter from time-based sequential steps to volume-based continuous monitoring. By using volume as the primary control parameter with precise measurement and calculation, the system achieves high accuracy in handling small volumes. The methodology includes detailed volume tracking through flow meters and automatic calculation of required volumes, providing precise control regardless of volume size.
Data Source
Figure 1
AI summary
The present invention relates to a method of controlling a process. The process is carried into effect in an installation or a facility which includes closed conduits (2, 3) filled with a liquid, process equipment filled with the liquid, control equipment, as well as at least one flow meter. The flow meter emits pulses to a register in the control equipment. The register is stepped forwards by the pulses, so that the register, together with the control equipment, emits signals for executing the process steps necessary for the process cycle.