Fluid Dispenser Sensor-Based Refill Correction
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Solution Overview
Problem
Existing paint delivery systems face inaccuracies in fluid metering due to incomplete refill from standard volume containers, leading to misformulation risks and incorrect stock monitoring, as the actual fluid level is not accurately determined before running dry.
Innovation Solution
A fluid dispenser system equipped with a fluid level sensor, such as a field effect sensor, and a control unit that calculates and corrects the fluid level based on input and dispensed amounts, generating alerts and stopping the dispensing cycle when necessary to ensure timely refills and accurate stock control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operator input is used to indicate refill amount, then the system is easy to operate, but measurement precision deteriorates due to incorrect data entry and accumulation of deviations
Solution Approach 1:
The patent replaces the manual operator input system with an automated sensor-based measurement system. Sensors directly measure the actual fluid level in the container and feed this data to the control unit, eliminating the need for operator estimation and manual data entry. This substitution of mechanical/manual operations with automated sensing resolves the contradiction by maintaining ease of operation while dramatically improving measurement precision.
Solution Approach 2:
The system implements feedback by continuously monitoring the actual fluid level through sensors and comparing it with the calculated fluid level based on dispensed amounts. The control unit uses this feedback to generate correction factors that compensate for deviations, ensuring long-term accuracy. This feedback mechanism resolves the contradiction by automating precision measurement while keeping the system simple to operate.
2Productivity
If standard volume packages are used for refilling, then the refill process is simple and fast, but manufacturing precision deteriorates because part of the fluid remains in the package
Solution Approach 1:
The system uses sensors to measure the actual amount of fluid transferred from standard packages and feeds this information back to the control unit. The control unit calculates correction factors based on the difference between the expected package volume and the actual transferred volume. This feedback mechanism allows the system to maintain high productivity by using standard packages while compensating for the incomplete transfer, thereby improving manufacturing precision.
Solution Approach 2:
The system dynamically adjusts the recorded refill amount parameter based on actual sensor measurements. Instead of always using the nominal package volume, the system modifies the effective refill parameter to reflect the actual fluid amount transferred, accounting for losses due to viscosity and package construction. This parameter adjustment resolves the contradiction by maintaining fast refilling with standard packages while achieving precise fluid quantity tracking.
3Device complexity
If fluid level is only monitored when low, then the system is simple, but reliability deteriorates because the actual fluid level is not known before running dry
Solution Approach 1:
The system performs preliminary action by continuously or frequently measuring the actual fluid level using sensors, well before the fluid runs dry. This allows the system to anticipate the need for refill and take corrective action in advance, preventing formulation errors. The control unit uses these preliminary measurements to generate early warnings and correction factors, improving reliability without significantly increasing device complexity.
Solution Approach 2:
The system implements continuous monitoring of the fluid level through sensors that continuously or periodically measure the actual fluid amount. This continuous useful action provides up-to-date information about the fluid level, allowing the system to maintain high reliability by always knowing the actual status. The continuous data stream enables the control unit to generate accurate correction factors and timely refill warnings without requiring complex additional hardware.
4Ease of operation
If calculated fluid amount is used without correction, then the system is simple to operate, but measurement precision deteriorates due to accumulation of deviations with each refill
Solution Approach 1:
The system implements feedback by continuously comparing the calculated fluid level (based on dispensed amounts) with the actual fluid level (measured by sensors). The control unit calculates correction factors from this comparison and applies them to future calculations. This feedback loop prevents the accumulation of deviations over multiple refills while keeping the system easy to operate, as the correction process is automated and requires no additional manual intervention.
Solution Approach 2:
The system dynamically adjusts the refill amount parameter by applying correction factors derived from sensor measurements. Instead of using the nominal refill amount, the system modifies the effective parameter to reflect actual conditions. This parameter change compensates for accumulated deviations and maintains measurement precision without complicating the operation, as the adjustment is performed automatically by the control unit.
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 provides continuous and accurate monitoring of fluid levels, reducing the risk of misformulation by ensuring timely refills and correcting refill data, thus preventing unexpected shortages and improving stock management.
Implementation Method 1
A fluid dispenser system equipped with a fluid level sensor, such as a field effect sensor
Data Source
AI summary
A fluid dispenser comprising a fluid container and a metering unit is disclosed. The container comprises a fluid level sensor and the dispenser comprises a control unit configured to determine a parameter value representative for an amount of fluid in the container after refill on basis of a signal from the sensor. The sensor can for example be configured to generate a signal at a predefined fluid level (B, C), while the control unit is configured to calculate a fluid level on basis of an input value indicative of the fluid level (A) after refill, and a dispense value indicative of amounts of fluid dispensed since the latest refill. The control unit can be configured to compare the signalled predefined fluid level (B, C) with the calculated fluid level to generate a correction factor.