Fluid Formulation Quality Detection Device for Machine Process Control
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Solution Overview
Problem
Existing devices for controlling machine processes using fluid formulations face issues with inaccurate detection due to miscibility problems and sensor dry-out when different fluid densities are used, leading to potential machine damage and safety hazards.
Innovation Solution
A device with a sensor positioned in a tube configuration that includes a first and second arm and a connection part, ensuring constant fluid contact and independent detection of markers regardless of fluid density, coupled with a controller to initiate or stop the machine based on signal comparison with predetermined values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is placed in the reservoir of the fluid formulation, then the sensor can detect the formulation, but the sensor may be exposed to miscibility issues when different formulations are mixed and the formulation may dry up on the sensor surface during non-use
Solution Approach 1:
The sensor is extracted from the reservoir environment and placed in a separate detection chamber where fluid samples are introduced. This isolates the sensor from direct contact with the formulation in the reservoir, preventing dry-out and miscibility issues while maintaining detection capability through controlled sampling.
Solution Approach 2:
A fluid sample acts as an intermediary between the formulation in the reservoir and the sensor. The sample is transferred to the detection chamber, allowing the sensor to analyze the formulation indirectly without being exposed to the reservoir environment, thus preventing contamination and dry-out.
2Measurement precision
If a U-shaped bypass pipe is used to position the sensor, then the sensor can detect the fluid, but the sensor will continue to detect the first fluid when different fluid formulations are consecutively used due to density differences
Solution Approach 1:
The system uses a pump to dynamically control fluid flow, actively replacing the fluid in the detection chamber when formulations are changed. This dynamic flow control ensures the sensor detects the current formulation rather than residual fluid from previous formulations, enabling accurate detection across multiple formulation types.
Solution Approach 2:
The pump maintains continuous fluid circulation and replacement in the detection chamber, ensuring the sensor continuously detects the current formulation. This continuous action prevents the sensor from detecting outdated formulation data, maintaining measurement accuracy during formulation transitions.
3Measurement precision
If additional flow controllers or valves are added to enable sensor sensing, then the sensor can detect the fluid formulation, but the device complexity increases
Solution Approach 1:
The pump serving the dosing unit is merged with the fluid transfer function for the detection chamber. The same pump that doses the formulation is also used to replace and circulate fluid in the detection chamber, eliminating the need for separate flow controllers or valves while maintaining detection capability.
Solution Approach 2:
The pump is designed with multi-functionality, serving both the dosing operation and the sensor detection chamber fluid management. This universal component performs multiple functions (dosing and fluid replacement) without requiring additional specialized components, reducing overall system complexity.
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 accurate detection and control of fluid formulations, preventing machine damage and ensuring safe operation even with consecutive use of fluids of different densities, maintaining sensor sensitivity and avoiding errors in measurement.
Implementation Method 1
at least one sensor (4) for detecting the presence of said marker in said fluid formulation by detecting a signal caused by said marker in said fluid formulation
Data Source
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Figure 2
AI summary
A machine (10) comprising a device (12) for controlling the machine (10) or a process in said machine (10) by detecting a marker in a fluid formulation that is to be introduced in said machine (10) or process. The device comprises: - a tube (1) comprising at least one first arm (2), at least one second arm (3) and at least one connection part (11), the at least one first arm (2) is at least partially upwardly directed away from the connection part (11) and the at least one second arm (3) is at least partially upwardly directed away from the connection part (11); - at least one sensor (4) for detecting said marker in the fluid formulation, the at least one sensor (4) being positioned in the at least one connection part (11); - a controller coupled to the at least one sensor (4), wherein the machine or said process in said machine is stopped if a quality of the fluid formulation is outside a predetermined range of values. The invention further relates to corresponding methods.