High-Speed Fluid Injection Feedback Control for Precise Dosing
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Solution Overview
Problem
Existing fluid injection systems in the container manufacturing sector face challenges in precisely controlling the amount of fluid applied, particularly sealants, due to variations in geometry, temperature, and viscosity, leading to imprecision and inefficiencies in high-speed production processes.
Innovation Solution
A control method and system utilizing a dynamic equivalent model to individually control the flow rate of each injector, with feedback loops and adjustable valve positions, pressure, and temperature regulation to maintain precise fluid application, incorporating high-precision flowmeters and PID controllers for continuous adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed fluid injection is used to maintain production capacity, then productivity is improved, but manufacturing precision deteriorates due to imprecision in fluid amount control
Solution Approach 1:
The patent implements a feedback control system where flowmeters continuously measure the actual flow rate of fluid from each injector, and this measurement is fed back to a control device that adjusts the injection parameters in real-time to maintain the desired flow rate despite variations in geometry, temperature, or viscosity
Solution Approach 2:
The system dynamically adjusts injection parameters during the high-speed production process. The control device modifies valve positions, pressure, or temperature in real-time based on feedback from flowmeters, allowing the system to adapt to changing conditions while maintaining precision at high speeds
2Manufacturing precision
If manual control methods are used to adjust production parameters, then manufacturing precision can be maintained, but productivity decreases due to time-consuming adjustments
Solution Approach 1:
The system performs self-adjustment through automated feedback control. The control device automatically modifies injection parameters based on real-time flow measurements without requiring manual intervention, enabling the system to maintain precision while operating continuously at high speed
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses electronic sensors (flowmeters), signal processing, and automated actuation to adjust injection parameters, eliminating the need for manual intervention while maintaining or improving precision
3Device complexity
If injector geometry varies due to wear or misalignment, then device complexity increases, but manufacturing precision deteriorates due to flow rate variations
Solution Approach 1:
The feedback control system compensates for injector geometry variations by continuously measuring actual flow rates and adjusting injection parameters in real-time. This allows the system to maintain consistent flow rates even when injector geometry changes due to wear or misalignment
Solution Approach 2:
The system compensates for injector geometry variations by dynamically changing other injection parameters such as pressure, temperature, or valve position to maintain the desired flow rate despite geometric variations in the injector
Data Source
Figure 1.a~1.c
Figure 2~4
Figure 5~6.b
AI summary
A control method for a high-speed fluid injection system and a system configured for implementing the control method; a monitoring system for the system configured for implementing the control method for controlling the amount of fluid injected or applied to a plurality of parts.