Fluid Mixing System with Load Cell Feedback Control
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Solution Overview
Problem
Existing chemical dispensing systems face challenges in achieving precise control of the diluent to concentrate ratio due to imprecise volumetric flow from pumps, leading to inconsistent dispensing cycles, which is critical for formulations requiring consistent ratios, especially in medical and veterinary applications.
Innovation Solution
A system that includes a mixing tank, two pumps for the first and second fluids, and a sensor to measure the weight of the fluids, with a controller that operates the pumps based on a recipe to achieve precise dilution ratios, using a load cell to monitor the weight and adjust pump operations accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If time-based pump control is used, then the system is simple to operate, but the dispensed volume consistency deteriorates
Solution Approach 1:
The system incorporates flow meters that continuously measure the actual flow rates of diluent and concentrate, providing real-time feedback to the control unit. The control unit adjusts pump operation based on this feedback to maintain precise volumetric ratios, resolving the contradiction between operational simplicity and dispensing consistency.
Solution Approach 2:
The patent replaces purely time-based mechanical control with an electronic control system that integrates flow meter data. This substitution allows for dynamic adjustment of pump operations based on actual flow conditions, improving volumetric consistency while maintaining ease of operation through automated control.
2Manufacturing precision
If flow meters are added to improve precision, then the dispensed volume control improves, but the device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it programs pump operation times, receives flow meter signals, calculates required volumes based on formulation recipes, and adjusts pump operations in real-time. This multi-functionality consolidates complexity into a single intelligent controller rather than adding separate devices for each function.
Solution Approach 2:
The flow meters act as intermediaries between the pumps and the control unit, providing accurate flow data that enables precise control. The control unit processes this intermediate data to achieve the desired formulation consistency, managing the complexity through structured information flow.
3Ease of manufacture
If concentrate and diluent are mixed in a mixing chamber, then the formulation is ready for use, but the ratio consistency deteriorates due to poor mixing
Solution Approach 1:
The system performs preliminary action by precisely controlling the volumetric flow rates of concentrate and diluent before they enter the mixing chamber. Flow meters measure and regulate each component's delivery, ensuring the correct ratio is established prior to mixing, which prevents ratio inconsistencies even if mixing is imperfect.
Solution Approach 2:
The control unit continuously monitors flow meter data during the mixing process, providing real-time feedback that ensures the concentrate and diluent are delivered in the precise volumetric ratios specified by the formulation recipe, maintaining composition stability throughout the mixing operation.
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 system provides precise control over the diluent to concentrate ratio, ensuring consistent mixing and reducing the risk of irritation, as demonstrated by its ability to create formulations like disinfectants and cleaning products with precise dilutions.
Implementation Method 1
a sensor positioned adjacent the mixing tank wherein the sensor outputs a signal based on a force exerted by the mixing tank in a direction toward the sensor. The signal from the sensor can be proportional to a weight of the first fluid and the second fluid in the mixing tank
Data Source
AI summary
A system for mixing a first fluid with one or more additional fluids to create a mixed fluid and for dispensing the mixed fluid is disclosed. The dispensing system includes a mixing tank; a first pump for the first fluid; a second pump for a second fluid; and a sensor positioned adjacent the mixing tank wherein the sensor outputs a signal based on a force exerted by the mixing tank in a direction toward the sensor. A controller of the system execute a program to: (i) receive the signal from the sensor, and (ii) operate the first pump for a first time period and operate the second pump for a second time period based on the signal from the sensor such that the first fluid and the second fluid are delivered to the mixing tank before being delivered to a storage tank for dispensing the mixed fluids.