Fluid Reclamation System for Automated Dispensing
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Solution Overview
Problem
In automated manufacturing systems, a significant volume of fluid materials such as sealers, adhesives, and sound deadeners is lost during application due to purging, misapplication, and overspray, leading to hazardous waste generation and increased environmental impact and costs.
Innovation Solution
A fluid delivery system that recovers and reclaims excess fluid through a network of pumps, check valves, filters, and a reusable fluid container, allowing the reconditioned fluid to be reused, reducing waste and ensuring continuous supply by switching between primary and backup fluid sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated fluid application is used to improve manufacturing efficiency, then productivity increases, but fluid material loss increases due to purging, misapplication, and overspray
Solution Approach 1:
The system captures and recovers excess fluid material that would otherwise be lost during automated application. A collection system with pumps and filters recovers overspray and misapplied material, returning it to the fluid supply system for reuse, thereby reducing material loss while maintaining automated application efficiency
Solution Approach 2:
An intermediary collection and filtration system is introduced between the application point and waste disposal. This intermediate system captures excess fluid, filters contaminants, and redirects recoverable material back to the supply drum, preventing direct loss while maintaining automated operation
2Reliability
If fluid supply drums are changed periodically to ensure material freshness, then reliability is maintained, but loss of time increases due to changeover interruptions
Solution Approach 1:
The system enables continuous fluid supply by implementing a backup drum configuration with automatic switching capability. When the primary drum requires changeover, the backup drum maintains uninterrupted supply, eliminating production interruptions and ensuring continuous operation without compromising material freshness through the use of properly stored backup supplies
3Object-affected harmful factors
If fluid material is disposed of as hazardous waste to comply with regulations, then environmental compliance is achieved, but loss of energy increases due to disposal processes
Solution Approach 1:
The system converts potentially hazardous waste fluid into a reusable resource. By filtering and returning excess fluid to the supply system, the process transforms what would be harmful waste requiring energy-intensive disposal into a beneficial reused material, simultaneously achieving environmental compliance and energy conservation
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
The system achieves significant cost savings, minimizes hazardous waste, and enhances environmental sustainability by effectively reusing reclaimed fluid, reducing material loss and disposal costs.
Implementation Method 1
A pump is provided in the system that moves fluid from the drum
Implementation Method 2
A check valve is provided in the system that prevents reverse flow fluid
Implementation Method 3
A filter is provided in the system that removes contaminants from the fluid
Implementation Method 4
A heater is provided in the system that controls a temperature of the fluid
Data Source
Figure 1
Figure 2
AI summary
A fluid application system includes a source of a fluid and a first pump for supplying the fluid under pressure to an applicator having a nozzle for dispensing the fluid. A fluid collection system collects reclaimed fluid dispensed from the applicator and a second pump provides the reclaimed fluid under pressure to a return fluid pipe. The return fluid pipe has a valve system that selectively directs the reclaimed fluid to either a reusable fluid container or the applicator. The valve system may selectively direct the reclaimed fluid from the return fluid pipe to an in-line reservoir and a third pump may be used to provide the reclaimed fluid under pressure from the in-line reservoir to the applicator.