Direct-Drive Fluid Sprayer Pump Control for High Pressure Output
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Solution Overview
Problem
Existing fluid displacement systems, such as those used in fluid dispensing systems, face challenges in efficiently controlling fluid output parameters like pressure and flow rate, particularly in applications requiring high pumping pressures, and often rely on complex gear reduction systems that can be inefficient and cumbersome.
Innovation Solution
A drive system for reciprocating fluid displacement pumps that utilizes an electric motor with a rotational output converted to linear movement by a drive mechanism, featuring a controller that adjusts motor operation based on sensor feedback to achieve target fluid parameters, including pressure and flow rate, and allows for multiple operating modes to accommodate different pressure ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If gear reduction systems are used to increase motor torque for high pressure pumping, then pumping pressure capability is improved, but device complexity and efficiency deteriorate
Solution Approach 1:
The patent removes the gear reduction system from the drive mechanism, directly coupling the electric motor to the pump. This extraction eliminates the intermediate mechanical components while maintaining the ability to achieve high pressures through direct motor power delivery, thereby reducing device complexity while preserving pressure capability.
Solution Approach 2:
The patent replaces the mechanical gear reduction system with an electrically-controlled system where the electric motor directly drives the pump. This substitution eliminates complex mechanical transmission components and uses electrical control to achieve the desired torque and pressure output, improving both simplicity and efficiency.
2Stress or pressure
If gear reduction systems are used to increase motor torque, then pumping pressure capability is improved, but energy efficiency deteriorates
Solution Approach 1:
By removing the gear reduction system, the patent eliminates energy losses associated with mechanical friction and inefficiencies in gear transmission. The direct drive configuration allows more of the motor's electrical energy to be converted directly into useful pumping work, improving overall energy efficiency while maintaining high pressure capability.
Solution Approach 2:
The patent replaces the inefficient mechanical gear reduction system with a direct electric drive system. This substitution reduces energy losses by eliminating intermediate mechanical conversion steps, allowing the electric motor to deliver power more efficiently to the pump while achieving the required high pressures.
3Stress or pressure
If complex drive systems are used to control fluid output parameters, then pressure control capability is improved, but ease of operation deteriorates
Solution Approach 1:
The patent incorporates feedback control where sensors monitor the actual fluid output parameters and the controller adjusts motor operation accordingly. This closed-loop feedback system simplifies operation by automatically maintaining desired pressure and flow rates without requiring complex manual adjustments or operator intervention, making the system easy to operate while preserving precise pressure control.
Solution Approach 2:
The controller automatically regulates fluid output parameters by monitoring sensor feedback and adjusting motor operation as needed. The system serves itself by autonomously maintaining optimal pressure and flow rates without requiring complex external control mechanisms or operator intervention, thereby improving ease of operation while preserving pressure control capability.
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 provides precise control over fluid output parameters, enabling high pumping pressures up to 69 MPa (10,000 psi) and efficient operation across varying pressure demands, enhancing the application of fluids like paint, water, and coatings by ensuring consistent and controlled atomization.
Implementation Method 1
an electric motor having a stator and a rotor configured to rotate about the stator
Implementation Method 2
a drive that is connected to the electric motor and that converts the rotational output into linear movement, such as reciprocating linear movement, to cause pumping by the pump
Implementation Method 3
positive displacement pumps such as axial displacement pumps to pull a fluid from a container and to drive the fluid downstream
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A pump drive system (10) is configured to drive operation of a pump (19) to pump spray fluid to a spray gun (5) for spraying. The drive system includes an electric motor (12) configured to provide a rotational output for powering the pump and includes a controller (15) configured to control operation of the electric motor. The controller controls operation of the electric motor based on a target pressure for the fluid output by the pump and/or based on a position of the fluid displacer (16) of the pump.