Liquid Dosing Monitoring via Supply-Pump Rate Comparison
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Solution Overview
Problem
Dosing inaccuracies or failures in dosing stations, especially when processing multiple materials in specific mixing ratios, are difficult to detect due to malfunctions in control systems or mechanical components, and conventional flow meters are prone to errors with materials containing solid fillers, leading to undetected errors in safety-critical applications.
Innovation Solution
A method that measures and compares the delivery rate of a supply pump with the predetermined dosing rate of a dosing pump, using various techniques to determine the actual amount of liquid dispensed, including monitoring the position of the piston rod with sensors, to detect deviations and potential errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flow meters are installed at the outlet of the dosing pump to monitor actual flow rate, then dosing monitoring capability is improved, but reliability deteriorates due to malfunctions with materials containing solid fillers
Solution Approach 1:
The patent introduces an intermediary measurement approach by using the supply pump's delivery rate as a proxy indicator for the dosing pump's actual delivery. Instead of directly measuring the dosing pump output with unreliable flow meters, the system measures the supply pump's delivery rate (which is more reliable) and uses this intermediate measurement to infer dosing accuracy, thereby resolving the contradiction between monitoring capability and reliability.
Solution Approach 2:
The patent replaces the mechanical flow metering system (which fails with solid fillers) with a different measurement approach based on the supply pump's delivery rate measurement. This substitution eliminates the unreliable mechanical flow meter while maintaining dosing monitoring capability through an alternative measurement pathway.
2Measurement precision
If weighing the dispensed material is used to detect dosing errors, then dosing accuracy monitoring is improved, but ability to identify specific component errors deteriorates when multiple materials are processed
Solution Approach 1:
The patent segments the dosing monitoring into individual component-level measurements by measuring the delivery rate of each supply pump separately. This segmentation allows the system to identify which specific component (first or second supply pump) has delivered an incorrect amount, thereby resolving the contradiction between detecting dosing errors and identifying the problematic component when multiple materials are involved.
3Productivity
If dosing errors are not detected, then productivity is maintained, but safety deteriorates in safety-critical applications
Solution Approach 1:
The patent implements a feedback mechanism where the measured delivery rate of the supply pump is continuously compared with the expected delivery rate, and any deviations are detected and reported. This feedback system allows the dosing process to maintain productivity while simultaneously ensuring safety by detecting and alerting operators to potential dosing errors before they cause harm in safety-critical applications.
Data Source
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AI summary
The invention relates to a method for monitoring the dosage of at least one liquid within a dosing station (1), wherein the dosing station (1) comprises: a material supply (2) of the liquid to be dosed, a supply pump (3), a dosing pump (4) and a delivery line (5) extending between the supply pump (3) and the dosing pump (4), wherein the supply pump (3) is suitable for pumping the liquid from the material supply (2) through the delivery line (5) to the dosing pump (4) and wherein the dosing pump (4) is configured to dose a predetermined quantity of liquid, wherein during a dosing process a delivery rate of the supply pump (3) is recorded and the recorded delivery rate of the supply pump (3) is compared with a predetermined dosing rate of the dosing pump (4).