Manifold Flow Control for Precise Fluid Turnover
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Solution Overview
Problem
Current fluid distribution systems face challenges in precisely controlling flowrates and efficiently managing fluid turnover due to limitations in valve actuators, complex control systems, and inefficiencies in responding to changing operational conditions, leading to suboptimal power consumption, chemical usage, and temperature management.
Innovation Solution
A manifold control system (MCS) with a processor that receives device settings, determines target flow conditions, and adjusts valve and supply device operations to achieve precise flowrates and optimize fluid turnover based on current usage and operational states, enabling real-time adjustments and efficient mode switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple valves and supply devices are used to convey and direct flow from multiple fluid handling devices, then flow control capability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines multiple valve functions into a single manifold assembly with integrated flow control capabilities. The manifold integrates multiple inlet ports, outlet ports, and internal flow paths into one unified component, eliminating the need for separate valves for each fluid handling device while maintaining precise flow control capability.
Solution Approach 2:
The manifold is designed as a universal component that can serve multiple fluid handling devices simultaneously. A single manifold can accommodate various inlet configurations and direct flow to multiple outlets, allowing one component to perform the functions of multiple separate valves and supply devices.
2Measurement precision
If multiple valves with controlled actuators are used to divert fluid flow, then flow distribution precision is improved, but valve actuator limitations reduce flowrate setting precision
Solution Approach 1:
The patent replaces traditional mechanical valve actuators with an electronic control system that uses electronic flow control valves. The electronic controller receives flowrate setpoints and directly controls electronically actuated valves, eliminating the limitations of manual or simple automatic actuators and enabling precise, programmable flowrate control.
Solution Approach 2:
The system enables continuous adjustment of flowrate parameters through electronic control. The electronic flow control valves can be programmed to operate across a wide range of flowrates, and the controller can dynamically adjust flowrate settings based on process requirements, overcoming the fixed positioning limitations of traditional actuators.
3Ease of operation
If each valve and supply device has its own controller with unique protocols, then individual device control is improved, but control system complexity and coordination difficulty increase
Solution Approach 1:
The patent consolidates multiple individual device controllers into a single electronic controller that manages all flow control functions. The electronic controller provides centralized control of all electronic flow control valves, eliminating the need for multiple separate controllers with different protocols and simplifying system coordination.
Solution Approach 2:
The electronic controller is designed as a universal control system that can manage multiple electronic flow control valves through a single interface. It provides unified control capabilities for all fluid handling devices, replacing the need for device-specific controllers and enabling consistent, coordinated operation across the entire system.
4Reliability
If traditional control schemes are used to operate valves and supply devices, then preset flowrate delivery is achieved, but responsiveness to changing operational conditions deteriorates
Solution Approach 1:
The patent implements dynamic flow control through electronic valves that can be adjusted in real-time based on changing process conditions. The electronic controller continuously monitors operational parameters and automatically adjusts valve positions to maintain precise flowrates, enabling the system to adapt quickly to varying demands while maintaining reliability.
Solution Approach 2:
The system incorporates feedback control where the electronic controller receives information about actual flow conditions and adjusts valve positions accordingly. This closed-loop control enables the system to maintain preset flowrates reliably while simultaneously responding to changing operational conditions, as the controller continuously corrects deviations from target flowrates.
Data Source
AI summary
A first valve of a manifold for a fluid distribution system may regulate a fluid flow to a first fluid handling device (“FHD”). A second valve of the manifold may communicate with a second FHD, a reservoir, or a recirculation line. A target flow condition for the manifold may be determined by a manifold control system (“MCS”) based on a device setting received for the first FHD. The MCS may determine a fluid distribution system operation for obtaining the target flow condition based on the target flow condition, a flowrate of the fluid flow, and an operational state of a supply device. The operation may include the MCS controlling at least one of the supply device, the first valve, and the second valve to change the flowrate. The MCS may continuously operate at least one manifold valve to maintain the target flow condition once exhibited by the manifold.