Metering Pump Control for Continuous Mixing Ratio
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Solution Overview
Problem
Existing metering and mixing systems for two-component products suffer from interruptions in flow rate due to pump reversals, leading to suboptimal pump usage and uneven mixing.
Innovation Solution
A method and system where the first component is fed continuously, and the second component is fed intermittently with higher pressure, using reciprocating pumps with movement detectors and controllers to maintain a predetermined ratio, preventing backflow and optimizing pump reversals to ensure continuous operation and improved mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sequential feeding with pump reversal is used, then metering ratio control is achieved, but flow rate interruptions occur
Solution Approach 1:
The patent implements continuous feeding of the first component without pump reversal, while the second component is fed intermittently. This eliminates flow rate interruptions for the first component while maintaining precise metering ratio control through coordinated control of both pumps.
Solution Approach 2:
The second pump operates with periodic intermittent feeding cycles, reversing direction to deliver doses of the second component. This periodic action maintains the predetermined metering ratio while the first pump provides continuous flow, resolving the contradiction between precision and continuity.
2Ease of operation
If pump reversal is triggered by end-of-travel abutment, then pump operation is simplified, but mixing evenness deteriorates
Solution Approach 1:
The control unit continuously monitors the volume remaining in each pump and uses this feedback to intelligently decide when to trigger pump reversal. This feedback mechanism ensures optimal timing for reversal, improving mixing evenness while maintaining operational simplicity.
Solution Approach 2:
The system predicts when pump reversal will be needed by continuously tracking remaining volume, and triggers reversal at the optimal moment before complete emptying. This preliminary action prevents flow interruptions and ensures even mixing while keeping the operation simple.
3Productivity
If both pumps feed continuously, then productivity is maximized, but metering ratio control becomes difficult
Solution Approach 1:
The system dynamically adjusts the operation mode of each pump based on real-time conditions. The first pump operates continuously while the second pump operates intermittently with periodic reversal, allowing both high productivity and precise metering ratio control through dynamic coordination.
Data Source
AI summary
A system includes a first pump feeding a first component into a mixer, and a second pump feeding a second component into the mixer. The movement of the piston of each pump can be reversed from a direction of suction and of expulsion of the volume of the pump to a direction of expulsion of the component and vice versa. A movement detector is associated with each pump and is connected to a controller programmed to trigger the reversal of a pump after having determined that the volume remaining in the pump is insufficient to ensure the predetermined metering ratio. The controller is programmed to provide the continuous feeding of the first component into the mixer through the operation of the system, and the intermittent feeding of the second component into the mixer in order to carry out cycles of feeding doses of the second component into the mixer.