Metering Pump Piston Stroke Control via Electromagnet Impedance
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Solution Overview
Problem
Existing metering pumps face inefficiencies due to wasteful energy consumption, excessive heating, reduced service life, and the need for mechanical calibration and regulation, particularly when dealing with low pressure systems and viscous liquids, as they rely on uncontrolled energy supply and mechanical means for piston stroke regulation.
Innovation Solution
A metering pump system that regulates the piston stroke through real-time control of the electromagnet's impedance, using incremental voltage adjustments and impedance measurements to precisely manage the piston's position and stroke, eliminating the need for mechanical calibration and additional sensors, and optimizing energy use based on the geometry of the electromagnet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a voltage pulse of fixed duration is applied to the electromagnet, then the piston stroke is maintained consistently, but energy is wasted especially when the system pressure is low and the thrust necessary for overcoming counterpressure is reduced
Solution Approach 1:
The patent applies dynamics by making the voltage pulse duration variable rather than fixed. The control device adjusts the pulse duration dynamically based on real-time feedback from the impedance sensor, which detects the actual piston position and system conditions. This allows the electromagnet to receive precisely the amount of energy needed for each stroke, reducing waste while maintaining consistent piston movement.
Solution Approach 2:
The patent implements feedback through an impedance sensor that continuously monitors the electromagnet's impedance, which correlates with piston position and system pressure. This feedback signal is fed to the control device, which adjusts the voltage pulse duration accordingly. This closed-loop control ensures energy-efficient operation by matching energy input to actual system needs while maintaining reliable piston stroke consistency.
2Reliability
If uncontrolled energy is supplied to the electromagnet, then the piston stroke can be maintained, but excessive heating occurs and service life is reduced
Solution Approach 1:
The control device dynamically adjusts the voltage pulse duration based on real-time impedance measurements, ensuring the electromagnet receives only the necessary energy for each piston stroke. This prevents excessive energy input that would cause overheating, while still maintaining consistent piston stroke performance. The dynamic control adapts to varying system conditions, preventing thermal buildup.
Solution Approach 2:
The patent changes the electrical parameter (voltage pulse duration) based on impedance measurements to optimize electromagnet operation. By adjusting this parameter dynamically, the system prevents excessive heating while maintaining reliable piston stroke, extending the service life of the electromagnet and other components.
3Manufacturing precision
If mechanical means are used for calibration of the piston stroke, then the desired pump capacity can be obtained, but the device complexity increases and mechanical wear occurs
Solution Approach 1:
The patent replaces the mechanical calibration system with an electronic control system based on impedance sensing. Instead of using physical shims or mechanical adjustments to calibrate piston stroke, the system uses electrical impedance measurements to detect piston position and control the electromagnet accordingly. This substitution eliminates mechanical wear and reduces device complexity while maintaining or improving calibration precision.
Solution Approach 2:
The control device performs self-calibration by using the electromagnet's own impedance characteristics as the sensing mechanism. The system automatically determines the correct pulse duration based on real-time impedance feedback, eliminating the need for external mechanical calibration tools or procedures. This self-service approach simplifies the overall system while maintaining manufacturing precision.
4Quantity of substance
If mechanical systems are used for regulation of the piston stroke, then the injection volume is reduced, but the electrical energy supplied remains constant leading to reduced efficiency
Solution Approach 1:
The control device dynamically adjusts the voltage pulse duration based on impedance feedback to match the actual injection volume requirements. When mechanical systems reduce the piston stroke, the electrical energy input is simultaneously reduced proportionally, maintaining efficiency. This dynamic coordination ensures that energy consumption is directly proportional to the actual work performed, eliminating the waste associated with constant energy supply despite reduced injection volume.
Solution Approach 2:
The impedance-based feedback system continuously monitors the actual piston stroke and injection volume, allowing the control device to adjust the electrical energy input in real-time. This feedback loop ensures that energy consumption matches the actual injection volume, preventing energy waste even when mechanical regulation reduces the piston stroke. The system automatically optimizes efficiency based on actual operating conditions.
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
This approach results in a high-performance, low-energy consumption metering pump with precise control over the injection volume, reduced energy waste, and extended service life, while maintaining efficiency and accuracy across varying conditions.
Implementation Method 1
The electromagnet is made up of a fixed part, housed in which is the armature, and a mobile part - referred to as 'plate' - fixed with respect to the piston
Implementation Method 2
the plate constitutes, in effect, the closing element for the magnetic flux of the electromagnet, said flux having as effect that of recalling said plate to the remaining fixed part of the electromagnet, thus producing a displacement
Implementation Method 3
measuring a physical quantity depending only and exclusively upon the geometry of the electromagnet, and in particular its impedance
Implementation Method 4
correlating the value of said physical quantity with the position assumed by the piston during its stroke
Data Source
Figure 1A~1B
Figure 2~5
AI summary
A device for controlling the stroke of a piston 3 of a metering pump comprising an electromagnet 1 formed by a fixed part and a mobile part fixed with respect to said piston 3 in such a way that at each displacement of the piston there corresponds a different value of inductance of the electromagnet 1 and hence of the piston stroke itself.