Multi-Component Mixture Control via Pump Velocity Feedback
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Solution Overview
Problem
Manual control systems for multi-component mixtures in applications like roadway markings fail to provide accurate and timely adjustments to mixing ratios due to variations in temperature, pressure, and viscosity, leading to inconsistent product quality.
Innovation Solution
A system utilizing sensors to monitor pump velocities and a control circuit with a programmable-logic controller (PLC) and flow control valve to adjust the mixing ratio of one pump based on the actual velocity of another, employing a PID equation and PWM signals to maintain precise flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control systems are used to adjust pump speeds for mixing ratios, then the system is simple to operate, but the mixing ratio consistency deteriorates due to temperature, pressure, and viscosity variations
Solution Approach 1:
The system employs sensors to detect actual pump output flows and feeds this information back to the control unit. The control unit compares the detected flow rates with target values and automatically adjusts pump speeds to maintain consistent mixing ratios, resolving the contradiction between manual operation simplicity and mixing precision by providing automated feedback control.
Solution Approach 2:
The patent replaces manual mechanical control of pump speeds with an automated electronic control system. The control unit uses electronic signals to adjust pump motor speeds based on sensor feedback, substituting the mechanical manual adjustment process with an automated electromechanical system that maintains precision while remaining operator-friendly through electronic interfaces.
2Device complexity
If pump speed settings are used to control mixing ratios, then the control method is simple, but the accuracy deteriorates because pump speed does not directly reflect actual flow output
Solution Approach 1:
The system uses flow sensors to directly measure actual pump output flows and feeds this information back to the control unit. This feedback mechanism allows the system to compensate for variations in temperature, pressure, and viscosity that affect flow rates, providing accurate measurement and control without increasing overall system complexity.
Solution Approach 2:
The patent introduces flow sensors as intermediary devices between the pumps and the control unit. These sensors act as mediators that directly measure the actual flow output and translate it into signals that the control unit can use for precise control, bridging the gap between pump speed settings and actual flow performance.
3Ease of manufacture
If hydraulic pressure control is used to adjust pump speeds, then the control mechanism is straightforward, but the responsiveness to flow changes deteriorates due to the nature of hydraulic systems
Solution Approach 1:
The system replaces hydraulic pressure control with direct electronic control of pump motor speeds. The control unit sends electronic signals to the pump motors, enabling rapid response to flow changes. This substitution of hydraulic mechanical control with electronic motor control maintains ease of manufacture while dramatically improving response speed.
Solution Approach 2:
The system uses real-time flow sensor feedback to continuously monitor actual flow rates and immediately adjust pump motor speeds in response to changes. This closed-loop feedback control enables the system to respond quickly to flow variations, overcoming the sluggish response characteristic of hydraulic systems while maintaining control simplicity.
Data Source
AI summary
A system for controlling the mixing ratio of a multi-component mixture including a first pump connectable to a source of a first component and a second pump connectable to a source of a second component. The first and second pump being associated with at least one linear sensor for generating an output indicative of actual pump speed or shaft displacement of the pump. The system further includes a control circuit operative to utilize the output of the linear sensor of one of the pumps to generate a control signal for controlling the output of the other pump.