Modular Dosing Pump System with Microprocessor Control
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Solution Overview
Problem
Existing dosing pump systems are limited to a narrow operational range, are expensive, and require complex and costly flow control systems, including additional sensors, which restrict their accessibility and adjustability across various fluid flow rates and viscosities.
Innovation Solution
A compact, modular dosing pump system utilizing a networked flow circuit with orifices and valves to manage fluid flow based on pressure differentials, combined with a microprocessor-based control system for closed-loop feedback, eliminating the need for external sensors and allowing precise control across a wide range of flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a dosing pump operates at low flow rates (0.01-5 mL/min) to achieve precise control, then measurement precision is improved, but productivity deteriorates due to limited flow rate range
Solution Approach 1:
The pump system divides fluid delivery into two separate channels: a microdose pump for precise low-flow delivery (0.01-5 mL/min) and a macrodose pump for higher flow rates (20-50 mL/min). This segmentation allows each pump to be optimized for its specific flow range, maintaining precision at microdose levels while expanding overall productivity through the macrodose channel.
Solution Approach 2:
The controller integrates control of both microdose and macrodose pumps into a single system, allowing the dosing pump system to universally handle both precise microdosing and higher-volume macrodosing operations. This multi-functionality resolves the contradiction by enabling the system to adapt its flow rate capability based on operational requirements while maintaining precision control.
2Adaptability or versatility
If multiple components (flow meters, sensors, adjustable flow controls) are added to expand flow rate range, then adaptability is improved, but device complexity worsens
Solution Approach 1:
The controller merges the control functions of multiple pumps and integrates flow management within a unified system architecture. By combining control logic and coordinating multiple pump operations, the system achieves high adaptability across wide flow rate ranges without requiring separate external flow meters, sensors, and flow controls for each pump, thus reducing overall device complexity.
Solution Approach 2:
The dosing pump system uses its own internal components (pump displacement mechanisms, controller coordination) to achieve precise flow control and monitoring without relying on external flow meters or separate sensing devices. The system self-regulates flow rates through controller-managed pump operations, eliminating the need for additional complexity-inducing external components.
3Measurement precision
If specialized microdosing sensors are used to achieve sufficient sensitivity, then measurement precision is improved, but cost worsens significantly
Solution Approach 1:
The system extracts the flow measurement function from external specialized sensors and implements it through the controller's coordination of pump displacement and operation. By taking out the need for expensive specialized microdosing sensors and replacing them with controller-based calculation methods using known pump displacement data, the system maintains measurement precision while dramatically reducing cost.
Solution Approach 2:
Instead of using expensive specialized microdosing sensors, the system creates a virtual measurement model through the controller that calculates flow rates based on pump displacement and operational parameters. This copied measurement approach achieves equivalent precision to specialized sensors without their high cost, making the system economically viable.
4Productivity
If a single pump is designed for high flow rates (20-50 mL/min) to improve productivity, then productivity is improved, but measurement precision deteriorates
Solution Approach 1:
The system segments the dosing function into two distinct pump channels: a microdose pump optimized for precise low-flow delivery (0.01-5 mL/min) and a macrodose pump optimized for higher flow rates (20-50 mL/min). Each pump is designed and controlled to excel in its specific flow range, allowing the system to achieve both high productivity through the macrodose pump and high precision through the microdose pump without compromise.
Solution Approach 2:
The controller dynamically selects and coordinates between microdose and macrodose pumps based on the required flow rate and dosing precision requirements. This dynamic operation allows the system to automatically switch between precision-oriented microdosing mode and productivity-oriented macrodosing mode, optimizing both measurement precision and productivity according to real-time operational needs.
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
The system achieves precise fluid delivery across microdose and macrodose flow rates with increased adjustability and reduced costs, eliminating the need for external sensors and flow control devices, enabling broader operational flexibility and cost reduction.
Implementation Method 1
The flow circuit utilizes a networked system of fluid paths, orifices, and valves to route fluid through the dosing pump system in response to a pressure differential between fluid inlet and fluid outlet ports
Data Source
AI summary
A compact, modular dosing pump system that is capable of microdose and macrodose volume flow rates, reduces or eliminates the need for additional flow control components such as temperature and pressure sensors, and utilizes a wider operational flow range than existing systems while maintaining the level of accuracy and precision exhibited by conventional dosing pump systems is provided. The dosing pump utilizes a a control system to deliver a range of fluid volumes. The control system monitors the motor emf voltage, calculates the flow rate, and makes adjustments to the pump motor voltage to precisely maintain the desired flowrate.