Modular Pump Control Unit for Expandable Multi-Component Dispensing
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Solution Overview
Problem
Existing pump systems for dispensing multi-component materials under pressure require significant effort and cost to expand, as the control unit must be adapted or replaced when adding new pumps or component materials, due to the need for ATEX compliance and complex electrical component reconfiguration.
Innovation Solution
A modular control unit structure with a data bus connecting control devices directly to metering valves, allowing independent operation of each pump and simplifying the expansion of the system by using a uniform control device for various pumps, reducing the need for extensive electrical cabling and ATEX conformity reassessments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a pump system is expanded to include additional pumps or component materials, then the functionality and versatility of the system is improved, but the control unit must be adapted or replaced, increasing complexity and cost
Solution Approach 1:
The control unit is designed with a universal architecture that can manage multiple pumps and component materials through standardized interfaces. The control device uses a data bus system that allows different pumps (e.g., piston pumps, diaphragm pumps) to be integrated without requiring control unit adaptation, as each pump communicates through the same protocol and data exchange mechanisms.
Solution Approach 2:
The control unit is segmented into modular components: a central control device and multiple pump control units that can be independently configured. Each pump has its own control module that communicates via data bus, allowing individual pumps to be added or removed without affecting the entire control system. This segmentation enables scalable system expansion while maintaining manageable complexity.
2Reliability
If electrical components are reconfigured for ATEX compliance when expanding the system, then safety standards are maintained, but the time and cost for conformity reassessment increases
Solution Approach 1:
The control unit is pre-designed and pre-certified for ATEX compliance with a standardized electrical architecture. Extrinsic electrical components are pre-configured to meet safety standards, and the data bus communication protocol is established beforehand to ensure intrinsic safety. This preliminary preparation allows system expansion without requiring repeated conformity reassessments, as the pre-certified modular components can be directly integrated.
3Ease of manufacture
If a uniform control device is used for various pumps, then the ease of manufacture and expansion is improved, but the precision of controlling different pump types may be compromised
Solution Approach 1:
While the control device architecture is uniform and standardized across all pumps, each pump control unit is locally adapted to its specific pump type through configurable parameters and communication protocols. The standardized control device communicates via data bus but allows pump-specific settings (e.g., piston pump cycle timing, diaphragm pump flow rates) to be configured locally, maintaining both manufacturing simplicity and operational precision.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for controlling a pump system and a pump system (10), wherein multi-component material is dispensed under pressure with a mixer (12) and a spray gun (11) of the pump system, wherein component material is conveyed with at least two pumps (13, 14, 15) of the pump system, wherein the component material is stored with liquid reservoirs (19, 20, 21) of the pump system, each assigned to a pump, wherein the component material is metered with metering valves (16, 17, 18) of the pump system, each assigned to a pump, wherein the pump system is controlled by means of a control unit (22) of the pump system, wherein the metering valve is controlled by an electrical control device (24, 25, 26) of the control unit, each assigned to a pump, and wherein a mixing ratio of the component materials is controlled by a control device (23) of the control unit.wherein the control devices are controlled by means of the control device.