Optical Concentration Sensor for Continuous Solution Mixing Control
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Solution Overview
Problem
Existing methods for producing chemical solutions, such as salt solutions for deicing, often fail to maintain accurate concentration levels due to interference from solids and lack of continuous measurement, leading to inefficiencies and potential safety hazards.
Innovation Solution
A system comprising a mixer with a concentration sensor that continuously monitors and adjusts the concentration of the solution, using a programmable logic controller to add solvent as needed, ensuring the solution is within a target concentration range by diverting solutions outside the tolerance to a storage tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If specific gravity measurement is used to monitor solution concentration, then a simple measurement method is provided, but the measurement accuracy deteriorates due to interference from solids and foreign material
Solution Approach 1:
The patent replaces mechanical/specific gravity-based measurement systems with optical measurement systems. The optical sensor uses light absorption or reflection properties to determine concentration, which is not affected by suspended solids or foreign materials in the same way that specific gravity measurements are affected.
Solution Approach 2:
The patent introduces an optical intermediary (light) as the measurement medium instead of directly measuring physical properties of the solution. This intermediary allows concentration measurement without direct contact with interfering solids, as the optical properties change predictably with concentration while being less sensitive to particulate interference.
2Device complexity
If separate spaced measurements are used to monitor solution concentration, then the measurement system is simpler, but the concentration control deteriorates due to lack of continuous monitoring
Solution Approach 1:
The patent implements continuous concentration monitoring using an optical sensor that continuously measures the solution as it flows through the mixing system. This continuous feedback allows for real-time adjustments to maintain accurate concentration, eliminating the gaps inherent in periodic sampling methods.
Solution Approach 2:
The patent establishes a feedback loop where the optical sensor continuously monitors concentration and provides signal to a control system that adjusts the mixing parameters or flow rates to maintain the desired concentration. This closed-loop control significantly improves reliability compared to open-loop periodic measurement systems.
3Device complexity
If unidirectional mixing is used to produce solution, then the mixing process is simpler, but the concentration accuracy deteriorates due to inability to account for process fluctuations
Solution Approach 1:
The patent transitions from a static unidirectional mixing process to a dynamic adaptive system. The mixing parameters (such as flow rates, agitation speed, or ingredient addition rates) are continuously adjusted based on real-time concentration measurements, allowing the system to adapt to fluctuations and maintain precise concentration control.
Solution Approach 2:
The patent implements feedback control where concentration measurements are continuously fed back to the control system, which then adjusts mixing parameters to compensate for process variations. This ensures that despite fluctuations in feed rates, environmental conditions, or mixing efficiency, the final solution concentration remains within specified tolerances.
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 ensures consistent production of solutions at precise concentrations, reducing the risk of safety hazards and improving operational efficiency by maintaining accurate salt concentrations in deicing solutions.
Implementation Method 1
a concentration sensor that continuously monitors and adjusts the concentration of the solution
Data Source
AI summary
A solution making system and apparatus are described. The solution maker mixes a chemical or slurry with a solvent to a desired concentration. The concentration of the solution is monitored by one or more methods. Based upon this measurement, the concentration of the solution may be adjusted.