Optical Load Beam Sensing for Precise Mass-Based Dispensing
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Solution Overview
Problem
Existing dispensing systems for chemical products in industrial applications often lack precise control over the amount dispensed, leading to inefficiencies and potential overuse or underuse of chemicals, particularly in systems that rely on conductivity measurements which are not always reliable.
Innovation Solution
A dispensing system utilizing a load beam to support a vessel containing the product, an optical displacement sensor to measure the displacement of the load beam related to the product's weight, and a controller to determine the dispensed amount based on the displacement, ensuring accurate and controlled dispensation of chemical products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conductivity measurement is used to determine when ingredient needs replenishment, then the system can monitor chemical levels, but the measurement reliability is insufficient leading to imprecise dispensing control
Solution Approach 1:
The patent replaces the electrical conductivity measurement system with an optical measurement system. An optical sensor detects the position of a float that moves with the chemical level, converting the measurement from electrical to optical domain. This substitution eliminates the reliability issues of conductivity measurements in various chemical environments while maintaining measurement functionality.
Solution Approach 2:
The patent introduces a float as an intermediary element between the chemical and the sensor. The float moves with the chemical level but can be detected optically without direct contact between the sensor and the chemical. This intermediary enables reliable measurement while isolating the sensing system from chemical interference.
2Adaptability or versatility
If predetermined amount dispensing is used for each cycle, then the dispensing process is simple, but the system cannot adapt to varying needs leading to overuse or underuse of chemicals
Solution Approach 1:
The patent implements a feedback mechanism where the optical sensor continuously monitors the chemical level and provides real-time data to the control system. The controller adjusts the dispensing amount based on this feedback, enabling the system to adapt to varying needs. The float position feedback allows dynamic adjustment of dispensing parameters throughout the cycle.
Solution Approach 2:
The patent transitions from static predetermined dispensing to dynamic adaptive dispensing. The system can modify dispensing rates and amounts in real-time based on float position and other process parameters. This dynamic capability allows the system to optimize chemical usage for each specific cycle condition.
3Manufacturing precision
If optical displacement sensor is implemented to measure load beam displacement, then precise weight-based control is achieved, but the device complexity increases
Solution Approach 1:
The patent replaces direct weight measurement with optical displacement measurement. Instead of using complex force sensors or load cells, the system uses an optical sensor to detect the position of a load beam that moves with weight changes. This substitution achieves precise measurement while using simpler, more reliable optical components.
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 control over the dispensation of chemical products, ensuring the right amount is dispensed, reducing waste and maintaining optimal chemical levels, thereby enhancing operational efficiency and consistency.
Implementation Method 1
an optical displacement sensor that measures a displacement of the load beam
Implementation Method 2
an emitter that emits an optical signal toward the load beam, wherein the optical signal is reflected from the load beam at an angle determined by a distance between the emitter and the load beam
Data Source
AI summary
A dispensing system and methods employed therein uses optical displacement sensing to control dispensation of one or more products. An optical displacement sensor measures displacement of a load beam supporting a vessel from which the product is to be dispensed. The displacement of the load beam is related to the amount (weight) of the product remaining in the vessel. The system may thus control dispensation of the product based on the optical displacement measurements.