Optical Viscosity Control for Slurries With Closed-Loop Fluid Adjustment
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Solution Overview
Problem
Conventional viscometers are inefficient for measuring and controlling the viscosity of highly viscous fluids like slurries, as they require manual measurement methods that are time-consuming and costly, due to incompatibility with abrasive or vibration-dampening suspended particles.
Innovation Solution
A viscosity control system comprising a sensor unit with a container and controller that senses the fluid height and modulates the flow of viscosity-adjusting fluids to maintain a predetermined viscosity range, using pumps and solenoid valves to adjust the fluid flow based on sensed viscosity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional automated viscometers are used for low viscosity fluids, then measurement is efficient and automated, but they cannot measure highly viscous fluids or slurries with suspended solids
Solution Approach 1:
The patent replaces conventional mechanical viscometer systems (paddle wheel rotation, vibration film) with an optical measurement system. The optical sensor measures fluid properties through light interaction without mechanical contact, enabling measurement of highly viscous fluids and slurries that contain suspended solids which would interfere with mechanical measurement systems.
2Adaptability or versatility
If manual Zahn cup method is used for viscous fluids, then measurement is possible, but the process is slow and time-consuming
Solution Approach 1:
The patent implements continuous measurement capability where the optical sensor continuously monitors fluid viscosity in real-time as the fluid flows through the system. This eliminates the discrete, sequential nature of manual Zahn cup measurements, enabling continuous process control and significantly increasing measurement productivity while maintaining adaptability to viscous fluids.
3Manufacturing precision
If multiple viscosity corrections are made manually, then viscosity control is achieved, but delays and costs increase due to manual measurement between corrections
Solution Approach 1:
The patent implements a closed-loop feedback control system where the optical sensor continuously measures fluid viscosity and feeds this information back to the control system. The controller automatically adjusts viscosity by controlling the addition of modifiers based on real-time measurements, eliminating delays associated with manual measurement and enabling precise viscosity control throughout the process.
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
This system enables continuous and automatic viscosity control of viscous fluids, increasing workflow efficiency, reducing worker-hours, and lowering production costs by maintaining predetermined viscosity levels.
Implementation Method 1
a sensor configured to sense a height of a surface of the viscous fluid in the container
Implementation Method 2
A diameter of the outlet and the flow of the viscous fluid are configured to generate a height of the viscous fluid in the container
Data Source
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AI summary
A viscosity control system for measuring and controlling a viscosity of a viscous fluid includes a viscosity sensor unit, a supply of viscosity adjusting fluid, and a controller. The viscosity sensor unit includes a container having an inlet and an outlet, a flow of the viscous fluid flowing into the inlet, and a sensor configured to sense a height of a surface of the viscous fluid in the container. A diameter of the outlet and the flow of the viscous fluid are configured to generate a height of the viscous fluid in the container that is within a predetermined height range. The controller is configured to receive the sensed height, compare the sensed height to the predetermined height range, and modulate a flow of fluid from the supply of viscosity adjusting fluid in response to the sensed height being outside the predetermined height range.