Rotary Peristaltic Pump Pressure Relaxation for Precise Dispensing
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Solution Overview
Problem
Peristaltic pumps face challenges in achieving precise and repeatable fluid dispensing due to variations in tubing diameter and rotor speed, leading to inaccuracies and waste in production, especially with dangerous or expensive fluids.
Innovation Solution
A rotary peristaltic pump system with a controller that manages the pressure on flexible tubing by using a stator or rotor that reciprocates or retracts, combined with a flow valve, to ensure consistent volume dispensing through controlled phases of pressure application and release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If peristaltic pumps are used for fluid dispensing, then contamination is eliminated and fluid changeover is simplified, but dispensing precision and accuracy deteriorate due to tubing diameter variations
Solution Approach 1:
The system incorporates sensors that continuously monitor the actual dispensed volume and provide feedback to the controller. The controller adjusts the pump operation in real-time to compensate for tubing variations, ensuring precise dispensing while maintaining the contamination-free advantage of peristaltic pumps
Solution Approach 2:
The system dynamically adjusts operating parameters such as rotor speed and pumping pressure based on monitored tubing characteristics. By changing these parameters in response to detected variations, the system maintains consistent dispensing precision despite tubing diameter changes
2Productivity
If rotor speed is increased to improve productivity, then output increases, but dispensing accuracy deteriorates due to speed-related variations
Solution Approach 1:
The system transitions from fixed-speed operation to dynamic speed control. The rotor speed is continuously adjusted based on real-time feedback from sensors, allowing the system to operate at high speeds for productivity while automatically compensating for speed-induced variations to maintain dispensing accuracy
Solution Approach 2:
Speed sensors and volume monitoring systems provide continuous feedback to the controller, which adjusts the rotor speed dynamically. This closed-loop control enables high productivity operation while maintaining precision by compensating for any deviations caused by speed variations
3Object-affected harmful factors
If tubing is used for fluid transport, then contamination-free operation is achieved, but consistency of dispensed volume deteriorates over time due to tubing changes
Solution Approach 1:
The system uses sensors to continuously monitor the actual volume dispensed and compares it to the target volume. The controller adjusts pumping parameters in real-time based on this feedback, compensating for tubing changes and maintaining consistent dispensed volumes throughout operation
Solution Approach 2:
The system performs self-adjustment by automatically detecting tubing variations through sensors and correcting its own operation. The controller modifies pumping parameters without external intervention, maintaining volume consistency while preserving the contamination-free benefits of tubing-based transport
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 enhances dispensing accuracy and reduces waste by maintaining consistent fluid volumes, even with varying tubing conditions, ensuring precise filling of containers with pharmaceutical fluids.
Implementation Method 1
Rotary peristaltic pumps are preferred for many filling applications due to their ability to pump fluids through tubing without any contact between pump components and the fluid being pumped. In a typical rotary peristaltic pump system, one or more lengths of tubing are compressed by a series of rollers that rotate to squeeze the tubing against a curved wall of a stator.
Implementation Method 2
one or more lengths of tubing are compressed by a series of rollers that rotate to squeeze the tubing against a curved wall of a stator. This provides one or more moving regions of compression along the length of tubing.
Implementation Method 3
In returning to its uncompressed condition, the tubing creates a partial vacuum, which results in forward flow of the fluid from the region behind the compressed region.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3G
AI summary
The present invention involves a rotary peristaltic pump and associated method employing the relaxation of pressure on flexible tubing between the rotor and stator of the pump to restore the rotor to a start angle while a valve on the output of the pump is closed to avoid progress of fluid through the system. Three different implementations of the pump and method are presented including reciprocating the stator, reciprocating the rotor, and retracting the idler rollers of the rotor into the rotor to relieve the pressure on the flexible tubing. A controller ensures the appropriate switching and timing of the valve and rotor of the pump. The pump and associated method are directed to the precision dispensing of pharmaceutical fluids into containers, including containers held in container nests.