High Viscosity Pump Pneumatic Return for Accurate Dosing
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Solution Overview
Problem
Current double diaphragm pumps are inadequate for accurately dosing high viscosity fluids containing particulates, such as beverage concentrates and food products, due to resistive forces affecting piston/diaphragm return to the neutral starting position.
Innovation Solution
A single piston portion pump system combined with a gas control system, featuring a piston/diaphragm assembly, an elastic member, and a piston position sensor, where the gas control system uses signaling to control gas flow for precise dosing and return of the piston/diaphragm assembly, ensuring accurate fluid delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double diaphragm pump is used to pump high viscosity fluids, then the pump can handle viscous fluids, but the dosing accuracy deteriorates due to resistive forces preventing the piston/diaphragm from returning to the neutral starting position
Solution Approach 1:
The patent replaces the mechanical spring-based return system with a pneumatic system. A pneumatic actuator applies controlled air pressure to the diaphragm to force it back to the neutral starting position, eliminating the unreliable mechanical return that failed under high viscosity resistive forces. This substitution of pneumatic for mechanical actuation resolves the contradiction by providing a more reliable return mechanism that overcomes viscous resistance.
Solution Approach 2:
The invention introduces pneumatic actuation where compressed air is supplied through a control valve to the pneumatic actuator. The pneumatic system provides controlled force to move the piston/diaphragm assembly both during the pumping stroke and during the return to neutral position, ensuring consistent and accurate dosing regardless of fluid viscosity. The pneumatic control system includes sensors and feedback mechanisms to maintain precise positioning.
2Productivity
If a double diaphragm pump with air control system is used, then the pump can dose fluids, but the dosing precision worsens due to the inherent behavior and resistive forces in the diaphragm
Solution Approach 1:
The patent incorporates feedback control through position sensors that monitor the actual position of the piston/diaphragm assembly. The sensor signals are fed back to the pneumatic control valve, which adjusts the air pressure in real-time to ensure the diaphragm reaches and maintains the precise neutral starting position. This closed-loop feedback system compensates for variations in fluid viscosity and diaphragm behavior, maintaining high dosing precision.
Solution Approach 2:
The invention dynamically adjusts pneumatic pressure parameters to optimize dosing accuracy. The control system varies the air pressure magnitude and duration based on the required dose volume and fluid viscosity characteristics. By changing the pneumatic actuation parameters rather than relying on fixed mechanical properties, the system achieves precise dosing across different operating conditions.
3Reliability
If a single piston portion pump with gas control system is used, then the dosing accuracy is improved through consistent piston return, but the device complexity increases due to the addition of pneumatic components and control systems
Solution Approach 1:
The pneumatic actuator serves multiple functions: it drives the diaphragm during the pumping stroke, forces the return to neutral position, and provides the actuating force for dose dispensing. The single pneumatic system replaces what would otherwise require separate mechanical return springs, pumping mechanisms, and dosing controls, consolidating multiple functions into one integrated component that reduces overall system complexity despite the added pneumatic elements.
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 provides accurate and controlled dosing of high viscosity fluids by ensuring consistent piston return and adjusting the axial spring force, enhancing the accuracy and reliability of fluid delivery.
Implementation Method 1
a combination of an elastic member arranged on a retainer coupled to the piston shaft in a compartment in a pump housing, the combination of the elastic member and retainer being configured to move the piston/diaphragm assembly back to the starting position
Implementation Method 2
the piston/diaphragm assembly being configured to move from a starting position and cause fluid having a high viscosity to be provided from the liquid chamber in response to gas being received by the gas chamber
Data Source
AI summary
A high viscosity portion pump system has a single piston portion pump having a piston/diaphragm assembly arranged on a piston shaft forming liquid and gas chambers, which moves from a starting-position and provides high viscosity fluid from the liquid chamber when gas is received by the gas chamber; has an elastic member arranged on a retainer coupled to the shaft in a compartment in a pump housing, which moves the assembly back to the position and draws further fluid into the liquid chamber when the gas is released; and has a piston position sensor that responds to the position of the shaft and provides signaling containing information about when the assembly is in the position or completed a stroke from the position. A gas control system includes a signal processor that receives the signaling, and provides corresponding signaling containing information about when to provide or release the gas.