Automatic fill control technique
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Solution Overview
Problem
Existing pump control systems maintain pressure in lines, causing pumps to run indefinitely if lines burst, leading to unnecessary energy consumption and inefficiency.
Innovation Solution
A control system that uses a level sensing PCB and a microcontroller to manage pump operation, implementing a flowchart-based logic to turn the pump on and off based on liquid levels, allowing for efficient refill and shutdown, including calibration procedures to set refill parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure is maintained in lines to keep pump shutdown, then pump remains off when not in use, but pump runs indefinitely if lines burst causing energy waste
Solution Approach 1:
The patent replaces the mechanical pressure-based pump control system with an electronic control system using a microcontroller and level sensing PCB. This substitution eliminates the need to maintain pressure for pump shutdown control, allowing the pump to be reliably turned off without energy waste when lines burst or reservoirs are full.
Solution Approach 2:
The patent implements feedback through level sensing PCBs that continuously monitor reservoir liquid levels and provide signals to the microcontroller. This feedback mechanism enables intelligent pump control based on actual reservoir conditions rather than relying on pressure maintenance, preventing unnecessary pump operation and energy consumption.
2Ease of operation
If solenoid valve is installed to shut off water flow, then pump can be controlled, but device complexity increases
Solution Approach 1:
The patent replaces mechanical solenoid valves with an electronic control architecture using a microcontroller and level sensing PCBs. This substitution provides pump control through electronic signals based on liquid level detection, eliminating the need for additional mechanical components like solenoid valves while maintaining ease of operation.
Solution Approach 2:
The system performs self-service control by automatically monitoring liquid levels through the level sensing PCBs and activating the pump only when needed. The microcontroller autonomously manages pump operation based on feedback from the level sensors, eliminating the need for manual intervention or complex valve mechanisms.
3Stress or pressure
If pump runs to deplete supply when lines burst, then pressure is relieved, but unnecessary energy is consumed
Solution Approach 1:
The level sensing PCBs provide continuous feedback to the microcontroller about reservoir liquid levels. When lines burst or reservoirs are full, the feedback signal immediately stops pump operation, preventing unnecessary energy consumption while still allowing pressure to equalize naturally without requiring the pump to run to deplete the supply.
Solution Approach 2:
The electronic control system replaces the mechanical pressure-based shutdown mechanism. Instead of requiring the pump to run until pressure is relieved, the electronic system can immediately stop the pump based on level feedback, eliminating wasted energy while achieving pressure balance through natural flow equalization.
Data Source
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AI summary
A pump includes a signal processor that receives signaling containing information about a low level of a liquid sensed in an appliance reservoir to be supplied to an appliance that uses the liquid to dispense a flavored beverage, and also about when the appliance reservoir is refilled based upon an indication that forms part of an appliance reservoir refill level calibration procedure programmed by an appliance user; and determines corresponding signaling containing information about automatically refilling the liquid in the appliance reservoir, based upon the signaling received.