Pump Diaphragm Abnormality Detection via Charge Chamber Pressure
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Solution Overview
Problem
Pumps used for precise fluid dispensing in devices like semiconductor manufacturing and medical equipment often experience diaphragm abnormalities due to material weakness, leading to decreased performance and potential malfunctions, which are difficult to detect early on.
Innovation Solution
A pump system equipped with a pressure detector and judgment processor that monitors the pressure of a non-compressible indirect medium in the charge chamber to detect diaphragm abnormalities, allowing for early detection and maintenance, and includes a notification unit and solenoid valve to halt operations when abnormalities are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a diaphragm made of elastic material is used in the pump, then the pump can achieve quantitative fluid discharge through expansion and contraction, but the diaphragm is prone to abnormalities due to material weakness and load accumulation
Solution Approach 1:
The patent implements preliminary detection of diaphragm abnormalities by continuously monitoring pressure in the charge chamber. The judgment processor analyzes pressure changes to detect abnormalities before they cause complete pump failure, enabling early maintenance intervention and preventing catastrophic malfunction.
Solution Approach 2:
The patent establishes a feedback mechanism where the pressure detector continuously monitors charge chamber pressure and provides real-time data to the judgment processor. This feedback loop enables continuous assessment of diaphragm health based on pressure variations during pump operation, allowing dynamic adjustment and early warning of abnormalities.
2Productivity
If the pump operates continuously for quantitative discharge, then productivity is maintained, but abnormalities accumulate due to load and aging
Solution Approach 1:
The system performs preliminary detection of performance degradation by monitoring pressure patterns during continuous operation. The judgment processor identifies early signs of abnormality before they affect discharge accuracy, allowing maintenance to be scheduled before productivity is compromised.
Solution Approach 2:
Continuous pressure monitoring provides real-time feedback on pump health during operational cycles. The judgment processor analyzes pressure variations to detect deviations from normal operation, enabling continuous assessment of reliability while maintaining productivity.
3Device complexity
If no detection mechanism is added, then device complexity is low, but abnormality detection is delayed
Solution Approach 1:
The pressure detector and judgment processor are integrated into the pump system to perform preliminary detection of abnormalities during normal operation. This enables early identification of issues without requiring separate inspection procedures or system shutdowns, reducing detection time while maintaining operational continuity.
Solution Approach 2:
The pressure detection system serves multiple functions: it monitors charge chamber pressure for operational control, detects diaphragm abnormalities, and provides diagnostic information. This multi-functionality reduces the need for separate detection systems, minimizing the increase in device complexity while enabling timely abnormality detection.
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
Enables rapid detection of diaphragm abnormalities, preventing malfunctions and maintaining consistent fluid discharge rates by interrupting fluid flow and preventing indirect medium leakage, thus enhancing the usability and reliability of the pump system.
Implementation Method 1
a pressure detector configured to detect a pressure of the indirect medium in the charge chamber
Implementation Method 2
a diaphragm disposed between the charge chamber and the pump chamber in the interior of the body, and configured to, under a flowing action of the indirect medium, cause the fluid to flow into and flow out of the pump chamber
Data Source
AI summary
A pump system is equipped with a body, a displacement body, a bellows member, an indirect medium, and a diaphragm. The pump system is further equipped with a pressure sensor configured to detect a pressure of the indirect medium in a charge chamber, the charge chamber being formed to include an interior space of the bellows member in the interior of the body. A controller of the pump system determines an abnormality of the diaphragm based on detection values detected by the pressure sensor.