Pump Flow Monitoring With Multi-Sensor Upstream Anomaly Detection
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Solution Overview
Problem
Conventional techniques for monitoring the upstream flow characteristics of pumps, such as peristaltic pumps, are inadequate in detecting gradual changes in drip rate and drop size due to conditions like backflow and partial occlusions, which can lead to undetected abnormalities.
Innovation Solution
A system incorporating a drop sensor, pressure sensor, and fluid level sensor to monitor the upstream flow characteristics, using time of flight measurements and threshold comparisons to detect abnormalities like full/partial occlusions, empty reservoirs, and backflows, with a controller adjusting pump operation based on sensor outputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional monitoring techniques are used, then the system is simple, but gradual changes in drip rate and drop size due to backflow and partial occlusions cannot be detected
Solution Approach 1:
The monitoring system is divided into multiple independent sensor components: a drop sensor for detecting drop characteristics, a pressure sensor for monitoring pressure changes, and a fluid level sensor for tracking fluid levels. Each sensor handles a specific aspect of flow monitoring, allowing the system to detect gradual changes with high precision while keeping individual sensor complexity low.
Solution Approach 2:
The patent introduces intermediate measurement parameters (drip rate, drop size, pressure changes, fluid level) that serve as mediators between the actual flow conditions and the control system. These intermediaries translate complex flow characteristics into measurable signals that can be processed to detect abnormalities like backflow and partial occlusions.
2Reliability
If multiple sensors are used to detect abnormalities, then detection accuracy improves, but device complexity increases
Solution Approach 1:
The system uses segmented sensing functions where each sensor type (drop sensor, pressure sensor, fluid level sensor) is responsible for a specific aspect of flow monitoring. This segmentation allows the system to achieve high reliability through multiple independent detection channels while managing complexity by assigning specific roles to each sensor.
Solution Approach 2:
The controller integrates multiple sensor inputs and performs multiple detection functions (detecting backflow, partial occlusions, empty reservoirs) using a unified processing architecture. This multi-functionality approach allows the system to achieve high detection reliability across various abnormal conditions without proportionally increasing overall system complexity.
3Measurement precision
If the fluid level sensor measures at high frequency, then detection of drop entry is improved, but energy consumption increases
Solution Approach 1:
The fluid level sensor operates using periodic measurements rather than continuous monitoring. By measuring at intervals synchronized with the expected drop frequency, the system achieves precise detection of drop entry events while significantly reducing energy consumption compared to continuous high-frequency sampling.
Solution Approach 2:
The system uses excessive measurement frequency only when needed for drop detection, rather than maintaining high frequency continuously. The fluid level sensor switches between high-frequency measurement mode (when drops are expected) and lower-frequency mode (between drops), optimizing the balance between detection precision and energy consumption.
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 precise detection of upstream flow abnormalities that evade conventional methods, ensuring accurate fluid delivery by adjusting pump operation to prevent issues like empty reservoirs and backflows.
Implementation Method 1
the fluid level sensor may measure a fluid level in the drip chamber by at least transmitting a signal and measuring a quantity of time required for the signal to travel through the fluid in the drip chamber
Implementation Method 2
The peristaltic pump may operate by applying continuous pressure to a flexible tube containing an intravenous fluid. For instance, the peristaltic pump may include a rotor having one or more rollers, wipers, and/or lobes disposed along its external circumference. As the rotor rotates, the rollers, wipers, and/or lobes may compress successive portions of the flexible tube, thereby forcing the intravenous fluid through the flexible tube
Data Source
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AI summary
A system for monitoring upstream flow characteristics for a pump is provided. The system may receive one or more outputs from a fluid level sensor coupled with a pump. The system may detect based on at least the one or more outputs, an abnormal upstream flow condition in the pump, such as a full upstream occlusion in the tube, a partial upstream occlusion in the tube, an empty reservoir, and/or a backflow of the fluid into the drip chamber. The system may adjust, based on the detection of an abnormal upstream flow condition in the pump, operation of the pump.