Pump Motor Back-EMF Flow Control for Beverage Dispensing
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Solution Overview
Problem
Standard beverage dispensing systems rely on complex and expensive mechanical flow control devices to achieve precise fluid flow, which are bulky, require frequent recalibration, and lack accurate feedback, leading to inconsistent beverage quality and waste due to the inability to self-adjust to changes in operating conditions.
Innovation Solution
A closed-loop flow control system using an electric motor and Back Electro-Motive Force (BEMF) measurement to monitor and control fluid flow, eliminating the need for external flow control components by modulating the pulse width of the motor voltage to maintain consistent flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical flow control devices are used to achieve precise fluid flow, then flow precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical flow control devices with an electrical control system that uses pulse width modulation (PWM) to control the motor driving the pump. This substitution eliminates complex mechanical components like pistons, sleeves, springs, and adjustment screws, while achieving precise flow control through electrical signal modulation.
Solution Approach 2:
The patent implements a feedback mechanism using a flow sensor to monitor actual fluid flow and a control system that compares this feedback with the desired flow rate. The control system automatically adjusts the PWM signal to the motor based on this feedback, maintaining precise flow control without complex mechanical adjustment devices.
2Manufacturing precision
If mechanical flow control devices are used to achieve precise fluid flow, then flow precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive mechanical flow control devices with a more economical electrical control system using PWM modulation and a flow sensor. This substitution reduces manufacturing costs by eliminating the need for precision-machined mechanical components while maintaining or improving flow precision.
Solution Approach 2:
The control system automatically adjusts flow rates based on feedback from the flow sensor, eliminating the need for manual calibration and adjustment that would require skilled technicians. The system self-regulates to maintain precise flow, reducing labor costs and simplifying manufacturing and maintenance.
3Manufacturing precision
If mechanical flow control devices are used to achieve precise fluid flow, then flow precision is improved, but ease of operation decreases due to frequent recalibration needs
Solution Approach 1:
The patent implements continuous feedback monitoring using a flow sensor that provides real-time data to the control system. This feedback mechanism automatically detects and compensates for flow variations, eliminating the need for frequent manual recalibration and allowing operators to maintain precise flow control without specialized training.
Solution Approach 2:
The control system automatically adjusts the motor speed and pump output based on feedback from the flow sensor, enabling the system to self-correct flow deviations. This self-regulating capability eliminates the need for operator intervention for recalibration, significantly improving ease of operation.
4Ease of operation
If BIB pumps operate under constant pressure with pressure switches, then pump operation is simplified, but flowrate control precision deteriorates
Solution Approach 1:
The patent replaces the pressure switch-based mechanical control system with an electrical control system using PWM modulation. This substitution allows for precise flowrate control by varying the motor speed electrically, while maintaining simplified operation through electronic control rather than mechanical pressure differential mechanisms.
Solution Approach 2:
The patent transitions from static constant-pressure operation to dynamic flow control by using PWM modulation to continuously adjust motor speed. This dynamic control allows the pump to maintain precise flowrates under varying conditions while keeping the control system simplified through electronic rather than mechanical means.
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 precise, self-adjusting flow control, reduces component complexity and cost, and minimizes recalibration needs, ensuring consistent beverage quality by automatically adapting to changes in operating conditions.
Implementation Method 1
a control system that measures Back Electro-Motive Force (BEMF) voltage of the motor to determine a speed of the motor and a flow rate of the pump
Implementation Method 2
The control system modulates a pulse width of a voltage applied to the motor to maintain the flow rate within a target flow rate range
Data Source
AI summary
The present system generally relates to a fluid flow system where a controller and motor pump assemblies are used to optimize the control of fluid flow through the system. The controller samples the back electromotive force of the motor and pump assemblies and is able to utilize the sampled back electromotive force in conjunction with predefined target back electromotive force values, preferably empirically determined and tuned to an induvial motor and for a select fluid, to tune the voltage applied to the system, control the back electromotive force of the system and, by extension, control the flow of fluid.