Positive Displacement Pump Stroke Detection via Suction Pressure

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Solution Overview

Problem

Conventional chemical injection systems face challenges in accurately measuring dose rates due to unconventionally shaped source tanks, low flow rates, and the need for expensive sensors, making it difficult to detect pump strokes without additional equipment.

Innovation Solution

A monitor and control system that uses a pressure sensor to measure low-pressure signals on the suction side of a positive displacement pump, equating each low-pressure point with a pump stroke, and calculates the dose by multiplying the number of low-pressure points with the volume of each full stroke, eliminating the need for additional sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If liquid level measurement is used to determine dose rate, then the measurement method is simple, but the accuracy is poor due to unconventionally shaped source tanks and temperature changes

Engineering Contradiction:

Improvemeasurement method simplicityVSAvoiddose rate measurement accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical/physical liquid level measurement system with an acoustic measurement system using a transducer that emits sound waves and measures their return time to calculate distance to the liquid surface. This substitution eliminates the problems of temperature sensitivity and tank shape dependency while maintaining measurement simplicity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If flow sensors are used to measure chemical volume, then measurement accuracy improves, but device complexity and cost increase significantly

Engineering Contradiction:

Improvechemical volume measurement accuracyVSAvoidequipment sophistication

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses acoustic wave propagation as a virtual copy or analog of fluid flow measurement. Instead of directly measuring chemical flow with complex flow sensors, it creates an acoustic model where sound wave travel time through the chemical column correlates to liquid level and volume, providing accurate measurement without sophisticated flow sensing equipment.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The acoustic transducer serves multiple functions: it measures liquid level, determines volume, and can potentially detect other parameters. This single device replaces what would otherwise require flow sensors, level sensors, and temperature compensation systems, reducing overall device complexity while maintaining measurement accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Difficulty of detecting and measuring

If additional sensors such as proximity sensors are installed on the pump, then pump stroke detection becomes possible, but device complexity and cost increase

Engineering Contradiction:

Improvepump stroke detection capabilityVSAvoidadditional sensors required

Core Design Contradiction:

Difficulty of detecting and measuringVSDevice complexity

Solution Approach 1:

The patent merges the level measurement function and pump stroke detection function into a single acoustic measurement system. The transducer mounted on the pump housing uses the pump's own acoustic signature during operation to detect strokes, eliminating the need for separate proximity sensors or other additional detection devices.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pump system uses its own acoustic emissions and vibrations during operation to provide stroke detection information. The transducer listens to the pump's self-generated acoustic signals, allowing the system to detect its own operational state without requiring external sensing equipment.

Inventive Principle:

Principle #25Self-service

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

This method allows for accurate determination of chemical injection dose rates without requiring complex or expensive equipment, such as flow sensors or proximity sensors, thereby improving measurement precision and reducing costs.

Implementation Method 1

A progress of the positive displacement pump piston is determined using a pressure sensor that measures a pressure in the source tank or on the suction side of the positive displacement pump.

Methodology Applied

Scientific EffectPressure measurement:

Data Source

PatentUS20250020113A1Alternative apparatuses and methods to determine chemical injection dose using a positive displacement pump

Publication Date: 2025.01.16 DETECHTION USA INC

AI summary

An alternative method and apparatus for determining a chemical injection dose to a fluid system is provided. The method and apparatus uses a monitor and control system processor connected to a pressure sensor and a positive displacement pump. The monitor and control system processor determines a stroke of a positive displacement pump by measuring a low-pressure on the suction side of the pump and equates each low pressure point with a pump stroke (or the discharge of a piston volume for dual stroke pumps). The monitor and control system processor calculates the dose by multiplying the number of low-pressure points with the volume of the discharge.