Peristaltic Pump Synchronization for Pig Collision Avoidance
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Solution Overview
Problem
Peristaltic pumps face challenges during color changes in painting systems, where paint residue cannot be efficiently recovered due to collisions between pigs and squeezing elements, leading to paint loss and high pressure requirements for pig movement, which can result in contamination and increased load on the pig.
Innovation Solution
A synchronization system that coordinates the movement and position of squeezing elements and pigs within the pump hose to prevent collisions, allowing the pig to pass through the pump hose without additional high-pressure thrust, enabling effective cleaning and paint recovery while maintaining the pump's conveying function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If additional high-pressure thrust is applied to move the pig through the pump hose, then the pig can pass through the pump, but paint loss increases and the pig becomes contaminated
Solution Approach 1:
The synchronization system performs preliminary action by detecting the pig's approach and pre-adjusting the squeezing element positions to create a clear passage before the pig arrives, eliminating the need for high-pressure thrust and preventing paint loss
Solution Approach 2:
The system uses feedback from pig detection sensors to continuously monitor pig position and dynamically adjust squeezing element timing, ensuring the pig passes through without collision and without requiring additional high-pressure thrust
2Force
If high pressure is used to push the pig through the supply line, then the pig can overcome resistance, but the pig becomes overloaded and contamination risk increases
Solution Approach 1:
The system preliminarily prepares the pump hose by coordinating squeezing element withdrawal before pig arrival, creating a smooth passage that reduces resistance and eliminates the need for high pushing force
Solution Approach 2:
The synchronization system dynamically changes the timing and position parameters of squeezing elements based on pig detection, transforming the pump hose from a high-resistance path to a low-resistance passage
3Productivity
If the pump operates normally during pig passage, then conveying function is maintained, but collisions between squeezing elements and pig occur
Solution Approach 1:
The system applies dynamics by making the squeezing element positions and timing variable rather than fixed, allowing real-time adjustment based on pig detection while maintaining normal pump operation
Solution Approach 2:
The synchronization system uses feedback from pig detection sensors to dynamically adjust squeezing element operation, maintaining pump productivity while preventing collisions through coordinated timing changes
4Loss of substance
If the pump hose is cleaned with a pig, then paint residue can be removed, but the pump must be taken offline
Solution Approach 1:
The pump hose and squeezing elements serve multiple functions - both normal paint conveying and pig passage facilitation - allowing the pump to remain operational during cleaning without taking it offline
Solution Approach 2:
The synchronization system maintains continuous useful action by coordinating squeezing element withdrawal with pig passage timing, allowing the pump to continue operating and conveying paint while the pig cleans the hose
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 synchronization system allows for safe passage of the pig through the peristaltic pump, reducing paint loss and pressure requirements, enabling efficient cleaning and paint recovery, and maintaining the pump's operational efficiency during the cleaning process.
Implementation Method 1
a synchronization system through which the movements and / or the positions of the at least one squeezing element and a pig located in the pump hose can be synchronized
Implementation Method 2
Peristaltic pumps are positive displacement pumps in which the medium to be conveyed is conveyed through the pump hose by being mechanically deformed from the outside
Implementation Method 3
movable squeezing elements, such as squeezing rollers, squeezing rollers or sliding shoes, press the pump hose against a hose bed or a counter element and pinch it off locally
Data Source
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AI summary
The peristaltic pump (46) has pump drive (34,36) that is cyclically moved along pump hose (12). A synchronization system (48) for synchronizing movements and/or positions of crimp (24) is provided in pump tube, such that active pump drive is concluded between the crimp and pig (40) to any position in a collision point (78). The movement of crimp with an active pump drive can be delayed or accelerated, before the crimp enters to collision point. The movement of pig with active pump drive can be delayed or accelerated before the pig enters the collision point. An independent claim is included for an application system for coating objects.