Real-Time Fluid Blending with Single Variable Speed Pump
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Solution Overview
Problem
In the de-icing industry, existing fluid blending systems face challenges in efficiently loading liquid chemicals into trucks of varying sizes, requiring significant storage capacity for pre-blended products and struggling with uniformity and safety due to multi-compartment tanks, while multi-pump systems are costly, power-intensive, and difficult to tune.
Innovation Solution
A real-time blending system using a single variable speed pump with flow control valves to maintain the target blend ratio, regulating flow rates and preventing pump cavitation by monitoring Net Positive Suction Head Available (NPSHA) to ensure efficient and safe blending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single pump system is used, then device complexity and power consumption are reduced, but manufacturing precision and control difficulty worsen
Solution Approach 1:
The system employs flow meters to continuously measure the flow rates of individual products and the blended output, with a controller that compares actual flow rates against target values and adjusts control valves accordingly. This closed-loop feedback mechanism enables precise blend ratio control despite using a single pump, resolving the contradiction between system simplicity and control precision.
Solution Approach 2:
The patent replaces complex mechanical multi-pump systems with a single pump controlled by electronic flow control valves and a programmable controller. This substitution of mechanical complexity with electronic control allows for precise blend ratio adjustment while maintaining system simplicity and reducing power consumption.
2Manufacturing precision
If multi-pump systems are used, then blending precision is improved, but device complexity and power consumption increase
Solution Approach 1:
The patent merges the functions of multiple pumps into a single pump system by controlling the flow rates of individual products through electronic control valves before they enter the blender. This consolidation achieves the blending precision previously requiring multiple pumps while dramatically reducing device complexity and power consumption.
Solution Approach 2:
The system replaces mechanical multi-pump configurations with a single pump combined with electronic flow control valves and a programmable controller. This substitution enables precise blend ratio control through electronic regulation rather than mechanical complexity, reducing both device complexity and energy requirements.
3Stability of the object's composition
If pre-blending is done in storage tanks, then blending uniformity is improved, but storage capacity requirements and operational flexibility worsen
Solution Approach 1:
The system performs preliminary mixing of products in a blender before delivery to the truck, rather than pre-blending in storage tanks. This preliminary action ensures uniform blend composition while maintaining the ability to adjust product ratios dynamically based on truck size and specific requirements, thereby achieving both blend uniformity and operational flexibility.
Solution Approach 2:
The patent implements a dynamic blending system where product ratios can be adjusted in real-time based on truck size and blend requirements. The programmable controller dynamically modifies flow rates of individual products to maintain consistent blend uniformity across different applications, eliminating the need for fixed pre-blended storage tanks while preserving blend quality.
4Manufacturing precision
If flow control valves are added to regulate individual product flow, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical flow control mechanisms with electronic control valves actuated by a programmable controller. This substitution provides precise flow rate control for each product while minimizing additional mechanical complexity, as the electronic system can be programmed to handle various flow requirements without requiring complex mechanical linkages.
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 reduces power consumption, manufacturing costs, and complexity, while ensuring accurate blending and preventing pump damage, offering a more efficient and safer method for filling trucks with variable fluid ratios.
Implementation Method 1
a pump configured to pump the blended liquid
Implementation Method 2
flow control valves to maintain the target blend ratio, regulating flow rates
Data Source
AI summary
Systems and methods for blending fluids are provided. A blended fluid may be obtained by mixing a first fluid from a first fluid source with a second fluid from a second fluid source. The blended fluid may be pumped by a pump arranged downstream of a point at which the first and second fluids are mixed, wherein no other pumps are upstream of the pump. First and second flow control valves that control the flow rate of the first and second fluids, respectively, are adjusted so as to reach a target flow rate of the blended fluid, the blended fluid having a target blend of the first fluid and the second fluid.