Two-Component Resin Dispensing With Feedback Ratio Control
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Solution Overview
Problem
The manual mixing and dispensing of multi-component coatings, such as epoxy and urethane resins, in flooring systems is labor-intensive, prone to human error, and requires significant manpower, leading to inconsistencies in mix ratios and increased waste due to the need for multiple small batches, which is exacerbated by environmental variables like temperature.
Innovation Solution
A multi-component coating dispensing system with integrated pumps, sensors, and a controller that automates the mixing and dispensing process, ensuring precise ratios and real-time adjustments based on environmental and operational data, reducing the need for manual handling and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual mixing and dispensing is used, then flexibility and simplicity are maintained, but labor intensity increases and mixing precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical mixing and dispensing operations with an automated pump system controlled by a controller. The controller regulates the drive rates of pumps that deliver coating components, automatically maintaining precise mix ratios without manual intervention. This substitution eliminates human error in ratio measurement while maintaining operational flexibility through programmable control.
Solution Approach 2:
The system incorporates sensors that monitor environmental conditions (temperature, humidity) and provide feedback to the controller. The controller adjusts pump drive rates in real-time based on this feedback to compensate for environmental variations that affect coating viscosity and mix ratios, thereby maintaining precision despite changing conditions.
2Manufacturing precision
If multiple small batches are prepared, then coating quality is maintained within working time, but productivity decreases and time consumption increases
Solution Approach 1:
The automated pump system enables continuous mixing and dispensing operations without the interruptions required by manual batch preparation. The controller maintains continuous operation by automatically managing multiple components and their mixing ratios, eliminating the need to stop and reset between batches. This continuity significantly increases productivity while maintaining coating quality consistency.
Solution Approach 2:
The system pre-configures pump drive rates and mixing parameters based on the specific coating application requirements. Environmental sensors continuously monitor conditions and pre-adjust parameters before dispensing begins, ensuring optimal mixing ratios are established in advance. This preliminary configuration eliminates setup time between batches and maintains quality consistency.
3Device complexity
If manual measurement and mixing is performed, then equipment complexity is minimized, but measurement precision deteriorates and human error increases
Solution Approach 1:
The patent replaces manual measurement tools (cups, scales, mixers) with an automated pump and controller system that electronically measures and delivers precise volumes of coating components. The controller calculates and regulates pump drive rates to achieve exact mix ratios, eliminating the imprecision of manual measurement methods while adding only moderate system complexity.
Solution Approach 2:
The system performs self-measurement and self-regulation of mixing ratios through integrated sensors and controller algorithms. The controller automatically adjusts pump operations based on real-time feedback from environmental sensors and flow measurements, eliminating the need for external measurement tools and manual intervention while maintaining high precision.
4Device complexity
If hand carrying mixed product is required, then equipment complexity is reduced, but loss of substance increases due to spillage and waste
Solution Approach 1:
The patent replaces manual hand-carrying of mixed coating product with an automated pumped dispensing system that delivers components directly to the application point. The controller regulates pump operations to ensure complete transfer of materials, minimizing spillage and waste. This substitution adds moderate system complexity but dramatically reduces material loss.
Solution Approach 2:
The automated pump system maintains continuous flow of coating components from storage through mixing to application without interruption. This continuous operation eliminates the transfer steps required in manual handling, preventing spillage and waste that occur when buckets are carried and poured. The system ensures complete material utilization throughout the dispensing process.
Data Source
AI summary
According to some embodiments, a system and method for dispensing a floor coating in a specified ratio of multiple components is disclosed. The system and method may set and maintain a desired ratio of the multiple components by controlling, with a controller, a drive rate of respective pumps configured for propelling the components from a reservoir to a mixer or a dispenser. The controller may be responsive to at least one of a measured actual drive rate, an environmental condition, an actual usage of each component, and an operational parameter of the system, for adjusting a drive rate of the respective pumps to compensate for discrepancies that may affect the ratio of the multiple components.