Smart Fluid Conduit Using PLC for Spray Foam Control

Solution Overview

Problem

In fluid delivery systems like Spray Polyurethane Foam (SPF) systems, there is a lack of real-time communication and control between the proportioning system located far from the application area, leading to inefficiencies such as poor foam quality and lower yield, as the spray foam applicator lacks access to critical system information and diagnostic data.

Innovation Solution

The integration of electrically conductive elements within fluid conduits to enable Power Line Communication (PLC), allowing for the transmission of digital data signals and power through the conduits themselves, eliminating the need for additional cables and enabling real-time communication and control between the proportioning system and the spray gun.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional cables are installed for communication and control, then real-time monitoring and control capability is improved, but device complexity and installation difficulty increase

Engineering Contradiction:

Improvereal-time monitoring and control capabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The fluid conduit is designed to perform multiple functions: delivering fluid from the proportioning system to the spray gun while simultaneously serving as a communication channel for PLC signals and a power transmission path. This eliminates the need for separate cables for these functions, reducing system complexity while maintaining real-time monitoring and control capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the fluid delivery function with communication and power transmission functions into a single integrated system. The electrically conductive elements are integrated within the fluid conduit structure, merging what would traditionally be separate components (fluid hose, communication cable, power cable) into one unified element.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If additional cables are installed for communication and control, then real-time monitoring and control capability is improved, but installation difficulty increases

Engineering Contradiction:

Improvereal-time monitoring and control capabilityVSAvoidinstallation difficulty

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The fluid conduit is designed to perform multiple functions: delivering fluid from the proportioning system to the spray gun while simultaneously serving as a communication channel for PLC signals and a power transmission path. This eliminates the need for separate cables for these functions, reducing system complexity while maintaining real-time monitoring and control capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If the proportioning system is located far from the application area, then work area accessibility is improved, but communication and control efficiency deteriorate

Engineering Contradiction:

Improvework area accessibilityVSAvoidcommunication and control efficiency

Core Design Contradiction:

Ease of operationVSLoss of information

Solution Approach 1:

Power Line Communication serves as an intermediary mechanism that enables information and control signal transmission through the existing fluid conduit infrastructure. This allows the proportioning system to maintain real-time communication with the spray gun even when located at a distance, eliminating information loss that would occur with traditional communication methods over long distances.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Loss of information

If extra cables are added for communication, then real-time communication capability is improved, but loss of substance and system weight increase

Engineering Contradiction:

Improvereal-time communication capabilityVSAvoidloss of substance

Core Design Contradiction:

Loss of informationVSLoss of substance

Solution Approach 1:

The fluid conduit is designed to perform multiple functions: delivering fluid from the proportioning system to the spray gun while simultaneously serving as a communication channel for PLC signals and a power transmission path. This eliminates the need for separate cables for these functions, reducing system complexity while maintaining real-time monitoring and control capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution provides real-time critical system information to the spray foam applicator, improving foam quality and efficiency by allowing for remote monitoring and control of pressure, temperature, and flow rates, reducing the need for extra cables and enhancing reliability.

Implementation Method 1

a first electrically conductive element configured to deliver electricity through a length of the smart hose

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS12030074B2Fluid delivery system

Publication Date: 2024.07.09 CARLISLE FLUID TECHNOLOGIES LLC

AI summary

A fluid delivery system includes a conduit. The conduit is configured to deliver a fluid. The conduit further includes a first electrically conductive element configured to deliver electricity through a length of the conduit. The fluid delivery system further includes master hub disposed on a fluid delivery device. The fluid delivery system also includes at least one slave hub disposed on the conduit and communicatively coupled to the master hub.