Solenoid Pump Stroke Monitoring via Coil Current Sensing
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Solution Overview
Problem
Existing processing systems are static and limited in product generation, requiring extensive modifications to produce different products due to non-reconfigurable devices and components, making them inefficient for versatile product creation.
Innovation Solution
A system that includes a solenoid pump with a solenoid coil, a PWM controller, a current sensor, and a control logic subsystem to monitor fluid flow and determine product container conditions, allowing for dynamic reconfiguration and efficient product switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a processing system uses non-reconfigurable devices and components, then the system structure is simple and stable, but the system cannot generate different products and requires extensive modifications for reconfiguration
Solution Approach 1:
The patent applies universality by enabling a single processing system to perform multiple product generation functions through software reconfiguration. The control logic subsystem can be programmed with different recipes to produce various products using the same physical components (solenoid pumps, valves, containers), eliminating the need for extensive hardware modifications when switching products.
Solution Approach 2:
The patent implements dynamics by making the processing system reconfigurable through software control. The control logic subsystem can dynamically adjust operating parameters, pump stroke sequences, and valve timing to accommodate different product requirements, transforming a static system into a dynamic one that adapts to various production needs without physical reconfiguration.
2Adaptability or versatility
If the system performs extensive modifications to produce different products, then new product capabilities are achieved, but the reconfiguration time and cost increase
Solution Approach 1:
The patent applies preliminary action by pre-programming multiple product recipes in the control logic subsystem. Before actual product switching is needed, all the control parameters, pump sequences, and process settings for different products are already prepared and stored in memory, allowing for rapid switching without time-consuming reconfiguration during production changes.
Solution Approach 2:
The patent implements parameter changes by allowing the control logic subsystem to modify operational parameters (pump stroke duration, valve timing, flow rates, temperature settings) through software rather than physical changes. This enables quick transitions between products by simply loading different parameter sets, dramatically reducing reconfiguration time compared to mechanical or electrical modifications.
3Reliability
If the system uses dedicated single-use components, then each component is optimized for its specific function, but the overall system flexibility is reduced
Solution Approach 1:
The patent applies universality at the system level, where dedicated components (solenoid pumps, valves, containers) are controlled by a universal control logic subsystem that can orchestrate these components for different product formulations. The control system acts as a universal coordinator that enables reconfigurability without requiring the physical components themselves to be reconfigurable, maintaining component reliability while achieving system flexibility.
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
Enables the system to determine functional and non-functional pump strokes, detect product container emptiness, and adapt to different product recipes, enhancing the flexibility and efficiency of product generation in processing systems.
Implementation Method 1
at least one solenoid pump comprising a solenoid coil, which, when energized, produces a stroke of the solenoid pump
Implementation Method 2
at least one current sensor for sensing the current flow through the solenoid coil and producing an output of the sensed current flow
Data Source
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AI summary
A system for monitoring flow conditions of fluid flowing from a product container through a solenoid pump. The system includes at least one solenoid pump comprising a solenoid coil, which, when energized, produces a stroke of the solenoid pump, at least one product container connected to the at least one solenoid pump wherein the at least one solenoid pump pumps fluid from the at least one product container during each stroke, at least one PWM controller configured to energize the at least one solenoid pump, at least one current sensor for sensing the current flow through the solenoid coil and producing an output of the sensed current flow, and a control logic subsystem for controlling the flow of fluids through the solenoid pump by commanding the PWM controller and for monitoring the current through the solenoid pump by receiving the output from the current sensor, wherein the control logic subsystem uses the measured current flow through the solenoid coil to determine whether the stroke of the solenoid pump is functional.