Surface Scrubber Flow and Pressure Control for Consistent Cleaning
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Solution Overview
Problem
Existing surface treating apparatuses face challenges in accurately adjusting flow rates of cleaning solutions, chemical dilution ratios, and scrubbing pressures, leading to inconsistent cleaning performance and inefficiencies due to the reliance on gravity feed systems and lack of precise control mechanisms.
Innovation Solution
A surface treating apparatus equipped with a solenoid valve flow control module, a solution sensor for level monitoring, and a controller that adjusts flow rates and chemical dilution ratios based on the solution level, along with a scrubbing pressure sensor and adjuster to maintain optimal scrubbing pressure, allowing for precise control of cleaning parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If gravity feed system is used for cleaning solution supply, then the system is simple and easy to operate, but the flow rate cannot be accurately controlled and decreases as solution level drops
Solution Approach 1:
The patent employs a feedback control system where a flow sensor continuously monitors the actual flow rate of cleaning solution and feeds this information back to the controller. The controller compares the measured flow rate with the desired flow rate and adjusts the solenoid valve duty cycle accordingly to maintain accurate flow control despite changes in solution level.
Solution Approach 2:
The system transitions from a static gravity feed system to a dynamic controlled system by implementing variable duty cycle operation of the solenoid valve. The duty cycle is continuously adjusted based on real-time flow measurements and solution level changes, enabling the system to adapt and maintain consistent flow rates throughout operation.
2Manufacturing precision
If solenoid valve is used to control flow rate, then flow control is improved, but the maximum flow rate decreases as solution level drops due to gravity feed limitations
Solution Approach 1:
The patent utilizes periodic pulsing of the solenoid valve through duty cycle control. Instead of maintaining a constant valve position, the valve is opened and closed periodically at high speed, with the average flow rate controlled by adjusting the proportion of time the valve is open (duty cycle). This periodic action enables precise flow control while compensating for gravity feed limitations.
Solution Approach 2:
The system changes the operational parameters of the solenoid valve by varying the duty cycle percentage based on solution level and desired flow rate. As the solution level drops and maximum available flow decreases, the controller adjusts the duty cycle parameter to maintain the target flow rate, optimizing productivity throughout the solution tank's depletion.
3Device complexity
If manual chemical pouring is used, then the system is simple, but the chemical dilution ratio cannot be exactly controlled
Solution Approach 1:
The patent replaces the manual mechanical pouring process with an automated electronic control system. A chemical injection pump delivers precise amounts of chemical concentrate, and a controller calculates and regulates the chemical-to-water ratio based on monitored flow rates, eliminating the imprecision of manual pouring while maintaining system simplicity.
Solution Approach 2:
The system introduces a chemical injection pump as an intermediary device between the chemical container and the solution stream. This intermediary component enables precise metering and controlled introduction of chemical concentrate into the cleaning solution, achieving exact dilution ratios that cannot be obtained through direct manual mixing.
4Stability of the object's composition
If operator control is used to maintain constant cleaning solution flow, then flow consistency is improved, but the control accuracy is not always sufficient
Solution Approach 1:
The patent implements a closed-loop feedback control system where a flow sensor continuously measures the actual cleaning solution flow rate and provides real-time data to the controller. The controller automatically adjusts the solenoid valve duty cycle based on the difference between measured and target flow rates, eliminating the inaccuracies of manual operator control and maintaining consistent flow throughout operation.
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 apparatus provides accurate and consistent adjustment of flow rates, chemical dilution ratios, and scrubbing pressures, enhancing cleaning efficiency, reducing solution and chemical consumption, and minimizing energy usage, while allowing for temporary spikes in cleaning power as needed.
Implementation Method 1
A flow control module in the most preferred form of a solenoid valve is in line with the fluid flow line
Implementation Method 2
A solution sensor senses a level of the cleaning solution in the tank
Implementation Method 3
The controller controls the flow control module to operate at an operating flow rate based on the level of the cleaning solution in the tank
Implementation Method 4
a scrub deck having one or more agitating elements such as in the form of brushes or pads for scrubbing a surface such as a floor with the cleaning solution
Data Source
AI summary
A surface treating apparatus (10) includes a tank (100) containing a cleaning solution (102) supplied to a supply point (SP) via a fluid flow line (106) under control of a flow control module (108). A chemical pump (144) controls flow of a chemical supplied to the fluid flow line (106). A controller (130) controls the flow control module (108) to operate at an operating flow rate based on a level of the cleaning solution (102) sensed by a solution sensor (120). The controller (130) controls the chemical pump (144) to operate at a flow rate based on the operating flow rate so that the chemical is supplied to the supply point (SP) at a selected chemical dilution ratio. An agitating element (105) agitates the surface with scrubbing pressure which is adjusted by the controller (130). A spike button (168) is coupled to controller (130) and operable to momentarily increase the flow rate, chemical dilution ratio, and/or scrubbing pressure to remove unusually dirty spots.