Two-Valve Dispensing Unit with Neural Network Control
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Solution Overview
Problem
The manufacturing process of filling containers with fluid faces issues such as overfilling and underfilling due to human error, viscosity of fluids causing clogging and flow rate unpredictability, and the need for precise control to avoid penalties and maintain brand value.
Innovation Solution
A system and method utilizing a two-valve dispensing unit with neural network logic to control fluid dispensing, continuously monitoring weight and adjusting flow rates to fill containers precisely, and automatically modifying parameters based on past and real-time data to prevent clogging and ensure accurate filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual inspection and manual valve control are used, then the system is simple to operate, but filling precision deteriorates due to human error
Solution Approach 1:
The patent replaces manual visual inspection and manual valve control with an automated system using a load cell sensor for weight detection and a microprocessor-controlled valve system. The mechanical/manual control system is substituted with an electronic control system that automatically monitors fluid weight and controls valve operation to achieve precise filling.
Solution Approach 2:
The patent implements a feedback mechanism where the load cell continuously monitors the weight of fluid in the container and provides real-time data to the microprocessor. The system compares the measured weight with the target fill weight and automatically adjusts valve operation to achieve the desired precision, eliminating human error in monitoring and control.
2Device complexity
If high-viscosity fluid is dispensed through a single outlet, then the dispensing system is simple, but clogging occurs and flow rate becomes unpredictable
Solution Approach 1:
The patent divides the single outlet into multiple outlets (first outlet and second outlet) with separate valves controlling each. This segmentation allows the system to manage high-viscosity fluid flow more effectively, preventing clogging by providing alternative flow paths and enabling independent control of each outlet to maintain predictable flow rates.
Solution Approach 2:
The patent implements dynamic control of the valve openings, where the microprocessor adjusts the opening degree of valves in real-time based on feedback from the load cell. This dynamic adjustment allows the system to adapt to changes in fluid viscosity and flow characteristics, maintaining consistent flow rates even with high-viscosity fluids.
3Productivity
If fast filling is performed to increase productivity, then filling speed improves, but precision deteriorates due to difficulty in detecting exact fill point
Solution Approach 1:
The patent replaces manual detection of the fill point with an automated electronic detection system using a load cell and microprocessor. This substitution enables continuous real-time monitoring of fluid weight during fast filling operations, allowing the system to precisely determine when the target fill weight is reached even at high speeds.
Solution Approach 2:
The patent implements continuous monitoring of fluid weight throughout the entire filling process using the load cell. Rather than relying on periodic checks or visual inspection, the system continuously tracks the fill weight, enabling precise control at high filling speeds by immediately detecting when the target weight is achieved.
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 achieves precise filling of containers, reducing errors and product loss, improving operational efficiency, and maintaining brand integrity by minimizing overfilling and underfilling, while adapting to the viscosity of fluids.
Implementation Method 1
weighing an empty container on a scale to obtain a container weight
Data Source
Figure 1
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Figure 5~6
AI summary
A system and method for filling containers with a precise amount of fluid is disclosed. The system and method use artificial neural network logic to sense conditions and to control the two-valve dispensing unit based on the sensed conditions to fill containers with a precise amount of fluid. Using neural network logic combined with sensors and controllers for equipment eliminates the significant human effort and human errors associated with manually filling containers with fluid. Furthermore, the neural network can log data quicker and with more accuracy than a human manually logging data. The system and method use a two-valve dispensing unit to precisely fill and to prevent and clear clogs caused by fluid solidifying within the dispensing unit.