Electronically Controlled Pump System
An electronically controlled pump system and methods of use of the same are disclosed herein. An electronically controlled pump system can include a first fluid pumping module and a second fluid pumping module. The first fluid pumping module can include a first pump module that can output a first fluid component at a first flow rate, and a first surge suppressor that can receive the output first fluid component. The second fluid pumping module includes a second pump module that can output a second fluid component at a second flow rate. The pump system includes a mixing manifold downstream of the first surge suppressor and the second fluid pumping module, which mixing manifold can mix the first fluid component and the second fluid component. The pump system can include a controller that can independently control the first pump module and the second pump module.
Coatings improve the performance of the underlying material to which a coating is applied. This can include simple coating such as paint, or high-performance coatings such as made from a resin and a catalyst. With high-performance coatings, the details of the application of the coating can be of critical significance. This is particularly the case when the coating is applied to an optical, light-transmitting component.
Current state of the art utilizes positive displacement pumps such as gear pumps for coating application. Gear pumps have several benefits, including a generally robust design and an ability to provide continuous operation. However, gear pumps also have limitations, including not being able to reliably maintain desired material flow rates and material ratios, high maintenance costs, and significant down-time in the event of a malfunction or maintenance. Accordingly, improved systems, devices, and methods for coating delivery are desired.
BRIEF SUMMARYOne aspect of the present disclosure relates to a pump system. The pump system includes a first fluid pumping module and a second fluid pumping module. The first fluid pumping module includes a first pump module that can output a first fluid component at a first flow rate and a first surge suppressor coupled to the first pump module and that can receive the output first fluid component. In some embodiments, the first surge suppressor can mitigate interruption in the first flow rate. The second fluid pumping module includes a second pump module that can output a second fluid component at a second flow rate. The pump system includes a mixing manifold downstream of the first surge suppressor and the second fluid pumping module. In some embodiments, the mixing manifold can mix the first fluid component and the second fluid component. The pump system can include a controller that can independently control the first pump module and the second pump module.
In some embodiments, the first surge suppressor includes at least one of a pneumatic surge suppressor or a nitrogen surge suppressor. In some embodiments, the first surge suppressor is pressurized to between 40 and 50 psi. In some embodiments, each of the first pump module and the second pump module includes at least one displacement pump. In some embodiments, the at least one displacement pump can be an electronic displacement pump. In some embodiments, the electronic displacement pump can include an electronic actuator controllable by the controller.
In some embodiments, the first pump module comprises at least two reciprocating displacement pumps. In some embodiments, each of the at least two reciprocating displacement pumps can include an electronic actuator controllable by the controller. In some embodiments, the controller can simultaneously control the electronic actuator of each of the at least two reciprocating displacement pumps in the first pump module such that the electronic actuators have the same position. In some embodiments, the controller can simultaneously control the electronic actuator of each of the at least two reciprocating displacement pumps in the first pump module such that a piston of each of the at least two reciprocating displacement pumps have different positions along their respective strokes.
In some embodiments, the controller can control the first pumping module and the second pumping module such that the first flow rate is different from the second flow rate. In some embodiments, the controller can control the first pumping module and the second pumping module such that the first flow rate is substantially the same as the second flow rate. In some embodiments, a flowrate of a combination of the first flow rate and the second flow rate is between 1000 and 3000 cubic centimeters per minute.
In some embodiments, the controller can interrupt the first flow rate. In some embodiments, the controller can interrupt the second flow rate. In some embodiments, the first pump module can includes at least one first reciprocating displacement pump, and the second pump module can include at least one second reciprocating displacement pump. In some embodiments, the controller can interrupt the first flow rate by changing a direction of movement of the at least one first reciprocating displacement pump. In some embodiments, the controller can interrupt the second flow rate by changing a direction of movement of the at least one second reciprocating displacement pump.
In some embodiments, the at least one first reciprocating displacement pump includes a first set of solenoid valves. In some embodiments, the at least one second reciprocating displacement pump includes a second set of solenoid valves. In some embodiments, changing the direction of movement of the at least one first reciprocating displacement pump includes controlling reconfiguring of the first set of solenoid valves, and in some embodiments, changing the direction of movement of the at least one second reciprocating displacement pump includes controlling reconfiguring of the second set of solenoid valves.
In some embodiments, the first pump module is fluidly connected to a first reservoir. The first reservoir can, in some embodiments, hold a resin. In some embodiments, the second pump module is fluidly connected to a second reservoir. The second reservoir can, in some embodiments, hold a catalyst. In some embodiments, the controller can control the first pump module and the second pump module such that the first flow rate is approximately 4 and 8 times greater than the second flow rate.
In some embodiments the pump system includes a dispenser fluidly coupled to the mixing manifold. In some embodiments, the dispenser can include a filter and a nozzle.
In some embodiments, the second fluid pumping module further includes a second surge suppressor coupled to the second pump module. The second surge suppressor can receive the output second fluid component. In some embodiments, the second surge suppressor can mitigate interruption in the second flow rate.
One aspect of the present disclosure relates to a method of continuous fluid delivery via a fluid delivery system. The method includes receiving, at a controller, parameters defining a desired output of the fluid delivery system, controlling, with the controller, a first pump module to output a first fluid component at a first flow rate, controlling, with the controller, a second pump module to output a second fluid component at a second flow rate, stopping pumping of one or both of the first pump module and the second pump module, resuming pumping with the one or both of the first pump module and the second pump module, and mitigating the interruption in the output of the fluid delivery system with at least one surge suppressor. In some embodiments, stopping and resuming pumping with the one or both of the first pump module and the second pump module interrupts an output of the fluid delivery system.
In some embodiments, the method includes determining first pumping parameters for the first pump module based on the received parameters defining the desired output of the fluid delivery system. In some embodiments, the method includes determining second pumping parameters for the second pump module based on the received parameters defining the desired output of the fluid delivery system.
In some embodiments, controlling the first pump module to output a first fluid component at a first flow rate includes setting valves of the first pump module to a first configuration. In some embodiments, the valves can be solenoid valves. In some embodiments, the valves can be electronically controlled valves. In some embodiments, stopping pumping of one or both of the first pump module and the second pump module includes stopping pumping of the first pump module. In some embodiments, resuming pumping with the one or both of the first pump module and the second pump module includes resuming pumping with the first pump module.
In some embodiments the method includes setting the valves of the first pump module to a second configuration. In some embodiments, the valves of the first pump module are set to a second configuration after stopping pumping of the first pump module and before resuming pumping with the first pump module. In some embodiments, the first pump module includes at least one displacement pump. In some embodiments, the at least one displacement pump includes an electronic displacement pump. In some embodiments, the first pump module includes at least two reciprocating displacement pumps. In some embodiments, each of the at least two reciprocating displacement pumps includes an electronic actuator controllable by the controller.
In some embodiments, the first flow rate is between 4 and 8 times the second flow rate.
In some embodiments, the first pump module is fluidly connected to a first reservoir holding the first fluid component, wherein the second pump module is fluidly connected to a second reservoir holding the second fluid component. In some embodiments, the first fluid component can be a resin, and the second fluid component can be a catalyst. In some embodiments, the at least one surge suppressor includes a first surge suppressor coupled to the first pump module and receiving the first fluid component output by the first pump module. In some embodiments, the at least one surge suppressor further includes a second surge suppressor coupled to the second pump module and receiving the second fluid component output by the second pump module. In some embodiments, the first surge suppressor includes at least one of a pneumatic surge suppressor and a nitrogen surge suppressor. In some embodiments, the first surge suppressor is pressurized to between 40 and 50 psi.
In the appended figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
DETAILED DESCRIPTIONThe ensuing description provides preferred exemplary embodiment(s) only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the preferred exemplary embodiment(s) will provide those skilled in the art with an enabling description for implementing a preferred exemplary embodiment. It is understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope as set forth in the appended claims.
In the appended figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
Delivery of a coating can be very demanding in that problems in the delivery system may degrade the integrity, durability, effectiveness, and/or utility of the coating. These challenges are particularly acute in the case of high-performance coatings. For example, successful coating may require consistent fluid pressures and the dispensing of specific ratios of two-component materials when delivering the coating.
Traditionally, these objectives have been achieved through the use of gear pumps to deliver coatings. However, a gear pump cannot be easily adapted to deliver different coatings at desired flow rate and/or achieve the desired mix ratio of two-component materials. Further, the gears and/or other mechanical features of gear pumps can degrade the integrity of materials. Additionally, resolution of issues with a gear pump, such as, for example, detecting and troubleshooting inaccurate flow rates or eliminating an entrained air bubble, can take large amounts of time and/or can be very labor intensive. In some embodiments, for example, entrainment of an air bubble can necessitate at least partial disassembly of the gear pump.
Further, a gear pump is not readily useable for different coatings or different flow rates. Rather, each coating and/or flow rate requires use of a distinct gear pump. Use of a distinct gear pump for each coating/flow rate combination increases the cost of applying coatings and decreases a company’s flexibility in applying diverse coatings.
Embodiments of the present disclosure relate to pump systems that use piston pumps, are computer controlled, and are flexible in that they can deliver fluid in a consistent manner and at the desired material ratios. Further, such pump systems as disclosed herein are useable with a range of fluids with varying viscosities and composition and/or fluid/flow rates combinations. Thus, in contrast to current devices, a single pump system as disclosed herein can deliver a number of different fluids at a number of different flow rates.
Some embodiments of the present disclosure include at least two pump modules. In some embodiments, a pump system with a plurality of pump modules can use at least one of the plurality of pump modules for each of the fluid components being pumped by the pump system. For example, when a pump system is delivering a compound fluid that, for example, is made of a resin and a catalyst, a first pump module can pump the resin and a second pump module can pump the catalyst. These pump modules can be hardware defined or can be software defined. For example, in some embodiments, multiple pumps can be fluidly connected in a single pump module. Alternatively, a plurality of pumps can be selectively connected into a pump module. For example, one or several switches can be configured such that a plurality of pumps may be switchably-fluidly connected to form a first pump module. These switches can be reconfigured to form a different pump module. Thus, via control of these switches, the pump modules can be software defined.
Each of these pump modules can include one or several pumps. In some embodiments, the number of pumps in each pump module can be selected based on a desired fluid output of that pump module. In some embodiments, a first pump module can include, for example, two pumps, and a second pump module can include one pump.
These pumps can, in some embodiments, be positive displacement pumps. These displacement pumps can be electronic displacement pumps that can be driven by an electrical actuator. This electrical actuator can be controllable by a controller to thereby control a flow rate coming from the pump module. In some embodiments, these displacement pumps can be reciprocating displacement pumps. In some embodiments, each of these reciprocating displacement pumps can include an electronic actuator, such as a step motor, that can move a piston in a reciprocating manner within the pump.
With reference now to
The first fluid pumping module 102 can include a one or several pumps 106, and specifically can include a first pump 106-A, and a second pump 106-B. In some embodiments, the one or several pumps 106 can include any number of pumps 106 up to an including an Nth pump 106-N. The pumps 106 can be positive displacement pumps, and specifically can be electronically actuated displacement pumps. In some embodiments, the pumps 106 can be electronically actuated reciprocating displacement pumps. Each of these electronically actuated reciprocating displacement pumps can include an electronic actuator that can move a piston of the reciprocating displacement pump to pump fluid. In some embodiments, the electronic actuator can control the position of the piston, the direction of movement of the piston, the speed of movement of the piston, or the like. In some embodiments, the electronic actuator can comprise a step motor.
The first fluid pumping module 102 further includes one or several first surge suppressors 108. In some embodiments, the first fluid pumping module 102 can include surge suppressors 108 in a one-to-one ratio with the pumps 106 such that each pump has a unique, associated surge suppressor 108. In some embodiments, the first fluid pumping module 102 can include a single surge suppressor 108, also referred to herein as a first surge suppressor 108, that is coupled to a plurality of pumps 106. In such an embodiment, the pumps 106 are arranged in a many-to-one configuration with the single first surge suppressor 108.
In some embodiments, the first pump module 104 can comprise at least two reciprocating displacement pumps. In some embodiments, each of the at least two reciprocating displacement pumps can comprise an electronic actuator that is controllable by the controller 110 (discussed below). In some embodiments, the controller 110 can be configured to, and/or can control the electronic actuators of the two or more reciprocating displacement pumps such that the electronic actuators, or more specifically, the pistons of the two or more reciprocating displacement pumps have the same location/position along the stroke of the reciprocating displacement pumps. Alternatively, in some embodiments, the controller 110 can be configured to, and/or can control the electronic actuators of the two or more reciprocating displacement pumps such that the electronic actuators, or more specifically, the pistons of the two or more reciprocating displacement pumps have different locations/positions along the stroke of the reciprocating displacement pumps.
The first surge suppressor 108 can received the output first fluid component from the pump(s) 106 and can be configured to mitigate any interruptions and/or inconsistencies in the first flow rate of the first fluid component. Thus, in some embodiments, the first surge suppressor 108 can buffer the first flow rate to mitigate any temporary spikes or shortfalls. In some embodiments, for example, due to the use of a reciprocating displacement pump 106, such interruptions including, for example, spikes and/or shortfalls, occur when the direction of movement of the piston changes. While such spikes and/or shortfalls may be short-lived, the spikes and/or shortfalls can be of significant consequence in many coating applications. Thus, the first surge suppressor 108 minimizes these spikes and/or shortfalls.
In some embodiments, the first surge suppressor 108 can comprise, for example, a pneumatic surge suppressor, a nitrogen surge suppressor, a spring surge suppressor, a piston surge suppressor, or the like. In some embodiments in which the first surge suppressor 108 comprises a pneumatic surge suppressor or a nitrogen surge suppressor, the first surge suppressor 108 can be pressurized to, for example, between 10 and 500 psi, between 20 and 100 psi, between 30 and 60 psi, between 40 and 50 psi, or to any or other intermediate pressure range.
The pump system 100 can include a second fluid pumping module 112 the second fluid pumping module 112 can output a second fluid component at a desired second flow rate. The second fluid pumping module 112 can include a second pump module 114 that can pump the second fluid component at the second flow rate. In some embodiments, the second flow rate canbe between 50 and 10,000 cubic centimeters per minute between 100 and 8,000 cc/minute, between 500 and 6,000 cc/minute, between 800 and 6,000 cc/minute, between 1,000 and 3,000 cc/minute, or any other or intermediate flowrate.
The second fluid pumping module 112 can include a one or several pumps 116, and specifically can include a first pump 116-A, and a second pump 116-B. In some embodiments, the one or several pumps 116 can include any number of pumps 166 up to an including an Nth pump 116-N. The pumps 116 can be displacement pumps, and specifically can be electronically actuated displacement pumps. In some embodiments, the pumps 116 can be electronically actuated reciprocating displacement pumps. Each of these electronically actuated reciprocating displacement pumps can include an electronic actuator that can move a piston of the reciprocating displacement pump to pump fluid. In some embodiments, the electronic actuator can control the position of the piston, and specifically the position of the piston along the stroke of that piston, the direction of movement of the piston, the speed of movement of the piston, or the like. In some embodiments, the electronic actuator can comprise a step motor.
In some embodiments, the second pump module 114 can comprise at least two reciprocating displacement pumps. In some embodiments, each of the at least two reciprocating displacement pumps can comprise an electronic actuator that is controllable by the controller 110 (discussed below). In some embodiments, the controller 110 can be configured to, and/or can control the electronic actuators of the two or more reciprocating displacement pumps such that the electronic actuators, or more specifically, the pistons of the two or more reciprocating displacement pumps have the same location/position along the stroke of the reciprocating displacement pumps. Alternatively, in some embodiments, the controller 110 can be configured to, and/or can control the electronic actuators of the two or more reciprocating displacement pumps such that the electronic actuators, or more specifically, the pistons of the two or more reciprocating displacement pumps have different locations/positions along the stroke of the reciprocating displacement pumps.
In some embodiments, the second fluid pumping module does not include a surge suppressor. In some embodiments, however, the second fluid pumping module 112 further includes one or several second surge suppressors 118. In some embodiments, the second fluid pumping module 112 can include second surge suppressors 118 in a one-to-one ratio with the pumps 116 such that each pump 116 has a unique, associated second surge suppressor 118. In some embodiments, the second fluid pumping module 112 can include a single surge suppressor 118, also referred to herein as a second surge suppressor 118, that is coupled to a plurality of pumps 116. In such an embodiment, the pumps 116 are arranged in a many-to-one configuration with the single second surge suppressor 118.
The second surge suppressor 118 can receive the output second fluid component from the pump(s) 116 and can be configured to mitigate any interruptions and/or inconsistencies in the second flow rate of the first fluid component. Thus, in some embodiments, the second surge suppressor 118 can buffer the second flow rate to mitigate any temporary spikes or shortfalls. In some embodiments, for example, due to the use of a reciprocating displacement pump 116, such interruptions including, for example, spikes and/or shortfalls, occur when the direction of movement of the piston changes. While such spikes and/or shortfalls may be short-lived, the spikes and/or shortfalls can be of significant consequence in many coating applications. Thus, the second surge suppressor 118 minimizes these spikes and/or shortfalls.
In some embodiments, the second surge suppressor 118 can comprise, for example, a pneumatic surge suppressor, a nitrogen surge suppressor, a spring surge suppressor, a piston surge suppressor, or the like. In some embodiments in which the second surge suppressor 118 comprises a pneumatic surge suppressor or a nitrogen surge suppressor, the second surge suppressor 118 can be pressurized to, for example, between 10 and 500 psi, between 20 and 100 psi, between 30 and 60 psi, between 40 and 50 psi, or to any or other intermediate pressure range.
In some embodiments, each of the first fluid pumping module 102 and the second fluid pumping module 112 can be controlled by a controller 110. The controller 110, as discussed in greater detail below, can include hardware and software components that together enable the pump system 100 to receive inputs from a user, and control the first fluid pumping module 102 and/or the second fluid pumping module 112 based on the inputs and according to stored instructions.
In some embodiments, the controller 110 can control the first pump module 104 and the second pump module 114 such that the first flow rate and the second flow rate are independent of each other. This independent control of the first pump module 104 and the second pump module 114 can help achieve the desired fluid pressures and mix ratios of the first fluid component and the second fluid component. In some embodiments, for example, this can include, a 1-to-1 mixture, a 2-to-1 mixture, a 3-to-1 mixture, a 4-to-1 mixture, a 5-to-1 mixture, a 6-to-l mixture, a 7-to-1 mixture, an 8-to-1 mixture, a 9-to-l mixture, a 10-to-1 mixture, an 11-to-1 mixture, a 12-to-1 mixture, a 13-to-l mixture, a 14-to-1 mixture, a 15-to-1 mixture, a 20-to-1 mixture, or any other or intermediate mixture ratio. In some embodiments, these mixtures can be achieved by having the same relationship between the first flow rate and the second flow rate. Thus, to achieve a 1-to-1 mixture, the first flow rate can be the same as the second flow rate. Similarly, to achieve a 6-to-1 ratio, the first flow rate can be 6 times greater than the second flow rate. As used herein, “approximately” refers to a value and/or range that is +/- 15% or +/- 20% of the base value or base range. In some embodiments, the first flow rate can be between 4 and 8 times greater than the second flow rate, between 3 and 9 times greater than the second flow rate, or between 2 and 10 times greater than the second flow rate. In some embodiments, the first flow rate can be approximately 6 times greater than the second flow rate.
In some embodiments, the controller 110 can control the first fluid pumping module 102 and/or the first pump module 104, and the second fluid pumping module 112 and/or the second pump module 114 such that the first flow rate is the same as the second flow rate, and in some embodiments, such that the first flow rate is different than the second flow rate. In some embodiments, the controller 110 can control the first fluid pumping module 102 and/or the first pump module 104, and the second fluid pumping module 112 and/or the second pump module 114 via control the electronic actuator(s) in each of the pumps 106 of the first pump module 104 and via control of the electronic actuator(s) in each of the pumps 116 of the second pump module 114.
The controller 110 can, in some embodiments, be configured to periodically interrupt the first flow rate and/or the second flow rate. In some embodiments, this can include, for example, changing a pumping speed of one or both of the first pump module 104 and the second pump module 114, stopping or starting pumping of one or both of the first pump module 104 and the second pump module 114, changing a direction of movement of the pistons of one or both of the first pump module 104 and the second pump module 114, or the like. In embodiments in which some or all of the pumps 106, 116 comprise reciprocating displacement pumps, periodically interrupting the flow rate of those pumps can include changing the direction of movement of one or more of the some or all of the pumps that are reciprocating displacement pumps via, for example, changing the direction of movement of the piston(s) of the one or more of the some or all of the pumps that are reciprocating displacement pumps. Thus, in some embodiments, the controller 110 can be configured to periodically interrupt the first flow rate by changing the direction of movement of the at least one first reciprocating displacement pump and/or periodically interrupt the second flow rate by changing the direction of movement of the at least one second reciprocating displacement pump.
The pump system 100 can include multiple storage containers 120, also referred to herein as reservoirs. The storage containers 120 can contain fluid pumped by the pump system 100. In some embodiments, there can be a storage container 120 for each fluid component pumped by the pump system 100. Thus, for a pump system 100 pumping two fluid components, and as shown in
In some embodiments, the first reservoir 120-A can be configured to hold a fluid such as a resin and/or can be holding a fluid such as a resin. In some embodiments, the second reservoir 120-B can be configured to hold a fluid such as a catalyst and/or can be holding a fluid such as a catalyst. In such embodiments, the first reservoir 120-A holding the resin can be fluidly connected and/or coupled to the first fluid pumping module 102 and specifically to the first pump module 104, and the second reservoir 120-B holding the catalyst can be fluidly connected and/or coupled to the second fluid pumping module 102 and specifically to the second pump module 104.
In some embodiments, one or both of the first and second storage containers 120-A, 120-B can comprise a pressure vessel. In some embodiments, a vacuum can be pulled on one of the storage containers 120-A, 120-B when liquid is being loaded into that one of the storage containers 120-A, 120-B. In some embodiments, pulling the vacuum can facilitate in drawing the liquid into the one of the storage containers 120-A, 120-B, and can decrease the prevalence of bubbles in the liquid. In some embodiments, one or both of the storage containers 120-A, 120-B can be slightly pressurized to facilitate in transporting liquid from the one or both of the storage containers 120-A, 120-B to their connected fluid pumping module 102, 112.
The pump system 100 can include a mixing manifold 122. The mixing manifold 122 can be connected to each of the first fluid pumping module 102 and the second fluid pumping module 112, and can be configured to mix the first fluid component from the first fluid pumping module 102 with the second fluid component from the second fluid pumping module 112. In some embodiments, the mixing manifold 122 can be configured to mix the first fluid component and the second fluid component while the first and second fluid components exit the mixing manifold 122. The mixing manifold can be downstream of each of the first fluid pumping module 102 and the second fluid pumping module 112.
The pump system 100 can include a dispenser 124. The dispenser 124 can be fluidly connected with, and downstream of the mixing manifold 122. The dispenser 124 can be configured to dispense the fluid from the pumping system 100. The dispenser 124 can include a filter 126. The filter 126 can comprise a variety of filter types, and can be configured to provide a desired level of filtering. In some embodiments, the filter can comprise, for example, a 1 micron filter, a 2 micron filter, a 3 micron filter, a 4 micron filter, a 5 micron filter, a 6 micron filter, a 7 micron filter, a 8 micron filter, a 9 micron filter, a 10 micron filter, a 15 micron filter, a 20 micron filter, a 25 micron filter, a 30 micron filter, a 50 micron filter, a between 1 and 50 micron filter, a between 1 and 100 micron filter, or any other or intermediate filter.
The dispenser 124 can further include a nozzle 128 configured to dispense liquid from the pump system 100. In some embodiments, the pump system 100 can further include a control 132 that can be configured to start and/or stop the dispensing of fluid by the pump system 100. This control can be in a variety of positions on the pump system 100. In some embodiments, the control 132 can comprise, for example, a button, a toggle, a lever, a ball valve, a trigger, or the like.
In some embodiments, the dispenser 124 can comprise a handheld dispenser 124 that can be held by an operator to dispense a fluid. In some embodiments, the dispenser 134 can be part of an automated system in which the dispenser 124 is not hand held, but is rather part of a machine used to control the movement of the dispenser 124. In some such embodiments, the dispenser 124 can be coupled to, and/or can be part of an movement feature 140. The movement feature 140 can be configured to control the dispenser 124 to deliver liquid from the pump system 100. In some embodiments, the movement feature 140 can comprise a robotic arm, a tele-operated arm, a robot, a tele-operated device, or the like. In some embodiments, the movement feature 140 can be controlled by the controller 110.
With reference now to
The pump 106/116 can further comprise a plurality of valves 206. In some embodiments, these valves can comprise electronically actuated valves and/or electronically controlled valves, and specifically can comprise solenoid valves. In some embodiments, the controller 110 can control a configuration of the valves 206, and specifically can control the valves 206 to be in a first configuration when the piston 204 is moving in a first direction, and can control the valves 206 to be in a second configuration when the piston 204 is moving in a second direction. The valves 206, as controlled by the controller 110 can cause fluid to be pumped by the pumps 106, 116 in a desired direction.
In some embodiments, at least one pump 106, which can comprise a reciprocating displacement pump, in the first pump module 104 comprises a first set of solenoid valves 206. In some embodiments, at least one pump 116, which can comprise a reciprocating displacement pump, in the second pump module 114 comprises a second set of solenoid valves 206. In some embodiments, changing the direction of movement of the at least one first reciprocating displacement pump 106 comprises controlling reconfiguring of the first set of solenoid valves 206, and, in some embodiments, changing the direction of movement of the at least one second reciprocating displacement pump 116 comprises controlling reconfiguring of the second set of solenoid valves 206.
With reference now to
Processor 302 may execute a variety of software processes embodied in program code, and may maintain multiple concurrently executing programs or processes. At any given time, some or all of the program code to be executed can be resident in processor(s) 302 and/or in memory 304. In some embodiments, controller 110 may include one or more specialized processors, such as digital signal processors (DSPs), outboard processors, graphics processors, application-specific processors, and/or the like.
The controller 110 may comprise memory 304, comprising hardware and software components used for storing data and program instructions, such as system memory and computer-readable storage media. The system memory and/or computer-readable storage media may store program instructions that are loadable and executable on processor 302, as well as data generated during the execution of these programs.
Depending on the configuration and type of controller 110, system memory may be stored in volatile memory (such as random access memory (RAM)) and/or in non-volatile storage drives (such as read-only memory (ROM), flash memory, etc.). The RAM may contain data and/or program modules that are immediately accessible to and/or presently being operated and executed by processor 302. In some implementations, system memory may include multiple different types of memory, such as static random access memory (SRAM) or dynamic random access memory (DRAM). In some implementations, a basic input/output system (BIOS), containing the basic routines that help to transfer information between elements within controller 110, such as during start-up, may typically be stored in the non-volatile storage drives. By way of example, and not limitation, system memory may include application programs, such as client applications, Web browsers, mid-tier applications, server applications, etc., program data, and an operating system.
Memory 304 also may provide one or more tangible computer-readable storage media for storing the basic programming and data constructs that provide the functionality of some embodiments. Software (programs, code modules, instructions) that when executed by a processor provide the functionality described herein may be stored in memory 304. These software modules or instructions may be executed by processor 302. Memory 304 may also provide a repository for storing data used in accordance with the present invention.
Memory 304 may also include a computer-readable storage media reader that can further be connected to computer-readable storage media. Together and, optionally, in combination with system memory, computer-readable storage media may comprehensively represent remote, local, fixed, and/or removable storage devices plus storage media for temporarily and/or more permanently containing, storing, transmitting, and retrieving computer-readable information.
Computer-readable storage media containing program code, or portions of program code, may include any appropriate media known or used in the art, including storage media and communication media, such as, but not limited to, volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage and/or transmission of information. This can include tangible computer-readable storage media such as RAM, ROM, electronically erasable programmable ROM (EEPROM), flash memory or other memory technology, CD-ROM, digital versatile disk (DVD), or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or other tangible computer readable media. This can also include nontangible computer-readable media, such as data signals, data transmissions, or any other medium which can be used to transmit the desired information and which can be accessed by controller 110.
By way of example, computer-readable storage media may include a hard disk drive that reads from or writes to non-removable, nonvolatile magnetic media, a magnetic disk drive that reads from or writes to a removable, nonvolatile magnetic disk, and an optical disk drive that reads from or writes to a removable, nonvolatile optical disk such as a CD ROM, DVD, and Blu-Ray® disk, or other optical media. Computer-readable storage media may include, but is not limited to, Zip® drives, flash memory cards, universal serial bus (USB) flash drives, secure digital (SD) cards, DVD disks, digital video tape, and the like. Computer-readable storage media 78 may also include, solid-state drives (SSD) based on non-volatile memory such as flash-memory based SSDs, enterprise flash drives, solid state ROM, and the like, SSDs based on volatile memory such as solid state RAM, dynamic RAM, static RAM, DRAM-based SSDs, magnetoresistive RAM (MRAM) SSDs, and hybrid SSDs that use a combination of DRAM and flash memory based SSDs. The disk drives and their associated computer-readable media may provide non-volatile storage of computer-readable instructions, data structures, program modules, and other data for controller 110
The pump system 100 can include a communication module 306 configured to communicate with other components within the pump system 100. Specifically, the processor 302 can receive information and send control signals via the communications module 306. In some embodiments, the communications module 306 can be wired or wirelessly connected with other components within the pump system 100.
The input/output module 308 (I/O module 308 or I/O subsystem 308) can be configured to receive inputs from the user of the pump system 100 and to provide outputs to the user of the pump system 100. In some embodiments, the I/O subsystem 308 may include device controllers for one or more user interface input devices and/or user interface output devices. User interface input and output devices may be integral with the controller 110 (e.g., integrated audio/video systems, and/or touchscreen displays). The I/O subsystem 308 may provide one or several outputs to a user by converting one or several electrical signals to user perceptible and/or interpretable form, and may receive one or several inputs from the user by generating one or several electrical signals based on one or several user-caused interactions with the I/O subsystem 308 such as the depressing of a key or button, the moving of a mouse, the interaction with a touchscreen or trackpad, the interaction of a sound wave with a microphone, or the like.
Input devices may include a keyboard, pointing devices such as a mouse or trackball, a touchpad or touch screen incorporated into a display, a scroll wheel, a click wheel, foot switch, trigger, a dial, a button, a switch, a keypad, audio input devices with voice command recognition systems, microphones, and other types of input devices. Input devices may also include three dimensional (3D) mice, joysticks or pointing sticks, gamepads and graphic tablets, and audio/visual devices such as speakers, digital cameras, digital camcorders, portable media players, webcams, image scanners, fingerprint scanners, barcode reader 3D scanners, 3D printers, laser rangefinders, and eye gaze tracking devices. Additional input devices may include, for example, motion sensing and/or gesture recognition devices that enable users to control and interact with an input device through a natural user interface using gestures and spoken commands, eye gesture recognition devices that detect eye activity from users and transform the eye gestures as input into an input device, voice recognition sensing devices that enable users to interact with voice recognition systems through voice commands, medical imaging input devices, MIDI keyboards, digital musical instruments, and the like.
Output devices may include one or more display subsystems, indicator lights, or non-visual displays such as audio output devices, etc. Display subsystems may include, for example, cathode ray tube (CRT) displays, flat-panel devices, such as those using a liquid crystal display (LCD) or plasma display, light-emitting diode (LED) displays, light towers, projection devices, touch screens, and the like. In general, use of the term “output device” is intended to include all possible types of devices and mechanisms for outputting information from the controller 110 to a user or other computer. For example, output devices may include, without limitation, a variety of display devices that visually convey text, graphics, and audio/video information such as monitors, printers, speakers, headphones, automotive navigation systems, plotters, voice output devices, and modems.
With reference now to
At block 404, and based on the received output parameters, one or several first pumping parameters are determined. In some embodiments, these first pumping parameters can be pumping parameters for operation of the first fluid pumping module 102 or the first pump module 104. The first pumping parameters can be determined by the controller 110.
At block 406, and based on the received output parameters, one or several second pumping parameters are determined. In some embodiments, these second pumping parameters can be pumping parameters for operation of the second fluid pumping module 112 of the second pump module 114. The second pumping parameters can be determined by the controller 110.
In some embodiments, for example, the output parameters received in block 402 can include, for example, a desired flow rate of fluid output by the pump system 100 and a desired mixture. The first pumping parameters can include the desired first flow rate output by the first fluid pumping module 102 or the first pump module 104, and the second pumping parameters can include the desired second flow rate output by the second fluid pumping module 112 or the second pump module 114.
At block 408, the first valves 206 of the first pump module 104 are set to a first configuration. In some embodiments, setting the first valves 206 to the first configuration can be a part of controlling the first pump module 104 to output a first fluid component at a first flow rate. In some embodiments, this first configuration can enable pumping by the pump(s) 106 in the first pump module 104, and specifically, in the case that the pump(s) 106 in the first pump module 104 are reciprocating displacement pumps, can enable pumping when the piston(s) move in a first direction.
At block 410, the second valves 206 of the second pump module 204 are set to a first configuration. In some embodiments, setting the second valves 206 to the first configuration can be a part of controlling the second pump module 114 to output a second fluid component at a second flow rate. In some embodiments, this first configuration can enable pumping by the pump(s) 116 in the second pump module 114, and specifically, in the case that the pump(s) 116 in the second pump module 114 are reciprocating displacement pumps, can enable pumping when the piston(s) move in a first direction.
At block 412, the first pump module 104 is controlled to pump/output the first fluid component according to the first pumping parameters and at a first flow rate. In some embodiments, this can include the generation and sending of control signals from the controller 110 to the pumps 106 in the first pump module 104. The pumps 106 in the first pump module 104 can be controlled according to these received signals.
At block 414, the second pump module 114 is controlled to pump/output the second fluid component according to the second pumping parameters and at a second flow rate. In some embodiments, this can include the generation and sending of control signals from the controller 110 to the pumps 116 in the second pump module 104. The pumps 116 in the second pump module 114 can be controlled according to these received signals. In some embodiments, steps 412 and 414 can be received subsequent to receipt of an input via control 132 directing the starting of delivery of fluid from the pump system 100.
At block 416, it is determined to interrupt pumping of one or more of the pump modules. In the embodiment of
At block 418, and as a result of determining to interrupt pumping, the pumping of one or more pumping modules is stopped. With specific reference to the embodiment of
At block 420, some or all of the valves associated with the pumping modules are changed from a first configuration to a second configuration. For example, in a pump 106, 116 in which the direction of movement of the piston is changing, pumping may require changing the configuration of valves associated with that pump 106, 116. In such an embodiment, the controller 110 can generate control signals that cause the valves of the one or several affected pumps within the one or several pump modules to change from a first configuration to a second configuration. In some embodiments, this can changing the configuration of valves of the first pump module 104 from a first configuration to a second configuration. In some embodiments, valves 206 can be changed from a first configuration to a second configuration after the step of block 418 and before the step of block 422.
At block 422, pumping is resumed. In some embodiments, this is the resuming of pumping by the one or several pumps 106, 116 and/or pump modules 104, 114 from which pumping was stopped at block 418. In some embodiments, this can include resuming pumping with the first pump module 104. Resuming pumping can include the generating and sending of control signals by the controller 110 to one or several pumps 106, 116 and/or pump modules 104, 114 directing those one or several pumps 106, 116 and/or pump modules 104, 114 to resume pumping. Upon receipt of these control signals, the one or several pumps 106, 116 and/or pump modules 104, 114 resume pumping.
In some embodiments, the performing of steps 418 through 422, and specifically the stopping and resuming of pumping of the pump modules 104, 114 causes an interruption in the output of the pump system 100.
At block 424, the interruption in the fluid flow arising from the performing of some or all of the steps of blocks 418 through 433 is mitigated by at least one associated surge suppressor. In the embodiment of
Specific details are given in the above description to provide a thorough understanding of the embodiments. However, it is understood that the embodiments may be practiced without these specific details. For example, circuits may be shown in block diagrams in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
Implementation of the techniques, blocks, steps and means described above may be done in various ways. For example, these techniques, blocks, steps and means may be implemented in hardware, software, or a combination thereof. For a hardware implementation, the processing units may be implemented within one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), processors, controllers, micro-controllers, microprocessors, other electronic units designed to perform the functions described above, and/or a combination thereof.
Also, it is noted that the embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a swim diagram, a data flow diagram, a structure diagram, or a block diagram. Although a depiction may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed, but could have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination corresponds to a return of the function to the calling function or the main function.
Furthermore, embodiments may be implemented by hardware, software, scripting languages, firmware, middleware, microcode, hardware description languages, and/or any combination thereof. When implemented in software, firmware, middleware, scripting language, and/or microcode, the program code or code segments to perform the necessary tasks may be stored in a machine readable medium such as a storage medium. A code segment or machine-executable instruction may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a script, a class, or any combination of instructions, data structures, and/or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, and/or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, network transmission, etc.
For a firmware and/or software implementation, the methodologies may be implemented with modules (e.g., procedures, functions, and so on) that perform the functions described herein. Any machine-readable medium tangibly embodying instructions may be used in implementing the methodologies described herein. For example, software codes may be stored in a memory. Memory may be implemented within the processor or external to the processor. As used herein the term “memory” refers to any type of long term, short term, volatile, nonvolatile, or other storage medium and is not to be limited to any particular type of memory or number of memories, or type of media upon which memory is stored.
Moreover, as disclosed herein, the term “storage medium” may represent one or more memories for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and/or other machine readable mediums for storing information. The term “machine-readable medium” includes, but is not limited to portable or fixed storage devices, optical storage devices, and/or various other storage mediums capable of storing that contain or carry instruction(s) and/or data.
While the principles of the disclosure have been described above in connection with specific apparatuses and methods, it is to be clearly understood that this description is made only by way of example and not as limitation on the scope of the disclosure.
Claims
1. A pump system comprising:
- a first fluid pumping module comprising: a first pump module configured to output a first fluid component at a first flow rate; and a first surge suppressor coupled to the first pump module and configured to receive the output first fluid component, wherein the first surge suppressor is configured to mitigate interruption in the first flow rate;
- a second fluid pumping module comprising: a second pump module configured to output a second fluid component at a second flow rate;
- a mixing manifold downstream of the first surge suppressor and the second fluid pumping module, wherein the mixing manifold is configured to mix the first fluid component and the second fluid component; and
- a controller configured to independently control the first pump module and the second pump module.
2. The pump system of claim 1, wherein the first surge suppressor comprises at least one of a pneumatic surge suppressor or a nitrogen surge suppressor.
3. The pump system of claim 2, wherein the first surge suppressor is pressurized to between 40 and 50 psi.
4. The pump system of claim 1, wherein each of the first pump module and the second pump module comprises at least one displacement pump.
5. The pump system of claim 4, wherein the at least one displacement pump comprises an electronic displacement pump.
6. The pump system of claim 5, wherein the electronic displacement pump comprises an electronic actuator controllable by the controller.
7. The pump system of claim 6, wherein the first pump module comprises at least two reciprocating displacement pumps, wherein each of the at least two reciprocating displacement pumps comprises an electronic actuator controllable by the controller.
8. The pump system of claim 7, wherein the controller is configured to simultaneously control the electronic actuator of each of the at least two reciprocating displacement pumps in the first pump module such that the electronic actuators have the same position.
9. The pump system of claim 7, wherein the controller is configured to simultaneously control the electronic actuator of each of the at least two reciprocating displacement pumps in the first pump module such that a piston of each of the at least two reciprocating displacement pumps have different positions along their respective strokes.
10. The pump system of claim 1, wherein the controller is configured to control the first pumping module and the second pumping module such that the first flow rate is different from the second flow rate.
11. The pump system of claim 1, wherein the controller is configured to control the first pumping module and the second pumping module such that the first flow rate is substantially the same as the second flow rate.
12. The pump system of claim 10, wherein a flowrate of a combination of the first flow rate and the second flow rate is between 1000 and 3000 cubic centimeters per minute.
13. The pump system of claim 1, wherein the controller is configured to interrupt the first flow rate.
14. The pump system of claim 13, wherein the controller is further configured to interrupt the second flow rate.
15. The pump system of claim 14, wherein the first pump module comprises at least one first reciprocating displacement pump, wherein the second pump module comprises at least one second reciprocating displacement pump, wherein the controller is configured to interrupt the first flow rate by changing a direction of movement of the at least one first reciprocating displacement pump, and wherein the controller is configured to interrupt the second flow rate by changing a direction of movement of the at least one second reciprocating displacement pump.
16. The pump system of claim 15, wherein the at least one first reciprocating displacement pump comprises a first set of solenoid valves, wherein the at least one second reciprocating displacement pump comprises a second set of solenoid valves, wherein changing the direction of movement of the at least one first reciprocating displacement pump comprises controlling reconfiguring of the first set of solenoid valves, and wherein changing the direction of movement of the at least one second reciprocating displacement pump comprises controlling reconfiguring of the second set of solenoid valves.
17. The pump system of claim 1, wherein the first pump module is fluidly connected to a first reservoir configured to hold a resin, wherein the second pump module is fluidly connected to a second reservoir configured to hold a catalyst.
18. The pump system of claim 17, wherein the controller is configured to control the first pump module and the second pump module such that the first flow rate is approximately 4 and 8 times greater than the second flow rate.
19. The pump system of claim 1, further comprising a dispenser fluidly coupled to the mixing manifold.
20. The pump system of claim 19, wherein the dispenser comprises a filter and a nozzle.
21. The pump system of claim 1, wherein the second fluid pumping module further comprises a second surge suppressor coupled to the second pump module and configured to receive the output second fluid component, wherein the second surge suppressor is configured to mitigate interruption in the second flow rate.
22. A method of continuous fluid delivery via a fluid delivery system, the method comprising:
- receiving, at a controller, parameters defining a desired output of the fluid delivery system;
- controlling, with the controller, a first pump module to output a first fluid component at a first flow rate;
- controlling, with the controller, a second pump module to output a second fluid component at a second flow rate;
- stopping pumping of one or both of the first pump module and the second pump module;
- resuming pumping with the one or both of the first pump module and the second pump module, wherein stopping and resuming pumping with the one or both of the first pump module and the second pump module interrupts an output of the fluid delivery system; and
- mitigating the interruption in the output of the fluid delivery system with at least one surge suppressor.
23. The method of claim 22, further comprising determining first pumping parameters for the first pump module based on the received parameters defining the desired output of the fluid delivery system.
24. The method of claim 23, further comprising determining second pumping parameters for the second pump module based on the received parameters defining the desired output of the fluid delivery system.
25. The method of claim 22, wherein controlling the first pump module to output a first fluid component at a first flow rate comprises setting valves of the first pump module to a first configuration.
26. The method of claim 25, wherein the valves comprise solenoid valves.
27. The method of claim 25, wherein the valves comprise electronically controlled valves.
28. The method of claim 25, wherein stopping pumping of one or both of the first pump module and the second pump module comprises stopping pumping of the first pump module, and wherein resuming pumping with the one or both of the first pump module and the second pump module comprises resuming pumping with the first pump module.
29. The method of claim 28, further comprising setting the valves of the first pump module to a second configuration.
30. The method of claim 29, wherein the valves of the first pump module are set to a second configuration after stopping pumping of the first pump module and before resuming pumping with the first pump module.
31. The method of claim 30, wherein the first pump module comprises at least one displacement pump.
32. The method of claim 31, wherein the at least one displacement pump comprises an electronic displacement pump.
33. The method of claim 31, wherein the first pump module comprises at least two reciprocating displacement pumps, wherein each of the at least two reciprocating displacement pumps comprises an electronic actuator controllable by the controller.
34. The method of claim 21, wherein the first flow rate is between 4 and 8 times the second flow rate.
35. The method of claim 34, wherein the first pump module is fluidly connected to a first reservoir holding the first fluid component, wherein the second pump module is fluidly connected to a second reservoir holding the second fluid component.
36. The method of claim 35, wherein the first fluid component comprises a resin, and wherein the second fluid component comprises a catalyst.
37. The method of claim 21, wherein the at least one surge suppressor comprises:
- a first surge suppressor coupled to the first pump module and receiving the first fluid component output by the first pump module.
38. The method of claim 37, wherein the at least one surge suppressor further comprises a second surge suppressor coupled to the second pump module and receiving the second fluid component output by the second pump module.
39. The method of claim 37, wherein the first surge suppressor comprises at least one of a pneumatic surge suppressor and a nitrogen surge suppressor.
40. The method of claim 37, wherein the first surge suppressor is pressurized to between 40 and 50 psi.
Type: Application
Filed: Aug 11, 2021
Publication Date: Feb 16, 2023
Applicant: Environmental Spray Systems, Inc. (San Diego, CA)
Inventor: Donald Fox (Clovis, CA)
Application Number: 17/400,005
