Testing colorant condition

Abstract

Liquid dispenser and method for operating such a liquid dispenser, such as a dispenser for tinting pastes. The dispenser comprises at least one liquid container and at least one reciprocating pump. First, a suction stroke is carried out at a set pump speed. After the suction stroke, the pump is closed off. Then, a pressure stroke is started while the pump is closed.

Claims

1. Method for operating a liquid dispenser comprising at least one liquid container and at least one reciprocating pump, the pump being configured to withdraw liquid from the container during a suction stroke, the method comprising the following steps: a suction stroke is carried out at a set pump speed; after the suction stroke, the pump is closed off; a pressure stroke is started while the pump is closed, wherein if the pressure stroke is larger than a set value: the pump is emptied; a second suction stroke is carried out using a lower pump speed and/or including a waiting time after completion of the suction stroke; after the second suction stroke and the optional waiting time the pump is closed off; a pressure stroke is started while the pump is closed off.

2. Method according to claim 1, wherein the pressure stroke by the piston is continued until resistance exceeds an upper limit.

3. Method according to claim 2, wherein subsequently the steps are repeated with a partial pump stroke.

4. A liquid dispenser comprising: a control unit for controlling the pump, wherein the control unit is programmed to run a test at a selected moment, the test involving the method steps of claim 1.

5. The dispenser of claim 4, comprising an electric motor with a rotor and at least one sensor operatively coupled with the rotor, the sensor comprising a home sensor, position sensor and/or an encoder.

6. The dispenser of claim 5, the electric motor comprising a stepper motor.

7. The dispenser of claim 6, wherein the control unit is programmed to receive the number steps counted by the encoder during a passive pressure stroke, and to generate a signal if the number exceeds a set value.

8. The dispenser of claim 6, wherein the control unit is programmed to: receive the number of steps counted by the encoder during the suction stroke; receive the number of steps counted by the encoder during a pressure stroke until stalling of the electric motor; and calculate the compressibility of the content in the pump chamber on basis of the difference between the two numbers.

9. The dispenser of claim 8, wherein the control unit is programmed to repeat the steps in claim 8 when applying a partial suction stroke and compare the calculated compressibility with the compressibility calculated with the complete suction stroke.

10. The dispenser of claim 8, wherein the control unit is programmed to repeat the steps in claim 8 when applying a partial suction stroke and compare the length of the pressure stroke after the first suction stroke with the length of the pressure stroke after the partial suction stroke.

11. The dispenser of claim 4, wherein the pump is a piston pump or a bellows pump.

12. Method for operating a liquid dispenser comprising at least one liquid container and at least one reciprocating pump, the pump being configured to withdraw liquid from the container during a suction stroke, the method comprising the following steps: a suction stroke is carried out at a set pump speed; after the suction stroke, the pump is closed off; a pressure stroke is started while the pump is closed, wherein the pressure stroke by the piston is continued until resistance exceeds an upper limit.

13. Method according to claim 12, wherein subsequently the steps are repeated with a partial pump stroke.

14. A liquid dispenser comprising: a control unit for controlling the pump, wherein the control unit is programmed to run a test at a selected moment, the test involving the method steps of claim 12.

15. The dispenser of claim 14, comprising an electric motor with a rotor and at least one sensor operatively coupled with the rotor, the sensor comprising a home sensor, position sensor and/or an encoder.

16. The dispenser of claim 15, the electric motor comprising a stepper motor.

17. The dispenser of claim 16, wherein the control unit is programmed to receive the number steps counted by the encoder during a passive pressure stroke, and to generate a signal if the number exceeds a set value.

18. The dispenser of claim 16, wherein the control unit is programmed to: receive the number of steps counted by the encoder during the suction stroke; receive the number of steps counted by the encoder during a pressure stroke until stalling of the electric motor; and calculate the compressibility of the content in the pump chamber on basis of the difference between the two numbers.

19. The dispenser of claim 18, wherein the control unit is programmed to repeat the step in claim 18 when applying a partial suction stroke and compare the calculated compressibility with the compressibility calculated with the complete suction stroke.

20. The dispenser of claim 18, wherein the control unit is programmed to repeat the steps in claim 18 when applying a partial suction stroke and compare the length of the pressure stroke after the first suction stroke with the length of the pressure stroke after the partial suction stroke.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is further explained with reference to the drawings by way of example.

(2) FIG. 1: shows an exemplary implementation of a colorant dispenser;

(3) FIG. 2: schematically shows one of the containers with an associated pump of the dispenser of FIG. 1;

(4) FIGS. 3A-D: show consecutive steps of a first method;

(5) FIGS. 4A-D: show consecutive steps of a the method of FIGS. 3A-D with a paste too viscous for the pumping speed;

(6) FIGS. 5A-D: show consecutive steps of a the method of FIGS. 3A-D with a paste containing air;

(7) FIGS. 6A-D: show consecutive steps of a the method of FIGS. 3A-D with a paste containing air and a partial suction stroke;

(8) FIGS. 7A-D: show consecutive steps of a the method of FIGS. 3A-D with an air leakage and a partial suction stroke.

DETAILED DESCRIPTION

(9) FIG. 1 illustrates the main parts of an exemplary implementation of a dispenser 1 for dispensing colorants or tinting pastes or similar paint modules for preparing a paint or lacquer of a desired formulation. The dispenser 1 includes a turntable 2, which is rotatable about a vertical axis by means of a drive (not shown) in order to rotate the turntable 2 between discrete positions. On the turntable 2, there are mounted a plurality of pumps 3, e.g., sixteen pumps. Each pump 3 is associated with a fluid container 4. Each container 4 contains a tinting paste.

(10) Via a user interface, a user can input a paint of a desired colour or quality. A control unit determines a paint formulation producing the selected colour or quality. This includes a selection of one or more of the tinting pastes in the respective containers 4 and the required amounts. The control unit consecutively moves the selected containers to a dispensing position above a receptacle and meters the required amount of each selected tinting paste.

(11) FIG. 2 shows a container or canister 4 in cross section. The container 4 contains a tinting paste 5 and comprises a stirrer 6 with an electric motor 9. At the lower side the container 4 is provided with an outlet 11 with a piston pump 12 for dispensing a desired amount of the tinting paste 5 and with a valve 10.

(12) The piston pump 12 comprises a pump chamber 13 and a piston 18 with a piston rod 14 reciprocating within the pump chamber 13. The piston pump 12 is driven by a stepper motor 16. The stepper motor 16 drives the piston 18 via a spindle transmission 15, or via any other suitable transmission. An encoder 17 is linked to the stepper motor 16 to count the steps made by the stepper motor 16. A control unit 19 is linked to the encoder 17 to receive information from the encoder 17. The control unit 19 is also linked to the stepper motor 16 and with the valve 10.

(13) To dispense the tinting paste, the control unit 19 triggers the stepper motor 16 to lift the piston 18 so as to make a suction stroke. During this suction stroke the valve 10 closes the outlet and clears a passage between the container 4 and the pump chamber 13. As a result, an amount of tinting paste flows into the pump chamber. When the pump chamber contains a desired amount of tinting paste, the valve 10 is turned to a position closing off the container and providing a passage between the pump chamber 13 and the dispense outlet 11. The control unit 19 triggers the stepper motor 16 to move the piston 18 downward, so as to make a dispense stroke to empty the pump chamber 18 and dispense the tinting paste via the outlet 11.

(14) The control unit 19 can also move the valve 10 into a third position, closing off the pump chamber 13, as explained hereafter.

(15) During the suction stroke the piston pump 12 is driven with a nominal speed. At the prevailing temperature and shear the viscosity of some tinting pastes may be too high. As a result the piston 18 draws a vacuum during the suction stroke in the pump chamber 13, so the pump chamber 13 is not completely filled with the desired amount of tinting paste. This will cause aberrant tinting of the final paint. The high viscosity can for instance be caused by aging, settling or evaporation of water, solvents or rheological agents.

(16) The viscosity of the tinting paste can be tested by a test method illustrated in FIG. 3A-D. The figures show a piston pump, but the same method can be carried out with other types of reciprocating pumps, such as bellows pumps.

(17) FIG. 3A shows the piston pump 12 in a position just before the start of a suction stroke. The piston 18 is at its lowest point within the pump chamber 13. The valve 10 opens the passage from the container to the pump chamber 13. The piston 18 is then moved upward to make a full suction stroke with a nominal speed to a level P1. An amount of tinting paste 5 is sucked into the pump chamber 13 (FIG. 3B). Then the valve 10 closes off the pump chamber 13 (FIG. 3C). In the shown case, the tinting paste 5 completely fills the pump chamber 13 without leaving a vacuum and without enclosing air. The tinting paste is not compressible, so any downward movement of the piston 18 is almost immediately blocked by the hydraulic counter pressure exerted by the tinting paste 5 (FIG. 3D). The stepper motor 16 stalls and the piston 18 remains essentially at the same level P1. In such a case, the viscosity of the tinting paste is sufficiently low to be pumped and metered with the used nominal pump speed and the content of the pump chamber does not contain air.

(18) Some movement may be possible during the attempted pressure stroke as a result from the mechanical flexibility of the system. For instance the encoder 17 may count a negligible number of steps not exceeding a set limit before stalling of the stepper motor 16. The control unit 19 can be programmed to compensate for this.

(19) The same test run is shown in FIGS. 4A-D with a tinting paste 5 having a higher viscosity at the prevailing shear and temperature. When the piston 18 is moved up during a suction stroke with the nominal pump speed the tinting paste 5 is too viscous to follow the piston 18 and a vacuum 20 is drawn. If the tinting paste would now be dispensed, the metered amount would be substantially less than needed for the selected formulation, eventually resulting in an incorrect paint tint. The test is continued by closing off the valve (FIG. 4C) and subsequently, the piston 18 is moved down until the encoder detects that the motor stalls and the piston is blocked by the fluid surface on a level P2 (FIG. 4D) or possibly by a layer of enclosed air. The volume of the drawn vacuum 20 in FIG. 4B is directly derivable from the travel distance P1−P2 of the piston 18. This travel distance is an indication of the viscosity profile of the tinting paste and the degree of settling or aging. A new reduced pumping speed can be calculated or selected in such way that no vacuum would be drawn or a signal can be generated to alert the operator to take appropriate measures, such as refilling the container 4 with a fresh amount of the same type of pigment paste.

(20) If the pump 12 is driven by a stepper motor 16 with an encoder 17, a more accurate indication of the volume of drawn vacuum 20 is given by the number of steps counted by the encoder 17 during the piston's return movement.

(21) FIGS. 5A-D shows a similar series of steps for checking the presence of enclosed air. In the start position of FIG. 5A, the composition below the piston is still unknown and may contain air. A tinting paste is used with a viscosity which is sufficiently low for the used pump speed, so no vacuum is drawn. The piston 18 is again moved upward to a level P1 (FIG. 5B) and the valve subsequently closes off the pump chamber 13 (FIG. 5C). A volume of air 21 is enclosed between the tinting paste and the piston 18. Subsequently, the piston 18 make a pressure stroke until the stepper motor stalls. At that moment, the piston is at a level P3 (FIG. 5D). The enclosed air 21 is compressed to a much smaller volume 21′. The observed compressibility (P1−P3)/P1 is an indication of the volume of the enclosed air. For example, if the pump is driven by a stepper motor with an encoder, the number of steps counted by the encoder 17 during the return movement from level P1 to level P3 is an accurate indication of the compressibility of the content in the pump chamber 13.

(22) If no air or vacuum is enclosed, then P1−P3=0, so the compressibility (P1−P3)/P1 would also be 0. This situation is in fact the same as the situation in FIGS. 3A-D.

(23) Enclosed air can be present as a layer between the fluid surface and the piston, as shown in FIGS. 5A-D, but it can also be present as encapsulated air entrapped homogenously as bubbles within the tinting paste. The first situation may be caused by a constructional leakage, while the second situation might require a recalculation of any formulation containing the examined tinting paste. Hence, if enclosed air is detected an operator might want to know how the enclosed air is distributed over the content of the pump chamber after the suction stroke.

(24) To check whether the enclosed air is entrapped within the tinting paste 5 or not, a further test is run with a partial suction stroke, as is shown in FIGS. 6A-D. The piston 18 is moved upward to a level P4, substantially below P1 of FIG. 5A. The valve 10 is closed (FIG. 6C) and the pump chamber content is compressed by the piston 18 traveling over a return distance to a level P5. If the compressibility (P4−P5)/P4 is about the same as the compressibility (P1−P3)/P1 in the full stroke test of FIGS. 5A-D, then the air must be entrapped homogenously within the tinting paste composition as (micro)bubbles. If, however, P4−P5≈P1−P3, then the enclosed air must come from a constructional leakage or insufficient venting of the pump, or the like. This situation is illustrated in FIGS. 7A-D. In the start position of FIG. 7A, the composition below the piston is still unknown and may contain air. In FIG. 7D a strip 21′ of compressed air remains between the piston 18 and the mass of tinting paste 5.

(25) If the air is partly within the paste and partly in a bubble, the measured results will be in between the above calculated values.

(26) It is noted that the drawings are schematic, not necessarily to scale and that details that are not required for understanding the present invention may have been omitted. The terms “upward”, “downward”, “below”, “above”, and the like relate to the implementations as oriented in the drawings, unless otherwise specified. Further, elements that are at least substantially identical or that perform an at least substantially identical function are denoted by the same numeral, where helpful individualised with alphabetic suffixes.

(27) The disclosure is not restricted to the above described implementations which can be varied in a number of ways within the scope of the claims.

(28) Elements and aspects discussed for or in relation with a particular implementation may be suitably combined with elements and aspects of other implementations, unless explicitly stated otherwise.