MULTI-DISPENSER PLURAL COMPONENT DISPENSING SYSTEM

Abstract

A plural component dispensing system individually delivers separate material components to each of a plurality of proportioners. Each of the proportioners regulates volumetric flow of each of the separate material components to produce a target ratio of the separate material components associated with the proportioner. The target ratios associated with the plurality of proportioners can be the same or different target ratios. Each proportioner delivers the separate material components at the associated target ratio to one of a plurality of dispensing devices. Each dispensing device mixes the separate components received at the corresponding target ratio and delivers the components as a mixture.

Claims

1. A system comprising: a first pump for delivering a first material component; a second pump for delivering a second material component; a first proportioner connected to each of the first and second pumps to regulate a volumetric flow of each of the first and second material components to produce a first target ratio of the first and second material components; a second proportioner connected to each of the first and second pumps to regulate the volumetric flow of each of the first and second material components to produce a second target ratio of the first and second material components; a first dispensing device connected to the first proportioner for receiving the first target ratio of the first and second material components; and a second dispensing device connected to the second proportioner for receiving the second target ratio of the first and second material components.

2. The system of claim 1, wherein each of the first proportioner and the second proportioner comprises: a first regulator connected to the first pump for regulating pressure of the first material component; a second regulator connected to the second pump for regulating pressure of the second material component; a first flow meter connected to measure a first volumetric flow rate of the first material component; and a second flow meter connected to measure a second volumetric flow rate of the second material component.

3. The system of claim 2, further comprising: a control system configured to control at least one of the first regulator and the second regulator of each of the first proportioner and the second proportioner based on the measured first volumetric flow rate and the measured second volumetric flow rate of the respective one of the first proportioner and the second proportioner.

4. The system of claim 3, wherein each of the first proportioner and the second proportioner comprises: a first actuator configured to control the first regulator of the respective one of the first proportioner and the second proportioner; and a second actuator configured to control the second regulator of the respective one of the first proportioner and the second proportioner.

5. The system of claim 4, wherein the control system is configured to control operation of at least one of the first actuator and the second actuator of each of the first proportioner and the second proportioner.

6. The system of claim 4, wherein the control system is configured to control operation of each of the first actuator and the second actuator of each of the first proportioner and the second proportioner.

7. The system of claim 3, wherein the control system comprises a user interface configured to receive user input defining the first target ratio and the second target ratio.

8. The system of claim 1, wherein the dispensing device comprises a mixer configured to mix the first material component and the second material component.

9. The system of claim 1, wherein the first material component comprises a base component; and wherein the second material component comprises a catalyst component.

10. The system of claim 1, wherein the first target ratio is different than the second target ratio.

11. A method comprising: individually pumping a first material component and a second material component to each of a first proportioner and a second proportioner; regulating volumetric flow of the first material component and the second material component through the first proportioner to produce a first target ratio of the first material component and the second material component; regulating volumetric flow of the first material component and the second material component through the second proportioner to produce a second target ratio of the first material component and the second material component; delivering the first target ratio of the first material component and the second material component from the first proportioner to a first dispensing device; and delivering the second target ratio of the first material component and the second material component from the second proportioner to a second dispensing device.

12. The method of claim 11, wherein regulating the volumetric flow of the first material component and the second material component through the first proportioner to produce the first target ratio comprises: individually measuring flow rate of each of the first material component and the second material component through the first proportioner; and individually regulating pressure of each of the first material component and the second material component based on the measured flow rates for each of the first material component and the second material component through the first proportioner to produce the first target ratio delivered to the first dispensing device; and wherein regulating the volumetric flow of the first material component and the second material component through the second proportioner to produce the second target ratio comprises: individually measuring flow rate of each of the first material component and the second material component through the second proportioner; and individually regulating pressure of each of the first material component and the second material component based on the measured flow rates for each of the first material component and the second material component through the second proportioner to produce the second target ratio delivered to the second dispensing device.

13. The method of claim 11, further comprising: receiving, at an interface device, user input defining the first target ratio and the second target ratio.

14. The method of claim 11, wherein the first target ratio is different than the second target ratio.

15. The method of claim 11, further comprising: mixing the first material component and the second material component at the first dispensing device to form a first mixture; and mixing the first material component and the second material component at the second dispensing device to form a second mixture.

16. The method of claim 11, wherein the first material component comprises a base material component; and wherein the second material component comprises a catalyst material component.

17. A system comprising: a plurality of pumps, each pump for delivering a separate material component; a plurality of proportioners, each proportioner comprising: a plurality of regulators, each regulator connected to one of the pumps for regulating pressure of one of the material components; and a plurality of flow meters, each flow meter configured to measure flow rate of one of the material components; a control system that controls the regulators of each of the plurality of proportioners based on the sensed flow rates of the respective proportioner to cause the respective proportioner to deliver the separate material components at a target ratio associated with the respective proportioner; and a plurality of dispensing devices, each of the plurality of dispensing devices connected to one of the plurality of proportioners to receive the separate material components at the target ratio associated with the respective proportioner.

18. The system of claim 17, wherein each of the plurality of proportioners includes a plurality of actuators, each actuator controlling one of the plurality of regulators of the respective proportioner; and wherein the control system includes a controller that controls at least one of the actuators of each of the plurality of proportioners based on the target ratio of the separate material components associated with the respective proportioner.

19. The system of claim 17, wherein each of the plurality of dispensing devices comprises a device for mixing the separate material components.

20. The system of claim 17, wherein the separate material components include a base component and a catalyst component.

21. The system of claim 17, wherein the control system further controls the regulators of each of the plurality of proportioners based on the sensed flow rates of the respective proportioner to cause the respective proportioner to deliver a target total flow rate of combined flow rates of each of the separate material components.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a block diagram of an example multi-dispenser plural component proportioning system including multiple proportioners that deliver separate material components to each of the multiple dispensing devices.

[0009] FIG. 2 is a block diagram illustrating further details of an example of one of the proportioners of FIG. 1.

DETAILED DESCRIPTION

[0010] As described herein, a plural component dispensing system delivers multiple material components for mixing and application through multiple dispensing devices utilizing one pump per component. That is, rather than utilize a separate set of pumps for each dispensing device (e.g., spray applicator or other dispensing device), a system implementing techniques of this disclosure utilizes one pump per material component to deliver each of the multiple material components (e.g., fluids) to each of the multiple dispensing devices. Each pump is connected to deliver a separate material component to each of a set of multiple proportioners. Each of the proportioners regulates volumetric flow of each of the multiple material components to produce a target ratio of the separate material components that is delivered to one of the dispensing devices. Each proportioner can deliver a same or different target ratio of the separate material components to the respective dispensing device. The separate material components are mixed at the dispensing device and delivered as an activated compound. As such, a system implementing techniques of this disclosure can support operation of multiple dispensing devices to mix and deliver the separate material components at one or more target ratios utilizing one pump per material component, thereby reducing the cost, complexity, and overall maintenance of the system.

[0011] FIG. 1 is a block diagram of multi-dispenser plural component proportioning system 10 which can be used, for example, in a multi-component spray system. As illustrated in FIG. 1, system 10 includes material components M.sub.1-M.sub.N, pumps P.sub.1-P.sub.N, proportioners PROP.sub.1-PROP.sub.M, and dispensing devices D.sub.1-D.sub.M. Though illustrated and described as including “N” material components M.sub.1-M.sub.N and “N” pumps P.sub.1-P.sub.N, as well as “M” proportioners PROP.sub.1-PROP.sub.M and “M” dispensing devices D.sub.1-D.sub.M, it should be understood that “N” and “M” as used herein represent arbitrary numbers, such that system 10 can include any number of material components, pumps, proportioners, and dispensing devices. In addition, the letters “N” and “M” should not be construed to require any particular relativity of the represented numbers, such that “N” can represent a number that is greater than, equal to, or less than the number represented by the letter “M.”

[0012] Material components M.sub.1-M.sub.N are each individual components (e.g., fluid components) that, when mixed, trigger an immediate chemical reaction to form an activated compound, such as an epoxy, a polyurethane, or other activated compound. One or more of material components M.sub.1-M.sub.N are referred to as a base component, and one or more of material components M.sub.1-M.sub.N are referred to as a catalyst component.

[0013] Pumps P.sub.1-P.sub.N are positive displacement or other types of pumps configured to deliver a corresponding one of material components M.sub.1-M.sub.N (e.g., fluid components) to each of proportioners PROP.sub.1-PROP.sub.M at pressures (e.g., 5000 psi) that are substantially greater the pressures at which they will be dispensed (e.g., 2000 psi). Pumps P.sub.1-P.sub.N can, in certain examples, draw material components M.sub.1-M.sub.N directly from material containers and deliver the individual components to each of proportioners PROP.sub.1-PROP.sub.M. In other examples, pumps P.sub.1-P.sub.N can receive material components M.sub.1-M.sub.N from separate pumps or other pressurized sources at a first pressure and deliver the material components to each of proportioners PROP.sub.1-PROP.sub.M at a second pressure that is higher than the first pressure. Each of proportioners PROP.sub.1-PROP.sub.M is connected to receive each of material components M.sub.1-M.sub.N from each of pumps P.sub.1-P.sub.N and regulate the volumetric flow of each of material components M.sub.1-M.sub.N to produce a target ratio of material components M.sub.1-M.sub.N that is delivered to a corresponding one of dispensing devices D.sub.1-D.sub.M. For instance, as is further described below, each of proportioners PROP.sub.1-PROP.sub.M can include regulators, flow meters, and actuators configured to regulate the volumetric flow of material components M.sub.1-M.sub.N via an electronic control system to produce a target ratio of material components M.sub.1-M.sub.N delivered to the corresponding one of dispensing devices D.sub.1-D.sub.M. In other examples, any one or more of proportioners PROP.sub.1-PROP.sub.M can be mechanically configured to passively regulate the volumetric flow of each of material components M.sub.1-M.sub.N (e.g., without automatic electronic regulation) to produce the target ratio of material components M.sub.1-M.sub.N, such as the passive flow synchronizer described in the currently co-pending application PCT/US2016/044046, entitled “PASSIVE FLOW SYNCHRONIZER,” filed on Jul. 26, 2016 and published under number WO 2017/019688, the entire contents of which are hereby incorporated by reference.

[0014] As illustrated in FIG. 1, each of dispensing devices D.sub.1-D.sub.M are sprayer devices or other dispensing devices connected to receive each of material components M.sub.1-M.sub.N from a corresponding one of proportioners PROP.sub.1-PROP.sub.M. Each of dispensing devices D.sub.1-D.sub.M receives material components M.sub.1-M.sub.N at a target ratio from the corresponding one of proportioners PROP.sub.1-PROP.sub.M and mixes the material components for dispensing as an activated compound. That is, each of dispensing devices D.sub.1-D.sub.M includes a mixing device (e.g., a mixing manifold or other mixer) that mixes the received material components (i.e., received at the target ratio) for dispensing as the activated compound.

[0015] In operation, material components M.sub.1-M.sub.N are individually pumped under pressure by pumps P.sub.1-P.sub.N to each of proportioners PROP.sub.1-PROP.sub.M. Each of proportioners PROP.sub.1-PROP.sub.M regulates the volumetric flow of each of material components M.sub.1-M.sub.N to produce a target ratio of material components M.sub.1-M.sub.N that are delivered to a corresponding one of dispensing devices D.sub.1-D.sub.M. For instance, as illustrated in the example of FIG. 1, material component M.sub.1 is delivered by pump P.sub.1 under pressure to each of proportioners PROP.sub.1-PROP.sub.M. Material component M.sub.2 is delivered by pump P.sub.2 to each of proportioners PROP.sub.1-PROP.sub.M, and material component M.sub.N is delivered by pump P.sub.N to each of proportioners PROP.sub.1-PROP.sub.M.

[0016] Proportioner PROP.sub.1 regulates the volumetric flow of each of material components M.sub.1-M.sub.N to produce a target ratio of material components M.sub.1-M.sub.N. Each of material components M.sub.1-M.sub.N are individually delivered to dispensing device D.sub.1 at the target ratio. Material components M.sub.1-M.sub.N are mixed at dispensing device D.sub.1 which, due to the mixing of the base component and the catalyst component, produces an immediate chemical reaction. The reacted mixture is delivered by dispensing device D.sub.1 for application to, e.g., a target product. Similarly, each of proportioners PROP.sub.1 and PROP.sub.M regulates the volumetric flow of each of material components M.sub.1-M.sub.N to produce a target ratio of material components M.sub.1-M.sub.N. The target ratios of material components M.sub.1-M.sub.N can be the same or different target ratios for each of proportioners PROP.sub.1-PROP.sub.M. Each of material components M.sub.1-M.sub.N are individually delivered from proportioner PROP.sub.2 to dispensing device D.sub.2 at the target ratio corresponding to proportioner PROP.sub.2. Each of material components M.sub.1-M.sub.N are individually delivered from proportioner PROP.sub.M to dispensing device D.sub.M at the target ratio corresponding to proportioner PROP.sub.M. Material components M.sub.1-M.sub.N are mixed at each of dispensing device D.sub.2 and D.sub.M to produce the immediate chemical reaction and delivery of the reacted mixture for application to a product, area, or other target. In some examples, any one or more of proportioners PROP.sub.1-PROP.sub.M can control a total flow rate of material components M.sub.1-M.sub.N (e.g., a sum of the combined flow rates of material components M.sub.1-M.sub.N) to a corresponding one of dispensing devices D.sub.1-D.sub.M, as is further described below.

[0017] Each of dispensing devices D.sub.1-D.sub.M can therefore be utilized for individual application of the reacted mixture produced by the mixing of material components M.sub.1-M.sub.N. Dispensing devices D.sub.1-D.sub.M can be physically remote from each other, separated by tens of feet, hundreds of feet, or other distances. Rather than require multiple sets of material component storage vessels and multiple sets of pumps (each individually regulated to produce the target ratio of material components M.sub.1-M.sub.N), system 10 utilizes a single pump per material component. Proportioners PROP.sub.1-PROP.sub.M regulate the volumetric flow of each of material components M.sub.1-M.sub.N to produce a target ratio of material components M.sub.1-M.sub.N delivered to each of dispensing devices D.sub.1-D.sub.M. As such, system 10 implementing techniques described herein utilizes one pump per material component to achieve the target ratio of the material components at each of the multiple dispensing devices D.sub.1-D.sub.M, thereby reducing the complexity, cost, and overall maintenance requirements of the system.

[0018] FIG. 2 is a block diagram illustrating further details of one example of proportioner PROP.sub.1 of FIG. 1. Though the example of FIG. 2 is described with respect to proportioner PROP.sub.1, it should be understood that the techniques described below are applicable to any one or more of proportioners PROP.sub.1-PROP.sub.M of FIG. 1.

[0019] As illustrated in FIG. 2, proportioner PROP.sub.1 includes regulators 12A-12N, actuators 14A-14N, flow meters 16A-16N, and controller 18. Proportioner PROP.sub.1 receives material components M.sub.1-M.sub.N as inputs from pumps P.sub.1-P.sub.N (FIG. 1) and provides material components M.sub.1-M.sub.N individually at a target ratio as outputs to dispensing device D.sub.1 (FIG. 1).

[0020] Regulators 12A-12N regulate fluid pressure (and hence the resulting volumetric flow) of material components M.sub.1-M.sub.N in response to actuators 14A-14N. Regulators 12A-12N can be air controlled flow regulators, hydraulically controlled flow regulators, electrically driven motor controlled flow regulators, manually controlled flow regulators, or other types of flow regulators. For instance, in some examples, one or more of regulators 12A-12N regulate flow by controlling a variable orifice. A larger orifice provides less pressure drop, and a smaller orifice provides more pressure drop. In certain examples, one or more of regulators 12A-12N include an on/off valve, with flow through the valve being regulated by a length of time that the valve stays open.

[0021] Actuators 14A-14N control operation of regulators 12A-12N to regulate pressure (and resulting volumetric flow) of material components M.sub.1-M.sub.N. Actuators 14A-14N, in some examples, provide air pressure to regulators 12A-12N, respectively, to set the regulated pressure of material components M.sub.1-M.sub.N, respectively. In some embodiments, one or more of actuators 14A-14N are manually set air regulators, and others of actuators 14A-14N are electrically controlled via controller 18. In other embodiments, each of actuators 14A-14N are electrically controlled via controller 18.

[0022] Flow meters 16A-16N measure volumetric flow of material components M.sub.1-M.sub.N, respectively. Examples of flow meters 16A-16N include, e.g., gear meters, Coriolis mass flow meters, or other types of flow meters. Each of flow meters 16A-16N measures a volumetric flow rate of a respective one of material components M.sub.1-M.sub.N as the material component passes through the respective flow meter and provides an indication of the measured flow rate to controller 18. That is, as illustrated in FIG. 2, flow meter 16A provides measured flow rate FR.sub.A to controller 18 indicating the measured volumetric flow rate of material component M.sub.1 through regulator 12A and flow meter 16A. Flow meter 16B provides measured flow rate FR.sub.B to controller 18 indicating the measured volumetric flow rate of material component M.sub.2, and flow meter 16N provides measured flow rate FR.sub.N to controller 18 indicating the measured volumetric flow rate of material component M.sub.N.

[0023] Controller 18 is electrically and/or communicatively connected to receive the measured flow rates FR.sub.A-FR.sub.N from flow meters 16A-16N. In addition, as illustrated in FIG. 2, controller 18 is electrically and/or communicatively connected to provide control commands to actuators 14.sub.A-14.sub.N based on the measured flow rates FR.sub.A-FR.sub.N to control operation of regulators 12A-12N to produce the target ratio of material components M.sub.1-M.sub.N individually delivered to dispensing device D1 (FIG. 1). Controller 18, in some examples, includes and/or presents a user interface (e.g., at a display device) configured to receive user input defining the target ratio associated with proportioner PROP.sub.1. While illustrated as included with proportioner PROP.sub.1, in other examples, controller 18 can be separate from proportioner PROP.sub.1. For instance, in certain examples, controller 18 can be connected to each of proportioners PROP.sub.1-PROP.sub.M and configured to provide control commands to actuators of each of proportioners PROP.sub.1-PROP.sub.M to produce the target ratio of material components M.sub.1-M.sub.N associated with the respective one of each of proportioners PROP.sub.1-PROP.sub.M.

[0024] Controller 18 includes one or more processors and computer-readable memory encoded with instructions that, when executed by the one or more processors, cause controller 18 to operate in accordance with techniques described herein. Examples of the one or more processors include any one or more of a microprocessor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry. Computer-readable memory of controller 18 can be configured to store information within controller 18 during operation. The computer-readable memory can be described, in some examples, as computer-readable storage media. In some examples, a computer-readable storage medium can include a non-transitory medium. The term “non-transitory” can indicate that the storage medium is not embodied in a carrier wave or a propagated signal. In certain examples, a non-transitory storage medium can store data that can, over time, change (e.g., in RAM or cache). Computer-readable memory of controller 18 can include volatile and non-volatile memories. Examples of volatile memories can include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile memories. Examples of non-volatile memories can include magnetic hard discs, optical discs, floppy discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories.

[0025] Controller 18, in some examples, includes user interface components including one or more input devices (e.g., a keyboard, buttons, mouse, microphone, or other input devices) configured to receive input from a user and one or more output devices (e.g., a display device, indicator lights, or other output devices) configured to present information to a user. In some examples, controller 18 includes a touch-sensitive display configured to receive user input in the form of gestures (e.g., touch gestures, swipe gestures, pinch gestures, or other gestures) and to display information to the user.

[0026] In operation, material components M.sub.1-M.sub.N are received by proportioner PROP under pressure from pumps P.sub.1-P.sub.N (FIG. 1). Material components M.sub.1-M.sub.N include one or more base material components and one or more catalyst material components. Often, the base material components are the major components of the resulting activated compound and are required at a higher concentration than the catalyst components. Controller 18 controls one or more of actuators 14A-14B which control operation of regulators 12A-12N to regulate the pressure of material components M.sub.1-M.sub.N and the resulting volumetric flow of each. For example, controller 18 can implement a proportional integral derivative (PID) or other control algorithm to control operation of one or more of actuators 14A-14N to produce the target ratio of material components M.sub.1-M.sub.N based on the measured feedback of flow rates FR.sub.A-FR.sub.N.

[0027] In some examples, one or more of actuators 14A-14N is manually controlled via operator input to produce a desired regulated fluid pressure at the output of the respective regulator. For instance, in one embodiment, actuator 14A is a manually controlled actuator and actuators 14B-14N are electrically controlled via commands from controller 18. In such an embodiment, an operator can manually set actuator 14A to produce a desired regulated fluid pressure at the output of regulator 12A. With that manually set fluid pressure, a flow rate of material component M.sub.1 is established and measured by flow meter 16A. Actuators 14B-14N are controlled by controller 18 such that the flow rate of material components M.sub.2-M.sub.N are scaled to the flow rate of material component M.sub.1 and to each other to produce the target ratio of material components M.sub.1-M.sub.N delivered to dispensing device D.sub.1 for mixing and application of the reacted compound. In other examples, controller 18 controls each of actuators 14A-14N to produce the target ratio of components M.sub.1-M.sub.N based on the measured volumetric flow rates FR.sub.A-FR.sub.N.

[0028] In some examples, controller 18 controls each of actuators 14A-14N to produce a total flow rate of material components M.sub.1-M.sub.N delivered by proportioner PROP.sub.1 to dispensing device D.sub.1 (FIG. 1) at the target ratio. For instance, controller 18 can receive input (e.g., via a user interface) defining a total flow rate of material components M.sub.1-M.sub.N to be delivered to dispensing device D.sub.1. Controller 18 can control operation of actuators 14A-14N to produce the total target flow rate of each of material components M.sub.1-M.sub.N delivered to dispensing device D.sub.1 at the target ratio. For example, controller 18 can control a first one of actuators 14A-14N (e.g., actuator 14A) to cause the corresponding one of regulators 12A-12N (e.g., regulator 12A) to produce a first flow rate of the corresponding one of material components M.sub.1-M.sub.N (e.g., material component M.sub.1). Controller 18 can control each of the remaining ones of actuators 14A-14N (e.g., actuators 14B-14N) based on sensed flow rates FR.sub.A-FR.sub.N to produce the target ratio of material components M.sub.1-M.sub.N delivered to dispensing device D.sub.1. Controller 18 can control each of actuators 14A-14N such that each of material components M.sub.1-M.sub.N are delivered to dispensing device D.sub.1 at the target ratio, and the sum of flow rates FR.sub.A-FR.sub.N is the target total flow rate.

[0029] Accordingly, proportioner PROP.sub.1 individually controls the regulated pressure and thus the flow rate of each of components M.sub.1-M.sub.N to establish and maintain the target ratio of material components M.sub.1-M.sub.N that are delivered to dispensing device D.sub.1 (FIG. 1) for mixing and application. Proportioner PROP.sub.1, in some examples, further controls the regulated pressure and corresponding flow rate of each of components M.sub.1-M.sub.N to produce a target total flow rate of material components M.sub.1-M.sub.N that are delivered to dispensing device D.sub.1 at the target ratio. Moreover, techniques of this disclosure enable multiple dispensing devices to receive any one or more target ratios and target total flow rates of material components M.sub.1-M.sub.N using one pump per material component, thereby reducing the cost, complexity, and overall maintenance of a multi-dispenser plural component dispensing system.

[0030] While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.