Intelligent Network For Chemical Dispensing System

• US 20130092704A1
• Filed: 10/14/2011
• Published: 04/18/2013
• Est. Priority Date: 10/14/2011
• Status: Active Grant

• Current Assignee: Delaware Capital Formation Incorporated (Dover Corporation)
• Original Assignee: Delaware Capital Formation Incorporated (Dover Corporation)
• Inventors: Tincher, Terry, Lafferty, Sean, Andersen, Bryan, McDaniel, Jason
• Granted Patent: US 9,447,536 B2
• Time in Patent Office: Days
• US Class Current: 222/1
• CPC Class Codes: A47L 15/4293 Arrangements for programme selection, e.g. control panels; Indication of the selected programme, programme progress or other parameters of the programme, e.g. by using display panels
• CPC Class Codes: A47L 15/4418 in the form of liquids A47L15/4409, A47L15/4436, A47L15/4445 take precedence
• CPC Class Codes: A47L 15/4463 Multi-dose dispensing arrangements
• CPC Class Codes: A47L 15/449 Metering controlling devices A47L15/4229 takes precedence
• CPC Class Codes: A47L 2401/023 Quantity or concentration of the consumable product
• CPC Class Codes: A47L 2501/07 Consumable products, e.g. detergent, rinse aids or salt
• CPC Class Codes: D06F 2101/00 User input for the control of domestic laundry washing machines, washer-dryers or laundry dryers
• CPC Class Codes: D06F 2101/14 Time settings
• CPC Class Codes: D06F 2103/00 Parameters monitored or detected for the control of domestic laundry washing machines, washer-dryers or laundry dryers
• CPC Class Codes: D06F 2103/16 Washing liquid temperature
• CPC Class Codes: D06F 2103/20 Washing liquid condition, e.g. turbidity
• CPC Class Codes: D06F 2103/22 Content of detergent or additives
• CPC Class Codes: D06F 2105/42 Detergent or additive supply
• CPC Class Codes: D06F 2105/46 Drum speed; Actuation of motors, e.g. starting or interrupting
• CPC Class Codes: D06F 2105/52 Changing sequence of operational steps; Carrying out additional operational steps; Modifying operational steps, e.g. by extending duration of steps
• CPC Class Codes: D06F 2105/58 Indications or alarms to the control system or to the user
• CPC Class Codes: D06F 2105/60 Audible signals
• CPC Class Codes: D06F 2105/62 Stopping or disabling machine operation
• CPC Class Codes: D06F 33/37 of metering of detergents or additives
• CPC Class Codes: D06F 34/05 for wireless communication between components, e.g. for remote monitoring or control
• CPC Class Codes: D06F 39/02 : Devices for adding soap or other washing agents
• CPC Class Codes: F04B 43/1292 : Pumps specially adapted for several tubular flexible members
• CPC Class Codes: F04B 49/065 : and making use of computers

Abstract

System and method for dispensing product to a washing machine. A chemical dispensing system includes a system controller, machine interface, and pump controller that communicate through serial data buses. The system controller provides a user interface, retrieves washing machine status information from the machine interface, and issues product dispensing commands to the pump controller. The pump controller monitors pump status and dispenses product in response to commands from the system controller. The pump controller: (1) determines pump activation periods based on calibration data stored in a pump controller memory; (2) tracks pump usage and adjusts the activation period to compensate for pump wear as the pump ages; (3) disables the pump if conditions exists that preclude operating the pump; (4) monitors product levels, and (5) reports pump status to the system controller. Integral channels are included in the pump housing to provide stress relief to a squeeze tube.

Claims

1. A chemical dispensing system comprising:

a peristaltic pump including a length of elastic tubing, a rotor that pumps fluid through the length of elastic tubing by progressively squeezing and releasing consecutive portions of the tubing, a motor that selectively rotates the rotor, a processor operatively coupled to the motor and that controls the motor, and a memory for storing pump calibration data; and

a system controller in communication with the peristaltic pump that provides data to the processor indicative of a desired volume of a product to be dispensed.

2. The system of claim 1, wherein the motor transmits information indicative of the position of the rotor to the processor, and the processor determines the volume of the product dispensed by the pump at least in part based on the position of the rotor.

3. The system of claim 1 further comprising:

a temperature sensor that provides temperature data to the processor, the temperature data being indicative of the temperature of the product being pumped, wherein the processor determines the volume of the product dispensed by the pump based at least in part on the temperature data.

4. The system of claim 1 wherein the processor determines a motor activation period that is expected to dispense the desired volume of the product and activates the motor for the motor activation period, the motor activation period determination being based at least in part on calibration data stored in the memory.

5. The system of claim 4, wherein the processor determines the motor activation period based at least in part on data received from the system controller.

6. The system of claim 4 wherein the processor accumulates a motor activation period associated with the current length of elastic tubing and determines an expected deterioration in the flow rate of the peristaltic pump based at least in part the accumulated motor activation period and adjusts the motor activation period to compensate for the expected deterioration in the flow rate of the peristaltic pump.

7. The system of claim 4 wherein the processor accumulates a motor activation period associated with the current length of elastic tubing and determines an expected percentage of life (POL) remaining for the length of elastic tubing based at least in part on the accumulated motor activation period.

8. The system of claim 7 wherein the memory contains data indicative of the type of material of which the length of elastic tubing is composed, the processor accumulates the age of the length of elastic tubing, and the processor determines the expected POL remaining for the length of elastic tubing based at least in part on the composition and age of the current length of elastic tubing.

9. The system of claim 7 wherein the processor compares the POL to a predetermined POL threshold, and activates an alarm if the POL is below the predetermined POL threshold.

10. The system of claim 6 wherein the system controller includes a user interface and causes the processor to reset the accumulated motor activation time in response to an input on the user interface indicating that the length of elastic tubing has been replaced.

11. The system of claim 1 wherein the calibration data is preloaded in the memory of the peristaltic pump.

12. The system of claim 1 wherein the system controller includes a user interface and causes the processor to update the calibration data in the memory in response to new calibration data being entered through the user interface.

13. A method of controlling the amount of a product dispensed by a chemical dispensing system including a system controller in communication with a peristaltic pump including a pump controller, the method comprising:

communicating from the system controller to the pump controller a desired volume of the product to be dispensed by the peristaltic pump;

calculating an activation period for the peristaltic pump to dispense the desired amount of the product based at least in part on calibration data stored in a memory in the pump controller; and

activating the peristaltic pump for the activation period.

14. The method of claim 13 further comprising:

accumulating an accumulated activation period of the peristaltic pump;

calculating an expected deterioration in a fluid flow rate of the peristaltic pump based at least in part on the accumulated activation period of the peristaltic pump; and

adjusting the activation period of the peristaltic pump based at least in part on the expected deterioration in the fluid flow rate.

15. The method of claim 14 further comprising:

accumulating the age of a length of elastic tubing in the peristaltic pump, wherein calculating an expected deterioration in the fluid flow of the peristaltic pump is further based at least in part on the age of the length of elastic tubing.

16. The method of claim 13 further comprising:

accumulating an accumulated activation period of the peristaltic pump; and

calculating an expected percentage of life (POL) left for a length of elastic tubing in the peristaltic pump based at least in part on the accumulated activation period.

17. The method of claim 16 further comprising:

comparing the POL to a predetermined POL threshold, and

activating an alarm if the POL is below the predetermined POL threshold.

18. The method of claim 16, wherein calculating the expected POL left for the length of elastic tubing in the peristaltic pump is further based at least in part on the type of material of which the length of elastic tubing is composed.

19. The method of claim 13 wherein the calibration data is preloaded into the memory.

20. The method of claim 13 further comprising:

sensing a temperature of the product;

calculating a viscosity of the product based at least in part on the sensed temperature; and

adjusting the activation period of the peristaltic pump based at least in part on the calculated viscosity of the product.

21. A chemical dispensing system comprising:

a pump including a memory for storing pump calibration data indicative of a product flow rate provided by the pump when the pump is activated.

22. The system of claim 21, further comprising:

a system controller in communication with the pump that determines a activation period for the pump based at least in part on the calibration data.

23. The system of claim 22 wherein the peristaltic pump further comprises:

a length of elastic tubing;

a rotor that pumps fluid through the length of elastic tubing by progressively squeezing and releasing consecutive portions of the length of elastic tubing; and

a processor that determines an expected deterioration in the flow rate of the peristaltic pump based at least in part on the age and accumulated operational time of the length of elastic tubing and adjusts the pump calibration data in response to the expected deterioration.

24. The system of claim 23 wherein the system controller includes a user interface and the processor resets the age and accumulated operational time of the length of elastic tubing stored in the non-volatile memory of the peristaltic pump in response to an input to the user interface indicating that the length of elastic tubing has been replaced.

25. The system of claim 23 wherein the processor of the peristaltic pump further determines an expected percentage of life (POL) left for the length of elastic tubing, compares the POL to a predetermined POL threshold, and activates an alarm in the system controller if the POL is below the predetermined POL threshold.

26. The system of claim 22 wherein the system controller provides data to the peristaltic pump indicating a desired volume of a product to be dispensed, and in response to receiving the desired volume data, the peristaltic pump dispenses the volume of the product based at least in part on the calibration data.

27. The chemical dispensing system of claim 22 wherein the controller updates the calibration data in the non-volatile memory of the peristaltic pump based on input to the user interface.

28. A peristaltic pump for dispensing a product from a container in a chemical dispensing system, the pump comprising:

a detection circuit including an electrical input port for receiving signals indicative of the presence of the product in the container, the detection circuit generating an output signal indicative of a low impedance state or a high impedance state at the electrical input port; and

a processor operatively coupled to the detection circuit that determines an amount of product present in the container based at least in part on the output signal generated by the detection circuit.

29. The pump of claim 28, wherein the processor generates a low product level indication in response to the signal indicative of one of the high impedance or low impedance states at the electrical input port of the detection circuit, and does not generate a low product level indication in response to the signal indicative of the other of the high impedance or low impedance states.

30. The pump of claim 29, further comprising:

a low product level alarm that is triggered by the low product level indication.

31. The pump of claim 29, further comprising:

a memory, wherein the processor stores time stamped data indicative of a low product level in the memory in response a low product level indication being generated.

32. The pump of claim 29, wherein:

in response generating a low product level indication, the processor begins accumulating pump activation periods to provide an indication of the total amount of product pumped since the low product level indication was generated; and

in response to the accumulated activation period exceeding a preset threshold, the processor disables the pump from being activated.

33. The pump of claim 32, wherein the processor triggers an out of product alarm in response to the accumulated amount of time exceeding the preset threshold.

34. The pump of claim 28, further comprising:

a probe assembly for operable orientation in the container and having a low impedance state when in contact with the product in the container and a high impedance state when not in contact with the product, the first probe assembly being electrically coupled to the electrical input port of the detection circuit.

35. The pump of claim 28, further comprising:

first and second conductive plastic inserts that each contact product passing through the pump, wherein

the first and second conductive plastic inserts are electrically coupled to the electrical input port of the detection circuit.

36. The pump of claim 35, further comprising:

a housing including an integral input channel and an integral output channel, wherein

the first conductive plastic insert is coupled to the integral input channel, and

the second conductive plastic insert is coupled to the integral output channel.

37. A peristaltic pump for a chemical dispensing system, the pump comprising:

a housing including a pumping chamber and integral input and output channels, each integral channel having a first end terminating in the pumping chamber and a second end terminating at a connection point accessible from the exterior of the housing;

a flexible channel located in the pumping chamber and fluidically coupling the first end of the integral input channel to the first end of the integral output channel; and

a rotor including at least one roller for pumping fluid through the flexible channel by progressively squeezing and releasing consecutive portions of the flexible channel, wherein

the integral input and output channels provide stress relief between the flexible channel and the connection points.

38. The peristaltic pump of claim 37 further comprising:

a first elbow fluidically coupling the flexible channel to the first end of the integral input channel so that the flexible channel is free to move axially with respect to the integral input channel; and

a second elbow fluidically coupling the flexible channel to the first end of the integral output channel so that the flexible channel is free to move axially with respect to the integral output channel.

39. The peristaltic pump of claim 38 wherein the first and second elbows are 90 degree elbows.

40. The peristaltic pump of claim 37 wherein the integrated input and output channels have a vertical orientation.

41. The peristaltic pump of claim 40 wherein the flexible channel includes a loop of tubing having a horizontal orientation so that the peristaltic pump operates in a horizontal plane.

42. The peristaltic pump of claim 41 further comprising:

a motor having an output shaft coupled to the rotor so that the roller pumps fluid through the flexible channel by progressively squeezing and releasing consecutive portions of the flexible channel in response to activation of the motor, the motor being located within the housing so that the output shaft is essentially parallel to the integrated input and output channels.

43. A chemical dispensing system comprising:

a peristaltic pump including a processor that selectively activates the pump to dispense a desired quantity of a chemical, the processor including an input port that receives a signal indicative of the existence of a condition in the chemical dispensing system, the processor disabling the pump in response to detecting the presence of the signal on the input port.

44. The system of claim 43, wherein the peristaltic pump further includes:

a pumping chamber;

a pumping chamber lid having an open state that exposes the pumping chamber and a closed state that covers the pumping chamber; and

a lid sensor that provides a signal indicative of the state of the lid to the input port of the processor;

the processor disabling the first peristaltic pump in response to the signal indicating the lid is in an open state.

45. The system of claim 44, wherein the lid sensor comprises a magnet and a hall effect sensor coupled to the processor, the magnet and hall effect sensor being in close proximity when the lid is closed, and separated when the lid is open.

46. The system of claim 43 further comprising:

a flush manifold including a flow sensor that generates a signal indicative of a flow of dilutant through the flush manifold, wherein the processor is in communication with the flow sensor and disables the peristaltic pump in response to the signal indicating the flow of diluent is below a minimum flow threshold.

47. The system of claim 46 further comprising:

a diluent valve coupling the flush manifold to a diluent source and in communication with the processor, wherein the processor controls the flow of diluent through the flush manifold by selectively activating the diluent valve.

48. The system of claim 47 further comprising:

a system controller in communication with the processor, wherein the system controller selectively activates the diluent valve by transmitting data to the processor.

49. A chemical dispensing system for a washing machine, the system comprising:

a system controller including a plurality of serial data bus interfaces;

a pump including a pump controller in communication with the system controller over a first serial data bus interface of the plurality of serial data bus interfaces; and

a machine interface including a machine interface controller in communication with the system controller over a second serial data bus interface of the plurality of serial data bus interfaces, wherein

the system controller obtains trigger data indicative of a state of the washing machine from the machine interface via the second serial data bus interface, and based at least in part on the trigger data, transmits data indicative of an amount of a chemical to be dispensed to the pump controller via the first serial data base.

50. The system of claim 49, wherein the pump controller includes a memory containing pump calibration data.

51. The system of claim 50, wherein the pump includes a squeeze tube and the pump controller accumulates an accumulated activation period of the pump with the current squeeze tube.

52. The system of claim 51, wherein the system controller obtains the accumulated activation period from the pump controller via the first serial data bus and determines an activation period of the pump based at least in part on the accumulated activation period associated with the squeeze tube.

53. The system of claim 50, wherein the system controller obtains the pump calibration data from the pump controller via the first serial data bus and determines an activation period for the pump based at least in part on the calibration data.

54. The system of claim 49 further including a network gateway in communication with the system controller over a third serial data bus interface of the plurality of serial data bus interfaces, wherein the network gateway provides a communication link between the system controller and an external data network.

55. The system of claim 54, wherein the system controller is remotely accessible from the external data network via the network gateway.

56. The system of claim 49, wherein the pump controller includes a detection circuit coupled to a probe assembly, the pump controller being configured to notify the system controller of a low product condition in a container associated with the pump controller in response to the detection circuit providing a signal indicative of the low level product condition.

57. The system of claim 56, wherein the pump controller is further configured to disable the pump in response to detecting the low level product condition.

58. A chemical dispensing system comprising a peristaltic pump, the peristaltic pump including:

a length of elastic tubing;

a rotor that pumps fluid through the length of elastic tubing by progressively squeezing and releasing consecutive portions of the length of elastic tubing; and

a processor that determines a remaining service life of the length of elastic tubing based at least in part on an accumulated operational time on the length of elastic tubing.

59. The chemical dispensing system of claim 58 further comprising:

a system controller including a user interface, the system controller receiving data indicative of the remaining service life of the length of elastic tubing from the processor and displaying an indication of the remaining service life on the user interface.

60. The chemical dispensing system of claim 59, wherein the system controller includes an alarm that is activated in response to the remaining service life dropping below a lower threshold.

61. The chemical dispensing system of claim 59, wherein:

the system controller causes the pump to dispense a desired amount of a product by communicating an activation period to the pump, and

the system controller determines the activation period based at least in part on the remaining service life of the length of elastic tubing.