Formulating chemical solutions based on volumetric and weight based control measurements

• US 7,803,321 B2
• Filed: 03/18/2005
• Issued: 09/28/2010
• Est. Priority Date: 03/18/2005
• Status: Active Grant

• Current Assignee: Ecolab USA Incorporated (Ecolab, Inc.)
• Original Assignee: Ecolab, Inc.
• Inventors: Pannkuk, Warren, Jahnke, Darren, Lark, Larry Mitchell, Willman, Eric
• Primary Examiner(s): Warden; Jill
• Assistant Examiner(s): TURK, NEIL N
• Application Number:
  US11/084,645
• Publication Number:
  US 20060210430A1
• Time in Patent Office: 2,020 Days
• Field of Search: 422/62, 422/905, 422/3, 222/77, 222/57, 222/55, 222/52, 700/266, 700/17, 700/1, 700/240
• US Class Current: 422/62
• CPC Class Codes: B01F 2101/2204 Mixing chemical components in generals in order to improve chemical treatment or reactions, independently from the specific application
• CPC Class Codes: B01F 23/483 using water for diluting a liquid ingredient, obtaining a predetermined concentration or making an aqueous solution of a concentrate
• CPC Class Codes: B01F 35/832 Flow control by weighing
• CPC Class Codes: G05D 11/132 by controlling the flow of the individual components G05D11/133 takes precedence
• CPC Class Codes: G05D 11/134 by sensing the weight of the individual components
• CPC Class Codes: Y10T 436/25 including sample preparation

Abstract

A system and method for formulating a chemical solution using both volumetric and weight based measurements of components of the chemical solution is disclosed. The components of the chemical solution include water and at least one other component, which may take any form, such as, without limitation, liquid, solid, powder or gaseous form. Formulation of the chemical solution is administered by combining water with the one or more other components at an output port, from which this combination is dispensed to a solution storage tank. In response to a user'"'"'s request to formulate a specified amount of the chemical solution, the volume of water provided to the output port is monitored by a flow meter and the weight of the other component(s) provided to the output port is monitored by one or more load cells. Based on such monitoring, appropriate amounts of water and the other component(s) are combined together to formulate the specified amount of the chemical solution in the solution storage tank.

Claims

1. A system comprising:

a storage tank that stores at least one component chemical concentrate;

a controller that receives an instruction requesting formulation of a specified amount of a chemical solution and determines a target volume of water and a target weight of the at least one component chemical concentrate based on the specified amount of the chemical solution;

an output port that receives water from a water source and the at least one component chemical concentrate from the storage tank and dispenses the water and the at least one component chemical concentrate to a solution container;

a flow meter that measures volumetric readings representing a volume of the water supplied from the water source to the output port; and

a weight measuring device that measures weight readings representing an actual weight of the at least one component chemical concentrate contained in the storage tank,

wherein the controller further controls supply of the water to the output port based on the volumetric readings and controls supply of the at least one component chemical concentrate to the output port based on the weight readings to form the specified amount of the chemical solution.

2. The system of claim 1 wherein the storage tank is a component sump, the system further comprising:

a concentrate container that stores the at least one component chemical concentrate prior to storage in the component sump;

a pump fluidly connected between the component sump and the concentrate container that pumps, under control of the controller, the target weight of the at least one component chemical concentrate from the concentrate container to the component sump; and

a control valve fluidly connected between the component sump and the output port that enables, under control of the controller, the flow of the at least one component chemical concentrate between the component sump and the output port.

3. The system of claim 2 wherein the weight measuring device measures the weight readings as the at least one component chemical concentrate is pumped from the concentrate container to the component sump and prior to any of the component chemical concentrate being dispensed to the output port by way of the control valve.

4. The system of claim 3 wherein the output port comprises:

means for evacuating the at least, one component chemical concentrate from the component sump when the control valve is activated by the controller.

5. The system of claim 4 wherein the evacuating means comprises an aspirator.

6. The system of claim 1 wherein the solution container comprises an automatic endoscope reprocessor (AER).

7. The system of claim 1 further comprising:

a control valve fluidly connected between the storage tank and the output port that enables the flow of the at least one component chemical concentrate from the storage tank to the output port; and

means for evacuating the at least one component chemical concentrate from the storage tank when the control valve is activated by the controller.

8. The system of claim 7 wherein the weight measuring device measures the weight readings as the at least one component chemical concentrate is evacuated from the storage tank and provided to the output port.

9. The system of claim 1 wherein the controller includes

a user interface that receives the instruction requesting formulation of the specified amount of the chemical solution from a user.

10. A method comprising:

storing at least one component chemical concentrate in a storage tank;

receiving an instruction from a user requesting formulation of a specified amount of a chemical solution;

determining a target volume of water and a target weight of the at least one component chemical concentrate appropriate to formulate the specified amount of the chemical solution;

measuring volumetric readings representing a volume of the water supplied to a solution container;

measuring weight readings representing an actual weight of the at least one component chemical concentrate remaining in the storage tank while the component chemical concentrate is supplied to the solution container; and

controlling the supply of the water and the supply of the at least one component chemical concentrate to the solution container based on the volumetric readings and the weight readings to formulate the specified amount of the chemical solution.

11. The method of claim 10 further comprising:

determining whether the target weight of the at least one component chemical concentrate has been supplied to the solution container;

determining whether the target volume of the water has been supplied to the solution container;

deactivating a water dispense valve when the target volume of water has been supplied; and

deactivating a concentrate supply valve when the target weight of the component chemical concentrate has been supplied.

12. The method of claim 10 wherein storing the at least one component chemical concentrate in a storage tank comprises:

transporting the at least one component chemical concentrate to the storage tank from a concentrate container;

prior to supplying water and the at least one component chemical concentrate to the solution container, measuring weight readings representing an actual weight of the at least one component chemical concentrate in the storage tank while the component chemical concentrate is transported from the concentrate container; and

stopping transportation of the at least one component chemical concentrate to the storage tank from the concentrate container if the actual weight of the at least one component chemical concentrate in the storage tank meets the target weight of the at least one component chemical concentrate appropriate for formulating the specified amount of the chemical solution.

13. The method of claim 10 further comprising communicating the weight readings and the volumetric readings to a remote computer over a network connection for analysis.

14. A system comprising:

a concentrate container that stores at least one component chemical concentrate;

a solution storage container that receives the at least one component chemical concentrate and water;

a controller, communicatively coupled to a weight measuring device, a flow meter, a first control valve, a second control valve, and a user interface selection device, that receives an instruction via the user interface selection device requesting formulation of a specified amount of a chemical solution and determines a target volume of water and a target weight of the at least one component chemical concentrate to be dispensed into the solution storage container based on the specified amount of the chemical solution;

a component sump connected to the weight measuring device, wherein the weight measuring device measures, as the at least one component chemical concentrate is pumped into the component sump, an actual weight of the at least one component chemical concentrate contained in the component sump;

a pump fluidly connected between the concentrate container and the component sump that pumps the at least one component chemical concentrate from the concentrate container into the component sump;

wherein the controller further receives the measured actual weight and controls the pump such that the target weight of the at least one component chemical concentrate is pumped into the component sump;

wherein the flow meter is fluidly connected to the first control valve, and the flow meter measures a volume of water supplied from the first control valve to the solution storage container,

wherein the controller further receives the measured volume of water and controls the first control valve such that the target volume of water is supplied to the solution storage container,

wherein the second control valve fluidly connected between the component sump and the solution storage container enables flow of the at least one component chemical concentrate from the component sump to the solution storage container, and

wherein the controller further controls the second control valve such that the target weight of the at least one component chemical concentrate flows from the component sump to the solution storage container.