DE202005013090U1 - Motor e.g. asynchronous motor, dosing pump for dosing e.g. oil, has position sensor providing motion sequence of displacement organ so that electronic controlling of pump responds to operating conditions of dosing circle and dosing pump - Google Patents

Abstract

The pump has a connection unit connected with a connecting rod, where a position of the unit is sensed by a position sensor (36) that works according to a non-contact principle. The connection unit and the position sensor are arranged outside of a dosing head (12), where the position sensor gives an actual signal for position of the connection unit such that a displacement organ stands in a fixed connection. The position sensor provides motion sequence of the displacement organ so that electronic controlling of the pump responds to operating conditions of a dosing circle and the pump.

Description

The The invention relates to a motor metering pump according to the preamble of the claim 1.

such Motor metering pumps are well known and are by additional equipment the adapted to the respective requirements. They work on the volumetric Principle, in which the dosing process from the transport of a completed Chamber volume through a displacement organ consists. The dosing volume per stroke corresponds to the volume difference in the movement of the repressive organ.

at Such an engine metering pump will generally be continuous Rotary movement of a drive motor through a gear unit in a implemented oscillating linear movement of the displacement element. The Speed and torque of the engine is reduced in a gearbox and to the speed and power requirement of the displacer customized. The output shaft of the transmission drives a device for converting the rotational movement into a lateral deflection, i. at right angles to the axis of rotation, at, e.g. a spring / cam or an eccentric drive. The lateral deflection movement actuates a push rod, the axially displaceable in the direction of the deflection movement in bearings guided is. This transmits the movement and the power on the repressive organ, which in one in the longitudinal axis the push rod arranged dosing in cooperation with a Outlet and inlet valve in alternating sequence to a pumping stroke (Pressure stroke) and a suction stroke and thus to a promotion of the dosing medium leads.

differences various embodiments lie on the one hand in the nature of the engine; usual are asynchronous motors, Synchronous motors and stepper motors outside or inside the actual pump housing are mounted. Furthermore, individual metering pump types differ in the execution of the gearbox, a worm gear, a spur gear or a belt drive can be. The drive of the push rod by the deflection device can be forced or one-sided form-fitting take place only when the deflection device. The push rod is driven in the pressure stroke by the deflection device, for sucking whereas in the latter case it is replaced by a return spring they are driven to the returning one Deflection device applies without play. The return spring is compressed in the pressure stroke and is in their dimensions on the power requirement during the intake laid out. As another distinguishing feature of different types of pumps The force is introduced from the push rod to a membrane as a repressive organ either by a rigid connection or by a hydraulic Link. As the hydraulic fluid, usually oil, not is compressible, a hydraulic coupling acts as a rigid Connection. In addition to the system described here with a dosing head Pump constructions are also known with two or more working on a common drive operated dosing heads. For one thing, as embodiment on both sides of an eccentric two opposing push rods in a common longitudinal axis be arranged in opposite directions be operated and each a dosing with its own displacement element drive. On the other hand, another well-known principle works with Mehrfachdosierköpfen with a lengthened Eccentric shaft, which carries several jointly driven eccentric, the everyone again for an associated unit of transverse to the eccentric axis arranged push rod and in the direction of the push rod axis lying dosing with displacement element drives.

All moving parts are in a simple case in a common pump housing through Ball or plain bearings are stored, in other versions are individual functional groups in further housing or assembly parts, which are also partially filled with oil, to functional groups summarized and assembled as building units. An example would be one outside of the pump housing mounted unit of motor and reduction gearbox with mounting flange and already squashed output shaft.

in the simple case is the drive motor for a continuous dosing continuous or to run single dosing strokes for one turned on certain time. Other designs control the drive motor via a Frequency converter according to a given time profile, whereby the engine speed and thus the metering performance better reproducible and independent of electrical parameters, e.g. the frequency or the current one height of Mains voltage is.

The engine speed is dictated by the electrical frequency of the motor drive and, together with the gear ratio and the transmission characteristic which is sinusoidal in an eccentric gear, determines the duration of each stroke. With continuous control, the duration per stroke results from the effective engine speed in the load condition and the gear reduction. In the so-called on / off operation, in which individual strokes or Hubpakete are processed, between which the engine is defined, for example, in Ansaugotpunkt stopped, start-up and braking times are added and extend the time per stroke accordingly. The stroke frequency is in continuum predefined operation by the duration per stroke or in the on / off mode by the repetition frequency of the engine starts, which of course can not be done more often than it dictates the time required to execute a stroke.

The stroke can be adjusted by limiting the lateral deflection. This can be done by adjusting an eccentricity, e.g. by using so-called wobble cylinders, which are based on two mutually rotatable slate planes work. To the Another is as another option an adjustable stop is common, the not forcibly guided Deflection systems can be used. This stop in the form of a mechanical adjustable spindle limited with appropriate setting the regression the push rod when sucking on an adjustable position Reaching the rear dead center of the deflection device. By the stop the starting point of the lifting movement is specified; the final position results at complete engineered Deflection movement. A possible execution is a Hubverstellbolzen with accessible from the device operating side Screw rotary knob and scale into a thread of the pump housing that holds the Stop for represents the push rod when sucking. For hydraulic systems if the stroke adjustment is e.g. realized by a sliding sleeve, their position by an accessible from the device operating side Rotary knob with scale is adjustable, which screwed into a thread of the pump housing is. The sleeve covers a bypass hole in the push rod, the after shutting off a certain way a shunt of the oil circuit releases and so the power coupling from the push rod to the membrane picks.

Of the Movement of the repressive organ results from the interaction of the gear and other mechanical Components. While the forward movement the drive works against those by the extruder and the (folding way existing) return spring force acting on the push rod. During the backward movement, the push rod becomes with positively driven deflection system also retracted by the drive, with one-sided operation presses the return spring the push rod back and brings the power for the suction of the dosing on. The movement of the push rod follows the characteristic of the deflection device; at a Eccentric this is e.g. a sinusoidal course, the full stroke length between the two dead centers of Exzenterhubs lies. In operation with reduced Stroke length is the movement with adjustment of an eccentricity continues to be purely sinusoidal with reduced amplitude, in rigidly coupled systems with adjustable stop or hydraulic systems with bypass bore remains the original Movement and the amplitude of the deflection device is received, is but not completely performed; Rather, the push rod movement is depending on the set stroke length and Coupling system in the beginning or in the end cut off (phase control). The forward movement for execution The pressure stroke plays depending on the control of the engine in one Time range well below one second (e.g., in the range 200ms), the intake stroke is also after one by the Deflection device predetermined course within similar Time like the pressure stroke. This results in both Hubphasen relatively high instantaneous speeds of the dosing medium; in an eccentric drive the maximum is about halfway along the movement.

at designs, where several units consisting of push rod and dosing, of a common, with multiple eccentrics eccentric shaft can be driven these eccentric out of phase be arranged on the shaft to the respective peak power requirement of each dosing heads in time to distribute a full rotation of the eccentric shaft and so the to disposal optimally exploiting stationary engine power.

Certain designs, So-called diaphragm metering pumps have a partially flexible displacement body Membrane. This is not rigid, but deforms in the walk area elastic by a certain amount when the pressure of the dosing medium interacting with them. The amount of this deformation, which in a first, for the Dosing unused part of the stroke movement is built up, goes the effectively executed Lost stroke movement and causes that the dosage decreases with increasing working pressure. These falling characteristic is much more pronounced in normal applications than it is would allow the required dosing accuracy. Motordosierpum pen can therefore usually not in a general attitude over a wide range of Working pressure with the desired Be operated accuracy; rather, the occurring error recorded by a calibration measurement and in the further calculations included. However, this calibration measurement must be in the concrete Application is done under real working conditions and is particular In conjunction with aggressive chemicals one step, the considerable Effort brings with it.

Although currently common motor metering pumps are powerful and have for many processes favorable metering properties, but still have disadvantages in terms of the hydraulic properties of the dosing over the desirable ideal condition. As an example, here are the relatively strong dependence of the metered amount of the working pressure of the dosing and disadvantages such as flow noise or pressure losses due to high instantaneous flow rates of the metering called.

task In particular, the present invention is the known disadvantages with regard to the hydraulic properties of the dosing process eliminate and thus a variable, wider range of application of the motor metering pumps to achieve without negatively affecting their production costs. Furthermore, the movement process of the push rod and the so connected displacer so the target information be adjusted so that both the dosing itself adjustable is as well as by manufacturing technology or adverse properties of components (e.g., the elastic membrane, if any) be considered and repaired by the electronic control. Through these measures should the exact dosage of a given volume of a dosing medium in a dosing by avoidance or detection of faulty operating conditions be ensured and manufacturing and / or occurring in the use Inaccuracies be compensated by the electronics used.

The solution of the problem is that with the push rod, a reference element is connected, whose position is scanned by a position sensor, wherein the position sensor outputs an actual signal (x _I ), which to the position of the reference element and thus of the displacement member in a fixed relationship stands and with the help of which knowledge about the movement sequence of the displacement element is obtained, so that the electronic control of the metering pump can react to operating states of the dosing circuit and the pump.

With Help of the position sensor detects the movement of the push rod and evaluated by the electronic control. For this purpose, the examined Control based on the framework of the movement on each characteristic features and responds by using influencing the motor control so that the dosage the default as possible follows well and the otherwise e.g. through the properties of the membrane arising inaccuracies are eliminated.

Especially It is advantageous that the position sensor for a non-contact Principle works because it ensures a wear-free operation of the sensor will be, given the high number of strokes during the lifetime of a Metering pump is required. Since that connected to the push rod Position element outside is arranged of the dosing, thus greater flexibility in terms of Mounting space for reached the position sensor.

influenced the reference element the beam path of a light source and works the cooperating with it position sensor, in the pump housing or is fixedly arranged on another stationary part, after one photosensitive receiver principle, On the one hand, it is a wear-free one Operation ensured, given the high number of strokes during the operation Life of a metering pump is essential, and the moving Parts become non-contact sampled. Another advantage of this arrangement is that one Such a design of a position sensor in principle insensitive across from magnetic stray fields.

is the reference element is a shadow body or a shadowing contour and consists of the cooperating with him Position sensor located in the pump housing or other stationary part is fixed, from a series of photosensitive charge-coupled receiver cells (so-called CCD cells, charge coupled device), has such an arrangement on an optical basis important properties that the position sensor fulfill got to. On the one hand, the arrangement works on the basis of the optical principle of operation wear and is insensitive to magnetic stray fields, on the other hand has such a trained Sensor virtually no linearity error on.

is the position sensor is still arranged on a separate sensor carrier, the one with the pump housing or another stationary part is firmly connected, one can Such arrangement can be pre-assembled and tested as a unit and thus facilitates the assembly. Is the sensor carrier as Part made of non-conductive plastic, this is additionally the electrical insulation of the sensor components against metallic parts of the housing or the transmission simplified.

Put the light source, the shadow body or the shadowing contour and the receiver a light barrier-like Arrangement and the measured values are continuous or intermittently supplied to the electronic control, provides such an arrangement the electronic control with a just the requirements Speed the position data available.

Consists the optical receiver the position sensor consists of a number of linearly arranged receivers (pixels), preferably 128 pixels, such an arrangement may be simple Make the position by counting the shadow border between illuminated and unlit cells determine and reach already with this simple method one resolution according to the distance of the cells of the used receiver module.

Is the light source a light emitting diode (LED), which is arranged opposite to the optical receiver of the position sensor, that their light beam on the direct path to the receiver is not hindered by the push rod, this has the advantage that the inexpensive LED has an approximately point-like spot, which is essential for a high optical resolution , and practically has an almost infinite life. The arrangement opposite the position sensor past the push rod results in a large distance between the light source and the receiver, which makes the projection angle of the relevant light beam relatively independent of the mounting position of the elements.

Becomes the output value of the position sensor by interpolation of the brightness values several in the shadow transition area lying pixel, so is for the output signal of the position sensor a finer resolution achieved as dictated by the mechanical grid of the cells of the CCD receiver is.

Become during the processing of the signals of the position sensor filter measures used, then the interference immunity of the position sensor improved.

The Sensitivity of the position sensor to assembly deviations and mechanical shifts during of operation, e.g. by heating or bearing wear, is reduced when zero position error of the position sensor by means of a reference memory or scaling error of the position sensor eliminated by approaching one or more reference positions become.

Become Exposure fluctuations of the position sensor by a controller or regulation of the light source based on the brightness values obtained balanced pixels, this reduces the sensitivity of the pixel Position sensors against fluctuations of component parameters.

Become Brightness variations between individual pixels of the optical receiver by incorporating a reference memory for the sensitivity of each Compensating pixels reduces the effects of contamination of the optical receiver.

He follows the detection of what value the Hubverstellorgan set is, by measurement during the dosage immediately above the position sensor, the otherwise necessary additional sensor for the mechanical Position of the associated Setting elements omitted.

Recognizes the electronic control by evaluation of the position sensor signal a blockade of the repressive organ or an incomplete executed Hub, increased this the reliability of Dosage. For dosing pumps of conventional design Without a position sensor, sensors are often used for monitoring the metering movement e.g. when passing one reference mark per stroke a feedback pulse deliver to the electronic control, from which measured the Hubperiodendauer and a trouble-free Flow of dosing can be derived. Opposite such Sensors has the described use of a position sensor the advantage that the desired Information is present at each time of the metering stroke, and not only when passing the reference mark, so that such additional Sensors without disadvantage can be omitted.

Is working the drive motor according to a slip-prone principle, e.g. an asynchronous motor is used, and determines the electronic control from the predetermined by the control target speed of the drive motor and the known transmission characteristic a Sollhubfrequenz or a Sollhubperiode for the repressive organ and records them additionally by evaluating the position sensor signal the actual Stroke frequency or the actual Lifting period of the displacement element, by comparing the actual stroke frequency with the Sollhubfrequenz or the actual Stroke period with the Sollhubperiode the displacer the slip of Drive motor calculated and its target speed changed so that the repressive organ ultimately with the desired Stroke frequency moves, this improves the accuracy of the dosage by eliminating the error in the stroke frequency caused by the slip of the drive motor would be caused. For dosing pumps conventional Type without position sensor often sensors are used, the for monitoring the metering movement e.g. when passing one reference mark per stroke a feedback pulse to the electronic control, from which likewise the Hubperiodendauer can be measured and corrected; such additional sensors may be included Use of a position sensor omitted.

The drive motor operates according to a slip-prone principle, for example by using an asynchronous motor, and determines the electronic control of the predetermined by the control target speed of the drive motor and the known transmission characteristics Sollhubfrequenz or Sollhubperiode for the displacement member and additionally detects by evaluating the position sensor signal the actual Hubfrequenz or the actual stroke period of the displacement member, wherein they by comparing the actual stroke frequency with the Sollhubfrequenz or the actual stroke period with the Sollhubperiode the Displacement organ calculated the slip of the drive motor and further determines the electronic control of the thus determined slip of the drive motor and the known transmission characteristics acting on the displacer force and thus makes a conclusion on the working pressure of the metering, can be realized with this information monitoring and compensation functions which improve the reliability and accuracy of the dosage. Determines the electronic control of the predetermined by the control target speed of the drive motor and any known transmission characteristic for each moment of dosing a target speed for the displacement member and detects it in addition by evaluating the position sensor signal, the actual speed of the displacement member, wherein they by comparison of the actual instantaneous speed with the desired speed of the displacement member calculates the current slip of the drive motor and from it, in turn in connection with the known transmission characteristics, closes on the momentary force curve on the displacement member, so there is the desired information about the force curve at each time of the dosing and the desired monitoring and compensation functions can be time differentiated, which further improves the reliability and accuracy of the dosage.

takes the electronic control of the observed force on Repressor one conclusion on the working pressure of the dosing medium, so may be known harmful Impact of working pressure on the dosing counteracted become.

Recognizes the electronic control from the determined working pressure of the Dosing medium an operation outside of the specified pressure range and sets the dosage when exceeding one by the specification of the dosing pump or by a user input predetermined maximum allowable Pressure or falls below a predetermined minimum pressure a, so erroneous operating conditions such as overpressure situations or pressure loss Detected by a defective piping and it can be security measures such as. adjusting the dosage to be taken, giving the reliability the dosage improved. The otherwise necessary additional Resources such as e.g. Überdruckbegrenzer can be saved, provided that the metering pump is the only pressure increasing Aggregate is in the process. The possibility, the working pressure also to values within the specified pressure range Controlling the metering pump expands the possibilities the pressure monitoring on situations where the surveillance system conventional Dosing pumps, which only responds when the dosing pump is blocked, can not be used.

is the repressive organ a partially elastic membrane and detects the electronic control from the measured working pressure of the metering and the known dependence the dosing of the working pressure, the deformation of the elastic Ver the membrane is causing an expected dosing error, and it affects the speed of the drive motor and thus the Stroke frequency so that counteracts this expected dosing error This improves the accuracy of the dosage.

The signal read out of the position sensor (x _I ) for the position of the push rod via a control loop within its control accuracy influences the speed of the drive motor and as a result the linear movement of the push rod and thus the displacement member so that it follows a predetermined setpoint profile, so this targeted influenceability of the movement of the displacement member to achieve or improve advantageous hydraulic properties of the dosage, for example in the slow dosing and / or the dosing accuracy in Teilhubbereich be exploited.

If the metering pump has a control device in addition to the position sensor and influences this alternatively the position (referred to below as x _I ), the speed (hereinafter referred to as v _I ) or the acceleration of the displacer via a control device influenced by changing the speed of the drive motor, can suitably For the requirements of a specific dosing task, the advantages of the respectively more suitable control method are specifically used. Control of the speed allows a direct control of the actual flow rate of the dosing medium, which is required, for example, for the slower suction to avoid cavitation. On the other hand, regulation of the position makes it possible to control situations near standstill, in which the speed information which is formed by differentiating the path signal becomes very small and can no longer be usefully processed by the control device. The control of the position avoids this difficulty and is advantageous to apply for example in the electronic stroke length limitation or slow dosing. The regulation of the acceleration is advantageous for easy controllability of the control, since the acceleration of the moving masses for fast processes is a direct reflection of engine power.

Does the metering pump in addition to the position sensor, a control device and sets this v _{I of} the displacement member in the intake phase and / or deliberately descend in the pressure phase, it is thus pressure losses, which are alleged by flow resistance Verur, or the formation of cavitation counteracted. When dosing highly viscous media, eg lecithin, high pressure losses occur at bottlenecks, such as in the valves, when the flow velocity is too high. These pressure losses must be applied in the form of an additional force by the drive and can be kept low when using the control of v _{I of} the displacer. In addition, flow noise is effectively reduced at reduced flow rate. During the metering of slightly outgassing media, for example of sodium hypochlorite, cavitation occurs, in particular during the suction at excessively high flow velocity due to falling below the vapor pressure of the metering medium, which results in increased mechanical wear. In a regulation of v _{I of} the displacement member in the intake and / or in the pressure phase, this is advantageously avoided.

has the metering pump in addition to the position sensor, a control device and is the desired stroke length an operator specification of the control device communicated and by the Regulating the movement of the displacer electronically the to be executed stroke limited by the control device, the drive motor after performing the desired stroke continues, switched to the reversing mode and so a suction stroke performs and then stop the engine or performs the subsequent pressure stroke, in principle, the associated mechanical Setting elements omitted.

has the metering pump in addition to the position sensor, a control device and distributes the control device the forward movement of the repressive organ while the printing phase by driving the drive motor so on the the repetition frequency of the metering strokes given time that the application of the dosing medium takes place as evenly as possible, to very slowly executed dosing strokes from e.g. a few minutes, can Concentration variations of the dosing largely avoided become.

The Metering accuracy is improved when the displacement element a partially elastic membrane is and the electronic control from the momentary force on the membrane the opening of the Exhaust valve detects and using this observation the dead zone, which arises due to the elastic deformation of the membrane measures and actually executed Stroke through targeted termination of the stroke depends on the determined membrane deformation influenced so that the dependence the dosage of the back pressure is substantially reduced. These Improvement is achieved by eliminating the error caused by the elastic deformation of the membrane under the influence of the working pressure This results in that the amount of this deformation is not for metering contributes. Due to the reduced dependence The dosing of the working pressure can recalibrations, the otherwise with significant change of operating parameters such as the working pressure required, omitted. The derivation of the membrane deformation from an observation the force curve is particularly important in evaluating the engine slip advantageous, because this is a good reflection of the actual power requirement represents and so no additional metrological Effort required.

The Metering accuracy is improved when the metering pump in addition to the position sensor has a control device, the displacement element is a partially elastic membrane and the actually executed stroke dependent is influenced by the determined membrane deformation by the Regulating the drive motor after performing the desired stroke from opening the exhaust valve stops, switched to the reversing mode and so a suction stroke performs and then stop the engine or performs the subsequent pressure stroke, so that by the Membrane deformation caused error contribution (related to the stroke or the metered volume), which arises because the amount This deformation does not contribute to the dosage is eliminated. By the diminished dependency The dosing of the working pressure can recalibrations, the otherwise with significant change of Operating parameters, such as the working pressure required, omitted, and the linearity of the relationship between set stroke length and indeed metered amount of the metering medium improves. The derivative the membrane deformation from an observation of the force curve is in evaluation of the engine slip particularly advantageous because of this a good reflection of the actual Required power and thus no additional metrological effort requires.

If the repressive organ is a partially elastic membrane and the metering pump in addition to the position sensor has a control device, and the actually executed stroke frequency depends on the determined membrane deformation is influenced by the control device a correction value for caused by the membrane deformation error contribution (related on the stroke or the metered volume) and determines the target speed of the drive motor using this correction value changed so that the error contribution caused by the membrane deformation is eliminated, becomes the dependency the dosage of the working pressure reduced.

following is as an embodiment the invention, a motor driven diaphragm metering pump with eccentric gear described in more detail with their various applications. It shows:

1 : Longitudinal section through a motor metering pump with position sensor

2 : Exploded view of the position sensor (magnification of section X off 1

3 : Components of the position control loop

4 : Components of the speed control loop

5 : Top view of the position sensor in the axial direction

6 : Side view of the position sensor across the axis

7 : Representation of the shadow area of the position sensor

8th : Display of the brightness values of the pixels as they correspond to the actual shadow course

9 : Representation of the image scale of the position sensor due to geometric arrangement

10 : Interpolation of position resolution

11 : Representation of the calculation basis for the interpolation of the position resolution

12 : Representation of the dosing rate as a function of the mechanical stroke length and the working pressure

1 shows the construction of a motor metering pump (partially cut). The motor metering pump consists, as is generally known, essentially of three groups of components, namely the drive motor 2 with gear unit, the eccentric drive in eccentric housing 1 and the electronics housing 28 with the electronic control contained therein and the electronic assemblies and components used therein. The electronics housing 28 has a bottom plate on the bottom 4 with mounting holes on the eccentric housing 1 on the electronics housing 28 Put on and firmly connected with this carries the drive motor 2 with gear unit, which is connected for example via screws with the eccentric housing.

In the so-called housing, which of the eccentric housing 1 and the electronics housing 28 is formed are in the upper part, the eccentric housing 1 , which fixes components of the eccentric drive. The components of the eccentric drive are in an eccentric carrier 22 stored, which ensures the positional alignment of the items to each other and in Exzentergehäuse 1 is attached. A three-phase asynchronous motor 2 is together with a reduction gear 11 , which is designed as an angle gear, as a unit from the outside of the eccentric housing 1 Flanged and connected with screws. The output shaft of the geared motor forms a right angle to the shaft axis of the motor and either directly forms the drive shaft of the eccentric drive or, as in the described embodiment, is connected to the same axis via a clutch. The drive shaft of the eccentric drive, the eccentric shaft 17 , is in the excentric carrier 22 rotatably mounted and carries as firmly connected to her part an eccentric. The eccentric shaft penetrates with the eccentric a correspondingly cut push bar 20 , The eccentric shaft 17 is through the motor / gear unit via the shaft coupling when the motor is driven 2 set in rotation and continues to drive the push bar 20 on an inner surface of its cutout, namely the contact surface, with the outer surface of the eccentric. The push bar 20 drives a push rod firmly connected to it, in the example injected 19 at. The unit from push bar 20 and push rod 19 is mounted longitudinally displaceable in two sliding bushes. The axis of the eccentric shaft 17 as well as the longitudinal axis 18 of the push bar 20 as well as the push rod 19 lie respectively in the horizontal plane and form a right angle to each other. One of the two sliding bushes 26 for the push rod 19 sits in a bearing disc 24 , the print head side on the eccentric carrier 22 is attached; another sliding bush 27 , which the struck away from the Dosierkopfseite pin of the push bar 20 sits in the Hubverstellbolzen 8th , Axially identical to the longitudinal axis 18 the push rod 19 is a manually operated adjusting 7 for the adjustment of Hubverstellbolzens 8th in a thread of the eccentric carrier 22 screwed in, which is the axial movement of the push bar 20 limited during suction and thus the stroke of the metering pump.

The housing further contains in its lower part in a closed space, the electronics housing 28 , the electronic control. The housing is splash-proof and protects the eccentric drive and the electronic control against moisture or corrosion, as dosing pumps are often used in conjunction with chemically aggressive media. The electronic control consists of a horizontal control electronics 34 with the power switching stages for the motor control 29 that as integrated The frequency converter are designed as well as one in a housing cover 5 arranged electronics 6 containing the necessary for the operation of the metering input and display elements. The controls are through a cover 9 protected. Below the cover 9 are connections for the control lines 10 or provided for the power supply.

On the control lines 10 or the power supply connection opposite side is coaxially with the longitudinal axis 18 the push rod is a dosing head 12 arranged in which as a displacement member, for example made of plastic membrane 13 works, which is firmly clamped at its periphery. The dosing head 12 continues to carry an inlet valve 14 and an exhaust valve 15 to the between membrane 13 and dosing head 12 in the dosing room 16 via the inlet valve 14 aspirated dosing via the outlet valve 15 to press into the dosing line. The motor metering pump works on the volumetric principle, ie a given volume should be sucked in on each stroke and on the other hand via the outlet valve 15 be ejected. The membrane 13 is by means of the eccentric drive, the push rod 19 moved back and forth in the longitudinal axis, set in an oscillating motion. To the side of Hubverstellbolzens 8th The unit acts as a push bar 20 and push rod 19 with the adjustment 7 as a manually adjustable Hubverstellvorrichtung together. At the opposite end is the dosing head 12 pointing part of the push rod 19 stuck to the core 30 the membrane 13 connected and puts them in an oscillating motion.

Between the push bar 20 and a covenant 25 the bearing disc 24 is a compression spring 23 , For example, a coil spring, arranged, which is the push bar 20 always forms a positive fit on the eccentric. In the preceding phase of the eccentric movement, ie the movement of the push rod towards the dosing head, the push handle is moved with the push rod to the compression spring, at the same time the membrane 13 in the mess room 16 pressed, which has the consequence that in the dosing chamber creates an overpressure, the exhaust valve 15 , For example, a spring-loaded ball valve, opens and the dosing medium is pressed into the dosing. In the returning phase of the eccentric movement, ie the movement of the push rod away from the dosing, the push bar is 20 through the compressed compression spring 23 , which may be formed, for example, as a spiral spring following the eccentric movement in the opposite direction to Hubverstellbolzen 8th moved, which has the consequence that with the membrane 13 connected push rod 19 entrains the membrane in its movement, whereby in the dosing 16 a negative pressure is created, which is the inlet valve 14 opens, so that once again dosing can be sucked into the dosing. By the alternating, oscillating movement of the membrane 13 by means of the eccentric drive, the flow of the metering medium in the metering line is formed. The eccentric drive creates a sinusoidal movement of the unit from push bar 20 , Push rod 19 and membrane 13 in the course of a metering stroke. Is by means of Hubverstellbolzens 8th set a reduced stroke length, the movement is in the intake before reaching the dead center by the adjustable stop of Hubverstellbolzens 8th braked prematurely, whereby the sine wave of the movement is cut off and a phase angle of the stroke movement is formed.

The position of the unit from push bar 20 , Push rod 19 and membrane 13 is through the position sensor 36 sampled, the measurement signal is in a defined relationship to this position; For example, this relationship may be strictly proportional to possible execution. The measuring signal of the position sensor 36 always refers to the position of the part of the mobile unit to which it acts. This point of attack is formed by the reference element, which in this context is to be understood in an abstract sense. Depending on the requirements of the position sensor, it may be designed as a concrete, in addition to be mounted component, but also only from a characteristic training as an edge or surface on one of the components required anyway, eg on the push bar 20 , consist.

In the embodiment is in Exzenterträger 22 a sensor carrier 31 attached (see also the schematic representation in 6 ), the one hand in the longitudinal direction photosensitive CCD cells 32 (CCD = charge coupled device; charge coupled optical receiver module) and opposite a light source 33 , eg a light emitting diode (LED), carries.

The sensor carrier connected to the eccentric carrier 31 and the components mounted thereon form a light barrier whose beam path is partially interrupted by the push bar. The reference element is defined by a shadow edge 35 of the push bar 20 formed in the field of light barrier arrangement. In the oscillating movement of the push rod 19 so covers the shadow edge 35 non-contact photosensitive cells 32 , How now in particular in 5 is shown schematically, which shows a plan view in the axial direction, the light source 33 be arranged so that the light beam on its way to the photosensitive cells 32 not by the push rod 19 is covered; ie that the light source 33 and the row of photosensitive CCD cells 32 above or below the push rod 19 is arranged. How now in particular in 7 is shown schematically, is by the light source 33 by means of the shadow edge 35 on the photosensitive cells 32 cast a shadow that basically divides the cells into light (h) and non-light (d) cells. Because the row is parallel to the longitudinal axis 18 arranged photosensitive cells, for example, 128 pixels, covering a distance of about 8mm, in the border area only partially exposed or shaded, arises in

8th illustrated transitional situation of the shadow profile SV. The amount of in 8th In this case, the illustrated rectangular areas represents the illuminance of the respective pixels. By a special method, which will be described later in detail and based on the 10 is explained, this limit situation is used to accurately determine the respective position of the shadow edge and thus the position of the push rod or the membrane. This measuring device, consisting of thrust-arm-side shadow edge and sensor carrier side light-sensitive CCD cells with opposite light source, serves to measure the actual position or the speed of the oscillating push rod and to use this information for the realization of the described functions.

The Push rod that puts the membrane in an oscillating motion, At each stroke, it returns a distance equal to the mechanical stroke length. To consider mounting tolerances must be the longitudinal extension the photosensitive CCD cells be slightly larger. This applies in principle also for any other conceivable position sensor used.

x_S:

Sollwert der Position des Verdrängungsorgans

x_I:

Istwert der Position des Verdrängungsorgans

x_SI:

Regelabweichung der Position des Verdrängungsorgans

v_S:

Sollwert der Geschwindigkeit des Verdrängungsorgans

v_I:

Istwert der Geschwindigkeit des Verdrängungsorgans

v_SI:

Regelabweichung der Geschwindigkeit des Verdrängungsorgans

SG:

Stellgröße

KSG:

Korrigierte Stellgröße

MA(U,f):

Motoransteuerung (Spannung bzw. Frequenz)

If, by means of the position sensor signal, a regulation of the diaphragm or generally of the displacement movement is to be realized, as is particularly apparent in US Pat 3 respectively. 4 schematically explained, the following mechanical and electronic components required. The short names contained in the two diagrams mean:

x _S:

Setpoint of the position of the displacer

x _I :

Actual value of the position of the displacement element

x _SI :

Control deviation of the position of the displacement element

v _S :

Setpoint of the speed of the displacement element

v _I :

Actual value of the velocity of the displacer

v _SI :

Control deviation of the speed of the displacement element

SG:

manipulated variable

KSG:

Corrected manipulated variable

MA (U, f):

Motor control (voltage or frequency)

The moving part of the drive whose movement is to be regulated consists of the push bar 20 with the push rod 19 , with the membrane core 30 is firmly connected. The return spring 23 retrieves the push bar after a successful stroke and thus causes the suction. The outer ring of the membrane 13 is in the dosing head 12 firmly mounted, the metal membrane core injected in the membrane 30 moves the central surface of the membrane as a displacement in the dosing. The inlet valve 14 closes on the suction side, the exhaust valve 15 on the pressure side of the dosing and offers each a connection option for the outer casing. With the push rod 19 or with a related component, here with the push bar 20 For example, at the end facing away from the dosing head, a reference element is connected whose position is determined by a position sensor operating without contact in the present case 36 is scanned. In the exemplary embodiment, the reference element is a shadow edge 35 of the push bar 20 and the position sensor, a light barrier-like arrangement consisting of the previously described light source 33 in conjunction with the series of photosensitive cells 32 indicating the position of the shadow edge 35 captured optically and thus without contact by their shadow formation. Because the push rod 19 the actual connection and the adhesion to the membrane 13 ensures and push bar and push rod are firmly connected in the present example, the following description always refers to the movement of the push rod 19 although, strictly speaking, the shadow edge 35 of the push bar 20 is measured.

The position sensor 36 outputs an actual signal x _I , which is the position of the reference element 35 is proportional. In the case of the speed controller this is in the exemplary embodiment by a differentiator 37 derived according to the time (dx _I / dt) and thus in addition a speed-proportional actual signal v _I formed. For the control, of course, other methods are suitable, which provide a proportional to the membrane velocity signal. Depending on the type of control and requirements of the dosage, a time profile for the setpoint 38 the position x _S or the Geschwin predefined v _S. By a target-actual comparison 39 the deviation is determined as position deviation x _SI = (x _S - x _I ) or velocity deviation v _SI = (v _S - v _I ), and the result is applied to a PID controller 40 given (PID controller = controller with proportional, integral and derivative). Its output, the manipulated variable SG, corresponds to a request value for the drive power. To improve the controller stability, the manipulated variable SG by a position correction 41 further processed. The position correction 41 takes into account the fact that the speed of the motor is converted into a speed at the push rod, depending on the rotational angle position of the eccentric (derived from the push rod position) in accordance with the sinusoidal characteristic of the eccentric drive. The position correction 41 calculates the output signal of the PID controller for this purpose 40 on the inverse characteristic of the eccentric gear in a corrected manipulated variable KSG, based on the input of the reduction gear 11 represents the necessary motor control required to move the push rod at the output of the eccentric gear 19 to obtain SG according to the desired manipulated variable. An amplifier 42 , which is designed as a frequency converter, includes the power switching stages and controls the motor according to the requested speed with the associated voltage and frequency. The amount of the position-dependent position correction, the conversion of the corrected manipulated variable KSG in a specific speed specification for the frequency converter and possibly the derivative constant for the formation of the speed signal v _I are determined by the three proportionality factors k1, k2, k3. The factor for the position-dependent position correction k1 is to be selected in accordance with the characteristic of the eccentric gear, the two factors k2 for the power amplifier and k3 for the derivative of the speed signal can be selected based on practical considerations, such as working with as good manageable value ranges of the associated variables ,

In the 3 is the control loop for a position controller, in 4 the control circuit is shown schematically when used as a speed controller. The described control circuit sets the predetermined time profile for the desired value of the position x _S or the speed v _S , of course within the scope of its possible control accuracy.

The Definition of the concrete profile for the position, the speed or acceleration and switching between these modes this happens based on the requirements arising from the example following functions, taking into account the functional limits of the controller such as control speed, achievable Accuracy, etc.

With such a control, it is possible with a motor metering pump, a desired speed of the membrane 13 , in general of the displacement element, and thus to control the effective flow rate of the metering medium.

As well the membrane position can be controlled directly. this function allows in selected Phases of the dosing process targeted approach certain positions and, if necessary, to be maintained at standstill.

By the control of the movement by means of a position sensor unlike an unregulated operation can change of farm sizes responded be over time or by environmental conditions or specimen spreads, ie statistical deviations within the production series are, and their harmful Influence can be minimized. Examples are the membrane stiffness or the viscosity called the metering medium. Both require a share of driving force, the additional must be applied to the force generated by the action of the Working pressure on the membrane surface arises. These disturbances can be caused by Detection of their effect and readjusting the motor control compensated become. For an unregulated metering pump with a given engine speed, even if this itself is kept stable by means of regulation, remain such disturbances are disregarded. at Such an unregulated metering pump is moreover due to the sinusoidal characteristic the Exzentergetriebes an exact prediction of the current speed of the repressive organ without knowledge of the push rod position, ie the angle of rotation of the Eccentric, not possible.

Furthermore It is through the regulation of the movement by means of a position sensor possible, in contrast to the spontaneous dosing process with unregulated Operation to react to internal and external factors, which are described below and to ensure operating conditions with their help selected hydraulic Properties of the dosage specifically caused or avoided can be. As an example be aware of the function of protection described below Cavitation referred to when sucking.

In the following, for example, individual applications of a motor metering pump of the previously described type will be explained, which has a position sensor and draws conclusions about the operating state of the dosing by means of an evaluation of the position signal or by a control and modification of the motor control Movement of the membrane influenced.

recognition the position of the stroke length adjustment regulator

Dosing pumps according to the prior art often provide a mode in which the dosing strokes carried out over the set volume of the displacement chamber (stroke length) are converted directly into a metered total volume and this example is displayed as a volume flow in the unit l / h. For such functions, knowledge of the stroke length set by the operator is required since this depends on the volume metered per stroke. The position of the Hubverstelleinrichtung must be converted for this purpose in metering pumps of previous design by a separate sensor into an electrical signal and read into the controller. An example of a practical realization would be a linear potentiometer on Hubverstellorgan 7 , which scans its setting via a plunger.

A dosing pump using the integrated position sensor 36 can detect the actually worn membrane path during the stroke, requires no additional sensor. By subtraction of the two position values in the end positions, which can be measured after reaching the mechanical stop, as soon as the movement has come to a halt, the stroke length can be calculated directly and is available for further processing.

Detection of a blockage or an incomplete stroke

In prior art metering pumps without a position sensor, sensors are often used which emit a feedback pulse to the electronic controller for monitoring the metering movement per stroke. A known embodiment is, for example, a small permanent magnet, on the output shaft of the transmission, ie on the eccentric shaft 17 is mounted outside of the axis and rotates with this, in conjunction with a fixed Hall sensor that generates a signal when passing the magnet in a certain angular position of the eccentric shaft. Based on this signal, the electronic control measures the stroke period, which is identical to the cycle time of the eccentric shaft, and deduces from this a trouble-free sequence of the dosing process. In the event of a blockage in the course of the metering stroke due to an overpressure situation, for example in the case of an accidentally closed shut-off device in the metering line, the signal of the Hall sensor remains off and, after a monitoring period has elapsed, leads to a fault message and further reactions, eg stopping the metering pump. In such a conventional system, the desired information is available only after the expiry of the monitoring time.

When using a position sensor 36 can at any time of the metering stroke, the speed of the push rod 19 in relation to the control of the motor 2 can be set, and a blockade can be detected virtually delay.

slip compensation

Used as a drive motor 2 For example, an asynchronous motor used, the effective mechanical speed at the motor output shaft under load is always slightly smaller than specified by the frequency of the electrical control. The difference between the two speeds, the so-called slip, is dependent on parameters of the motor and within a reasonable load range approximately proportional to the load torque. The slip can be measured by various methods described below. From it, a correction value can be calculated, which can be included in the use of a frequency converter in the predetermined engine speed in the form of a frequency increase and thus compensated.

Of the Slippage can be achieved, for example, by comparing the measured stroke period determined by the predetermined by the electrical control become. This method is also used with dosing pumps according to the state the technique by measuring the time interval of two Hall sensor pulses applied. In the case of a metering pump with position sensor is to Period measurement a characteristic point along the stroke, e.g. midway, defined and in successive dosing operations respectively the date on which this point is passed; the time difference between two such times is the period of the search.

For motor metering pumps with position sensor 36 works a more direct method for slip detection with the observation of the instantaneous speed of the push rod 19 , From the predetermined by the electrical control motor speed can be calculated at any time an ideal push rod speed on the known transmission and eccentric characteristics. By comparing the ideal and the measured speed, the slip can be determined at any time during the eccentric revolution and corrected by readjusting the frequency of the motor control.

pressure detection

If, for example, an asynchronous motor is used, it can be described using one of the previously described NEN determined methods determined by the force acting on the displacer force and thus made a conclusion on the working pressure of the metering medium. However, it should be noted that the eccentric on the push rod 19 acting force according to its sinusoidal characteristic depending on instantaneous angular position via the gearbox 11 to the engine 2 transfers. In the two dead centers, ie the turning points of the lifting movement, the motor is decoupled from the push rod force, ie load-free, in the two points exactly in between the eccentric transmits the load torque maximum to the engine. Accordingly, assuming a constant push rod force, the torque to be applied to the motor output shaft and thus also the slip will approximate to a sine function. The fluctuation range is an image of the push rod force.

If, as described above, the deviation of the stroke period from the ideal value is determined, this represents the slip averaged over the sinusoidal curve of the eccentric, which in turn represents a measure of the average stroke rod force, ie the working pressure. If the slip continuously determined from the comparison of the predetermined by the electrical control motor speed with the push rod speed, using the known eccentric and the knowledge of the instantaneous angle of rotation of the eccentric, which follows from the push rod position, the temporal force curve on the push rod 19 be calculated. From the force curve at the push rod, in turn, the working pressure can be derived.

Becomes the deflection mechanism realized by a solution other than an eccentric, whose characteristic is analogously applicable to what has been said.

Pressure limitation, detection of pressure loss

Becomes the working pressure is determined according to one of the described methods, it can be monitored for compliance with certain limits, and on response the surveillance can Fault messages and further reactions such as e.g. Shutting down the dosing pump to be triggered. A surveillance to exceed limit can be used to protect the pump or other equipment components; Occasionally, a factory preset limit of e.g. 130% the maximum pressure of the dosing pump is monitored for overshoot the monitoring limit However, within the specified workspace, the Metering pump lie when e.g. more sensitive plant components are protected should be specified by the operator in this case. It is also possible a surveillance maintaining specified operating conditions; in this case will be a fault message e.g. then triggered if a once predominant and (for example, by an operator) reference pressure is a percentage changed up or down. If the working pressure is set to maintain a minimum pressure of e.g. 1 bar monitored, is it possible to detect a leak caused by damage in the piping was caused.

pressure compensation

Depending on the version, the exact dosing capacity of motor metering pumps is influenced differently by the working pressure. For one, the drive motor works 2 if, for example, it is designed as an asynchronous motor, with increasing working pressure with increasing slip, which results in a speed drop and an associated reduced stroke frequency. On the other hand experiences a used as a displacement member membrane 13 during the metering stroke an elastic deformation under the influence of the working pressure. At the beginning of the metering stroke is in the dosing 16 with the exhaust valve still closed 15 the internal pressure is continuously increased by the diaphragm core 30 through the push rod 19 under build up of pressure in the dosing chamber 16 is moved into and the elastic Walk region of the membrane 13 to the same extent the pressure yielding in opposite directions to the movement of the membrane core 30 recedes. The membrane 13 deforms in itself, but in the sum there is virtually no change in volume, which is due to the fact that the metering medium is virtually incompressible and at this time both valves are closed. At the end of this deformation phase, the chamber pressure corresponds to the external working pressure. The so far covered path of the push rod 19 corresponds to the amount of membrane deformation, ie the dead zone at the beginning of the dosage, and practically does not contribute to the dosage. The deformation or the dead zone typically moves in a range of about 0.1-0.5 mm depending on the diaphragm size, working pressure, etc. At the point of pressure equilibrium, the pressure-side outlet valve opens 15 , Now it's on the membrane 13 acting pressure virtually identical to the external working pressure and remains, as well as the membrane deformation, for the remaining part of the metering approximately constant. The point of pressure equilibrium at which the pressure-side outlet valve opens marks the actual beginning of the metering so that the amount of membrane deformation is lost to the metering stroke, ie the effective stroke length is calculated from the mechanically predetermined minus the membrane deformation. Since the membrane deformation itself increases more or less proportionally with the working pressure, the typical dependency is a falling metering performance curve with increasing working pressure. He himself giving negative deviation is the more significant, the smaller the set stroke length.

In a motor metering pump according to the prior art, the dosing is not only pressure-dependent, but also in Teilhubbetrieb not strictly proportional to the set mechanical stroke length. Rather, the effective metering on stroke only begins after an initial dead zone from the point of complete membrane deformation with the opening of the exhaust valve 15 , If one plots a characteristic which shows the metering power as a function of the set mechanical stroke length, a linearly rising curve results, which only after a minimum stroke length corresponding to the dead zone of x _T1 , x _T2 , x _T3 ... X _{Tn is} a real metering performance has (s. 12 ). Since this minimum stroke length corresponds to the membrane deformation, it is also dependent on the working pressure p ₁ , p ₂ , p ₃ ... P _n .

This characteristic shift x _T1 , x _T2 , x _T3 ... x _Tn requires prior art recalibration under real working conditions as soon as the previously set stroke length is significantly changed, since the new dosing with sufficient accuracy via a proportional conversion from the previous and the newly set stroke length can be determined.

Becomes the working pressure is determined according to one of the previously described methods, Is it possible, based on the described dependencies, the in preliminary tests for a device type can be determined quantitatively the error-generating influence of the working pressure on the dosing capacity to predict and compensate. For this purpose, based on the determined Working pressure and the set stroke length, which, as described above, can also be measured using the position sensor the known error dependence calculates a correction value, which added to the set stroke frequency becomes. It should be noted that under practical and economic Aspects only the systematic part of the influence can be eliminated can. The pressure-dependent Dosing performance error is mainly due to material properties and Dimensions of the involved components determined, which in some Measure through Change aging can or specimen discrepancies in the production series. These Variations are made by the method described here the membrane deformation induced errors using predefined, derived from component parameters or determined in measurement series To correct values, not taken into account; rather would have at regular intervals or at each stroke on the present device specimen the concrete conditions be re-measured metrologically.

Becomes the defect-causing influence of membrane deformation as previously described compensated by the working pressure according to one of the previously described Methods are determined and the set stroke frequency by a correction value is adapted, so is the proportional error in Teilhubbetrieb eliminated, so that the metering pump practically over the full usable adjustment range of stroke from e.g. 20% -100% can be operated without the previously necessary recalibrations carry out to have to, the at a conventional Dosing pump with an adjustment of the stroke length by more than e.g. 10% necessary are to ensure the specified dosing accuracy.

avoidance of flow losses for high-viscosity media

The function, the speed of the displacer, here the membrane 13 , to regulate, especially with highly viscous media (eg lecithin) can be used to limit flow losses in valves and other bottlenecks. High flow rates have a negative influence on the dosing accuracy in such media by additional pressure losses due to flow resistance. In addition, it is advantageous here if the limited speed allows more time for the defined opening and closing of the valves. Overall, both effects improve the dosing accuracy of highly viscous media. To achieve this, the membrane velocity is kept limited to a selectable maximum value during the entire dosing process. This maximum speed depends, inter alia, on the viscosity of the specific medium to be metered and is to be selected by the operator or specified directly in the form of several predefined values adapted to common applications. By means of the position sensor and the above-described control of the speed of the displacer, the desired limitation of the membrane velocity can be ensured.

cavitation

In slightly outgassing media (such as sodium hypochlorite) cavitation may occur especially when sucking, but also in Dosierhub at too high flow velocity at bottlenecks by locally falling below the vapor pressure, inter alia, on the chemical composition of the metering and its temperature depends, the increased wear Episode has. Cavitation can be avoided by both the pressure stroke and during the suction, ie the return of the membrane 13 , the speed is limited by regulation or by simple speed setting to values well below a critical flow velocity. The Geschwin For this purpose, the engine speed is set in such a way that the membrane speed corresponding to the medium speed is limited to, for example, 1 mm / 50 ms.

Especially the suction process is for the formation of cavitation prone, since here the static Pressure is particularly low and therefore the security area up falls below the vapor pressure very low. For a refinement The method therefore makes sense, the membrane velocity in Suction to lower values than to limit in the pressure stroke. meaningful Values are, for example, 1 mm / 50 ms in the compression stroke or 1 mm / 100 ms while of sucking, however, are natural also different values possible. Essential for One such individual treatment of dosing is that using the position sensor the exact position of the membrane at any time and thus the beginning of the (especially critical) intake phase reliably detected can be.

electronic Stroke length

The invention makes it possible, the mechanical device for stroke length adjustment (adjusting 7 and Hubverstellbolzen 8th ) save. For this purpose, the control device, the desired stroke length electronically, eg by an operator input, communicated. When the desired stroke length has been carried out, the position of the diaphragm is reached 13 by slowing down the engine 2 held and these are then returned to the intake with reversed direction of rotation of the engine. The following stroke can be carried out by further rotation of the engine beyond the suction-side dead center with a reversed direction of rotation (printing phase in reverse operation, suction in normal operation) or in the same order as the previous stroke; in the former case, deceleration and starting operations of the engine between the strokes and the associated time and energy requirements can be saved. It should be noted that the permanent change of direction makes it impossible for a passive fan fixedly mounted on the motor shaft to fulfill its function sufficiently, so that the use of an externally driven fan is indispensable for the motor if it requires cooling measures.

slowly dosage to avoid concentration fluctuations

For use cases, at which requires good mixing with a process medium stream, is one possible even introduction of the Dosing medium required in the process. Certain applications also require the option smallest subsets over distributed as long as possible to dose evenly, with which a quasi-continuous dosage should be achieved. For this Cases become used in the prior art Motor Metering pumps, the e.g. work with a stepper motor and a self-locking gearbox. A total stroke is performed reduced speed at these metering pumps or divided into several sub-steps with intermediate pauses, at the end of the total stroke becomes a complete (fast) intake phase executed and then continue the dosing in the manner described.

In the case of a motion-controlled motor metering pump, the available time, which results from the repetition frequency of the metering strokes, can be divided so that the portion remaining after deduction of the suction duration is utilized to a maximum for the forward movement, except for a short rest phase. The speed to be controlled is calculated from the distance to be traveled (set stroke length) and the available time. In contrast to a prior art metered-dose pump, when using a position sensor 36 and a control device from the known at any time position of the push rod 19 the instantaneous angular position of the eccentric gear is recalculated and calculated into the engine speed so that the characteristic of the deflecting device, which is sinusoidal when using an eccentric, is compensated and the metering stroke can be carried out as an exactly linear movement with correspondingly constant application of the metering medium. The speed can be in a very wide range of eg 1 mm / min to 1 mm / s and beyond.

The previously described uses the position sensor z.T. along with a scheme show that through the use of a position sensor e.g. at the push rod while the entire lifting and suction the exact position of the displacement element detected and monitored can be. The situation assessment and monitoring leads to that situational tax rules that describe the described Lead to benefits, be exactly maintained by means of the actual value measurement.

position sensor

As already stated, serves as a reference element for the position sensor in the described embodiment, the shadow edge 35 on the push bar 20 for scanning the position whose shadow is on the line of CCD cells 32 (CCD = charged coupled device) is mapped. The active sensor elements described in more detail in this embodiment, which detect the position, are on the side facing the dosing of the push bar 20 arranged. As a light source 33 serves an LED, the optical receiver is an electronic component with a CCD line 32 , which together here on an intermediate part, the sensor carrier 31 , are mounted. The mounting on the sensor carrier 31 allows the position sensor 36 to be treated as an independent module in the production process and, for example, to be pre-assembled separately and tested in its function outside the final installation site. In addition, the described photocell-like arrangement is a touch and thus wear-free working sensor.

For the basic mode of operation is the location of the sensor in the moving unit from push bar 20 and push rod 19 irrelevant, the relevant determination can rather be made according to structural considerations such as space, assembly order, etc. Moreover, the parts described here as fixedly mounted (light source 33 , Receiver 32 ) and those that move together with the push rod (shadow edge 35 ), also change their function.

The CCD module 32 is driven in the embodiment of an evaluation unit that contains a microprocessor and generates the required control signals. Instead of a microprocessor, the evaluation unit can also be realized by a DSP (Digital Signal Processor) or in discrete technology.

As a light source 33 is in principle any component suitable, which has a sufficiently narrow confined spot. Together with the in 7 this imaging geometry determines the width of the shadow area SV, s. also 8th ,

As a light source 33 It is also possible to use a plurality of elements or a line emitter, with the aid of which the shadow profile SV can be specifically designed according to specific aspects. As an example, the achievement of a higher brightness, without affecting the image sharpness in the direction of movement.

The CCD line 32 is a linear array of M optical receivers (hereinafter called pixels) arranged in a regular raster R of several μm. In the example, these are 128 pixels in the grid of about 64μm on a total length of about 8mm, ie M = 128 and R = 64μm.

The control signals generated by the evaluation unit determine the exposure time during which the individual pixels of the CCD line 32 integrate the incident light in each case in a separate measuring amplifier within the CCD module and buffer it for later evaluation. This integration occurs not only over the exposure time, but also across the photosensitive area of each pixel. After the exposure, the brightness values belonging to the pixels are successively read out of the CCD module by further control signals as analog values and detected by the evaluation unit.

exposure and readout of the brightness values take place alternately in the simple case instead of. Depending on the design, some commercially available CCD line components are available also possibilities for a Simultaneous execution of both processes by using the integrated Store measured values after exposure and the integrators immediately back for release a subsequent measurement. By simultaneous reading the results of a measurement run during the exposure phase for the following passage can be increased so the measuring speed.

Im in 8th 2, the integrated brightness values H are shown corresponding to the actual shadow progression in the area of the addressed pixels in the specific exemplary embodiment. The shadow area SV extends over the pixels # 60 to # 63 in this example.

As a simple evaluation method, a decision threshold H _V (in 8th shown as a dashed line) arbitrarily set at, for example, half of the maximum brightness and searched for that pixel whose brightness value H at the shadow transition first _falls below the threshold H _V ; in the example this would be Pixel # 62.

In other embodiments, the brightness profile may be in opposite directions from unlit to illuminated CCD cells with increasing pixel number; On the one hand, this depends on the arrangement of the elements of the light source 33 , CCD module 32 and shadow bodies 35 and on the other hand, the internal organization of the CCD used 32 , In this case, the pixel whose brightness value at the shadow transition exceeds the threshold first is searched for.

To Sequence of the three phases exposure, readout and processing is a position value. The total time requirement of the three phases determines the Repetition frequency at which position values are obtained. The measurement resolution is equal to the pixel raster R of the CCD line, corrected for the imaging ratio A, which is the assembly distance with the individual components results.

s

= Tatsächliche Bewegung der Schattenkante

s'

= Projizierte Bewegung der Schattenkante in der Ebene des CCD

x₂

= Abstand zwischen optisch wirksamer Schattenkante und Lichtquelle

x₃

= Abstand zwischen CCD-Ebene und Lichtquelle

For the imaging ratio A (cf. 9 ): A = s' / s = x 3 / x 2 Here is

s

= Actual movement of the shadow edge

s'

= Projected movement of the shadow edge in the plane of the CCD

x ₂

= Distance between optically effective shadow edge and light source

x ₃

= Distance between CCD plane and light source

This method determines the position by counting pixels, so it is to be regarded as a digital method. Deviations and displacements of linear parameters such as component sensitivities have practically no effect on the result compared to analogous methods. If the imaging ratio A is determined for practical values, assembly tolerances also have only a small influence. In a practical embodiment with x ₃ = 21 mm and x ₂ = 20 mm results in a nominal value for the imaging ratio A of 1.05; ie a movement of the shadow edge 35 by a certain distance gives a 1.05-fold shift of the shadow area SV in the plane of the CCD cells 32 , Assume now a mounting tolerance for x ₃ , ie a possible variation of the distance of the CCD cells 32 from the light source 33 ± 0.3mm, and a concrete mounting case at the top of this tolerance range with x ₃ = 21.3mm and x ₂ = 20mm. In this case, the imaging ratio A is calculated to be 1.065. The imaging ratio changes by 1.065 / 1.05 = 1.014 or + 1.4% in this example. This deviation can easily be eliminated by a one-time calibration, eg during production. The linearity is determined almost exclusively by the accuracy of the pixel grid within the chip geometry, deviations are thus negligible.

Although the previously described method for determining the position of the shadow edge 35 and thus the position of the membrane 13 Already results in very accurate and linear position values, an even more accurate position resolution can be achieved by interpolation. In this extended embodiment, a position resolution is achieved by evaluating the pixel brightnesses H, eg between pixels 61 and 62 (Comp. 10 ), which is finer than the pixel raster R, by interpolating the brightness values of the pixels in the region of the decision threshold. The goal is to determine the point at which the brightness curve intersects the decision threshold H _V and to assign this point of intersection a value on a virtual position scale whose x-values in the middle of the pixel correspond exactly to the pixel number.

For this purpose, the two pixels to the left and to the right of the decision threshold H _{V are} searched for and the distances ΔH of the associated brightness values are evaluated from this threshold. As in 10 or in 11 represented, applies: AH l = H l - H V AH r = H r - H V

The distances .DELTA.x calculated from the respective center axis of each of the two adjacent pixels, in this example pixels # 61 and # 62, in multiples of the pixel width to the intersection form the following relationship with the brightness distances .DELTA.H relative to the pixel # 61 to the left of the searched intersection (left-side neighboring pixel): Ax l / (Ax l + Δx r ) = ΔH l / (AH l + ΔH r )

With (Δx _l + Δx _r ) = 1 (1 pixel width) results Ax l = ΔH l / (AH l + ΔH r )

Relative to the pixel # 62 (right-hand neighboring pixel) on the right of the desired intersection, the relationship applies: Ax r / (Ax l + Δx r ) = ΔH r / (AH l + ΔH r )

With (Δx _l + Δx _r ) = 1 (1 pixel width) the result is: Ax r = ΔH r / (AH l + ΔH r )

In In this example, the intersection point is 61.7. Follows Brightness curve in the interpolation range of an ideal line, so lead both calculation paths to the same result, so it is sufficient in principle, to carry out one of the two calculations. aid this property can however error contributions by a not exactly straight brightness curve in the considered transition range or be minimized by always expected measuring inaccuracies, for example, by performing both calculations and averaging their results become.

at other versions can depending on the brightness gradient, the conditions on both sides of the point of intersection in terms of unlit and illuminated CCD cells to be reversed; in this Case change the direction information left and right if necessary their function and the interpolation equations are corresponding adapt.

In addition, other embodiments are possible in which the brightness values of more as two pixels are used for the calculation. The position can then be formed by redundant multiple calculation and, for example, averaging of several results. As a further possibility, a different linear interpolation than shown here or an interpolation with the data other than the direct neighbor pixels can be used.

deviations and displacements of linear parameters, e.g. components sensitivities affect the result only within the interpolation range out. The steepness of the brightness gradient in the shadow transition, as a result of the sharpness of the Shadow edge mapping to the CCD plane is child Meaning, because of the interpolation within wide limits not impaired becomes; only the linearity the brightness gradient is for the accuracy of interpolation is crucial.

Independent of The previously described interpolation method can be described on the Basic principle building on further methods for improving the sensor properties be used. These methods are described below:

• Improvement of the interference immunity by filtering

The Noise immunity of the sensor can by filtering action be improved. Filtering can be done both at the level of brightness values the pixel as well as the result of the position determination itself be applied. In the first case, the method works with brightness values, the above several pixels or over several passes In the second case, several are determined first Position results combined to a derived position value, with which then the further processing is made.

• Compensation of mounting deviations

In a defined phase, e.g. in the resting phase before the end of the actual Dosierhubs, the position value for this phase can be determined and stored in a reference memory. During the active movement phase then the position values relative to the previously determined Reference value processed. By this method, it is possible production-related Mounting deviations of the rest position and shifts during the Operating e.g. by thermal expansion compensate automatically and thus improve the accuracy.

• Compensation of scaling errors

at An extended alternative can be achieved by starting two or more known positions, here called reference positions, the scaling of Position sensors are compensated. This can be unique in the course of the production or testing procedure or recurring in operation.

in the first case can the reference positions by external devices, e.g. detent positions or external measuring devices. Out of those in these Reference positions measured position values can together with of knowledge about the actual position of the reference positions a correction value for the scaling derived from the position sensor and for further processing get saved.

in the The second case of recurrent scaling adjustment is known Positions, e.g. mechanical stops or reference signals from Further existing devices for position detection necessary. Is the membrane during the Operating on such a known position, can from the on this If the measured position value is also a correction value for the scaling derived from the position sensor and for further processing get saved.

• Compensation of the optical sensitivity parameters

In an extended version can the brightness values of the fully illuminated pixels are used be a representative Value for the illuminance to investigate. For this purpose, for example, from a suitable group of pixels the mean of the brightness are formed. Based the determined illuminance the exposure can be controlled so that the available Value ranges are optimally utilized; for example, the Light source in their brightness or their duty cycle so controlled be that the illuminance the fully lit pixels just below the overdrive limit of the CCD module is located. During each measurement, the illuminance is then determined the circumstances of the previous passage corrected so that a sliding Adjustment of the exposure parameters to possible changes of Component properties, e.g. due to aging.

• Compensation of contamination and pixel deviations

In an expanded embodiment, the mechanical structure of the sensor can be designed so that in a defined phase, for example in the idle phase before the actual dosing stroke, the entire pixel area used for the working path or an interesting partial area can be exposed. One possible implementation is, for example, one of Membrane-facing shadow edge 35 used for the evaluation, whereby the shadow edge in the course of the stroke movement sweeps over the sensor and darkens a portion of the CCD cells, which was illuminated in the previous resting state. In this phase, the brightness values of all relevant pixels can be determined and stored individually in a reference memory. Deviations of the measured values of individual pixels from the ideal value can, for example, be stored in the form of correction values. During the active movement phase, the brightness values of each pixel are then first corrected with the aid of the previously determined reference values for each measurement and only then further processed. By this method, it is possible to compensate for manufacturing-related sensitivity deviations of individual pixels and contamination in a certain scope and thus to improve the accuracy and to increase the reliability.

Of course they are for the CCD receiver line too two- or multi-row arrangements possible to redundancy one increased Security against failures, e.g. by pollution, or by averaging the Increase measurement accuracy. For special size stroke can two or more CCD lines are combined to set the measuring range over the Extend the functional limits of a single line.

The in the embodiment described in detail motor metering pump can in some areas and arrangements of components such as the engine, the transmission, the Eccentric drive and other construction details of other variants differ. It is essential, however, that the oscillating motion, which is generated by a drive, scanned by means of a position sensor is, wherein the position sensor outputs an actual signal, which for Position of the reference element and thus also to that of the displacement element is in a committed relationship, so using that value Knowledge about the movement of the repressive organ is won.

1

eccentric housing

2

engine (Asynchronous motor)

3

housing ribs

4

baseplate

5

housing cover

6

electronics in the housing cover

7

adjusting

8th

Hubverstellbolzen

9

cover

10

control lines

11

transmission (Speed reducer)

12

dosing

13

membrane

14

intake valve

15

outlet valve

16

metering

17

eccentric shaft

18

longitudinal axis

19

pushrod

20

push handle

21

Contact surface for eccentric

22

excenter

23

compression spring (Return spring)

24

bearing disk

25

Federation for compression spring

26

Rifle in bearing disc

27

Rifle in Hubverstellbolzen

28

electronics housing

29

Power switching stages for the motor Controller

30

diaphragm core

31

sensor support

32

Receiver, CCD module

33

light source

34

control electronics

35

shadow edge as a reference element

36

position sensor

37

differentiator

38

Setpoint

39

Target-performance comparison

40

PID controller

41

Position correction

42

amplifier

SV

shadow History

H

brighter Area

d

dark Area

# 58 ... # 65

 cell (Pixels) of the CCD

H

brightness values the pixel

H _V

brightness the comparison threshold (VS)

H _l

brightness of the pixel to the left of the intersection with the VS (left-hand neighbor pixel)

ΔH _l

brightness distance of the left-side neighboring pixel to the brightness value of the comparison threshold

H _r

brightness of the pixel to the right of the intersection with the VS (right-hand neighbor pixel)

ΔH _r

brightness distance of the right-hand neighboring pixel to the brightness value of the comparison threshold

Δx _l

position distance the center line of the left-side neighboring pixel to the intersection with the VS

Δx _r

position distance the center line of the right-hand neighbor pixel to the intersection with the VS

x ₁

distance between shadow edge and CCD plane

x ₂

distance between shadow edge and light source

x ₃

distance between the CCD plane and the light source

p ₁

Working pressure p ₁

p ₂

Working pressure p ₂

p ₃

Working pressure p ₃

p ₄

Working pressure p ₄

x _T1

Dead zone at working pressure p ₁

x _T2

Dead zone at working pressure p ₂

x _T3

Dead zone at working pressure p ₃

x _T4

Dead zone at working pressure p ₄

s

actual Movement of the shadow edge

s'

projected Movement of the shadow edge

D

Dosing capacity

HL

mechanical stroke

SG

manipulated variable

KSG

corrected manipulated variable

MA (U, F)

motor Controller (Voltage frequency)

k1

factor for the position-dependent position correction

k2

factor for the power amplifier

k3

factor for the Derivation of the speed signal

x _S

setpoint the position of the displacement element

x _I

actual value the position of the displacement element

Claims (29)

Dosing pump with rotating drive motor and oscillating displacer, in which the rotational movement of a drive motor ( 2 ) by acting as a gear arrangement in an oscillating movement of a push rod ( 19 ) is reacted, so that a displacer operated by this with continuously rotating drive motor ( 2 ) performs an oscillating linear movement, which in one in the longitudinal axis of the push rod ( 19 ) arranged dosing ( 12 ) in interaction with an outlet and inlet valve in an alternating sequence to a pumping stroke (pressure stroke) and a suction stroke and thus to a promotion of the metering medium, characterized in that with the push rod ( 19 ) a reference element ( 35 ) whose position is determined by a position sensor ( 36 ) is scanned, which operates on a non-contact principle, with the push rod ( 19 ) related reference element ( 35 ) and the position sensor ( 36 ) are arranged outside the dosing and the position sensor outputs an actual signal (x _I ), which is in a fixed relationship to the position of the reference element and thus of the displacement member and with the aid of which knowledge about the movement of the displacement member is obtained, so that the electronic Controlling the metering pump can respond to operating conditions of the dosing circuit and the pump. Dosing pump according to one or more of the preceding claims, characterized in that the reference element ( 35 ) the beam path of a light source ( 33 ) and the co-operating position sensor ( 36 ), which is fixedly mounted in the pump housing or other stationary part, works according to a photosensitive receiver principle. Dosing pump according to one or more of the preceding claims, characterized in that the reference element ( 35 ) is a shadow body or a shadowing contour and the position sensor ( 36 ), which is fixedly arranged in the pump housing or on any other stationary part, from an optical receiver ( 32 ) in the form of a series lichtemp-sensitive charge-coupled receiver cells consists (charged coupled device, called CCD for short). Dosing pump according to one or more of the preceding claims, characterized in that the position sensor ( 36 ) on its own sensor carrier ( 31 ) is arranged, which is fixedly connected to the pump housing or other stationary part. Dosing pump according to one or more of the preceding claims, characterized in that the light source ( 33 ), the shadow body or the shadowing contour ( 35 ) and the recipient ( 32 ) represent a light barrier-like arrangement and the measured values are continuously or cyclically fed to the electronic control. Dosing pump according to one or more of the preceding claims, characterized in that the optical receiver ( 32 ) of the position sensor ( 36 ) consists of a number of linearly arranged receivers (pixels), preferably 128 pixels. Dosing pump according to one or more of the preceding claims, characterized in that the light source ( 33 ) is a light-emitting diode (LED), which is opposite to the optical receiver ( 32 ) of the position sensor ( 36 ) is arranged, that their light beams on the direct way to the receiver by the push rod ( 19 ) is not hindered. Dosing pump according to one or more of the preceding claims, characterized in that the output value of the position sensor ( 36 ) is formed by interpolating the brightness values of a plurality of pixels lying in the shadow transition region. Dosing pump according to one or more of preceding claims, characterized in that during the processing of the signals of the position sensor ( 36 ) Filter measures are used. Dosing pump according to one or more of the preceding claims, characterized in that zero position error of the position sensor ( 36 ) are eliminated by means of a reference memory. Dosing pump according to one or more of the preceding claims, characterized in that scaling error of the position sensor ( 36 ) are eliminated by approaching one or more reference positions. Dosing pump according to one or more of the preceding claims, characterized in that exposure fluctuations of the position sensor ( 36 ) by a control or regulation of the light source ( 33 ) are compensated on the basis of the obtained brightness values of the pixels. Dosing pump according to one or more of the preceding claims, characterized in that brightness fluctuations between individual pixels of the optical receiver ( 32 ) can be compensated by including a reference memory for the sensitivity of each pixel. Dosing pump according to one or more of the preceding claims, characterized in that the detection to which value the Hubverstellorgan ( 7 ) is set by measuring during dosing directly via the position sensor ( 36 ) he follows. Dosing pump according to one or more of the preceding claims, characterized in that the electronic control by evaluation of the position sensor signal ( 36 ) detects a blockage of the displacement element or an incomplete stroke. Dosing pump according to one or more of the preceding claims, characterized in that the drive motor ( 2 ) operates on a slip-prone principle, for example, by an asynchronous motor is used, and the electronic control of the predetermined by the control target speed of the drive motor and the known transmission characteristics a Sollhubfrequenz or Sollhubperiode for the displacement member determined and additionally by evaluation of the position sensor signal ( 36 ) detects the actual stroke frequency or the actual stroke period of the displacement member, wherein it calculates the slip of the drive motor by comparing the actual stroke frequency with the Sollhubfrequenz or the actual stroke period with the Sollhubperiode the displacement member and its target speed changed so that the displacement member ultimately with the desired stroke frequency moves. Dosing pump according to one or more of the preceding claims, characterized in that the drive motor ( 2 ) operates on a slip-prone principle, for example, by an asynchronous motor is used, and the electronic control of the predetermined by the control target speed of the drive motor and the known transmission characteristics a Sollhubfrequenz or Sollhubperiode for the displacement member determined and additionally by evaluation of the position sensor signal ( 36 ) detects the actual stroke frequency or the actual stroke period of the displacement member, wherein it calculates the slip of the drive motor by comparing the actual stroke frequency with the Sollhubfrequenz or the actual stroke period with the Sollhubperiode the displacement member and further the electronic control of the thus determined slip of the drive motor and the known transmission characteristic determines the force acting on the displacement member and so makes a conclusion on the working pressure of the metering. Dosing pump according to one or more of the preceding claims, characterized in that the drive motor ( 2 ) operates on a slip-prone principle, for example, by an asynchronous motor is used, and the electronic control determined from the predetermined by the control target speed of the drive motor and the known transmission characteristics for each moment of the metering a target speed for the displacement member and additionally by evaluating the position sensor signal ( 36 ) detects the actual speed of the displacement element, and it calculates the current slip of the drive motor by comparing the actual instantaneous speed with the desired speed of the displacement member and, in turn, in conjunction with the known transmission characteristic, on the current force curve on the displacement member closes. Dosing pump according to claim 18, characterized in that that the electronic control of the observed force curve on the repressive organ a conclusion on the working pressure of the dosing medium makes. Dosing pump according to claim 17 or claim 19, characterized in that the electronic control detects from the determined working pressure of the dosing an operation outside the specified pressure range and the dosage when exceeding a by the specification of the metering pump or by a user set given maximum allowable pressure or falls below a predetermined minimum pressure. Dosing pump according to claim 17 or claim 19, characterized in that the displacement member is a partially elastic membrane ( 13 ) is, in which the electronic control from the determined working pressure of the metering and the known dependence of the metering of the working pressure determined an expected metering error and the speed of the drive motor ( 2 ) and thus the stroke frequency influenced so that this expected dosing error is counteracted. Dosing pump according to one or more of the preceding claims, characterized in that the from the position sensor ( 36 ) read out signal (x _I ) for the position of the push rod ( 19 ) via a control loop within its control accuracy, the speed of the drive motor ( 2 ) and as a result, the linear movement of the push rod and thus of the displacement member is influenced so that it corresponds to a predetermined setpoint profile ( 38 ) follows. Dosing pump according to claim 22, characterized in that the control device alternatively the position (hereinafter called x _I ), the speed ( _hereinafter called v _I ) or the acceleration of the displacement member via a control device by changing the rotational speed of the drive motor ( 2 ). Dosing pump according to claim 22, characterized in that the control device v _{I of} the displacement member in the suction phase and / or in the pressure phase can selectively reduce to counteract pressure losses caused by flow resistance, or the emergence of cavitation. Dosing pump according to claim 22, characterized in that the desired stroke length communicated by an operator specification of the control device and the movement of the displacement member is electronically limited by the control device to the stroke length to be executed by the control device, the drive motor ( 2 ) stops after executing the desired stroke length, switches to the reversing mode and then carries out a suction stroke and then stops the motor or carries out the subsequent pressure stroke. Dosing pump according to claim 22, characterized in that the control device, the forward movement of the displacement member during the printing phase by driving the drive motor ( 2 ) So distributed to the predetermined by the repetition frequency of the metering strokes time that the application of the metering medium as evenly as possible, up to very slowly running Dosierhüben of eg a few minutes. Dosing pump according to claim 18, characterized in that the displacement member is a partially elastic membrane ( 13 ) and the electronic control from the momentary force on the membrane ( 13 ) the opening of the exhaust valve ( 15 ) recognizes and by means of this observation the dead zone, due to the elastic deformation of the membrane ( 13 ) arises, measures. Dosing pump according to claim 27, characterized in that the actually executed stroke is influenced depending on the determined membrane deformation by the control device, the drive motor ( 2 ) after executing the desired stroke length from the opening of the exhaust valve ( 15 ) stops, switches to the reversing mode and then performs a suction stroke and then stops the engine or performs the subsequent pressure stroke, so that caused by the membrane deformation error contribution (based on the stroke away or the metered volume) eliminated and so the Dependence of the dosing amount is significantly reduced by the back pressure. Metering pump according to claim 27, characterized in that the actually executed stroke frequency is influenced as a function of the determined membrane deformation by the control device determining a correction value for the error caused by the membrane deformation error contribution (based on the stroke or the metered volume) and the target speed of the drive motor ( 2 ) using this correction value to eliminate the error contribution caused by the membrane deformation.