The present invention relates to an apparatus and method for controlling fluid flow.
Devices that control both negative (vacuum) and positive (pressure) fluid flow are known in the prior art. Such devices typically include a bi-directional pump, such as a diaphragm pump, having both a pressure port and a vacuum port. The pump includes a plurality of internal, mechanical valves (usually flap type) that cyclically open and close to create sustained negative fluid flow at the vacuum port and sustained positive fluid flow at the pressure port.
To control bi-directional fluid flow through a common utility port, it is known to connect the pressure and vacuum ports of the pump to a second mechanical valve, which selectively connects in fluid communication the common utility port with one of either the pressure or vacuum ports of the pump. The valve is controlled by an operator to selectively create either vacuum or pressure at a downstream utility port. An operator may control the valve by, for example, depressing one of either a positive or negative pressure trigger. An example of a bi-directional, fluid-flow device is a laboratory pipetting device that admits and emits fluid to a disposable pipette.
The present invention provides an apparatus for controlling fluid flow. In a preferred embodiment, the invention controls bi-directional fluid flow through a utility port by synchronizing movement of a single, electrically-actuated control valve with the alternating phases of a pump. An embodiment of the invention comprises a pipetting device for admitting and emitting fluid from a disposable pipette.
In one embodiment, the bi-directional, fluid-flow control device generally comprises a utility port, a bi-directional pump, an electrically-controlled valve, a detector, and a controller. The controller is connected to the detector and the valve. The user activates the device using a user interface connected to the controller.
The pump produces bi-directional fluid flow at a common port and operates in a continuous pump cycle having a pressure phase and a vacuum phase. A conduit connects the common pump port to the utility port. In one embodiment, the pump includes a reciprocating volume-displacement element that creates positive air pressure during one half of the pump cycle and creates negative air pressure during the other half of the pump cycle.
The electrically-controlled valve regulates air flow through the conduit. The valve operates between a first position isolating the pump and the utility port, and a second position connecting the pump and the utility port in fluid communication. In a preferred embodiment, the valve comprises a three-way solenoid valve having a common port connected to the pump, a normally-open (NO) port vented to the atmosphere, and a normally-closed (NC) port connected to the utility port. The valve connects the NC port and the common port in fluid communication in the second position and connects the NO port and the common port in fluid communication in the first position. In an alternative embodiment, the valve comprises a first, electrically-actuated, two-way valve controlling fluid flow through the conduit, and a second, electrically-actuated, two-way valve controlling fluid flow from the pump to the atmosphere.
The detector continuously detects and communicates a signal identifying whether the pump is operating in the pressure or vacuum phase of the pump cycle. For example, the detector may comprise a photosensor that detects movement of the volume-displacement element or other cyclically-moving element of the pump. Alternatively, the detector may comprise an ultrasonic sensor that detects movement of the volume-displacement element.
The controller uses the detector signal to synchronize actuation of the valve with the pump cycle to generate either continuous positive or continuous negative pressure at the utility port. Negative pressure is generated at the utility port by cyclically actuating the valve to the second position during the negative pressure phase and then actuating the valve back to the first position during the pressure phase. Positive pressure is generated at the utility port by cyclically actuating the valve to the second position during the pressure phase and then actuating the valve back to the first position during the vacuum phase of the pump cycle.
In a further embodiment of the invention, the device includes means for controlling the flow rate through the utility port. In this embodiment, the controller changes the length of time the valve is actuated to the second position during either phase of the pump cycle.
In yet another embodiment of the invention, the device includes means for controlling the flow of a measured volume (V) of fluid through the utility port. In this embodiment, the volume displacement per stroke (DPS) of the pump is either calculated or experimentally determined and programmed into the controller. The controller calculates and operates the pump for a calculated number (N) of pump cycles based on the DPS of the pump. In this embodiment, the device may include a sensor that measures the head pressure at the utility port and communicates the head pressure to the controller. The controller uses the head pressure to calculate more accurately the number (N) of pump cycles needed to meet the predetermined required volume.
The invention also provides a method of controlling positive and negative fluid flow through a utility port. In accordance with the method, a fluid flow source is provided that cyclically produces positive and then negative fluid pressure during a pressure phase and then vacuum phase, respectively, of a repeating cycle. The source is continuously detected to determine whether the source is operating in the pressure phase or vacuum phase. To produce positive fluid flow through the utility port, the fluid flow source is connected in fluid communication with the utility port during the pressure phase and isolated from the utility port during the vacuum phase. To produce negative fluid flow through the utility port, the fluid flow source is connected in fluid communication with the utility port during the vacuum phase and isolated from the fluid flow source port during the pressure phase.
In a further embodiment of the method of the invention, the flow rate through the utility port is controlled by changing the length of time the fluid flow source is connected in fluid communication with the utility port during either the pressure or vacuum phase of each cycle.
In an additional embodiment of the method of the invention, a predetermined, measured volume (V) of fluid is delivered through the utility port by calculating and operating the pump for a calculated number (N) of pump cycles based on the volume displacement per stroke (DPS) of the pump. In this embodiment, the head pressure at the utility port may be measured to more precisely calculate the number (N) of pump cycles, especially for controlling fluid flow of compressible fluids.
In an additional embodiment, the apparatus controls uni-directional fluid flow through the utility port by controlling actuation of an electrically-actuated control valve.
a-3d are fragmentary schematic illustrations of a pump motor shaft and detector in accordance with alternative embodiments of the invention;
For the purpose of illustration, there is shown in the accompanying drawings several embodiments of the invention. However, it should be understood by those of ordinary skill in the art that the apparatus and method of the present invention are not limited to the precise arrangements and instrumentalities shown therein and described below.
As used herein, the term “bi-directional pump” means a pump that alternately creates positive (pressure) and then negative (vacuum) displacement during a repeating pump cycle. The term “uni-directional pump” means a pump that creates only either positive or negative displacement.
A fluid flow device in accordance with a first embodiment of the present invention is shown in
In a preferred embodiment, the pump 20 comprises a diaphragm pump having a housing 30, a single, common fluid flow port 46, and a flexible diaphragm 34 bifurcating the piston chamber 32 as seen in
The detector 44 continuously monitors whether the pump 20 is operating in the positive pressure or negative pressure phase of the pump cycle. In a preferred embodiment, the detector 44 monitors the phase of the pump cycle by tracking movement of a cyclically-moving (either linear or rotational movement) element of the pump 20. In the embodiment shown in
Additional embodiments of detector/flywheel arrangements are shown in
In the embodiment shown in
In the embodiment shown in
In the embodiment shown in
In yet another embodiment shown in
The electrically-actuated valve 22 is located intermediate the conduit 19 connecting the pump 20 to the outlet port 29. In a preferred embodiment, the valve 22 comprises a three-way solenoid valve such as shown in
The solenoid valve has a ferrous reciprocating element 60, which has a valve head 61 at one end and a cylindrical base 63 at the other end. An induction coil 64 surrounds the base 63 while a compression spring 68 surrounds the head 61. First and second seals 70, 72 are seated on opposed ends of the head 61. The compression spring 68 normally biases the valve head 61 to a first position wherein the common port 56 is arranged in fluid connection with the NO port 58 and the NC 54 port is closed. In the first position, the internal conduit 19 between the pump 20 and the utility port 29 is closed. When the induction coil 64 is energized, a magnetic field urges the valve head 61 to a second position wherein the common port 56 is arranged in fluid connection with the NC 54 port 58 and the NO port 58 is closed. In the second position, the internal conduit 19 between the pump 20 and the utility port 29 is open.
In the embodiment shown
The valve 22, detector 44, and user interface 26 communicate with the controller 24. The detector 44 continuously transmits to the controller 24 a signal identifying the phase of the pump cycle in which the pump is operating. The controller 24 synchronizes actuation of the valve 22 with the cycle of the pump 20 to create a sustained flow of either positive or negative air flow to the utility port 29. If positive pressure is desired at the utility port 29, the solenoid is energized only during the positive pressure phase of the pump cycle, i.e., t=0 to t=T/2. Then, from t=T/2 to t=T, the solenoid valve is de-energized. When the valve 22 is energized, it moves from the first position to the second position, described above. Conversely, if vacuum pressure is desired at the utility port 29, the solenoid valve 22 is energized only during the negative pressure phase of the pump cycle, i.e., t=T/2 to t=T. Because the detector 44 and solenoid valve 22 have very fast response times, the aforementioned cycle (either positive or negative pressure) can be repeated at a very high frequency to create a continuous, sustained flow of fluid either into or out of the utility port 29.
If a digital detector is provided, such as the detector 44 of the embodiment shown in
In another embodiment of the invention, the device not only selectively creates negative or positive pressure at the utility port 29, but also controls additional fluid flow properties. For example, the flow rate through the utility port 29 can be varied by controlling the amount of time the valve 22 is energized during either phase of the pump cycle. Referring to
To communicate the desired flow rate to the controller, the triggers 26, 27 may be connected to potentiometers. The user controls the volumetric flow rate by controlling the distance each trigger 26, 27 is depressed. Other known user interface devices such as described above could be substituted for the triggers 26, 27.
In another embodiment of the invention shown in
In this embodiment, the user interface 125 may comprise a keypad or a computer. The keypad 125 may include a plurality of input keys 127 and an LCD 128, which displays a wide variety of additional control options that have been programmed into the controller.
In this embodiment, the device 110 includes a sensor 178 that measures the external pressure or head at the utility port 129. The pressure sensor 178 communicates the head pressure to the controller 124, which factors this value into the ideal gas equation of state (pV=nRT) and Boyle's law to more accurately calibrate the number (N) of strokes of the pump 20 required to deliver the specified volume (V) of fluid. The pressure sensor 78 is preferably provided if the device 110 is controlling the flow of a compressible fluid at constant temperature such as air, whose properties are governed by the equation P1V1=P2V2.
The aforementioned embodiments have been described with reference to a motor-driven diaphragm pump. However, it should be appreciated that other types of bi-directional pumps may be used without departing from the invention. For example, a solenoid-activated diaphragm pump, such as manufactured by MEDO U.S.A., Inc., may be used. Other types of bi-directional pump may be used so long as the detector can continuously determine the phase of the pump cycle in which the pump is operating.
Similarly, the aforementioned embodiments have been described with reference to a detector that continuously determines the phase in which the pump is operating by tracking movement of a cyclically-moving element of the pump. However, depending on the type of pump, other types of detectors may be used so long as it is capable of continuously determining the phase in which the pump is operating and electronically transmitting a signal to the controller that identifies the phase. For example, if a solenoid-activated pump is used, the detector may identify the transition from one phase to another by detecting a change in polarity created by the solenoid.
The aforementioned embodiments have been described with reference to an electrically-actuated, three-way solenoid valve. However, it should be appreciated that the three-way valve could be replaced by other arrangements of electrically-actuated valves such as shown in
Using the input signal from the detector 218, the controller 224 selectively opens and closes the valves 280, 281 in synchronization with the phases of the pump cycle to create either positive or negative pressure at the utility port 229. In the embodiment shown in
The aforementioned embodiments have been described with reference to a bi-directional pump. However, in a further embodiment of the invention, the device controls uni-directional fluid flow. In this embodiment, the device 310 includes a uni-directional pump 385, controller 324, user interface 325, and electrically-actuated, three-way valve 322. The device 310 may also include a detector 318. In this embodiment, the valve 322 comprises a solenoid valve such as described above. Similar to the embodiments described above, the controller 324 selectively actuates the valve 322 to deliver fluid at preset intervals, controlled quantities, measured volumes (V), defined flow rates, and other properties or steps.
It should be appreciated by those of ordinary skill in the art that the above-described embodiments of the invention may be used to control the flow of both compressible and incompressible fluids in a wide variety of environments. By way of example only, one specific embodiment is described below.
A pipetting device in accordance with a further embodiment of the present invention is shown in
In the embodiment shown in
The housing 411 of the pipetting device 412 has a handle portion 414 and a barrel portion 415 oriented transversely to the handle portion 414. A nosepiece or pipette connector 416 is fixed to and oriented downwardly transverse to the barrel portion 415. The pipette connector 416 is constructed and arranged to removably attach pipettes 406 of various lengths and diameters. The pipette connector 16 may include a hydrophobic filter 417, which may be removed and replaced. The filter 417 prevents contamination of the pipetting device 410 in the event the pipette 18 is overadmitted with fluid.
The device 412 has a bi-directional pump 420, control valve 422, and controller 424. An internal conduit 419 connects the pump 420 to the pipette connector 416. The control valve comprises a three-way, electrically-actuated solenoid valve 422 and is located intermediate the internal conduit 419. A detector (not shown) is built into the pump 420. A positive air flow trigger 426 and negative air flow trigger 428 extend from the handle portion 414 and are connected to the controller 424.
In the manner described above, the controller 424 actuates the valve 422 in response to signals generated by depression of either the positive air flow trigger 426 or negative air flow trigger 428. Additionally, the pipetting device may be provided with a more sophisticated user interface, which would allow the user to control the wide variety of fluid flow properties described above.