U.S. patent application number 11/276890 was filed with the patent office on 2006-09-21 for coupling device.
This patent application is currently assigned to Colder Products Company. Invention is credited to William John Rankin.
Application Number | 20060207345 11/276890 |
Document ID | / |
Family ID | 36587236 |
Filed Date | 2006-09-21 |
United States Patent
Application |
20060207345 |
Kind Code |
A1 |
Rankin; William John |
September 21, 2006 |
Coupling Device
Abstract
An assembly for estimating consumption of a fluid includes a
coupling device enabling fluid flow, a carrier assembly slidingly
coupled to the coupling device, a biasing mechanism positioned
between the coupling device and the carrier assembly, and a
displacement sensing mechanism including a sensor coupled to one of
the coupling device and the carrier assembly, and a magnet coupled
to the other of the coupling device and the carrier assembly. The
displacement sensing mechanism is configured to sense a
displacement of the magnet relative to the sensor due to coupling
of a fluid source to the coupling device.
Inventors: |
Rankin; William John;
(Burnsville, MN) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
Colder Products Company
St. Paul
MN
|
Family ID: |
36587236 |
Appl. No.: |
11/276890 |
Filed: |
March 17, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60662665 |
Mar 17, 2005 |
|
|
|
Current U.S.
Class: |
73/861.93 |
Current CPC
Class: |
G01G 3/02 20130101; G01F
23/20 20130101; Y10T 137/8225 20150401; B41J 2/17566 20130101; G01G
23/3735 20130101; G01F 1/24 20130101; G01G 17/04 20130101; B41J
2/175 20130101 |
Class at
Publication: |
073/861.93 |
International
Class: |
G01F 1/11 20060101
G01F001/11 |
Claims
1. An assembly for estimating consumption of a fluid, the assembly
comprising: a coupling device enabling fluid flow; a carrier
assembly slidingly coupled to the coupling device; a biasing
mechanism positioned between the coupling device and the carrier
assembly; and a displacement sensing mechanism including a sensor
coupled to one of the coupling device and the carrier assembly, and
a magnet coupled to the other of the coupling device and the
carrier assembly; wherein the displacement sensing mechanism is
configured to sense a displacement of the magnet relative to the
sensor due to coupling of a fluid source to the coupling
device.
2. The assembly of claim 1, wherein the sensor is a magnetic
position sensor coupled to the carrier assembly, the magnet is
coupled to the coupling device, the magnet moves with the coupling
device, and the magnetic position sensor detects a relative
displacement of the magnet.
3. The assembly of claim 2, further comprising a microcontroller
programmed to estimate a volume of fluid in the fluid source based
on the displacement of the magnet.
4. The assembly of claim 1, further comprising a data
communications module programmed to communicate the displacement to
a host controller.
5. The assembly of claim 1, wherein the biasing mechanism is a
spring.
6. A system for estimating consumption of a fluid, the system
comprising: a coupling device; a carrier assembly slidingly coupled
to the coupling device; a biasing mechanism positioned between the
coupling device and the carrier assembly; a displacement sensing
mechanism coupled to the carrier assembly; and a data
communications module coupled to the carrier assembly; wherein,
subsequent to connecting a mating insert to the coupling device, a
fluid from a fluid source is delivered through the coupling device,
and the fluid source applies a load to the coupling device; wherein
the displacement sensing mechanism is configured to sense a
displacement of the coupling device relative to the carrier
assembly due to the load associated with the fluid source; and
wherein the data communications module is programmed to estimate a
volume of fluid in the fluid source based on the displacement.
7. The system of claim 6, further comprising the fluid source
containing the fluid.
8. The system of claim 7, further comprising the mating insert
coupled to the fluid source.
9. The system of claim 6, wherein the displacement sensing
mechanism includes: a magnetic position sensor coupled to the
carrier assembly; and a magnet coupled to the coupling device;
wherein the magnet moves with the coupling device, and the magnetic
position sensor detects a displacement of the magnet.
10. The system of claim 9, wherein the data communications module
includes a microcontroller, and the magnetic position sensor
communicates the displacement of the magnet to the microcontroller,
and the microcontroller is programmed to estimate the volume of the
fluid in the fluid source based on the displacement of the
magnet.
11. The system of claim 10, wherein the data communications module
communicates the volume of the fluid to a host controller, and the
host controller estimates a fill level of the fluid source based on
the volume of the fluid.
12. The system of claim 11, wherein the data communications module
writes the fill level of the fluid source to a data tag associated
with the fluid source.
13. The system of claim 6, wherein the biasing mechanism is a
spring.
14. A coupling device, comprising: a magnet coupled to the coupling
device; and a magnetic position sensor coupled to the coupling
device and configured to sense an angle of magnetic flux of the
magnet; wherein the coupling device is programmed to estimate a
connected or disconnected state of the coupling device relative to
a mating coupling device based on the angle of the magnetic flux of
the magnet measured by the magnetic position sensor.
15. A method for estimating consumption of a fluid in a fluid
source, the method comprising: coupling a carrier assembly and
biasing mechanism to a coupling device; coupling an insert of the
fluid source to the coupling device; sensing a displacement of the
coupling device relative to the carrier assembly when the fluid
source is coupled to the coupling device; and estimating a volume
of a fluid in the fluid source based on the displacement.
16. The method of claim 15, wherein the displacement is sensed
using a sensing mechanism including a magnetic position sensor, and
a magnet, wherein the magnet moves with the coupling device, and
the magnetic position sensor detects a displacement of the
magnet.
17. The method of claim 15, further comprising communicating the
displacement to a host controller.
18. The method of claim 15, further comprising estimating a fill
level of the fluid source based on the displacement.
19. The method of claim 18, further comprising writing the fill
level of the fluid source to a data tag associated with the fluid
source.
Description
RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. .sctn.
119(e) of U.S. Patent Provisional Application Ser. No. 60/662,665
filed on Mar. 17, 2005, the entirety of which is hereby
incorporated by reference.
BACKGROUND
[0002] The use of weight scales to meter consumable media is known
and widely employed. For example, applications employing industrial
inkjet printers to print billboard displays or other large
printouts need to monitor the consumption of ink during printing.
Being able to effectively monitor ink consumption enables print
production to determine whether there is enough of a particular ink
to create the next billboard or printout.
[0003] Weight scales, in the form of strain gauges linked with a
controller, have been used to determine a remaining amount of ink
or consumable. Other systems have required manually removing a
container with a particular consumable such as ink, weighing the
consumable separately, cleaning the container housing the
consumable, and then reconnecting it to the dispensing device
(e.g., the printer). Still other systems have employed
off-the-shelf flow sensors to monitor consumption.
[0004] These systems, however, have their shortcomings and
improvements may be made. In the example systems described, an
excess of parts may exist that can require different fittings,
resulting in a less uniform system. Further, previous systems may
not provide effective automated and integrated mechanisms for
metering use of consumable media. Safety of end users can be
jeopardized, as additional handling of the consumables and their
containers may be required. Furthermore, previous systems do not
provide a mechanism to help regulate warranty-repair in the event
end users or customers inadvertently or purposely refill consumable
containers to continue dispensing. For fluid dispensing
applications that dispense at low flows (e.g., inkjet printing),
the systems cannot cost-effectively employ off-the-shelf flow
sensors.
SUMMARY
[0005] According to one aspect, an assembly for estimating
consumption of a fluid includes a coupling device enabling fluid
flow, a carrier assembly slidingly coupled to the coupling device,
a biasing mechanism positioned between the coupling device and the
carrier assembly, and a displacement sensing mechanism including a
sensor coupled to one of the coupling device and the carrier
assembly, and a magnet coupled to the other of the coupling device
and the carrier assembly. The displacement sensing mechanism is
configured to sense a displacement of the magnet relative to the
sensor due to coupling of a fluid source to the coupling
device.
[0006] According to another aspect, a system for estimating
consumption of a fluid includes a coupling device, a carrier
assembly slidingly coupled to the coupling device, a biasing
mechanism positioned between the coupling device and the carrier
assembly, and a displacement sensing mechanism coupled to the
carrier assembly. The system also includes a data communications
module coupled to the carrier assembly. Subsequent to connecting a
mating insert to the coupling device, a fluid from a fluid source
is delivered through the coupling device, and the fluid source
applies a load to the coupling device, and the displacement sensing
mechanism is configured to sense a displacement of the coupling
device relative to the carrier assembly due to the load associated
with the fluid source. The data communications module is programmed
to estimate a volume of fluid in the fluid source based on the
displacement.
[0007] According to yet another aspect, a coupling device includes
a magnet coupled to the coupling device, and a magnetic position
sensor coupled to the coupling device and configured to sense an
angle of magnetic flux of the magnet. The coupling device is
programmed to estimate a connected or disconnected state of the
coupling device relative to a mating coupling device based on the
angle of the magnetic flux of the magnet measured by the magnetic
position sensor.
[0008] According to another aspect, a method for estimating
consumption of a fluid in a fluid source includes: coupling a
carrier assembly and biasing mechanism to a coupling device;
coupling an insert of the fluid source to the coupling device;
sensing a displacement of the coupling device relative to the
carrier assembly when the fluid source is coupled to the coupling
device; and estimating a volume of a fluid in the fluid source
based on the displacement.
[0009] These and other various advantages and features of novelty
are pointed out in the following detailed description. Reference
should also be made to the drawings in which there are illustrated
and described specific embodiments.
DESCRIPTION OF THE DRAWINGS
[0010] Like reference numbers generally indicate corresponding
elements in the Figures.
[0011] FIG. 1 is a schematic block diagram of an example embodiment
of a system for metering consumption of fluid transfer
material.
[0012] FIG. 2 is a schematic block diagram of one embodiment of a
data communication module.
[0013] FIG. 3 is a partial cross-sectional view of an example
embodiment of a weight sensing coupling assembly including one
embodiment for a coupling device and a carrier assembly.
[0014] FIG. 4 illustrates an example magnetic flux angle of the
magnet of FIG. 3 as measured by the magnetic position sensor of
FIG. 3.
[0015] FIG. 5 is a partial cross-sectional view of another
embodiment for a weight sensing coupling assembly including one
embodiment of a coupling device and carrier assembly.
[0016] FIG. 6 is a graph showing the results of a sample experiment
of recording magnetic position sensor output against a load applied
to the carrier assembly.
[0017] FIG. 7a is a side view of the housing for the carrier
assembly shown in FIG. 5.
[0018] FIG. 7b is a partial cross-sectional view of the housing for
the carrier assembly shown in FIG. 5.
[0019] FIG. 8 is a partial cross-sectional view of a carrier tail
for the carrier assembly shown in FIG. 5.
[0020] FIG. 9 is a partial cross-sectional view of the housing for
the carrier assembly shown in FIG. 3.
[0021] FIG. 10 is a partial cross-sectional view of the housing for
the carrier assembly shown in FIG. 3.
DETAILED DESCRIPTION
[0022] Referring to FIGS. 1 and 2, an example system 26 includes a
consumable container 10 with an associated mating insert 20 and
RFID tag 11. A weight sensing coupling assembly 24 is defined by a
coupler assembly 18. Weight sensing coupling assembly 24 has a data
communications module 14 and displacement sensing mechanism 28
associated therewith and is housed in a carrier assembly 61a
(described further below).
[0023] In example embodiments, system 26 is configured to meter
consumption of fluid transfer material. System 26 includes a host
controller 17, which communicates via a data communications module
14 to the RFID tag 11. In the example shown, RFID tag 11 is
attached to the insert 20. It will be appreciated that other
arrangements may also be suitable. For example, in alternative
embodiments, RFID tag 11 can be disposed directly on a fluid
source, such as consumable container 10.
[0024] The data communications module 14 is attached to a coupler
assembly 18. Data communication module 14 provides antenna or coil
13 to communicate wirelessly with antenna or coil 12 of RFID tag
11, and antenna or coil 15 to communicate with host controller 17.
In the example embodiment shown in FIG. 1, data communications
module 14 is operatively connected with a displacement sensing
mechanism 28. In one embodiment shown in FIG. 3, the displacement
sensing mechanism 28 includes a magnetic position sensor 22
positioned proximate to a magnet 64. Displacement sensing mechanism
28 is further discussed below.
[0025] In the example shown, coupler assembly 18 and mating insert
20 are disposable couplings known in the art. In some embodiments,
these couplings are quick connect/disconnect couplings such as the
couplings disclosed in U.S. Pat. No. 6,649,829 filed on May 21,
2002, which is hereby incorporated by reference.
[0026] RFID technology, including transponders and tags, utilizes
data that is carried, retrieved, and transferred using an antenna
and transceiver. Such tags are known to carry data which may
provide identification for an item in manufacture or in transit,
such as consumables in fluid dispensing applications, or any item
that requires tracking or identification. Typically, an RFID system
includes antenna or coil 13, an RFID transceiver 54, and a
transponder or RFID tag 11. A radio signal emitted by the
transceiver antenna 13 activates the RFID tag 11, allowing it to be
read or written to. Antennas are available in a wide variety of
shapes and sizes to suit specific applications. Coupling assemblies
employing RFID tags and reader embedded therein have been disclosed
in U.S. Pat. No. 6,649,829, U.S. patent application Ser. No.
11/233,939 filed on Sep. 22, 2005, and U.S. patent application Ser.
No. 11/117,083 filed on Apr. 27, 2005, all of which are hereby
incorporated by reference.
[0027] Referring to FIGS. 3 and 4, one embodiment of a weight
sensing coupling assembly 24 is illustrated, in which a coupler
assembly 18a is designed for a fixed or non-hanging application. In
this configuration, a load applied to a coupling device 60, such as
a consumable media from a container 10, pushes down on the coupling
device 60. In the example embodiment, the displacement sensing
mechanism 28 includes magnetic position sensor 22 and measures the
displacement of a magnet 64 mounted on a carrier tail member 65a of
coupling device 60. This disposition of the magnet 64 is an
example, as other arrangements may also be equally suitable.
[0028] For example, magnet 64 may be disposed inside coupling
device 60 and disposed within valved parts of the same. In such a
configuration, the movement of the valving parts of coupling device
60 can indicate whether coupling device 60 is in an open or closed
position, and can also indicate a connected or disconnected state
relative to mating insert 20. Such a disposition of the magnet 64
can be utilized, for example, in fluid dispensing applications
requiring high pressure, where certain thresholds can be determined
to enable or disable fluid flow.
[0029] In the shown embodiment, magnetic position sensor 22 is
embedded in the body of the carrier assembly 61a. It will be
appreciated, however, that this disposition is an example, as other
arrangements may be equally suitable. For example, magnetic
position sensor 22 may also be disposed on any number of external
or outer surfaces 66 of carrier assembly 61a or embedded in any
number of positions therein.
[0030] Referring to FIG. 5, another possible embodiment of a
coupler assembly 18b including a carrier assembly 61b is
illustrated, in which coupler assembly 18b is designed for a
non-fixed or hanging application. In this configuration, a load
applied to coupling device 60, such as a consumable media from a
container 10, pulls down on coupling device 60. Magnetic position
sensor 22 measures the displacement of a magnet 64 mounted on
coupling device 60. This disposition of the magnet 64 is an
example, as other arrangements may also be equally suitable.
Similarly, in other embodiments, magnetic position sensor 22 can be
arranged in other locations, such as on external surface 66 of the
carrier assembly 61b.
[0031] In both the hanging and non-hanging embodiments, when a
fluid source, such as consumable container 10, is coupled with the
coupler assembly 18a, 18b, such as for fluid dispensing, the
movement of coupling device 60 resulting from the weight of the
container 10 is measured by magnetic position sensor 22. Magnetic
position sensor 22 measures the changes in magnetic flux angle 70
of magnet 64 mounted either on coupling device 60 or carrier tail
member 65b. As coupling device 60 moves in response to being
coupled to a consumable container 10, mounted permanent magnet 64
moves in relation to magnetic position sensor 22.
[0032] In an example embodiment, the magnetic position sensor 22 is
included as part of the data communications module 14 and can be
mounted on outer 66 or inner surface of the carrier assembly 61a,
61b. In the illustrated embodiment, magnetic position sensor 22 is
embedded within carrier assembly 61a, 61b. The relative movement of
magnet 64 with respect to magnetic position sensor 22 results in a
change of magnetic flux angle 70 at magnetic position sensor 22.
Magnetic position sensor 22 outputs a voltage, proportional to
magnetic flux angle 70, to a microcontroller or microprocessor 51
or like processing element.
[0033] Carrier assembly 61a, 61b enables displacement or movement
of coupling device 60, along with carrier tail member 65a, 65b, and
a biasing mechanism 63. Biasing mechanism 63 enables coupling
device 60 to slidingly engage carrier assembly 61a, 61b and
reciprocate within an opening of carrier assembly 61a, 61b. Carrier
assembly 61a, 61b and carrier tail member 65a, 65b are discussed in
further detail in FIGS. 7-10 below.
[0034] In one embodiment, biasing mechanism 63 is a coiled spring.
In example embodiments, biasing mechanism 63 is chosen so that it
does not approach its elastic limits or minimizes hysteresis. Thus,
biasing mechanism 63 can repeatedly translate a force applied to a
coupling device 60, such as from a load provided by a fluid
material contained in a consumable container 10. Biasing mechanism
63 serves as a mounting means for coupling device 60.
[0035] In example embodiments, biasing mechanism 63 is chosen as a
coiled spring having approximately 0.300 inches of deflection at a
full load of 15 lbs. The size of biasing mechanism 63 is chosen to
fit around a standard coupling device. In some embodiments, the
material of biasing mechanism 63 is such that the biasing force may
remain constant over an expected temperature range.
[0036] The spring depicted for biasing mechanism 63 is merely an
example. Other biasing mechanisms may be employed that are equally
suitable. For example, the biasing mechanism 63 may be a closed
chamber of fluid that is compressible by a press or piston when a
load is applied to coupling device 60. The pressure can be
translated to a position or force sensor. The fluid, in turn,
applies a force and presses on a plate of the position/force sensor
mounted to the side of coupling device 60. The force may be divided
by the ratio of area between coupling device 60 piston and a sensor
plate. In such a configuration, the use of an incompressible fluid
to couple the force to the force sensor develops a static pressure
within the fluid when the piston presses on the fluid. The pressure
exists in the complete volume of the fluid and, therefore, exerts
pressure on the force sensor. In one embodiment, the fluid is
completely confined in a chamber and there is negligible movement
in the force sensor, therefore the fluid may be static when
pressure is applied. Because the fluid is static and because there
are no voids in the fluid, viscosity effects of the fluid may be
removed. Thus, the amount of force exerted on the force sensor is
proportional the ratio of the piston pressing on the fluid and the
area of the sensor. A weight capacity of the scale can be tailored
by changing the size of the force sensor.
[0037] In other examples of biasing mechanism 63, a pressure disk
or donut may be employed, such as by filling the disk or donut with
a flexible fluid or jell. The disk or donut may be compressed by a
piston or the like and translate the force to a force sensor. Such
a flexible disk can be made with a temperature resistant material.
Furthermore, such a flexible disk can be formed to minimize
air-bubbles so that an accurate force may be measured. It will be
appreciated that these embodiments are examples and others may be
equally suitable.
[0038] Referring to FIG. 6, in one possible embodiment,
microprocessor 51 calculates applied force 80, or the weight of
consumable container 10, based on the voltage input from magnetic
position sensor 22. Microprocessor 51 performs a polynomial curve
fit, or transfer function (a), shown below. Transfer line 80,
representing the calculated weight, is not linear. Flux angle 70
does not vary linearly with magnetic position sensor 22
displacement from an axis line of magnet 64. In one possible
embodiment, the transfer function (a) is sufficiently accurate when
approximated with a second order equation according to the
following regression equation: Weight=9.98e-4*(X 2)+0.214*X+6.45
(a) It can be appreciated that, in other possible embodiments
requiring a larger or smaller maximum weight threshold, a different
transfer function may be used. In the typical embodiment, it is
sufficient that the data points of actual load applied 81 fall
within a +/-5% accuracy threshold 82 of the data points resulting
from weight calculating transfer function 80. It will be
appreciated that an accuracy rate may be as high as up to 2%.
[0039] Turning back to FIGS. 1 and 2, in one possible embodiment,
calculated weight 80 is communicated to host controller 17 from the
data communications module 14. Communication between host
controller 17 and data communications module 14 of coupler assembly
18 is provided by a two-way serial interface. In the example
embodiment, a RS-232 wireless protocol is used to communicate
between antenna 16 of host controller 17 and antenna 15 of data
communications module 14. Other possible embodiments include a data
transceiver 53, which bidirectionally communicates using Bluetooth,
IEEE 801.11, Zigbee wireless protocols, or RS-232, RS-485,
Ethernet, or USB wired protocols. In another possible embodiment, a
fiber optic cable is used. In wired embodiments, antennas 15 and 16
can be replaced with a wired connection.
[0040] In one possible embodiment, host controller 17 is connected,
via wired or wireless means, to each data communications module 14
in a multi-coupler system. In another possible embodiment, host
controller 17 is connected, via wired or wireless means, to one
coupler in a multi-coupler system, wherein each coupling device is
linked to another coupling device, forming a chain. A multi-drop
protocol is known in the art and is implemented, for example, by
using a RS-485 protocol.
[0041] In one possible embodiment, host controller 17 calculates
the amount of remaining fluid in consumable container 10, based on
a function of calculated weight 80 as received from data
communication module 14, and subsequently writes fill level data to
RFID tag 11 associated with the consumable container 10. In one
possible embodiment, host controller 17 displays a "fuel gauge"
type fill level on a control panel or screen. It will be
appreciated that the metering system can further enable end users
to run a dispensing system for a short time after an indication
that a fluid material is low or empty.
[0042] In the example embodiment, host controller 17 writes data to
RFID tag 11 memory by communicating the desired data to data
communications module 14, by the method previously described,
which, in-turn communicates the data via RFID transceiver 54 of
data communications module 14 and antenna 13 to antenna 12 of RFID
tag 11. The data is written to RFID tag 11 memory. In one possible
embodiment, the data is written to RFID tag 11 to ensure that a
user cannot add unapproved fluid to consumable container 10.
[0043] In one possible embodiment, memory of RFID tag 11 includes a
46-byte EEPROM for general-purpose use. It can be appreciated that
other embodiments may use other types and sizes of memory for
storing data specific to consumable container 10 to which the
memory is attached.
[0044] In yet another possible embodiment, RFID tag 11 is attached
directly to the consumable container 10, rather than to mating
insert 20.
[0045] In one possible embodiment, the maximum weight of consumable
container 10 is approximately 11 lbs. Readings of up to 4 times the
maximum weight are possible due to initial impact upon connecting
consumable container 10 to coupler assembly 18a, 18b. It can be
appreciated that other embodiments can require a weight sensing
coupling assembly that is adapted to support a larger or smaller
maximum consumable container weight.
Sample Experiment
[0046] Referring back to FIG. 6, an example experiment was
conducted in which the calculated weight 80 linearity, calibration,
and transfer function (a) accuracy were tested. A force was applied
to reader coupling device 60, representing the force resulting from
the weight of consumable container 10 being coupled to coupler
assembly 18a, 18b. Results were compared between weight calculated
80 by microcontroller 51, using the regression equation (a), based
on a function of the voltage input from magnetic position sensor
22, and weight actually applied 81, as read by an electronic scale.
Regression line 80 derived from the regression equation (a) fell
within a +/-5% accuracy threshold 82 of actual data 81, throughout
the useful range of magnetic position sensor 22. In this
experiment, the maximum weight of consumable container 10 was
approximately 11 lbs.
[0047] Referring to FIGS. 7a, 7b, and 8, one embodiment of a
hanging weight sensing coupler housing 61b and tailpiece 65b are
illustrated. A flange 62 is provided on an external surface of
carrier assembly 61b, providing a means to hang the coupler
assembly 18b.
[0048] Referring to FIGS. 9 and 10, one embodiment of a non-hanging
weight sensing coupler housing 61a and tailpiece 65a are
illustrated. Common to both hanging and non-hanging embodiments, an
end of the carrier tail member 65a, 65b inserts into a first end 92
of carrier assembly 61a, 61b. The non-beveled edge or blunt end 101
is pressed into coupling device 60. Carrier tail member 65a, 65b
may be connected via a press fit for the upright/non-hanging
coupler assembly 18a. The carrier tail may be glued for the hanging
coupler assembly 18b. It will be appreciated that these
configurations are examples. Other examples for connecting carrier
tail member 65a, 65b to coupling device 60 may be employed such as,
but not limited to, ultrasonic bonding. Carrier tail member 65a,
65b provides an extended hose member connected at first end 92 of
coupling device 60.
[0049] The metering system may operate as follows. Coupling device
60 is fitted with carrier assembly 61a, 61b including carrier tail
member 65a, 65b and biasing mechanism 63. Referring to FIG. 3, in
the non-hanging embodiment of coupler assembly 18a, biasing
mechanism 63 resides between a shoulder portion 94a of carrier
assembly 61a and a shoulder portion 95a of coupling device 60.
Referring to FIG. 5, in the hanging embodiment of coupler assembly
18b, biasing mechanism 63 resides between a shoulder portion 94b
and a second shoulder portion 95b of the carrier assembly 61b. In
either embodiment, carrier tail 65a, 65b serves as a bearing
surface and guide for biasing mechanism 63. Biasing mechanism 63
repeatedly translates a force applied to coupling device 60 into
displacement, such as from a load applied to coupling device 60
that is provided by a fluid material contained in consumable
container 10.
[0050] As fluid is transferred from consumable container 10 and
through weight sensing coupling assembly 24, biasing mechanism 63
deflects as a force is applied to coupling device 60. The
deflection is measured and communicated to microcontroller 51 of
data communication module 14. The readings are scaled and
translated to weight reading 80, representing the load applied to
coupling device 60. Weight data 80 is subsequently used by host
controller 17 to determine the amount of consumable or fluid
transfer material remaining.
[0051] The displacement of coupling device 60 within carrier
assembly 61a, 61b is measured using magnetic position sensor 22.
Displacement of coupling device 60 is sensed by magnetic position
sensor 22, which is mounted to a circuit board such as, but not
limited to, data communication module 14. Magnetic position sensor
22 senses the angle of magnetic flux 70 produced by permanent
magnet 64 that moves in relation to magnetic position sensor
22.
[0052] As the relative position of magnet 64 with respect to
magnetic position sensor 22 changes, angle of magnetic flux 70 at
magnetic position sensor 22 changes. Magnetic position sensor 22
yields a voltage that is proportional to angle of the magnetic flux
70. Magnetic position sensor 22 may be operatively connected to a
microcontroller, such as microcontroller 51 of data communication
module 14. Microcontroller 51 performs a transformation of the
output of magnetic position sensor 22 to yield weight 80 of
consumable container 10. Microcontroller 51 returns weight data 80
to host controller 17. The system employs a power supply, and is
powered by 8-24 volts in example embodiments.
[0053] Coupling device 60 can be molded constructed and arranged as
known in the art, for instance as in U.S. Pat. No. 6,649,829.
Bearing carrier tail member 65a, 65b can be made of a molded
plastic material and spin welded onto such a standard quick
connect/disconnect coupling as known. Carrier tail member 65a, 65b
can include an alignment key on an inner surface. However, in some
embodiment, standard spin welding methods can allow for the
alignment of welded tail member 65a, 65b within a degree.
[0054] In example embodiments, acetal is used for constructing
coupling device 60 and carrier assembly 61a, 61b. Such a material
is desired that can provide adequate bearing surfaces on coupling
device 60. Further qualifying of the material for parts
construction may be modified as desired, for instance, in any
applications requiring specific chemical compatibility.
[0055] In example embodiments, system 26 is suitable for metering
consumption of fluid in industrial inkjet printing applications.
System 26 is also suitable for incorporation into any number of
applications including but not limited to, bag-in-box and
blow-molded fluid dispensing. Other applications may include
chemical processing and measurement of reagents and/or chemical
vats. Furthermore, measurement of pharmaceuticals, such as for
dosage or other medical applications employing fluid dispensing,
may also be employed. These are examples. It will be appreciated
that the metering system 26 and weight sensing coupling assembly 24
may be employed in any number of applications for a fluid
dispensing system.
[0056] The term "fluid" is used herein to denote any substance that
may be made to flow. This includes, but is not limited to, liquids,
gases, granular or powdered solids, mixtures or emulsions of two or
more fluids, suspensions of solids within liquids or gases,
etc.
[0057] The example systems disclosed herein can allow users to
monitor how much fluid or other product material is connected to a
weight sensing coupling assembly. The systems can allow customers
to track the last known weight of a consumable container. The RFID
tag enables periodic reading therefrom and writing thereto when
communicating with a data communications module. Thus, the amount
of remaining fluid in a consumable container can be periodically
written to and read from the RFID tag. In this configuration, a
consumable container can be tracked to determine if and when more
fluid transfer material has been added to the consumable container.
The systems disclosed herein can provide a means to notify the user
or equipment manufacturer of inadvertent or purposeful introduction
of additional material to the consumable container or fluid source,
thereby controlling warranty repair.
[0058] The above specification provides a complete description of
the composition, manufacture and use of the improved poppet valve
member. Many embodiments can be made without departing from the
spirit and scope of the disclosure.
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