How to improve the filling accuracy of peristaltic pump

Filling refers to the process of transferring a measured amount of liquid within a specific time frame. Filling accuracy error is defined as the variation in the amount dispensed per measurement over multiple fills. The formula used to calculate filling accuracy is: (Maximum - Minimum) / Average. To ensure consistent dispensing, it's crucial to improve the accuracy of the filling process. Stepping motors are often used in filling systems because they allow precise control over rotation angle and speed, which remains unaffected by load. This makes them ideal for creating reliable open-loop control systems.

Currently, there are various technologies used in peristaltic pump filling systems. Below are the key characteristics of each approach:

First, some systems use a timer to control the volume of liquid dispensed. This method is simple to implement but suffers from significant errors. Temperature changes can affect the crystal oscillator frequency, which in turn influences the timing accuracy of the microcontroller. While high-quality oscillators can reduce this impact, it cannot be completely eliminated. Additionally, using software to generate precise timing values is not always reliable, as interrupt operations during execution can introduce unpredictable delays, leading to unmeasurable errors.

Second, some systems rely on pulse counting to regulate the filling amount. This method ensures that the peristaltic pump rotates through the same number of steps each time, resulting in higher accuracy compared to time-based control. However, due to the pulsating nature of the fluid flow, the actual flow rate at the moment the pump stops may vary depending on where the roller is positioned. This inconsistency can lead to small distribution errors, especially when dealing with smaller volumes.

Third, angle control technology improves upon the pulse-counting method by ensuring that the pump stops at the same position every time. This eliminates the effects of pulsation and significantly enhances the precision of small-volume dispensing. These methods are all based on open-loop control, meaning they do not account for factors like hose wear or flow attenuation. As a result, regular calibration is necessary to maintain high accuracy in real-world applications.

In addition to these methods, some systems integrate non-contact sensors—such as infrared or capacitive sensors—to monitor liquid levels. These sensors help compensate for hose degradation over time, ensuring consistent dispensing throughout the lifespan of the tubing.

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