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Filling refers to the process of transferring a precise amount of liquid within a specified time frame. The filling accuracy error is defined as the variation in the amount of liquid dispensed over multiple fillings. It can be calculated using the formula: filling accuracy = (maximum - minimum) / average. To ensure consistent dispensing volume, improving filling accuracy is essential. Stepping motors are commonly used in filling systems because they allow for precise control of rotational angle and maintain stable speed regardless of load, making them ideal for open-loop control systems.
Currently, various technologies are employed in peristaltic pump filling systems, each with its own advantages and limitations. Here’s an overview of the most common approaches:
First, some systems use a timer-based approach to control the filling amount. This method is simple to implement but suffers from significant inaccuracies. Temperature fluctuations can affect the crystal oscillator frequency in microcontrollers, which in turn influences the timing accuracy. While high-quality oscillators can minimize this effect, it cannot be completely eliminated. Additionally, relying on software to generate precise time intervals is not reliable, as interrupts and other background processes can introduce unpredictable delays, further reducing accuracy.
Second, some systems use pulse counting to regulate the amount of liquid dispensed. By controlling the number of motor steps, the total rotation angle can be kept consistent, resulting in higher accuracy compared to time-based control. However, peristaltic pumps inherently produce pulsating flow, meaning that even with the same number of pulses, the actual flow rate during the stop phase may vary depending on where the roller stops. This inconsistency can lead to small but measurable errors, especially when dealing with small volumes.
Third, advanced systems incorporate angle control technology, which ensures that the pump rollers stop at the same position every time. This eliminates the impact of flow pulsation and significantly improves precision, particularly for low-volume dispensing. Unlike the previous two methods, angle control provides more consistent results by maintaining a fixed stopping point, thus reducing distribution errors.
All three methods mentioned above are open-loop control systems, meaning they do not account for changes in the peristaltic pump hose's flow characteristics over time. In practice, regular calibration is necessary to maintain high filling accuracy.
Another way to enhance accuracy is by integrating non-contact sensors, such as infrared or capacitive sensors, which can monitor the liquid level in real-time. These sensors help compensate for hose wear and flow attenuation, ensuring consistent performance throughout the hose’s lifespan.
Dear Customer,
Thank you for your interest in Shanghai Jiapeng's products. In addition to our peristaltic pump filling systems, we also offer a range of other scientific instruments, including UV analyzers, nucleic acid and protein detectors, gel imaging analysis systems, photochemical reaction instruments, and automatic fraction collectors. If you're looking for high-quality, reliable equipment for your laboratory, feel free to reach out to us. We'd be happy to provide more information and support.
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