INDUSTRIAL AUTOMATION

Programmable Fluid Dispensing Controller

Project Overview

A compact handheld control unit designed for accurate fluid dispensing, featuring a programmable keypad interface, flow metering, and solenoid control. Built around an 8-bit microcontroller, the device supports industrial input voltages (12–24V) and has seen successful deployment of over 5,000 units across the U.S. market.

HARDWARE | FIRMWARE | MOBILE/WEB APPS | EMS MANUFACTURING

Client Requirement & Objectives

Precision Fluid Dispensing

The device needed to allow operators to program and deliver specific quantities of fluid per batch, with high repeatability.

User Interface & Interaction

Required a backlit LCD to display flow status and settings, and a multi-functional keypad for input and menu navigation.

PIndustrial Compatibility

The controller had to support wide-range DC inputs from 12V to 24V and drive solenoids up to 120W for industrial-grade integration.

Production-Ready Hardware:

The client required a robust, manufacturable design ready for scale-up and regulatory compliance for U.S. distribution.

System Design & Build

Microcontroller-Based Architecture

Built using a reliable 8-bit microcontroller optimized for real-time control of solenoids and flow meter integration.

User-Friendly Interface

Integrated a dot matrix LCD with backlighting and a durable membrane keypad for easy navigation and real-time monitoring.

Flexible Power Design

Designed the PCB and power stage to handle variable 12–24V input ranges, suitable for diverse industrial environments.

Scaled Manufacturing

Engineered the product for manufacturability and successfully delivered over 5,000 units with consistent quality control and testing.

Key Challenges & Solutions

Handling Wide Input Voltage

Ensuring the controller worked reliably across a 12–24V input range was challenging due to voltage fluctuation and noise. We implemented a robust power regulation circuit with over-voltage and reverse-polarity protection to stabilize the system.

Consistent Fluid Accuracy

Achieving batch-level accuracy required precise synchronization between the flow meter and solenoid valve. We developed calibration routines and debounce filtering to ensure repeatable fluid delivery.

Interface Responsiveness

Ensuring the keypad and LCD worked seamlessly without interfering with timing-critical operations was key. We used interrupt-driven input handling and task prioritization to maintain a smooth user experience.

Manufacturing Scale & Quality

Scaling up production to 5,000+ units demanded high consistency across batches. We created comprehensive test jigs and QA protocols to validate every unit before shipment.