INDUSTRIAL AUTOMATION
Programmable Fluid Dispensing Controller
HARDWARE | EMS MANUFACTURING
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.
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.
Industrial 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.
Project Tech Stack
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..
Client
Assured Automation is a leading provider of actuated valves and flow components for industrial process control applications.
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