Patent Application
20230279850
The present invention concerns a pump controller and fluid pumping systems. More particularly, some embodiments of the present invention concern a pump controller that can be coupled with a pump, pump fluid sensors, fluid level sensors, fuel sensors, and oil pressure sensors. Some embodiments of the present invention concern a pump controller for characterizing, operating, and exchanging information with connected devices which may use mathematical techniques, such as proportional-integral-derivative control. The present invention also concerns a pumping system for draining and filling fluid containers or reservoirs.
Conventional systems and methods of controlling fluid pumps are limited by pump controller devices which comprise basic “start-and-stop” technology—capable of solving only basic pumping system needs. Conventional pump controllers are also typically very cumbersome, making it difficult for the average user to set up and operate. Due to their limited capabilities, conventional controllers lack the ability to protect and properly maintain pump health. Furthermore, conventional controllers are limited to manual operation—that is, a user must initiate every operation or action the controller makes. Furthermore, conventional pump controllers are inefficient and can waste resources such as water and energy. Conventional pumping systems and devices also have limited adaptability for future changes in technology due to outdated architecture and interfaces.
There is therefore a need for a pump controller which is easy to operate, adaptable, efficient, and can handle complex pumping situations. Furthermore, there is a need for a pump controller which can automate a fluid pumping system with little to no user interaction. Moreover, there exists a need for a pump controller which can interface with other devices and sensors to characterize and protect a pump and its internal components, while also maximizing the output and efficiency of the pump and pumping system.
The present invention concerns a controller for controlling a pump. The controller may include one or more interfaces, ports, devices, or processors by which a user may operate the controller and by which the controller operates, or communicates with, connected devices. The controller may include a processor, a memory device for storing processor instructions, a user interface, a pump interface, and a fluid sensor interface.
In some embodiments, the controller may include a user interface which has a display, such as, but not limited to, a human-machine interface (“HMI”), human interface device (“HID”), or graphical user interface (“GUI”). One or more buttons, switches, and/or knobs, or the like, may be provided as a means by which the user can make selections shown on the user interface display or by which the user can turn on (or off) the controller, toggle between modes, configure the controller, or otherwise operate the controller. One or more lights may also be provided within the user interface which, depending on the state of the light (i.e., on or off), may provide information about the current status or condition of the controller or any of its connected devices. In certain embodiments, the user interface may include a touchscreen display, allowing the user to select an action by touching an area of the screen corresponding to the action. In other embodiments, the user interface may also have a transceiver and a remote user device (e.g., smartphone, tablet, laptop) which are operatively engaged with a computer network, allowing the user to remotely connect to, and operate, the controller.
In some embodiments, the controller can connect to the engine controller of the pump by means of the pump interface. Using this interface, the controller may communicate with the engine controller in order to power, operate, and/or exchange information with the pump. For example, the user can use the controller to turn the pump on or off, adjust the engine speed, and/or retrieve data about the current status of the pump (e.g., oil pressure, coolant temperature, fuel level, voltage, etc.). In certain embodiments, an emergency stop switch may be connected to the controller via the pump interface. When activated, the emergency stop switch suspends, or freezes, the currently active mode or program of the controller and immediately removes power to the pump engine to shut it down.
In some embodiments, a pump controller may use pump data, received through the various sensor interfaces, to map a pump curve. For example, while a pump is running, the pump controller can store and plot current running parameters to determine the pump curve associated with the pump. The pump controller can also compare current running parameters to a pump curve to determine if a pump is running within the pump curve. The pump controller can display a warning message indicating if the pump is operating outside of the pump curve.
In accordance with some embodiments of the present invention, the controller can also connect to one or more fluid level sensors by means of the fluid sensor interface. Using this interface, the controller may be adapted to exchange information with a fluid level sensor. For example, the controller may be connected to a float, which, depending on the state thereof (i.e., activated or inactivated), can provide information to the controller about a fluid level within a fluid container, such as a tank. The controller may also be connected to a transducer, which can provide an indication of the current fluid level. The controller can also connect to a fluid pressure sensor, which can provide fluid pressure readings at a given time and position. In certain embodiments, the controller may be connected to fluid pressure sensors provided within the inlet and outlet of a volute of the pump in order to monitor inlet and outlet pressure (which may be indicative of operational issues within the pump, such as cavitation).
In some embodiments, a pump controller may use pump data, received through the various sensor interfaces, to map a pump curve. For example, while a pump is running, the pump controller can store and plot current running parameters to determine the pump curve associated with the pump. The pump controller can also compare current running parameters to a pump curve to determine if a pump is running within the pump curve. The pump controller can display a warning message indicating if the pump is operating outside of the pump curve.
As described above, the controller of the present invention can interface with devices and sensors to form a system for controlling a pump. For example, the system may comprise a pump controller, a pump, and one or more sensors. Within the system, the pump controller may act as the central communication hub, through which information is received, processed, and transmitted. More specifically, the controller can send commands to the pump based on user input (e.g., by selecting a mode or program, or by setting parameters) or based on feedback from a fluid level or pump sensor. The system may also include a remote connection, allowing a user to remotely access and operate the pump controller via a remote user device. In some embodiments, the system may include: a pump controller; a pump having an engine and electronic engine controller; one or more fluid level sensors; a fuel level sensor; inlet and outlet oil pressure sensors for detecting pressure in an oil line of the pump engine; and inlet and outlet fluid pressure sensors for detecting fluid pressure in the pump. In certain embodiments, the system network may also include one or more floats and/or transducers.
The pump controller may include one or more programs, or modes of operation. For example, the controller may include a manual mode, an automatic mode, a diagnostics mode, and a configuration mode. Prior to operation, the user may configure the controller for use with a connected pump by selecting configuration mode on the user interface or by connecting a user device, such as a laptop, to the pump controller. On the user interface, or user device, the user may enter characterization parameters for the connected devices (e.g., pump engine type), as well as operational parameters (e.g., engine throttle set point). Once the controller is configured, the user may run the controller in manual mode or automatic mode.
In manual mode, the pump engine may be started by pressing a button or switch on the controller user interface. Once the engine is running, the user may adjust the engine throttle by adjusting the revolutions-per-minute (“RPM”) on the user interface. In automatic mode, the pump engine may be started by the pump controller via a signal from a fluid level sensor. Once the engine is running, the pump may operate on a fixed throttle based on the RPM set by the user during configuration. Alternatively, the engine throttle may be automatically adjusted, as fluid levels (or pressure) rise or fall, by the controller based on feedback received from a fluid level or pressure sensor. In this case, the throttle may be adjusted at a linear rate, relative to the fluid level or pressure (noting that RPM is proportional to fluid level or pressure). The engine throttle may also be adjusted by proportional-integral-derivative (PID) control, based on feedback from one or more fluid level or pressure sensors.
In accordance with some embodiments of the present invention, the system may be coupled with one or more containers (e.g., tanks, pits, reservoirs, or the like), which may comprise fluid. In manual mode, a user can drain fluid from a tank, or fill a tank with fluid, by turning the pump engine on using the pump controller. Once the fluid has reached a desired level, the user can turn the pump off using the pump controller. In automatic mode, the pump controller may start the pump engine upon receiving a signal from a fluid sensor. For example, the pump controller system may be coupled with a tank having a float which is connected to the pump controller. In a suction application (i.e., when the pump is configured to drain fluid from the tank), the pump may be turned on once the fluid level within the tank rises to the level (or set point) of the float. In a discharge application (i.e., when the pump is configured to fill the tank with fluid), the pump may be turned on once the fluid level within the tank lowers to the level of the float. The pump engine may then run according to a predefined duration, in which the pump turns off upon expiration of a set time limit, or until the float relay clears.
In some embodiments, the pump controller system may be coupled with a tank having two floats which are connected to the pump controller. The first float may be at a first position (e.g., near the top of the tank) and the second float may be at a second position, below the first float (e.g., near the bottom of the tank). In this configuration, the pump may be turned on by one float and turned off by the other. For example, in a suction application, the pump may be turned on once the fluid level within the tank rises to the level of the first float. The pump engine may then run until the fluid level lowers to the level of the second float.
In certain embodiments, the pump controller system may be coupled with a tank having a fluid level transducer which is connected to the pump controller. The transducer may be positioned at the top of the tank, such that the signal is directed toward the fluid surface. In this configuration, the pump may be turned on and off by the transducer, depending on the predefined set points programmed to the controller by the user. For example, in a suction application, the pump may be turned on once the fluid level within the tank rises to a first set point. The pump engine may then run until the fluid level lowers to a second set point, at which point the controller shuts down the pump. While the pump is running (i.e., while the fluid is between the first and second set points), the engine may be throttled at a constant rate, linear rate, or using PID.
In some embodiments, the pump controller system may be coupled with a tank having a transducer and one or more floats, each of which are connected to the pump controller. In such configurations, the floats may provide the “on/off” signal to the controller, while the transducer provides feedback to the controller to dynamically adjust the pump engine speed. Alternatively, the transducer may provide feedback for the engine throttle, as well as the “on” (“off”) signal to the controller. The “off” (“on”) signal may be provided by a float. It is to be appreciated, however, that the pump controller system may be coupled with one or more tanks which may include any number and combination of floats and transducers (or other types of fluid sensors).
A controller system may include digital and/or analog inputs. These inputs may provide information to the controller about the pump or a fluid tank. For example, a fuel level sensor may allow the user and controller to monitor fuel level and manually, or automatically, shut off the pump when the fuel is nearly depleted. As a protective and safety mechanism, an emergency stop device (“e-stop”) may be coupled with the controller, allowing the user to immediately stop the pump engine by removing power to the controller.
In some aspects, the invention concerns a pump controller for controlling a pump having an engine and an engine controller. In preferred embodiments the pump controller may include: a processor; a memory device for storing processor instructions; a user interface; a pump interface; and a fluid level sensor interface for communication with a fluid level sensor. The pump interface may be used to communicate with the engine controller (for example, and without limitation an engine control unit). The fluid level sensor interface may be used to communicate with a fluid level sensor (for example, and without limitation, a float in a tank). The pump controller may receive, from the fluid level sensor through the fluid sensor interface, an indication of the level of a fluid in a fluid tank. As more fully described herein, the pump controller may interface with a float or other sensor in a tank for determining whether to turn on or off the pump.
In some implementations, a user may interface with the pump controller directly at the pump controller location. For example, and without limitation, the user interface may include one or more touchscreens, buttons, switches, and/or lights. In some implementations, the user may interface with the pump controller from a remote location via wired or wireless connection. For example, and without limitation, the pump controller may include: a transceiver operatively engaged to a computer network; and a remote user device operatively engaged to the computer network. The computer network may be an open or closed network, and may be a cloud based server network on the internet.
The remote user device may be a remote desktop computer, or a wireless computing device (for example, and without limitation, a mobile phone, tablet, or computer). In some implementations, the transceiver may include an antenna for wireless communication (including but not limited to cellular, point-to-point, microwave, short range communication such as near field communication under ISO/IEC standards, or one or more IEEE 802.xx standards, such as “WiFi” or “Bluetooth” communication).
In preferred embodiments, the engine controller is an electronic engine controller (for example, and without limitation, an engine control unit (ECU) or engine control module (ECM)). In some of such embodiments, the pump controller may, through the pump interface, provide instructions to the engine controller and/or receive engine data from the engine controller. In some other embodiments, the engine controller may include a motor and an armature attached to the motor. The armature may engaged and cooperate with a throttle assembly of the engine.
In some implementations, the pump controller may include a pump fluid sensor interface for communication with a pump fluid sensor. The pump controller may receive, from the pump fluid sensor through the pump fluid sensor interface, an indication of the pressure of a fluid in the pump and/or an indication of the flow rate of a fluid in the pump via a fluid pressure sensor and/or a flow rate sensor, respectively. The pump may include a volute (or “wet end” of the pump) and the fluid pressure sensor and/or flow rate sensor may be engaged to a fluid inlet and/or outlet of the volute.
In some implementations, the pump controller may include a fuel sensor interface for communication with a fuel level sensor. The pump controller may receive, from the fuel level sensor through the fuel sensor interface, an indication of the level of fuel in a fuel tank.
In some implementations, the pump controller may include an oil pressure sensor interface for communication with an oil pressure sensor. The pump controller may receive, from the oil pressure sensor through the oil pressure sensor interface, an indication of the pressure of oil in an oil line. The oil line may be one that is engaged with an oil inlet and/or outlet of the engine of the pump.
In some other aspects, the invention concerns a system for pumping a fluid with a pump having a volute, an engine and an electronic engine controller. In some embodiments, the system can include one or more fluid level sensors for detecting a level of the fluid in a fluid tank. The fluid level sensors may be floats and/or transducers.
The transducer for detecting the level of the fluid in a fluid tank may be contact or non-contact level sensors. In some implementations, the transducer may include a non-contact optical or ultrasonic level sensor for determining the distance from the sensor to the level of fluid in the fluid tank. In some implementations, the transducer may include a contact capacitive sensor for determining, much like a float, when the level of fluid in the fluid tank is at the position where the sensor is mounted in the tank. In some implementations, the transducer may include a submersible hydrostatic pressure sensor for determining the hydrostatic pressure on the bottom of the tank, which is reflective of the volume of fluid in the tank.
In some embodiments, the system can also include: a fuel level sensor for detecting a level of fuel in a fuel tank; an inlet oil pressure sensor for detecting an inlet pressure of oil in an inlet oil line associated with the engine; an outlet oil pressure sensor for detecting an outlet pressure of the oil in an outlet oil line associated with the engine; and a pump fluid sensor for detecting a condition of the fluid in the volute of the pump. In some embodiments, the pump fluid sensor may comprise an inlet fluid pressure sensor for detecting an inlet pressure of the fluid in an inlet of the volute of the pump and/or an outlet fluid pressure sensor for detecting an outlet pressure of the fluid in an outlet of the volute of the pump. In some embodiments, the pump fluid sensor may comprise a flow rate sensor for detecting a flow rate of the fluid in the volute of the pump.
The pump controller may be operatively engaged with the engine controller, the fluid level sensors, the fuel level sensor, the inlet oil pressure sensor, the outlet oil pressure sensor, and the pump fluid sensor
In some embodiments, the pump controller may include a processor, a memory device storing processor instructions, and a user interface. The processor instructions, when executed by the processor, may provide instructions to the engine controller. The instructions may be in response to the level of fluid in the fluid tank, the level of the fuel, the inlet pressure of the oil, the outlet pressure of the oil, and the condition of the fluid in the volute.
In some implementations, the user interface may include a touchscreen device. In some implementations, the user interface may include a transceiver and a remote user device. The transceiver and the remote user device may be operatively engaged with a computer network. The transceiver may, in some implementations, may be wireless and include an antenna.
In some other aspects, the invention concerns a system for pumping a fluid. The system may include a first fluid tank for containing the fluid, the first fluid tank having a tank port, and a first fluid level sensor for detecting the level of the fluid in the first fluid tank. The fluid level sensor may include one or more floats or transducers. As above, the transducers may be contact or non-contact level sensors, and may include optical level sensors, ultrasonic level sensors, capacitive sensors, or hydrostatic pressure sensors.
The system may further include a fuel tank and a fuel level sensor for detecting the level of fuel in the fuel tank. The system may further include an inlet and an outlet oil line, and an inlet and outlet oil pressure sensor for detecting a pressure of oil in the oil lines, respectively. The system may further include a first fluid pressure sensor for detecting a first pressure of the fluid and a pump fluid flow rate sensor for detecting a flow rate of the fluid.
In preferred embodiments, the pump may include: a volute having a first port engaged with the tank port of the first fluid tank and also being engaged with the pump fluid flow rate sensor; an engine engaged with the fuel line and the inlet and outlet oil lines; and an engine controller.
In preferred embodiments, the pump controller may be engaged with the engine controller, the first fluid level sensor, the fuel level sensor, the inlet and outlet oil pressure sensors, the first fluid pressure sensor, and the pump fluid flow rate sensor. The pump controller may provide instructions to the engine controller in response to the level of the fluid in the first fluid tank, the level of the fuel in the fuel tank, the pressure of the oil in the inlet oil line, the pressure of the oil in the outlet oil line, the first pressure of the fluid in the pump, the flow rate of the fluid in the pump, and a user interface of the pump controller.
In some embodiments, the system may further include: a second fluid tank for containing the fluid, the second fluid tank comprising a tank port; a second fluid level sensor for detecting the level of the fluid in the second fluid tank; and a second fluid pressure sensor of detecting a second pressure of the fluid. The volute may further include a second port engaged with the tank port of the second fluid tank and the second fluid pressure sensor. The pump controller may further be engaged with the second fluid level sensor and the second fluid pressure sensor, and provide instructions to the engine controller in response to the level of the fluid in the second fluid tank and the second pressure of the fluid in the pump.
In some aspects, the invention concerns a method of controlling a pump having an engine and an electronic controller. In preferred embodiments, the method may include the steps of: characterizing the operation of a pump; performing a safety check of the pump; determining a level of a fluid in a fluid tank; and providing instructions to the electronic controller. The method may further include the step of determining a target speed of the pump. The method may further include the step of charging a battery.
In preferred embodiments, characterization of the pump may include the steps of: providing instructions to the electronic engine controller to cause the engine to rotate at a first characterization speed; and, while the engine is rotating at the first characterization speed, detecting a first pump condition of the pump. Detecting the first pump condition may include the steps of detecting an inlet fluid pressure of the fluid at a fluid inlet of a volute of the pump and/or detecting an outlet fluid pressure of the fluid at a fluid outlet of the volute of the pump. Detecting the first pump condition may include the step of detecting a flow rate of the fluid in the volute of the pump.
In some embodiments, characterization of the pump may further include the steps of: providing instructions to the electronic engine controller to cause the engine to rotate at a second characterization speed; and, while the engine is rotating at the second characterization speed, detecting a second pump condition of the pump. Detecting the second pump condition may include the steps of detecting the inlet and/or outlet fluid pressures of the volute. Detecting the second pump condition may include the step of detecting a flow rate of the fluid in the volute of the pump.
The instructions may be provided to the electronic engine controller by a pump controller having a processor, a memory device storing processor instructions thereon, and a user interface. The instructions may cause the engine to rotate at a target speed. In preferred embodiments, the target may be determined from the level of the fluid in the tank, the first characterization speed, the first pump condition, the second characterization speed, and the second pump condition.
In preferred embodiments, the safety check may include the steps of: detecting a pressure of oil in an inlet oil line engaged with the engine; detecting a pressure of oil in an outlet oil line engaged with the engine; and detecting the level of fuel in a fuel tank. In some embodiments, the safety check may include the step of receiving an engine condition of the engine from the electronic engine controller. The engine condition could be one or more of the engine block temperature, a torque of the engine, a temperature of the oil in the engine, a pressure of the oil in the engine, a pressure of a coolant in the engine, a temperature of the coolant in the engine, a temperature of a fuel, an indication of the amount of the fuel that has been used, an indication of the rate at which the fuel is used, a temperature of an inlet air at an air inlet of the engine, a pressure of the inlet air, a temperature of an outlet air at an air outlet of the engine, a pressure of the outlet air, a temperature of air at an exhaust of the engine, the running hours of the engine, the total hours of the engine, and a fault code.
In some embodiments, the battery may be charged by the steps of: determining whether the battery needs to be charged; opening a volute of the pump; and providing instructions to the electronic engine controller, the instructions causing the engine to rotate at a charging speed for a charging time.
The invention, in its various aspects, will be explained in greater detail below. While the invention will be described in conjunction with several exemplary embodiments, the exemplary embodiments themselves do not limit the scope of the invention. Similarly, the exemplary illustrations in the accompanying drawings, where like elements have like numerals, do not limit the scope of the exemplary embodiments and/or invention, including any length, angles, or other measurements provided. Rather the invention, as defined by the claims, may cover alternatives, modifications, and/or equivalents of the exemplary embodiments.
The present invention generally concerns a pump controller for controlling a pump, as well as systems, methods, and software for controlling a pump and for pumping a fluid. In some embodiments, the pump controller may include one or more interfaces, ports, devices, or processors by which a user may operate the controller and by which the controller operates, or communicates with, connected devices. More specifically, the controller may include a processor, a memory device for storing processor instructions, a user interface, a pump interface, and a fluid sensor interface. For example, as illustrated in
As part of the user interface, lights 110 may provide information to a user about the current status or condition of controller 100, or any of its connected devices, based on the current state of light(s) 110 (i.e., on or off, emitted color). For example, and without limitation, if light 110 is on and emitting a red color, it may indicate an issue with a connection between pump controller 100 and a fluid sensor. It is to be appreciated, however, that a pump controller can include any number of lights, or other audio or visual devices such as, but not limited to, a horn, which may serve as status indicators or warnings related to the pump controller or its connected devices.
In some embodiments, a pump controller may be adapted to communicate with an electronic engine controller of a pump. For example, pump controller 100 can exchange information with a pump by means of pump interface 121 in order to power, operate, or otherwise control the pump. Through this interface, pump controller 100 can provide instructions to the electronic engine controller in order to start, stop, or adjust the throttle of the pump engine. In some embodiments, the pump controller may be adapted to communicate with an engine controller of a pump which may have an armature engaged with the throttle of the pump engine.
In accordance with some embodiments of the present invention, the pump controller can also be coupled with one or more fluid sensors, which may provide feedback to the pump controller regarding fluid level or fluid pressure. For example, controller 100 may be adapted to exchange information with a fluid level sensor by means of fluid level sensor interface 122. The fluid level sensor may provide feedback to controller 100, which, depending on the signal, may cause controller 100 to turn the pump on or off, or to adjust the speed of the pump engine. In some embodiments, the pump controller may be connected to one or more floats which serve as feedback mechanisms for determining when, or at what fluid level within a fluid tank, the pump engine is to be turned on and off. The controller may also be connected to one or more transducers, which, for example, can provide readings of a fluid level or pressure. In certain embodiments, a transducer may serve as a feedback mechanism for determining the levels at which the pump engine is turned on and off. Additionally, feedback from a transducer can be used to determine throttle adjustment of the pump engine by the pump controller, thereby adjusting the speed of the pump.
In some embodiments, a pump controller may also be adapted for remote operation. As further illustrated in
According to some embodiments of the present invention, the user interface may include a display, buttons, switches, and/or knobs, which may provide a means by which the user can turn on (or off) the controller, toggle between modes, enter data, or otherwise operate the controller. For example, controller 100 may include display 141, one or more switches 142, and knob 143. Switches 142 and knob 143 may be used to select an option or field shown on display 141. Switches 142 and knob 143 may also be used to send a command to a connected pump, such as initiating the startup sequence to the pump engine.
According to some embodiments of the present invention, a pump controller may be adapted to characterize a pump, which may provide a user with information pertaining to the health of the pump. For example, pump controller 100 may be further adapted to receive pump engine data from the engine controller by means of pump interface 121. In certain embodiments, a pump controller may also include fuel sensor and/or oil pressure sensor interfaces, through which the controller can communicate with a fuel level sensor and oil pressure sensor, respectively. A fuel level sensor may be used to measure the level of fuel within a fuel tank associated with the pump engine. An oil pressure sensor may be used to measure pressure within oil lines engaged with the oil inlet and/or outlet of the pump engine.
In some embodiments, the pump controller may be adapted to automatically charge a pump battery. For example, pump controller 100 can receive information about battery 240 of pump 200 through pump interface 121. Pump controller 100 can then determine if the voltage of battery 240 is low and if it needs charging. If battery 240 requires charging, pump controller 100 can turn on and run pump engine 220 at a predefined charge speed for a predefined duration of time. Once the set runtime expires, the pump controller will shut down the engine.
Pump controller 100 may also be adapted to receive data from one or more fluid sensors associated with a pump volute and connected via pump fluid sensor interface 125. For example, fluid pressure sensors and/or fluid flow meters may be provided to measure fluid pressure or fluid flow, respectively, through an inlet or outlet of the pump volute. It is to be appreciated that the pump controller may be adapted to receive a wide variety of information regarding the status of a pump (e.g., oil pressure, fluid flow, fuel level, coolant temperature, voltage, etc.). This information can be used to protect and maintain pump health, either by built-in mechanisms within the pump controller, or by user action. For example, the pump controller may determine, by volute inlet and outlet flow rates measured by flow meters, that the pump is undergoing cavitation. In response, the pump controller may automatically shut down the pump engine. Alternatively, the user may determine, based on the pump data, to manually shut down the engine. In such cases, a pump controller may be coupled with an emergency stop switch to immediately cut power to the controller and, thus, pump engine. In some cases, the pump data may be indicative of worn out or malfunctioning pump parts, which allows the user to determine if and when a part should be replaced—thus extending the life of the pump.
A pump controller can interface with a number of devices and sensors to form a system network for controlling a pump. The pump controller may act as the central processor, receiving signals from one or more sensors and, based on sensor feedback or user input, providing commands to a pump. For example, as illustrated in
A pump controller may include one or more programs, or primary modes of operation. For example, as illustrated in
Before the user can operate the pump in automatic mode, the user may configure connected sensors and specify the job type and operational parameters. For example, as illustrated in
To use the pump with one or more fluid sensors, the user may also enter fluid sensor information through configuration mode. For example, the user can set parameters related to a connected float and/or a connected transducer, as shown in
In manual mode, the pump engine may be started by pressing a button or switch on the user interface. As shown in
In automatic mode, the pump engine may be started by the pump controller via a signal from a fluid sensor. For example, a connected float may be tripped by a fluid, or a connected transducer may detect that the fluid has reached a predefined set point, causing the pump controller to attempt to start the pump engine. If the pump engine does not start after a predefined maximum number of attempts, the start sequence may be aborted. Once the pump engine is running, the pump may operate on either: a fixed throttle (single speed), based on the speed set by the user during configuration; linear throttling, based on predefined parameters and feedback from a transducer; or PID throttling, based one predefined parameters and feedback from a transducer.
In the case of a malfunction, poor performance, or other general issues, or if a user wants to obtain real-time information about the pump and connected devices, the user can enter diagnostics mode. As shown in
A pump controller and a pump, in accordance with some embodiments of the present invention, may be coupled with one or more tanks, which may comprise fluid, for the purpose of pumping fluid into or out of a tank. In certain embodiments, a pump controller may be coupled with a pump connected to a single tank. In a suction (drain) application, an inlet of the pump may be engaged with an outlet of the tank. In a fill (discharge) application, an outlet of the pump may be engaged with an inlet of the tank. In other embodiments, the pump may be connected to two tanks—one tank engaged with the pump inlet and the other tank engaged with the pump outlet. In such embodiments, fluid may be transferred between tanks when the pump is on (i.e., one tank drains, while the other tank fills). In manual mode, a user can drain fluid from a tank, or fill a tank with fluid, by turning the pump engine on using the pump controller. Once the fluid reaches a desired level, the user can turn the pump off using the pump controller.
In automatic mode, the pump controller may start the pump engine upon receiving a signal from a fluid sensor. In some embodiments, the pump controller and pump may be coupled with a tank having a float connected to the pump controller. In a suction application, the pump may be turned on once the fluid level within the tank rises to the level of the float and activates it. In a discharge application, the pump may be turned on once the fluid level within the tank lowers to the level of the float and activates it. If the float circuit is normally open, then the float is considered activated when the float circuit closes. If the float circuit is normally closed, then the float is considered activated when the float circuit opens. The pump engine may then run according to a predefined duration, in which the pump turns off upon expiration of a set time limit, or until the float circuit closes (or opens). In preferred embodiments, a float may include a hysteresis function to delay the closing of the float circuit. In certain embodiments, a float may have an activated range—that is, once activated, the float may stay activated until the fluid level rises above or lowers below the activated range. In this case, the pump may turn off after a fixed increase or decrease in fluid levels.
In some embodiments, the pump controller and pump can be coupled with a tank having a transducer which is connected to the pump controller. The transducer may be positioned at the top of the tank, such that the signal is directed toward the fluid surface, or, alternatively, the transducer may be positioned near the bottom of the tank, submerged in a fluid. In this configuration, the pump may be turned on and off by the transducer, depending on the predefined set points programmed to the controller by the user. For example, in a suction application, the pump may be turned on once the fluid level within the tank rises to a first set point. The pump engine may then run until the fluid level lowers to a second set point, at which point the controller shuts down the pump.
A transducer can also be in used in controlling the pump engine throttle while the pump is running (i.e., while the fluid is between the first and second set points). In a linear application, the pump controller calculates the engine throttle based on a linear correlation between a fluid level and pump engine RPM. To perform this calculation, the pump controller uses the ratios of the high fluid level set point to the low fluid level set point, and the maximum pump engine RPM to the minimum pump engine RPM (these parameters are predefined by the user). In a PID application, the pump controller uses feedback from the transducer and uses PID to calculate throttle adjustment based on the target transducer value (e.g., fluid level).
In some embodiments, the pump controller and pump may be coupled with a tank having one or more transducers and one or more floats, each of which are connected to the pump controller. In such configurations, a float may provide the “on/off” signal to the controller, while a transducer may provide feedback to the controller to adjust the pump engine speed. Alternatively, a transducer may provide feedback for the engine throttle, as well as the “on” (“off”) signal to the controller and the “off” (“on”) signal may be provided by a float. In certain embodiments, the tank may have two or more transducers and no floats, where a first transducer provides the “on/off” signal and a second transducer provides feedback to the pump controller. It is to be appreciated, however, that a pump controller and pump may be coupled with one or more tanks which may include any number and combination of floats and transducers (or other types of fluid sensors).
Referring, generally, to
Referring now to
To execute the above-described implementation, a user must turn on pump controller 100 and properly configure the controller for a single float suction program prior to use. Afterwards, the user selects automatic mode via the user interface to initiate the program. Once the fluid level within tank 700 rises to the level of float 311A, the circuit of float 311A becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Upon activation, a signal is sent to, and processed by, pump controller 100. As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200. Once pump 200 is running, the engine runs at a single speed predefined by the user through configuration mode of pump controller 100. As the fluid level lowers below the level of float 311A, the circuit becomes deactivated (circuit re-opens if float circuit is normally open; circuit re-closes if float circuit is normally closed). Pump controller 100 then sends a signal to pump 200 to continue to run at the predefined engine speed for a predefined duration. The predefined duration is set by the user in configuration mode of pump controller 100 by specifying the amount of time the engine runs after float 311A is deactivated. Once this time period expires, pump controller 100 sends a signal to pump 200 to shut down the engine.
Referring now to
To execute the above-described implementation, a user must turn on pump controller 100 and properly configure the controller for a single float discharge (drain) program prior to use. Afterwards, the user selects automatic mode via the user interface to initiate the program. Once the fluid level within tank 700 lowers to the level of float 313B, the circuit of float 313B becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Upon activation, a signal is sent to, and processed by, pump controller 100. As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200. Once pump 200 is running, the engine runs at a single speed predefined by the user through configuration mode of pump controller 100. As the fluid level rises above the level of float 313B, the circuit becomes deactivated (circuit re-opens if float circuit is normally open; circuit re-closes if float circuit is normally closed). Pump controller 100 then sends a signal to pump 200 to continue to run at the predefined engine speed for a predefined duration. The predefined duration is set by the user in configuration mode of pump controller 100 by specifying the amount of time the engine runs after float 313B is deactivated. Once this time period expires, pump controller 100 sends a signal to pump 200 to shut down the engine.
Referring now to
To execute the above-described implementation, a user must turn on pump controller 100 and properly configure the controller for a dual float suction program prior to use. Afterwards, the user selects automatic mode via the user interface to initiate the program. Once the fluid level within tank 700 rises to the level of float 311C at depth 700C, both the circuit of float 311C and the circuit of float 313C are activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Once floats 311C and 313C are activated, a signal is sent to, and processed by, pump controller 100. As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200. Once pump 200 is running, the engine runs at a single speed predefined by the user through configuration mode of pump controller 100. As the fluid level lowers below the level of float 311C, the circuit becomes deactivated (circuit re-opens if float circuit is normally open; circuit re-closes if float circuit is normally closed). Pump 200 continues to run until the fluid level lowers below the level of float 313C, deactivating the circuit. Pump controller 100 then sends a signal to pump 200 to shut down the engine.
Referring now to
To execute the above-described implementation, a user must turn on pump controller 100 and properly configure the controller for a dual float discharge program prior to use. Afterwards, the user selects automatic mode via the user interface to initiate the program. Once the fluid level within tank 700 lowers to below depth 760D, below floats 311D and 313D, both the circuit of float 311D and the circuit of float 313D are deactivated (circuit opens if float circuit is normally open; circuit closes if float circuit is normally closed). Once floats 311D and 313D are deactivated, a signal is sent to, and processed by, pump controller 100. As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200. Once pump 200 is running, the engine runs at a single speed predefined by the user through configuration mode of pump controller 100. As the fluid level rises above float 313D to the level of float 311D at depth 740D, the circuits of floats 311D and 313D become activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Once float 311D is activated, pump controller 100 sends a signal to pump 200 to shut down the engine.
Referring now to
To execute the above-described implementation, a user must turn on pump controller 100 and properly configure the controller for a transducer feedback suction program prior to use. If engine throttling is desired, the user must also configure the controller for linear and PID throttling submodes. Afterwards, the user selects automatic mode via the user interface to initiate the program. While the program is running, transducer 320E provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320E to the fluid surface). Once the fluid level within tank 700 rises to a point where transducer 320E detects that the fluid level is above high setpoint 745E, a signal is sent to, and processed by, pump controller 100 to start the pump engine. If the user has set the engine throttle to a single speed, the engine of pump 200 will run at a single speed until transducer 320E detects that the fluid level has reached low setpoint 765E. At this point, based on the feedback from transducer 320E, pump controller 100 sends a signal to pump 200 to shut down.
If instead, the user is running the program with a linear throttling submode, the speed of the engine of pump 200 will decrease, linearly, as the fluid lowers from high setpoint 745E to low setpoint 765E. For example, if the fluid is at depth 750E, pump controller 200 determines the instantaneous fluid level from transducer 320E and then uses this value to calculate the engine throttle adjustment, based on the high setpoint and low setpoint, and the maximum and minimum speeds of the engine (predefined by the user). As the fluid level continues to lower, pump controller 100 continues to adjust the engine throttle in predefined time or distance increments until transducer 320E detects that the fluid level has reached low setpoint 765E. At this point, based on feedback from transducer 320E, pump controller 100 sends a signal to pump 200 to shut down.
Alternatively, if the user is running the program with a PID throttling submode, the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to a fluid level corresponding to depth 750E, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320E detects that the fluid level is below depth 750E. If transducer 320E detects that the fluid level is above depth 750E, pump controller 200 will send a signal to pump 200 to increase the engine speed. Pump 200 will continue to run as long as the fluid level is above the low setpoint.
Referring now to
To execute the above-described implementation, a user must turn on pump controller 100 and properly configure the controller for a transducer feedback discharge program prior to use. If engine throttling is desired, the user must also configure the controller for linear and PID throttling submodes. Afterwards, the user selects automatic mode via the user interface to initiate the program. While the program is running, transducer 320F provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320F to the fluid surface). Once the fluid level within tank 700 lowers to a point where transducer 320F detects that the fluid level is below low setpoint 765F, a signal is sent to, and processed by, pump controller 100 to start the pump engine. If the user has set the engine throttle to a single speed, the engine of pump 200 will run at a single speed until transducer 320F detects that the fluid level has reached high setpoint 745F. At this point, based on the feedback from transducer 320F, pump controller 100 sends a signal to pump 200 to shut down.
If instead, the user is running the program with a linear throttling submode, the speed of the engine of pump 200 will decrease, linearly, as the fluid rises from low setpoint 765F to high setpoint 745F. For example, if the fluid is at depth 750F, pump controller 100 determines the instantaneous fluid level from transducer 320F and then uses this value to calculate the engine throttle adjustment, based on the high setpoint, the low setpoint, and the maximum and minimum speeds of the engine (predefined by the user). As the fluid level continues to rise, pump controller 100 continues to adjust the engine throttle in predefined time or distance increments until transducer 320F detects that the fluid level has reached high setpoint 745F. At this point, based on feedback from transducer 320F, pump controller 100 sends a signal to pump 200 to shut down.
Alternatively, if the user is running the program with a PID throttling submode, the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to value corresponding to depth 750F, pump controller 100 will send a signal to pump 200 to increase the engine speed (calculated via the PID algorithm) if transducer 320F detects that the fluid level is below depth 750F. If transducer 320F detects that the fluid level is above depth 750F, pump controller 100 will send a signal to pump 200 to decrease the engine speed. Pump 200 will continue to run as long as the fluid level is below the high setpoint.
Referring now to
To execute the above-described implementation, a user must turn on pump controller 100 and properly configure the controller for a transducer feedback suction program prior to use. The user must also configure the controller for linear or PID throttling submodes. Afterwards, the user selects automatic mode via the user interface to initiate the program. While the program is running, transducer 320G provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320G to the fluid surface). When the fluid level reaches depth 740G, the circuit of float 311G becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Upon activation, a signal is sent to, and processed by, pump controller 100. As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200. Once pump 200 is running, the engine speed is adjusted at a linear rate (if set to linear throttle submode) based on high and low setpoints, and maximum and minimum engine speeds (analogous to the procedure described previously). As the fluid level lowers below the level of float 311G, the circuit becomes deactivated (circuit re-opens if float circuit is normally open; circuit re-closes if float circuit is normally closed). Pump controller 100 then sends a signal to pump 200 to shut down.
Alternatively, if the user is running the program with a PID throttling submode, the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to depth 750G, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320G detects that the fluid level is below depth 750G. If transducer 320G detects that the fluid level is above depth 750G, pump controller 200 will send a signal to pump 200 to increase the engine speed. Pump 200 will continue to run as long as float 311G is activated.
Referring now to
To execute the above-described implementation, a user must turn on pump controller 100 and properly configure the controller for a transducer feedback suction program prior to use. The user must also configure the controller for linear or PID throttling submodes. Afterwards, the user selects automatic mode via the user interface to initiate the program. While the program is running, transducer 320H provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320H to the fluid surface). When the fluid level reaches depth 760H, the circuit of float 313H becomes deactivated (circuit opens if float circuit is normally open; circuit closes if float circuit is normally closed). Upon activation, a signal is sent to, and processed by, pump controller 100. As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200. Once pump 200 is running, the engine speed is adjusted at a linear rate (if set to linear throttle submode) based on high and low setpoints, and maximum and minimum engine speeds (analogous to the procedure described previously). As the fluid level rises above the level of float 313H, the circuit becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Pump controller 100 then sends a signal to pump 200 to shut down.
Alternatively, if the user is running the program with a PID throttling submode, the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to depth 750H, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320H detects that the fluid level is above depth 750H. If transducer 320H detects that the fluid level is below depth 750H, pump controller 100 will send a signal to pump 200 to increase the engine speed. Pump 200 will continue to run as long as float 313H is deactivated.
Referring now to
To execute the above-described implementation, a user must turn on pump controller 100 and properly configure the controller for a transducer feedback suction program prior to use. The user must also configure the controller for linear or PID throttling submodes. Afterwards, the user selects automatic mode via the user interface to initiate the program. While the program is running, transducer 320I provides real-time feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320I to the fluid surface). When the fluid level rises to depth 760I, the circuit of second float 313I becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). When the fluid level rises to depth 7401, the circuit of first float 3111 becomes activated. Upon activation, a signal is sent to, and processed by, pump controller 100. As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200. Once pump 200 is running, the engine speed is adjusted at a linear rate using transducer 320I feedback (if set to linear throttle submode) based on high and low setpoints, and maximum and minimum engine speeds (analogous to the procedure described previously). As the fluid level lowers below first float 3111 at depth 7401, the circuit becomes deactivated (circuit re-opens if float circuit is normally open; circuit re-closes if float circuit is normally closed). As the fluid level continues to lower to below second float 313I at depth 760I, the circuit becomes deactivated. Pump controller 100 then sends a signal to pump 200 to shut down.
Alternatively, if the user is running the program with a PID throttling submode, the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to a value corresponding to depth 750I, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320I detects that the fluid level is below depth 750I. If transducer 320I detects that the fluid level is above depth 750I, pump controller 100 will send a signal to pump 200 to increase the engine speed. Pump 200 will continue to run as long as second float 313I is activated.
Referring now to
To execute the above-described implementation, a user must turn on pump controller 100 and properly configure the controller for a transducer feedback suction program prior to use. The user must also configure the controller for linear or PID throttling submodes. Afterwards, the user selects automatic mode via the user interface to initiate the program. While the program is running, transducer 320I provides real-time feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320I to the fluid surface). When the fluid level lowers below first float 3111 at depth 7401, the circuit of first float 3111 becomes deactivated (circuit opens if float circuit is normally open; circuit closes if float circuit is normally closed). When the fluid level lowers below second float 313I at depth 760I, the circuit of second float 313I becomes deactivated. Upon deactivation, a signal is sent to, and processed by, pump controller 100. As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200. Once pump 200 is running, the engine speed is adjusted at a linear rate using transducer 320J feedback (if set to linear throttle submode) based on high and low setpoints, and maximum and minimum engine speeds (analogous to the procedure described previously). As the fluid level rises above second float 313J at depth 760J, the circuit becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). As the fluid level continues to rise and reaches first float 311J at depth 740J, the circuit becomes activated. Pump controller 100 then sends a signal to pump 200 to shut down.
Alternatively, if the user is running the program with a PID throttling submode, the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to depth 750J, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320J detects that the fluid level is above depth 750J. If transducer 320J detects that the fluid level is below depth 750J, pump controller 100 will send a signal to pump 200 to increase the engine speed. Pump 200 will continue to run as long as first float 311J is deactivated.
Referring now, generally, to
proceed to Step 25017
if float is untripped; proceed to Step 29116
Referring, generally, to
In some embodiments, the pump controller may include one or more interfaces for displaying warning messages. For example, as illustrated in
As further illustrated in
It is to be understood that variations, modifications, and permutations of embodiments of the present invention may be made without departing from the scope thereof. It is also to be understood that the present invention is not limited by the specific embodiments, descriptions, or illustrations or combinations of either components or steps disclosed herein. Thus, although reference has been made to the accompanying figures, it is to be appreciated that these figures are exemplary and are not meant to limit the scope of the invention.
This application claims priority to, and the benefit of, U.S. Provisional Patent Application No. 62/636,579, filed Feb. 28, 2018, which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62636579 | Feb 2018 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16289545 | Feb 2019 | US |
| Child | 17956285 | US |
