Patent Grant
11713237
The present invention relates generally to liquid discharge systems, and more particularly, to a liquid discharge system including a liquid product pump having a vibration sensor. The invention further relates to a system and method for controlling the operation of a liquid product pump in an engine-driven hydraulic discharge system. In an exemplary embodiment, the invention is a liquid discharge system including a vibration sensor for detecting cavitation within a liquid product pump, and a method for controlling the operating speed of the liquid product pump to avoid the potentially damaging effects of cavitation.
A liquid discharge system is employed on a tank truck to off-load a liquid product from a tank trailer to a storage tank. The liquid discharge system typically includes a fluid pump, referred to herein as a liquid product pump, to transfer the liquid product from the tank trailer through a suction conduit and to the storage tank through a discharge conduit. The liquid product pump receives mechanical power from a variable speed hydraulic motor that in turn receives fluid pressure from a hydraulic pump powered by a constant speed power take-off (PTO) of the tank truck. The optimum operating speed of the liquid product pump for efficient off-loading of liquid product is determined primarily by the maximum speed at which the pump can operate before cavitation begins.
Cavitation can occur as a result of changes in operating temperature, but more commonly occurs as a result of changes in vacuum pressure at the inlet side of the liquid product pump. Excessive vacuum at the inlet side of the liquid product pump forms vapor bubbles in the liquid product that implode (collapse violently) when they reach the discharge side of the liquid product pump. The violent implosion of vapor bubbles releases heat energy that adds to the system heat and produces acoustic energy forces that cause pitting in the metal surfaces of the liquid product pump. Over time, cavitation will damage wear plates, gears and impeller vanes in addition to the outer casing of the liquid product pump. Eventually, if not avoided, cavitation will destroy the operation of the liquid product pump by causing erosion and/or seal failure.
Vacuum pressure at the inlet side of the liquid product pump is influenced by a number of factors, including the operating temperature, the ambient pressure, the density of the liquid product and the operating speed of the liquid product pump. The engine speed of the tank truck, and thus the power delivered by the power take-off (PTO) to the hydraulic pump, is constant. As a result, the liquid product pump operates at predetermined speed regardless of the density of the liquid product. The operator of a liquid discharge system can easily cause cavitation to occur within the liquid product pump by allowing the pump to operate in excess of the optimum operating speed for efficient off-loading. An untrained or inexperienced operator may not recognize an occurrence of cavitation. Even an experienced operator may not detect an occurrence of cavitation due to the noise in the ambient environment from the engine and power take-off (PTO) of the tank truck. As previously mentioned, repeated occurrences of cavitation over time will eventually destroy the operation of the liquid product pump by causing erosion and/or seal failure. Off-loading liquid product at the optimum operating speed of the liquid product pump is cost efficient. Conversely, downtime for repair or replacement of a liquid product pump in a liquid discharge system due to failure of the liquid product pump as a result of the damaging effects of cavitation is costly and inefficient.
U.S. Pat. No. 5,332,356 issued Jul. 26, 1994, to Gülich discloses a device and process for determining the erosion rate caused by cavitation in a liquid product pump by detecting the vibration in the pump casing. A noise measuring device secured to an outer wall of the pump casing or inserted a predetermined depth into the outer wall detects the vibrations of the outer wall to produce a casing vibration signal. The maximum local erosion rate is a known function of the fluid-borne noise level caused by cavitation. A signal processing unit of a computer processes the vibration signal by amplifying, filtering and/or digitizing the vibration signal and calculates a fluid-borne noise level. The computer then calculates a specific erosion rate from an empirical correlation with the fluid-borne noise level. A maximum local erosion rate is then determined from a known relationship between a material-dependent material constant and the specific erosion rate. The computer may indicate the accumulated erosion or may provide an alarm when a predetermined threshold of the maximum local erosion rate is exceeded.
Gülich further discloses the use of additional measuring devices including an outlet pressure measuring device and a suction (inlet) pressure measuring device that permit the computer to calculate the present flow rate of the pump, the operating point of the pump, and a reference pressure with a reference velocity of a rotating shaft of the pump. A regulating device controlled by the computer can control the operating speed of the motor of the pump. The closed control loop permits the flow rate of the pump to be determined independently of the erosion rate. Thus, the working point of the pump can be altered by adjusting the motor speed so that the pump operates to avoid cavitation.
U.S. Pat. No. 5,846,056 issued Dec. 8, 1998, to Dhindsa et al. discloses a method for operating a reciprocating pump. The reciprocating pump includes a control circuit and a vibration sensor affixed to the body of the reciprocating pump and electrically coupled to the control circuit. The vibration sensor provides signals representative of the vibration level of the pump to the control circuit. The control circuit processes the vibration sensor signals and activates an alarm in the event that the vibration level of the pump exceeds a predetermined value. The control circuit may be programmed to reduce the operating speed of the pump in response to the vibration sensor signals indicating an excessive vibration of the pump, or may shut down the pump until an improper installation or a malfunction of the pump is corrected.
U.S. Pat. No. 6,882,960 issued Apr. 19, 2005, to Miller discloses a system and a method for monitoring and analyzing the performance of a reciprocating piston positive displacement pump, commonly referred to as a “power pump.” The system includes a signal processor electrically connected to pressure sensors and to various other sensors, including a fluid temperature sensor, a power input sensor and a pump vibration sensor. The signal processor monitors the various sensors and analyzes the performance of the pump to determine pump efficiencies and operating parameters. The pump efficiencies and operating parameters may be displayed on a visual display directly connected to the signal processor or via an associated network.
In one aspect, the present invention is embodied by a liquid discharge system including a liquid product pump having an outer casing and a sensor operably coupled to the outer casing of the liquid product pump. The sensor monitors vibrations passing through the outer casing of the liquid product pump to detect an occurrence of cavitation within the liquid product pump. In one embodiment, the liquid product pump is a positive displacement pump. The positive displacement pump may be selected from the group consisting of a gear pump, a lobe pump and a rotary vane pump. In one embodiment, the sensor is selected from the group consisting of an acoustic sensor, a knock sensor and an accelerometer. In an advantageous embodiment, the sensor is a vibration sensor.
In one embodiment, the sensor is affixed to the exterior of the outer casing of the liquid product pump by a casing bolt that secures portions of the outer casing together. In another embodiment, the sensor is disposed at least partially within the outer casing.
In one embodiment, the liquid product pump has an intake connection configured for receiving a suction conduit and an outtake connection configured for receiving a discharge conduit. In an advantageous embodiment, the suction conduit extends between a tank trailer and the intake connection of the liquid product pump on a vacuum side of the liquid product pump and the discharge conduit extends between the outtake connection on a pressure side of the liquid product pump and a storage tank, and the liquid product pump operates to transfer a liquid product from the tank trailer to the storage tank.
In another aspect, the present invention is embodied by a system for controlling a liquid product pump in an engine-driven hydraulic discharge system. The system includes a hydraulic pump operably coupled to a power take-off (PTO) of a tank truck, a hydraulic motor operably coupled to the hydraulic pump to receive a fluid pressure produced by the hydraulic pump, and a liquid product pump operably coupled to the hydraulic motor to receive mechanical power produced by the hydraulic motor. The liquid product pump includes a sensor operably coupled to an outer casing of the liquid product pump. The sensor is operable for monitoring vibrations passing through the outer casing to detect an occurrence of cavitation within the liquid product pump and for providing an electrical vibration signal corresponding to a level of cavitation within the liquid product pump. The system further includes a speed control module in electrical communication with the sensor. The speed control module is operable for receiving the vibration signal provided by the sensor and for producing an electrical speed control signal corresponding to the vibration signal. The system further includes an electronic actuator in electrical communication with the speed control module. The electronic actuator is operable for receiving the speed control signal and for actuating the hydraulic motor to adjust an operating speed of the liquid product pump.
In one embodiment, the liquid product pump is selected from the group consisting of a gear pump, a lobe pump and a rotary vane pump. In one embodiment, the sensor is selected from the group consisting of an acoustic sensor, a knock sensor, an accelerometer and a vibration sensor. In one embodiment, the electronic actuator is selected from the group consisting of an electrically actuated ball valve and a linear actuator.
In another embodiment, the system further includes a pressure sensor disposed at a discharge side of the liquid product pump. The pressure sensor is operable for providing an electrical pressure signal to the speed control module corresponding to a flow rate of a liquid product through the liquid product pump.
In another aspect, the present invention is embodied by a method for controlling a liquid product pump in an engine-driven hydraulic discharge system. The method includes providing a liquid product pump having an outer casing and a sensor operably coupled to the outer casing. The method further includes operating the liquid product pump to transfer a liquid product from a tank trailer to a storage tank. The method further includes using the sensor to monitor vibrations through the outer casing of the liquid product pump to detect an occurrence of cavitation within the liquid product pump. The method further includes producing an electrical vibration signal corresponding to a level of cavitation detected within the liquid product pump. The method further includes providing the vibration signal to a speed control module to process an electrical speed control signal. The method further includes providing the speed control signal to an electronic actuator operable for adjusting the operating speed of the liquid product pump.
In one embodiment, the sensor is selected from the group consisting of an acoustic sensor, a knock sensor, an accelerometer and a vibration sensor. In one embodiment, the liquid product pump is a positive displacement pump selected from the group consisting of a gear pump, a lobe pump and a rotary vane pump.
In another embodiment, the method further includes using the electronic actuator to actuate a motor control lever of a variable speed hydraulic motor to adjust the operating speed of the liquid product pump. In yet another embodiment, the electronic actuator is selected from the group consisting of an electrically actuated ball valve and a linear actuator.
Additional aspects, objects, features and advantages of the present invention will be made apparent, or will be readily understood and appreciated by those skilled in the relevant art, as exemplary embodiments of the invention shown in the accompanying drawing figures are described in greater detail hereinafter. It is intended that all such aspects, objects, features and advantages of the invention envisioned by this disclosure of exemplary embodiments be encompassed by the appended claims given their broadest reasonable interpretation consistent with this disclosure from the viewpoint of one of ordinary skill in the art. Consequently, the various terms used in this disclosure should be construed according to their ordinary and customary meaning to one of ordinary skill in the art at the time of this invention. The aspects, objects, features and advantages of the invention, as well as others not expressly disclosed, may be accomplished by one or more of the exemplary embodiments described herein and illustrated in the accompanying drawing figures. However, it should be appreciated that the exemplary embodiments and drawing figures are merely illustrative of the invention and its various forms, and that many modifications, changes, revisions and substitutions may be made to any of the exemplary embodiments without departing from the general concepts of the invention when broadly interpreted and properly construed.
The aforementioned aspects, objects, features and advantages of the present invention, as well as the exemplary embodiments of the invention, will be more fully understood and appreciated when considered in conjunction with the accompanying drawing figures, in which like reference characters designate the same or similar parts throughout the several views.
The following is a detailed description of exemplary embodiments of a liquid discharge system including a liquid product pump having a vibration sensor for detecting an occurrence of cavitation within the liquid product pump. A system and method for controlling the operation of a liquid product pump in an engine-driven hydraulic discharge system is shown and described in further exemplary embodiments of the present invention. A liquid discharge system is utilized to discharge or “off-load” a liquid product transported by a tank truck from a tank trailer into a storage tank. The liquid discharge system typically includes a liquid product pump for transferring the liquid product from the tank trailer to the storage tank. The liquid product pump, also referred to herein as a “fluid pump,” “liquid pump” or “product pump,” transfers the liquid product by creating a pressure differential between an inlet line, also referred to herein as a “suction” line, and an outlet line, also referred to herein as a “discharge” line. The liquid product pump may be powered by a constant speed power take-off (PTO) of an engine-driven hydraulic discharge system mounted on the tank truck.
Embodiments of the present invention are described more fully hereinafter with reference to the accompanying drawing figures. Exemplary embodiments show and describe a liquid discharge system including a liquid product pump having a vibration sensor for detecting an occurrence of cavitation within the liquid product pump. Other exemplary embodiments show and describe a system and method for controlling the operation, and more particularly the operating speed, of a liquid product pump in an engine-driven hydraulic discharge system. However, it is not intended for the present invention to be limited in any manner by the exemplary embodiments shown and described herein. Instead, it is expected that the present invention will be given the broadest reasonable interpretation and construction consistent with the disclosure as would be understood by one of ordinary skill in the art. Furthermore, unless another specific interpretation or construction is expressly provided, the exemplary embodiments illustrated herein and the various terms used herein should be given their ordinary and customary meanings as would be understood by a person of ordinary skill in the art at the time of the invention.
The present invention is broadly embodied by a liquid discharge system, indicated generally by reference character 10, as shown in
The liquid discharge system 10 off-loads liquid product from a tank trailer using either a hydraulic pump, referred to herein as a liquid product pump 14, or a pneumatic air compressor 16. Liquid product pump 14 may be any type of centrifugal or positive displacement pump suitable for off-loading a liquid product from a tank trailer to a storage tank using the liquid discharge system 10 of the tank truck. By way of example and not limitation, the liquid product pump 14 is a rotary, reciprocating or linear positive displacement pump. In a particularly advantageous embodiment, the liquid product pump 14 is a positive displacement rotary pump selected from the group consisting of a gear pump, a lobe pump and a rotary vane pump. Preferably, the liquid discharge system 10 is powered by an external hydraulic pump operatively coupled to a conventional power take-off (PTO) of the tank truck. However, the present invention is not intended to be limited in any manner to a particular source of power for operating the liquid product pump 14 of the liquid discharge system 10. Conversely, it is envisioned that the liquid product pump 14 may be powered by any other suitable source of power, including by way of example and not limitation, by an electric motor and hydraulic pump, or alternatively, an auxiliary gasoline or diesel motor and hydraulic pump.
Regardless, hydraulic oil is pumped by the external hydraulic pump through a high pressure fluid outtake line to a hydraulic fluid intake connection 18 provided on the liquid discharge system 10. The intake connection 18 is operatively coupled to a selection and/or direction valve 20 disposed within the enclosure 12 so that the selection and/or direction valve 20 is in fluid communication with the external hydraulic pump. In turn, the selection and/or direction valve 20 is in fluid communication with a hydraulic motor 22 (
Another hydraulic motor 28 (
The liquid product pump 14 has a liquid intake connection 30, such as a conventional liquid coupling, that is configured to receive a free end of a first liquid conduit (not shown) extending between a liquid discharge connection provided on the tank trailer and a vacuum side of the liquid product pump 14. The liquid product pump 14 further has a liquid outtake connection 32, such as a conventional liquid coupling, that is configured to receive a free end of a second liquid conduit (not shown) extending between a pressure side of the liquid product pump 14 and a liquid intake connection provided on a storage tank. Thus, the liquid product pump 14 operates to off-load the liquid product from the tank trailer by suctioning the liquid product through the first liquid conduit and discharging the liquid product into the storage tank through the second liquid conduit. Similarly, the air compressor 16 has a pneumatic outtake connection 34 that is configured to receive a free end of a pneumatic line (not shown) extending between the air compressor 16 and a pneumatic intake connection provided on the tank trailer. A movable lever 36 provided on the outside of the enclosure 12 of the liquid discharge system 10 operates to open a valve (not shown) to deliver compressed air through the pneumatic line to the tank trailer, and to close the valve to prevent compressed air from being delivered to the tank trailer.
As shown herein, the selection and/or direction valve 20 is provided with an actuator handle 21 that extends outwardly from the enclosure 12 for permitting an operator to select the operation of the liquid discharge system 10 between the liquid product pump 14 and the air compressor 16. By way of example and not limitation, the operator may select the liquid product pump 14 of the liquid discharge system 10 to off-load liquids that will not cause damage to the liquid product pump 14. Conversely, the operator may select the air compressor 16 of the liquid discharge system 10 to off-load liquids that could potentially cause damage to the liquid product pump 14. In addition, the actuator handle 21 of the selection and/or direction valve 20 may be configured to allow the operator to manually adjust the operating speed of the liquid product pump 14, for example to off-load a liquid that is sensitive to a shear force, and/or to select the flow direction of a bi-directional liquid product pump 14.
The vibration sensor 40 may be provided at any suitable location on the liquid product pump 14. Preferably, however, the vibration sensor 40 is disposed on an outer casing 42 of the liquid product pump 14, or alternatively, is only partially disposed within the outer casing 42. In this manner, sensor 40 will not be subjected to damage or malfunction as a result of exposure to the flow of the liquid product through the liquid product pump 14, or to the cavitation forces that may occur within the liquid product pump 14. In a particularly advantageous embodiment, the sensor 40 is installed onto the exterior of the outer casing 42 of the liquid product pump 14 through a casing bolt 41 that secures separable portions of the outer casing 42 together. Regardless, the sensor 40 monitors vibrations through the outer casing 42 of the liquid product pump 14 to detect cavitation that occurs within the liquid product pump 14. In the event the vibrations indicate an occurrence of excessive cavitation, an operator can manually adjust the operating speed of the liquid product pump 14 and/or other operating parameters of the liquid discharge system 10 to eliminate or reduce the potentially damaging effects of the cavitation.
An exemplary embodiment of a system 50 for controlling the operation of a liquid product pump in an engine-driven hydraulic discharge system is shown in
The liquid product pump 58 further has a sensor 60 for detecting an occurrence of cavitation within the liquid product pump 58. The sensor 60 monitors acoustic noise in the form of vibrations through the outer casing of the liquid product pump 58 that indicate an occurrence of cavitation within the liquid product pump 58. Preferably, the sensor 60 is a vibration sensor selected from the group consisting of an acoustic sensor, a “knock” sensor, and an accelerometer. The sensor 60 produces an electrical vibration signal 61 corresponding to a measurement of the vibrations through the outer casing of the liquid product pump 58, and consequently, the level of cavitation detected within the liquid product pump 58. Sensor 60 is operatively coupled to a speed control module 62 and provides the vibration signal 61 corresponding to the measurement of the vibrations to the speed control module 62. The speed control module 62 in turn processes a speed control signal 63 in response to the occurrence of cavitation detected within the liquid product pump 58. Speed control module 62 provides the speed control signal 63 to an electronic actuator 64 that is operatively coupled to the speed control module 62. The electronic actuator 64 in turn is operatively coupled to the variable speed hydraulic motor 56. The electronic actuator 64 operates to actuate a motor control lever of the variable speed hydraulic motor 56 to adjust the operation, and more specifically, the operating speed of the liquid product pump 58. Electronic actuator 64 may be any type of actuator suitable for automatically repositioning the motor control lever of the variable speed hydraulic motor 56. By way of example and not limitation, the electronic actuator 64 may be an electrically actuated ball valve, a linear actuator or the like.
The system 50 for controlling the operation of the liquid product pump 58 in the engine-driven hydraulic discharge system may further comprise a pressure sensor 66 disposed at the discharge side of the liquid product pump 58. For example, the pressure sensor 66 may be located within the discharge conduit 59 adjacent to the outer casing of the liquid product pump 58 at the outlet of the liquid product pump 58, as depicted in
Regardless, the operation of the liquid product pump 58 can be controlled in an engine-driven hydraulic discharge system by a method 70 according to the invention shown in
The liquid discharge system 10 comprising a liquid product pump 14 having a vibration sensor 40 shown and described herein operates to automatically adjust the operating speed of the liquid product pump 14. The system 50 and method 70 for controlling the operating speed of a liquid product pump 58 having a vibration sensor 60 in an engine-driven hydraulic discharge system similarly operates to automatically adjust the operating speed of the liquid product pump 58. Controlling the operating speed of the liquid product pump 14, 58 serves to avoid an occurrence of cavitation that can potentially damage the liquid product pump and/or the liquid product being transferred from the tank trailer to the storage tank. Automatically adjusting the operating speed of the liquid product pump 14, 58 removes the responsibility of monitoring the discharge operation for cavitation within the liquid product pump 14, 58 from an undertrained and/or inexperienced operator that may not recognize an occurrence of cavitation, or that may be unable to discern an occurrence of cavitation given the noise level in the ambient environment from the engine and power take-off (PTO) of the tank truck.
Regardless of the foregoing detailed description of exemplary embodiments of the invention, the optimum configuration of the article of manufacture, apparatus, device or system, and the manner of use, operation and steps of the associated methods, as well as reasonable equivalents thereof, are deemed to be readily apparent and understood by those skilled in the art. Accordingly, equivalent relationships to those shown in the accompanying drawing figures and described in the written description are intended to be encompassed by the present invention given the broadest reasonable interpretation and construction of the appended claims, the foregoing written description and the drawing figures being considered as merely illustrative of the general concepts and principles of the invention. Furthermore, as numerous modifications and changes will readily occur to those skilled in the art, the invention is not intended to be limited to the specific configuration, construction, materials, manner of use and operation of the exemplary embodiments shown and described herein. Instead, all reasonably predictable and suitable equivalents and obvious modifications to the invention should be construed as falling within the scope of the invention as defined by the appended claims given their broadest reasonable interpretation and construction to one of ordinary skill in the art within the context of the foregoing written description and accompanying drawing figures.
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