Patent Application
20240247658
Embodiments of the present disclosure relate to controllers utilized with pumps, and more particularly to multifunction controllers possibly having leak detection capability employed with pneumatic diaphragm pumps.
There are various types of controllers available on the market for various purposes. Tapflo sells single-use controllers which perform various pump functions such as pneumatic level control, pneumatic batch control, pneumatic stroke counters, life counters, start/stop units, low pressure alarms, etc. Sandpiper also sells a number of individual solutions for use with pumps including an electronic speed control, a stroke counter/batch controller, a liquid level controller, a pulse output kit, and even a leak detector. However, for both companies, and likely others, all of these units are single-function controllers. If multiple functions are desired, different controllers are installed in a system. By having multiple controllers, operators must operate and check multiple units, particularly in an alarm situation to be able to diagnose a particular issue.
While it is possible to add multiple single-use controllers to address multiple functions in industrial pumping systems, having multiple controllers contributes to the inefficiency of a particular system and may require additional pneumatic systems, multiple alarm locations and indications, and general complexity to industrial systems. Such complexity may confuse workers and contribute to mistakes. Also, a single-use controller has a single use. If it is a level controller, it controls level. It cannot be made to detect leaks or perform other functions.
The presently preferred embodiments are directed to overcoming these disadvantages and achieving other objectives.
It is a present objection of many embodiments of the present invention to provide a single pump controller configured to provide at least two functions selected from the group of a leak detector, a level control, a rate control, and a count controller.
Accordingly, the present application provides a controller for a pump-based system which provides at least two functions selected from the group of a leak detector, a level control, a rate control, and a count controller. The leak detector can use a plurality of sensors such as capacitive sensors that detect leaks and communicate with the controller. Upon detecting the leak, the controller preferably provides an output to a valve to stop the pump (such as a solenoid air valve providing air to the pump, when on), such as an air operated diaphragm pump while simultaneously displaying an alarm condition on a display of the controller. For many embodiments the pump has two sensors while a damper has a sensor and the controller has the capability of monitoring whether a leak is detected at the pump, at the damper, or either location.
Level sensors, such as ultrasonic sensors may be utilized with the controller to switch on and off the pump such as the valve used on the pneumatic supply (which can be shared with the leak detector). High and low levels can trigger stopping the pump with the controller.
Finally rate and/or count control can control the speed of the pump by switching the valve on and off in a “flip flop” between solenoid valves on the pump controlling air supply to the appropriate side of the diaphragm pump, possibly for up to millions of cycles and for continuous operation. A continuous running mode may be achieved at a preset speed, or a countdown to stop from an adjustable pre-set number of cycles at the preset speed may be set with the pump stopped upon reaching the pre-set number of cycles.
The display on the controller, and/or an output of data for use by remote processors, may be used with input to perform at least some of (a) changing the pump speed, (b) changing the countdown number of cycles, (c) setting whether the pump, the damper or both should be monitored for leaks, if either, (d) pressure monitoring, and/or (e) whether a low or high level, and possibly at what levels should be monitored. The display may also output any of the above information as well as cycles remaining and whether an alarm, on, off or fault condition exists.
The controller housing preferably provides a display, inputs, a stop button, microprocessor control, at least two, if not three or more modes of operation selected from the group of leak detection, level control, rate control, pressure detection/reporting, rate control and/or count controlling. The controller also can preferably detect when a capacitive sensor is disconnected, and then report a fault condition as well as whether an air isolation (or other valve) solenoid valve is disconnected. RS485 industrial network connections may be employed. High and/or low level ultrasonic PNP switches may provide level input. Pressure sensor may provide pressure status.
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
Various indications may be provided at the controller 12 including power 40, running 42, fault 44 and/or display 58. Start 46 and stop 48 buttons are provided for many embodiments. Inputs such as arrows 50,52,54,56 allow users to adjust operation of the controller and or investigate various functions controlled by the controller 12.
Using side to side arrows at step 102 may take the user to Pump status step 118. Side to side arrow inputs 50,56 may take the user to step 120 for initializing. Downward arrow 54 may take the user to step 122 for Running. Another downward arrow may take the user to level control at step 124. Another downward arrow may take the user to stopped at step 126 and another downward arrow may take the user to fault step 128. Upward arrow inputs 52 may take the user back towards step 120, in increments as would be understood by those of ordinary skill in the art.
Using down arrow input 54 from step 118 will take the user to leak detector step 130. Let and right arrow may show the amount of leakage at step 132 and another toggle may permit or change reporting from left or right side of pump and/or damper. From the leak detector step 130, another down arrow 54 may take the user to leak faults at step 136. Toggling left/right may take the user to step 138 displaying a number of leak faults. Toggling again may display step 140 showing the location of the fault. From the leak fault step 136, another down arrow 54 may take the user to solenoid fault at step 142. Toggling left/right may take the user to step 144 displaying a number of solenoid faults. Toggling again may display step 146 showing the location of the fault. From the solenoid fault step 142, another down arrow 54 may take the user to alarm step 148. Toggling left/right may take the user to step 150 displaying an alarm condition. From the alarm step 148, another down arrow 54 may take the user to pressure step 152. Toggling left/right may take the user to step 154 displaying the pressure. From the pressure step 152, another down arrow 54 may take the user to level step 156. Toggling left/right may take the user to step 158 displaying the level. From the level step 156, another down arrow 54 may take the user to count step 160. Toggling left/right may take the user to step 162 displaying the count. From the count step 160, another down arrow 54 may take the user to last step 164. Toggling left/right may take the user to step 166 displaying the last fault or the time of the last fault. Last faults could be a leak fault right at step 168, a leak fault left at step 170, a leak at the damper at step 172, a leak right at step 174, a leak left at step 176, a leak fault at the damper at step 178, a pressure fault at step 180, a solenoid left fault at step 182, a solenoid right fault at step 184, and/or a solenoid air valve fault at step 186.
When initiating setup at step 104, left/right toggles may take the user to step 188 to recognize the pump type at step 188. Toggling left/right and/or up down may take to various options such as 14 inch at step 190, 12 inch at step 192, 10 inch at step 194 and/or 7 inch at step 196. Other pump configurations could be selected with other embodiments. Down arrow 54 may be used to proceed from pump type step 188 for enabling leak detection. Toggling may allow a user to choose between pump and damper at step 200, pump only at step 202, damper only at step 204 or disabled at step 206.
Level control may be selected at step 208. It may be placed into slave status at step 210, empty (low level) at step 212, high level (fill) at step 214 or disabled at step 216. Rate control may be set at step 218 such as up to a maximum at step 220, up to a minimum at step 222 or disabled at step 224. Counting of thousands of cycles may be set at step 226, such as a maximum at step 228, a minimum at step 230, or disabled at step 232. Counting up to a thousand may be set at step 234 with a maximum or minimum at steps 236, 238 as appropriate. Pressure threshold may be set at step 240 such as minimum pressure at step 242, a maximum pressure at step 244 or disabled at step 246. Remember, different inputs 50-56 or others may switch between various steps with other embodiments.
The controller 12 of a basic system 10 is shown installed in
Controller 12 has an internal processor and display 58. Controller 12 can provide leak detection of pump 300 by monitoring capacitive sensors 250,252 with sensors. Damper sensor 254 can also be monitored by controller 12. Air safety solenoid valve 256 may be closed to stop the pump 300 in a fault event. Controller 12 may also operate a relay to change the state of volt free contacts such as pressure vfc 260 and/or running vfc 266. LED indicators can indicate Power, System, OK and Fault such as Power 40, Running 42, Fault 44 and/or others.
Controller 12 may provide leak detection capability, level controller (so as to be able to stop pump 300 when a predetermined high level 276 is reached or a low level 274 is reached), and rate and/or count control (to control the pump rate of operation or number of cycles).
Display 58 on housing 8 containing processor 6 may be an OLED display. Like an LCD, text messages may displayed about the current mode of operation. Inputs appear as buttons 50-56 which may be arrows, or other inputs may be provided.
Leak detection functionality may be provided in many embodiments (or not). Capacitive sensors 250,252 and/or 254 may be used with a three wire (or other appropriate) connection. In the illustrated embodiment, a sensor 250,252 or 254 is located on either side of the pump 300 and one is used with the damper. The sensor's mode of operation may be selected at the controller 12 as described above. The controller 12 preferably remembers the selection input.
Level control may be provided, such as with dual input (possibly from a single device as a level sensor 272) as an ultrasonic sensor. Control operations may start the pump 300 if a low level is active and stop the pump 300 when the high level becomes active, or visa versa, as shown. Controller 12 can control emptying or filing of a given tank 302,304. This feature may also be disabled at the controller 12 as described above and can be remembered even when powered off.
Rate and/or count control may be provided to allow the Controller 12 to set a pump speed. Setting the rate at which two air solenoid valves 262,264 are opened to operate pump 300 can be achieved by the controller 12. A flip flop arrangement, such as feedback from a flip flop speed control, may be provided to either set a rate of operation or set a number of operations (at the set rate) to the controller 12. Since different pump 300 sizes have different maximum rates of operation, the pump 300 being controlled will preferably be selectable (or otherwise input) from the menu as described above. This feature may also be disabled at the controller 12 as described above and can be remembered even when powered off.
The power LED 40 preferably illuminates when power is on (such as received at power connection 36). Running 42 preferably illuminates when the pump 300 is running. Fault LED 44 preferably illuminates in a fault condition. A description of the fault condition is preferably simultaneously displayed on display 58. Start and stop buttons 46,48 may also be useful. Start button 46 may open the air solenoid valve 256. It may also start the rate control valves 262,264 at the desired rate and (if configured) for the required number of operations.
The stop button's first press will stop the pump 300 by de-energizing the valve 256 but preferably not reset any cycle count in process. A second press of the stop button 48 may reset any cycle count in process. This may enable a user to either continue to run a batch or start fresh.
The communication port 32 is to provide a means of monitoring pumps 300 remotely. All the I/O data (start/stop switch operation, capacitive sensor status, level sensor status, pressure sensor reading, sensor connection fault and solenoid fault) may be transmitted. Control options at controller 12 may start and stop the pump remotely over the port 32 which may be indicated on the display 58. A modbus RTU register protocol with an 8 way DIP switch may be utilized. Pump data may be presented remotely such as to a device 270.
Pressure sensor input is received at input 22. Pressures may be reported. High/low thresholds may be set, above/below which an alarm may activate. If rate control solenoids valves are fitted, the pump can be controlled to maintain a set pressure on the controller by a user and the controller 12.
Output of the controller 12 may be 24V 30 W PSU. Input at power connection 36 may be 85-264 Vac, 50/60 Hz. The air valve 256 may be rated at 16 W. Volt free contacts for pressure/running may be NO/COM/NC indicating unit status. Processor 6 may be a microprocessor. Capacitor sensor inputs may be an appropriate sensor, possibly having an operating voltage of 12-30 VDC for at least some embodiments. The safety solenoid valve 256 may be 24V. Running volt free contact 266 may be a running relay. It may be energized when the pump 300 is running and de-energized when the pump 300 is not running.
Air rate solenoid valve outputs may be 24V and may be 10 W if internally power, if powering air safety solenoid valve 256, 26 W if internally powered, no separate safety solenoid valve.
The ultrasonic level indicator input may be an appropriate sensor. Pressure sensor may be a 1-5 V sensor or other sensor. Pressure sensor volt free relay may be a pressure sensor alarm relay. It preferably energizes above a certain threshold (triggering and alarm, and possibly stopping pump 300 by shutting valve 256) and den-energizes when pressure falls below a certain level. Other sensors, valves, and components may be utilized with other pumps 300 and systems 10.
Controller 12 preferably at least controls two functions selected from the group of (a) stopping pump if pressure exceeds or drops below a predetermined pressure, (b) if a sensor fault is detected, (c) if a level (too high or too low) is sensed, (d) if a leak of a sufficient amount is detected, (e) if a desired number of cycles has been run, and/or (f) to maintain a specific ump speed. In other embodiments, at least three, if not four, five or all six functions can be provided, possibly along with direct starting and stopping of the pump and/or an ability to reset counting of cycles.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to an example embodiment of the presently disclosed technology which is for purposes of illustration only and not to be construed as a limitation of the presently disclosed technology. All such modifications which do not depart from the spirit of the presently disclosed technology are intended to be included within the scope of the appended claims.
This application claims the benefit of U.S. patent Application No. 63/440,602 filed Jan. 23, 2023, which is incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63440602 | Jan 2023 | US |
