PUMP CONTROL BASED ON BUBBLE DETECTION

INTRODUCTION

Aspects of the present disclosure generally relate to positive displacement pumps and systems for controlling such pumps.

BACKGROUND

Fluid handling apparatuses such as positive displacement pumps are used in various environments to supply fluids at set rates. Positive displacement pumps are often used due to their precision and durability. For example, positive displacement pumps may operate unattended for continuous laboratory or manufacturing processes.

Although positive displacement pumps can operate for long periods of time without malfunctioning, errors can occur. For example, a catastrophic failure for a positive displacement pump may include rupture of the tubing, which may cause fluid to spill on the pump or other equipment. Additionally, a rupture may stop the flow of fluid and cause failure of a process.

Accordingly, there remains an unmet need in the related art for positive displacement pumps and systems and methods of control thereof that mitigate the effects of a tubing rupture.

SUMMARY

The following presents a simplified summary of one or more aspects of the present disclosure in order to provide a basic understanding of such aspects. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements of all aspects, nor delineate the scope of any or all aspects. Its purpose is to present some concepts of one or more aspects in a simplified form as a prelude to the more detailed description that is presented later.

In an aspect, the present disclosure provides a pump system. The pump system may include a drive motor and a pump head including a rotor coupled to the drive motor. The pump head may be configured to receive tubing. The pump system may include a controller coupled to the drive motor and configured to control a rotation of the drive motor and rotor. Rotation of the rotor may compress the tubing to move a liquid within the tubing from an inlet to an outlet of the pump head. The pump system may include a bubble sensor coupled to the tubing downstream from the outlet. The bubble sensor may be configured to send a signal to the controller in response to presence of a gas bubble within the tubing. The controller may be configured to determine a quantity of bubbles detected based on the signal. For example, the quantity of bubbles may include a number of bubbles and/or a size of the bubbles. The controller may be configured to determine an alert in response to the quantity of bubbles detected exceeding a threshold. The controller may be configured to stop the drive motor after a safe operating time from the alert, wherein the threshold and the safe operating time are based, at least in part, on a characteristic of the tubing.

These and other aspects of the present disclosure will become more fully understood upon a review of the detailed description, which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is schematic diagram of an example operating environment for a positive displacement pump and bubble sensor, according to an aspect of the disclosure.

FIG. 1B is schematic diagram of an example operating environment for a positive displacement pump, external pump controller, and bubble sensor, according to an aspect of the disclosure.

FIG. 2 is schematic diagram of an example positive displacement pump and bubble sensor, according to an aspect of the disclosure.

FIG. 3 is chart illustrating an example of a flow rate and a detected quantity of bubbles for a pump, according to an aspect of the disclosure.

FIG. 4 is a chart illustrating a second example of a flow rate and a detected quantity of bubbles for a pump, according to an aspect of the disclosure.

FIG. 5 is chart illustrating a third example of a flow rate and a detected quantity of bubbles for a pump, according to an aspect of the disclosure.

FIG. 6 is a chart illustrating a fourth example of a flow rate and a detected quantity of bubbles for a pump, according to an aspect of the disclosure.

FIG. 7 is a flow diagram showing an example method of controlling a pump, according to an aspect of the disclosure.

FIG. 8 presents an exemplary system diagram of various hardware components and other features, for use in accordance with aspects of the present disclosure.

FIG. 9 is a block diagram of various exemplary system components, for use in accordance with aspects of the present disclosure.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of various concepts. However, it will be apparent to those skilled in the art that these concepts may be practiced without these specific details. In some instances, well known components are shown in block diagram form in order to avoid obscuring such concepts.

In an aspect, the disclosure provides for a positive displacement pump with a bubble sensor and methods for controlling such a positive displacement pump based on a signal from the bubble sensor. In particular, a bubble sensor may detect bubbles within a tubing of the positive displacement pump. In an aspect, the bubbles may be formed due to micro-tears in the tubing that allow air to enter. The bubbles may be indicative of a deteriorated condition of the tubing and may be predictive of a failure of the tubing. In some cases, however, the bubbles may occur for other reasons, for example, due to dissolved gas in the liquid or air entering at a tubing connection. Further, even if the tubing does start to experience bubbles due to micro-tears, the tubing may not rupture for a significant amount of time after bubbles are detected. The time may be sufficient to complete a pumping process and avoid waste. Accordingly, in order to complete a process, the pump may continue to operate for a safe operating time after bubbles are detected.

FIG. 1A is a representative schematic diagram of a first example operating environment 100a for a positive displacement pump 110. The operating environment 100a may include the positive displacement pump 110, a fluid source 120, a fluid destination 130, and a bubble sensor 112. The positive displacement pump 110 may pump fluid from the fluid source 120 to the fluid destination 130 via tubing, which may include an inlet tube 122 and an outlet tube 124. The bubble sensor 112 may be located along the outlet tube 124. The bubble sensor 112 may detect gas bubbles in the outlet tube 124 and provide a signal 114 to the positive displacement pump 110 via a connection 116. For example, the bubble sensor 112 may be an ultrasonic bubble detector that fits around the outlet tube 124 and detects the gas bubbles without coming into contact with the liquid within the outlet tube. An example ultrasonic bubble detector is described in U.S. Pat. No. 9,546,983, which is incorporated herein by reference. Other example bubble sensors may include optical bubble detectors. In some implementations, the bubble sensor 112 may provide a pulsed signal that includes a pulse every time a bubble is detected. Accordingly, the signal 114 may indicate a time of each bubble, and a number of bubbles may be counted. In some implementations, the bubble sensor 112 may provide an analog signal where an amplitude of the signal 114 indicates a size of the bubble.

FIG. 1B is a representative schematic diagram of a second operating environment 100b for a positive displacement pump 110. The operating environment 100b may include the positive displacement pump 110, an external pump controller 160, the fluid source 120, the fluid destination 130, and the bubble sensor 112. The positive displacement pump 110 may pump fluid from the fluid source 120 to the fluid destination 130 via tubing, which may include the inlet tube 122 and the outlet tube 124. The bubble sensor 112 may be located along the outlet tube 124. As discussed with respect to FIG. 1A, the bubble sensor 112 may detect gas bubbles in the outlet tube 124. The bubble sensor 112 may provide the signal 114 to the external controller 160 via a connection 116. The external controller 160 may provide control signals to the pump 110 via a connection 118.

The connections 116 and 118 may be wired or wireless. For example, the connections 116 and 118 may include a wired connection carrying an analog signal (e.g., current, voltage, or frequency) or a digital (e.g., serial communication, RS232/485, ModBus, ProfiBus, EtherNet/IP, or ProfiNet). A wireless connection may include Radio, Bluetooth, Wi-fi, ZigBee, or ZWave.

The positive displacement pump 110 may be a positive displacement pump including the communications hardware (e.g., network interface) and software described herein for providing control of the positive displacement pump 110. As discussed above, the positive displacement pump 110 may include a pump controller or may be controlled by an external pump controller 160. In either case, the positive displacement pump 110 may include a motor controller that controls a motor of the positive displacement pump 110 based on the output signal 114 of the bubble sensor 112. In particular, the positive displacement pump 110 may be controlled to operate for a safe operating time after bubbles are detected.

FIG. 2 is a representative schematic diagram of an example positive displacement pump 110 usable in accordance with aspects of the present disclosure. The term “positive displacement pump” as used herein describes a category of fluid pumps that trap a fixed amount of fluid and force the trapped fluid to a discharge pipe. Positive displacement pumps are conventionally used in processes that require precise measurement or dosing of fluid. Positive displacement pumps may be driven by an electric motor under the control of a controller (e.g., electronic control unit (ECU) and/or other processor) that moves fluid at a desired rate. In an aspect, a positive displacement pump may include a detachable pump head that includes a casing and fluid contacting components of the positive displacement pump. The pump head may be driven by the motor via a magnetic coupling, for example. The positive displacement pump may be fitted with a different pump head, depending on the desired operation. For example, in an aspect, a positive displacement pump may include a housing including the drive motor, controller, and user interfaces, and a detachable pump head may be fitted in or on the housing. The selection of different pump heads may configure the positive displacement pump 110 as, for example, one of a peristaltic pump, gear pump, or diaphragm pump.

The positive displacement pump 110 may include a wet end 220 and a case 230. The wet end 220 may include fluid handling components including a pump head 222, a liquid supply 224, an inlet tube 226, and an outlet tube 228. The wet end 220 may be detachable from the case 230 to allow replacement or substitution of the wet end 220. For example, different pump heads 222 may be selected for use in pumping different fluids.

The pump head 222 may include a mechanism for pumping fluid. In an aspect, the positive displacement pump 110 may use a pump head that allows precise monitoring of the fluid being pumped (e.g., volume pumped). Example pump heads may include a peristaltic pump head, a quaternary diaphragm pump head, and/or a gear pump head. The pump head 222 may be connected to a liquid supply 224 via an inlet tube 226. The pump head 222 may pump the fluid to the outlet tube 228. In an aspect, for example, using a peristaltic pump, the inlet tube 226 and the outlet tube 228 may be or include a continuous tube extending through the pump head 222.

The case 230 may include electronic components of the positive displacement pump 110. For example, the case 230 may include a network interface 232, a local user interface 234, a drive motor 240, a processor 250, and a memory 252. Further, the memory 252 may store instructions executable by the processor 250 for implementing a pump controller 260, which may include a motor controller 262, a signal processor 264, a configuration component 266, an alert component 268, and a timing component 270. In some implementations, one or more of the electronic components may be located in the external pump controller 160.

The network interface 232 may include a wired or wireless network interface for transmitting and receiving data packets. In an aspect, the network interface 232, for example, may utilize transmission control protocol/Internet protocol (TCP/IP) packets that may carry commands, parameters, or data. The network interface 232 may forward commands to the processor 250 for processing by the pump controller 260. Conversely, the network interface 232 may receive data generated by the pump controller 260 from the processor 250 and transmit the data, for example, to an external pump controller 160.

The local user interface 234 may include any suitable controls provided on the positive displacement pump 110 for controlling the positive displacement pump 110. In an aspect, the local user interface 234 may include a display screen that presents menus for selecting commands (e.g., set target volume) and configuring parameters (e.g., select tubing). In another aspect, the local user interface 234 may include dedicated buttons and/or other selection features that perform specific commands. For example, the local user interface 234 may include a button for selection to start/stop pumping. The local user interface 234 may generate commands to the processor 250 for processing by the pump controller 260. In some implementations, the positive displacement pump 110 may operate in a remote mode in which the local user interface 234 is at least partially disabled to prevent local input.

The drive motor 240 may be or include an electric motor that provides a force for pumping the fluid. In an aspect, the drive motor 240 may be magnetically coupled to the pump head 222 to drive the pump head 222. The drive motor 240 may be controlled by the pump controller 260. For example, the pump controller 260 may generate a control signal indicating a speed and direction of the drive motor 240 based on received commands.

The processor 250 may include one or more processors for executing instructions. An example of processor 250 may include, but is not limited to, any suitable processor specially programmed as described herein, including a controller, microcontroller, application specific integrated circuit (ASIC), field programmable gate array (FPGA), system on chip (SoC), or other programmable logic or state machine. The processor 250 may include other processing components, such as an arithmetic logic unit (ALU), registers, and a control unit. The processor 250 may include multiple cores and may be able to process different sets of instructions and/or data concurrently using the multiple cores to execute multiple threads, for example.

Memory 252 may be configured for storing data and/or computer-executable instructions defining and/or associated with the pump controller 260, and processor 250 may execute such instructions with regard to operation of the pump controller 260. Memory 252 may represent one or more hardware memory devices accessible to processor 250. An example of memory 252 can include, but is not limited to, a type of memory usable by a computer, such as random access memory (RAM), read only memory (ROM), tapes, magnetic discs, optical discs, volatile memory, non-volatile memory, and any combination thereof. Memory 252 may store local versions of a pump controller application being executed by processor 250, for example.

The pump controller 260 may control operation of the positive displacement pump 110 based on commands received from either the network interface 232 or the local user interface 234, for example. The pump controller 260 may include a motor controller 262 for controlling operation of the drive motor 240, a signal processor 264 for determining a quantity of bubbles based on a signal from a bubble sensor, a configuration component 266 for determining a system configuration including tubing characteristics, an alert component for determining an alert in response to the quantity of bubbles detected exceeding a threshold, and a timing component 270 for stopping the drive motor after a safe operating time from the alert.

FIG. 3 is a chart 300 illustrating an example of a flow rate 310 and a detected quantity of bubbles 320 for a pump (e.g., the pump 110) configured with a thermoplastic PVC based tubing over time. The detected quantity of bubbles 320 may be based on an analog output that indicates a size of detected bubbles. The pump 110 was run at a constant speed starting at time T1. The flow rate 310 gradually decreased due to changing properties of the tubing. For example, the tubing may wear due to the motion of the pump or the liquid may accumulate or harden within the tubing, thereby restricting the flow of fluid. The quantity of bubbles 320 remained relatively low compared to a threshold 322 during a normal operating time 330 between a time T1 and a time T2 that occurred at about 88% of tube life. A small number of bubbles 324 occurred during the normal operating time 330 without exceeding the threshold 322. At time T2, the quantity of bubbles 320 began to steadily increase such that by time T3, the quantity of bubbles exceeded the threshold 322. Although the quantity of bubbles 320 exceeded the threshold 322 after time T3, the flow rate 310 remained fairly stable. The pump 110 operated with a stable flow rate 310 until a time T4, when the tubing ruptured. After time T4, the quantity of bubbles 320 sharply increased as the tubing filled with air and the flow rate 310 quickly dropped to 0.

A time to failure 332 may be measured between time T3, when the quantity of bubbles 320 exceeds the threshold 322, and the time T4, when the tubing ruptured. The time to failure 332 may be fairly consistent for a configuration of a pumping system. In particular, the time to failure 332 may be closely correlated with a material formulation of the tubing. For instance, the time to failure 332 for silicone tubing may be on the order of a minute or less, whereas the time to failure 332 for a polypropylene-based thermoplastic elastomer tubing may be on the order of hours. Other factors that affect the time to failure 332 include: pressure within the tubing, flow rate within the tubing, a speed of the rotor, and a composition of the liquid. There may also be variation in the time to failure 332 based on the manufacturer of the tubing.

A safe operating time 334 may occur after the time T3 when the quantity of bubbles 320 exceeds the threshold 322, but before a rupture occurs. The safe operating time 334 may be configured based on the time to failure 332. For example, the safe operating time 334 may be a fraction or percentage of a calibrated mean time to failure or a minimum time to failure for a similar system configuration (e.g., a system configuration with the same tubing characteristics). In an aspect, the fraction or percentage to use for the safe operating time 334 may be configured by an operator via the network interface 232 or the local user interface 234.

In an aspect, threshold 322, the time to failure 332, and/or safe operating time 334 for a particular configuration of a pumping system may be determined empirically. The configuration component 266 may include a computer-readable medium storing empirical values for the threshold 322, time to failure 332, and/or the safe operating time 334 associated with one or more characteristics of the tubing (e.g., tubing formulation, size, or manufacturer). The configuration component 266 may be configured with baseline values determined by a manufacturer of the pump 110. In an aspect, the baseline values may be altered or weighted by an operator. For example, the operator may reduce the baseline value of the threshold 322, the time to failure 332 and/or the safe operating time 334 or configure a negative weighting factor to be applied when pumping a caustic liquid or operating with the tubing under pressure. In an aspect, the pump controller 260 (e.g., the alert component 268) may record the quantity of bubbles detected over time during each pumping operation. If a tubing rupture occurs, the alert component 268 may detect the rupture (e.g., based on an increase of the quantity of bubbles at time T4). The alert component 268 may update the time to failure 332 and/or safe operating time 334 based on values recorded for the pumping operation. Alternatively, an operator may manually indicate the particular pumping operation as a tubing rupture, and the time to failure 332 and/or the safe operating time 334 may be adjusted based on the observed tubing failure.

FIG. 4 is a chart 400 of a second example of a flow rate 410 and a detected quantity of bubbles 420 for a pump 110 configured with a thermoplastic PVC based tubing. The detected quantity of bubbles 420 may be based on a pulsed output of a bubble sensor 112. In this example, the tubing had a larger size than in FIG. 3, but a similar bubble pattern occurred. In this example, the flow rate 410 gradually decreases over time during a normal operating time 430. The number of bubbles 420 remains at practically zero for 89% of the life of the tubing. At time T2, a significant number of bubbles are detected, and the number of bubbles 420 exceeds the threshold 422 at time T3. The number of bubbles plateaus for a period of time, then increases rapidly before the tubing fails at time T4. In this example, the threshold 422 may be set relatively low because the detection of a small number of bubbles indicates a beginning of tubing failure. The time to failure, however, is approximately 10% of the life of the tubing, so a significant safe operating time 434 may be allowed.

FIG. 5 is a chart 500 of a third example of a flow rate 510 and a detected quantity of bubbles 520 for a pump configured to run at 600 rpm with a thermoplastic elastomer (TPE) tubing. The detected quantity of bubbles 520 may be based on a pulsed output of a bubble sensor 112. The chart 500 omits most of the normal operating time 530, where the flow rate 510 remains constant and the number of bubbles 520 is zero. The number of bubbles 520 starts increasing after 76% of the tube life. The number of bubbles increases gradually until the tubing fails at time T4. The threshold 522 may be set relatively low because once a small number of bubbles occur, the number increases gradually until tubing failure. The time to failure 432 may be approximately 20% of the life of the tubing, so a significant safe operating time 534 may be allowed.

FIG. 6 is a chart 600 of a fourth example of a flow rate and a detected quantity of bubbles for a pump configured with TPE tubing as in FIG. 5, but run at a slower speed of 300 rpm. The detected quantity of bubbles 420 may be based on a pulsed output 610 of a bubble sensor 112. In this example, the bubbles developed after 99% of tube life expired. Accordingly, most of the normal operating time 630 is not shown. In this example, once the number of bubbles 620 reached the threshold 622, the tubing quickly failed, resulting in a short time to failure 632 compared to the time to failure 532. In an aspect, the safe operating time 634 may be based on a total operating time of the tubing. In this instance, because the normal operating time 630 is over three times as long as the normal operating time 530, the safe operating time 634 may be greatly reduced. In another aspect, the safe operating time 634 may be based on the speed of the pump. A slower speed may be less likely to generate bubbles, so the safe operating time 634 may be lower for lower speeds.

FIG. 7 is a flow diagram showing an example method 700 of controlling a positive displacement pump, in accordance with aspects of the present disclosure. The method 700 may be performed by the pump 110 of FIG. 1A, pump controller 160 of FIG. 1B, or the pump controller 260 of FIG. 2, for example. Optional blocks are shown with dashed lines.

In block 710, the method 700 may include identifying a configuration of a pump system including characteristics of a tubing. In an aspect, for example, configuration component 266 may receive the configuration of the pump system via the local user interface 234 or the network interface 232. In an aspect, in sub-block 712, the block 710 may include receiving an indication of the characteristic of the tubing. For example, an operator may select the characteristics of the tubing. For instance, the operator may enter an identifier of the tubing or select the characteristics from one or more menus. The characteristics of the tubing may include a material formulation of the tubing, a size or diameter of the tubing, or a manufacturer of the tubing. The operator may configure other properties of the pump system such as a target flow rate, a composition of a liquid to be pumped, or a total pumping time. In an aspect, in sub-block 714, the block 710 may include looking up a threshold and a safe operating time in a memory storing preconfigured values. For example, the pump controller 260 and/or the configuration component 266 may look up the threshold 322 and the safe operating time 334 in the memory 252 or an internal memory of the configuration component 266.

In block 720, the method 700 may include operating the pump system according to the configuration to pump liquid to a destination via the tubing. For example, the pump controller 160, 260 may operate the pump 110 in the operating environment 100a, 100b according to the configuration to pump liquid to the destination 130 via the tubing 124. The motor controller 262 may control the drive motor 240 to drive the pump head 222 to achieve the target flow rate.

In block 730, the method 700 may include receiving a signal from a bubble detector indicating presence of a gas bubble within the tubing. For example, the signal processor 264 may receive a signal 114 from the bubble sensor 112 indicating presence of the gas bubble within the tubing 124, 228. In an aspect, the signal 114 from the bubble sensor 112 may be a pulsed signal, where each pulse indicates a detected bubble. In another aspect, the signal 114 from the bubble sensor 112 may be an analog signal, where an amplitude of the signal indicates a size of a detected bubble.

In block 740, the method 700 may include determining a quantity of bubbles detected based on the signal. In an aspect, for example, the signal processor 264 may determine the quantity of bubbles 320 based on the signal 114. For instance, at sub-block 742, the signal processor 264 may accumulate a number of detected bubbles over a time period. For instance, the signal processor 264 may determine a number of bubbles per second, minute, or hour. As another example, where the signal 114 indicates a size of each detected bubble, the signal processor 264 may determine the quantity of bubbles based on a number of bubbles and the size of each detected bubble. For instance, the quantity of bubbles may be a total volume of bubbles. The total volume of bubbles may also be determined over a period of time.

In block 750, the method 700 may include determining an alert in response to the quantity of bubbles detected exceeding a threshold. For example, the alert component 268 may continuously or periodically compare the quantity of bubbles 320 to the threshold 322. The alert component 268 may generate the alert when the quantity of bubbles 320 exceeds the threshold 322 (e.g., at time T3). In an aspect, the alert component 268 may generate the alert when the quantity of bubbles 320 exceeds the threshold 322 for a threshold amount of time. For example, the alert component 268 may generate an alert when the number of bubbles per minute exceeds a threshold number of bubbles per minute (e.g., 20 bubbles per minute) for a threshold period of time (e.g., 3 minutes). Accordingly, the alert may be subject to both a threshold quantity and a threshold time. A sustained number of bubbles may be more indicative of impending tubing failure than brief period of bubbles. Accordingly, the use of a threshold quantity and a threshold time may reduce false alarms.

In block 760, the method 700 may optionally include transmitting the alert to one or more devices in the pump system. For example, the alert component 268 may transmit the alert to another pump or a pump controller. For instance, the other pump or pump controller may be associated with a second liquid being pumped to the liquid destination 130. The alert may indicate the safe operating time 334. The alert may allow the one or more other devices to coordinate a response to the alert with the pump 110. For example, the other pump may be stopped at the same time as the pump 110 to maintain a ratio of the liquids at the liquid destination 130.

In block 770, the method 700 may include stopping the drive motor after a safe operating time from the alert. For example, the timing component 270 may stop the drive motor 240 after the safe operating time 334, which may be measured from the time T3. The safe operating time 334 may allow the pump 110 to complete a pumping operation and/or safely stop a pumping operation to prevent waste. For example, the pumping operation may complete a batch or process cycle during the safe operating time 334.

Aspects of the present disclosure may be implemented using hardware, software, or a combination thereof and may be implemented in one or more computer systems or other processing systems. In one aspect, the disclosure is directed toward one or more computer systems capable of carrying out the functionality described herein. FIG. 8 presents an example system diagram of various hardware components and other features that may be used in accordance with aspects of the present disclosure. Aspects of the present disclosure may be implemented using hardware, software, or a combination thereof and may be implemented in one or more computer systems or other processing systems. In one example variation, aspects of the disclosure are directed toward one or more computer systems capable of carrying out the functionality described herein. An example of such a computer system 800 is shown in FIG. 8.

Computer system 800 includes one or more processors, such as processor 804. The processor 804 is connected to a communication infrastructure 806 (e.g., a communications bus, cross-over bar, or network). Various software aspects are described in terms of this example computer system. After reading this description, it will become apparent to a person skilled in the relevant art(s) how to implement aspects of the disclosure using other computer systems and/or architectures.

Computer system 800 may include a display interface 802 that forwards graphics, text, and other data from the communication infrastructure 806 (or from a frame buffer not shown) for display on a display unit 830. Computer system 800 also includes a main memory 808, preferably random access memory (RAM), and may also include a secondary memory 810. The secondary memory 810 may include, for example, a hard disk drive 812 and/or a removable storage drive 814, representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive 814 reads from and/or writes to a removable storage unit 818 in a well-known manner. Removable storage unit 818, represents a floppy disk, magnetic tape, optical disk, etc., which is read by and written to removable storage drive 814. As will be appreciated, the removable storage unit 818 includes a computer usable storage medium having stored therein computer software and/or data.

In alternative aspects, secondary memory 810 may include other similar devices for allowing computer programs or other instructions to be loaded into computer system 800. Such devices may include, for example, a removable storage unit 822 and an interface 820. Examples of such may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an erasable programmable read only memory (EPROM), or programmable read only memory (PROM)) and associated socket, and other removable storage units 822 and interfaces 820, which allow software and data to be transferred from the removable storage unit 822 to computer system 800.

Computer system 800 may also include a communications interface 824. Communications interface 824 allows software and data to be transferred between computer system 800 and external devices. Examples of communications interface 824 may include a modem, a network interface (such as an Ethernet card), a communications port, a Personal Computer Memory Card International Association (PCMCIA) slot and card, etc. Software and data transferred via communications interface 824 are in the form of signals 828, which may be electronic, electromagnetic, optical or other signals capable of being received by communications interface 824. These signals 828 are provided to communications interface 824 via a communications path (e.g., channel) 826. This path 826 carries signals 828 and may be implemented using wire or cable, fiber optics, a telephone line, a cellular link, a radio frequency (RF) link and/or other communications channels. In this document, the terms “computer program medium” and “computer usable medium” are used to refer generally to media such as a removable storage drive 814, a hard disk installed in hard disk drive 812, and signals 828. These computer program products provide software to the computer system 800. Aspects of the disclosure are directed to such computer program products.

Computer programs (also referred to as computer control logic) are stored in main memory 808 and/or secondary memory 810. Computer programs may also be received via communications interface 824. Such computer programs, when executed, enable the computer system 800 to perform various features in accordance with aspects of the present disclosure, as discussed herein. In particular, the computer programs, when executed, enable the processor 804 to perform such features. Accordingly, such computer programs represent controllers of the computer system 800.

In variations where aspects of the disclosure are implemented using software, the software may be stored in a computer program product and loaded into computer system 800 using removable storage drive 814, hard disk drive 812, or communications interface 820. The control logic (software), when executed by the processor 804, causes the processor 804 to perform the functions in accordance with aspects of the disclosure as described herein. In another variation, aspects are implemented primarily in hardware using, for example, hardware components, such as application specific integrated circuits (ASICs). Implementation of the hardware state machine so as to perform the functions described herein will be apparent to persons skilled in the relevant art(s).

In yet another example variation, aspects of the disclosure are implemented using a combination of both hardware and software.

FIG. 9 is a block diagram of various example system components (e.g., on a network) that may be used in accordance with aspects of the present disclosure. The system 900 may include one or more accessors 960, 962 (also referred to interchangeably herein as one or more “users”) and one or more terminals 942, 966. In one aspect, data for use in accordance with aspects of the present disclosure may, for example, be input and/or accessed by accessors 960, 962 via terminals 942, 966, such as personal computers (PCs), minicomputers, mainframe computers, microcomputers, telephonic devices, or wireless devices, such as personal digital assistants (“PDAs”) or a hand-held wireless devices coupled to a server 943, such as a PC, minicomputer, mainframe computer, microcomputer, or other device having a processor and a repository for data and/or connection to a repository for data, via, for example, a network 944, such as the Internet or an intranet, and couplings 945, 946, 964. The couplings 945, 946, 964 include, for example, wired, wireless, or fiber optic links. In another example variation, the method and system in accordance with aspects of the present disclosure operate in a stand-alone environment, such as on a single terminal.

The aspects of the disclosure discussed herein may also be described and implemented in the context of computer-readable storage medium storing computer-executable instructions. Computer-readable storage media includes computer storage media and communication media. For example, flash memory drives, digital versatile discs (DVDs), compact discs (CDs), floppy disks, and tape cassettes. Computer-readable storage media may include volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, modules or other data.

The following provides an overview of aspects of the present disclosure:

Aspect 1: A pump system comprising: a drive motor; a pump head including a rotor coupled to the drive motor, wherein the pump head is configured to receive tubing; a controller coupled to the drive motor and configured to control a rotation of the drive motor and rotor, wherein rotation of the rotor compresses tubing to move a liquid within the tubing from an inlet to an outlet of the pump head; a bubble sensor coupled to the tubing downstream from the outlet, wherein the bubble sensor is configured to send a signal to the controller in response to presence of a gas bubble within the tubing, wherein the controller is configured to: determine a quantity of bubbles detected based on the signal; determine an alert in response to the quantity of bubbles detected exceeding a threshold; and stop the drive motor after a safe operating time from the alert, wherein the threshold and the safe operating time are based, at least in part, on a characteristic of the tubing.

Aspect 2: The pump system of Aspect 1, wherein the controller is further configured to: receive an indication of the characteristic of the tubing; and look up the threshold and the safe operating time in a memory storing preconfigured values.

Aspect 3: The pump system of Aspect 1 or 2, wherein the characteristic of the tubing includes a material formulation of the tubing.

The pump system of Aspect 1 or 2, wherein the characteristic of the tubing includes a manufacturer of the tubing.

Aspect 5: The pump system of any of Aspects 1-4, wherein the threshold and the safe operating time are further based on one or more operating parameters of the pump system.

Aspect 6: The pump system of Aspect 5, wherein the one or more operating parameters include one or more of: pressure within the tubing, flow rate within the tubing, a speed of the rotor, or a composition of the liquid.

Aspect 7: The pump system of any of Aspects 1-6, wherein the controller being configured to determine the quantity of bubbles detected based on the signal includes the controller being configured to accumulate a number of detected bubbles over a time period.

Aspect 8: The pump system of any of Aspects 1-8, wherein the signal indicates a size of each detected bubble, and wherein the quantity of bubbles is based on a number of bubbles and the size of each detected bubble.

Aspect 9. A method of operating a pump system, comprising: identifying a configuration of a pump system including characteristics of a tubing; operating the pump system according to the configuration to pump liquid to a destination via the tubing; receiving a signal from a bubble sensor indicating presence of a gas bubble within the tubing; determining a quantity of bubbles detected based on the signal; determining an alert in response to the quantity of bubbles detected exceeding a threshold; and stopping the pump system after a safe operating time from the alert, wherein the threshold and the safe operating time are based, at least in part, on the characteristics of the tubing.

Aspect 10: The method of Aspect 9, wherein identifying the configuration of the pump system comprises: receiving an indication of the characteristic of the tubing; and looking up the threshold and the safe operating time in a memory storing preconfigured values.

Aspect 11: The method of Aspect 9 or 10, wherein the characteristic of the tubing includes a material formulation of the tubing.

Aspect 12: The method of Aspect 9 or 10, wherein the characteristic of the tubing includes a manufacturer of the tubing.

Aspect 13: The method of any of Aspects 9-12, wherein the threshold and the safe operating time are further based on one or more operating parameters of the pump system.

Aspect 14: The method of Aspect 13, wherein the one or more operating parameters include one or more of: pressure within the tubing, flow rate within the tubing, a speed of a rotor, or a composition of the liquid.

Aspect 15: The method of any of Aspects 9-14, wherein determining the quantity of bubbles detected based on the signal comprises accumulating a number of detected bubbles over a time period.

Aspect 16: The method of any of Aspects 9-14, wherein determining the quantity of bubbles detected based on the signal comprises determining a volume of the bubbles.

Aspect 17: The method of any of Aspects 9-16, further comprising transmitting the alert to one or more devices in the pump system.

Aspect 18: A pump controller, comprising: a memory storing computer executable instructions; and a processor communicatively coupled to the memory and configured to execute the instructions to perform the method of any of Aspects 9-17.

This written description uses examples to disclose aspects of the present disclosure, including the preferred embodiments, and also to enable any person skilled in the art to practice the aspects thereof, including making and using any devices or systems and performing any incorporated methods. The patentable scope of these aspects is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. Aspects from the various embodiments described, as well as other known equivalents for each such aspect, can be mixed and matched by one of ordinary skill in the art to construct additional embodiments and techniques in accordance with principles of this application.

PUMP CONTROL BASED ON BUBBLE DETECTION

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