Patent Application
20220381237
Aspects of the present disclosure generally relate to pumps and systems for controlling such pumps.
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 positive displacement pump may utilize tubing that can rupture during use. Such a. error may be a catastrophic failure for a laboratory or manufacturing process.
Accordingly, there remains an unmet need in the related art for positive displacement pumps and systems and methods of control thereof.
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. The pump may include a user interface, a memory storing processor executable instructions, and a processor coupled with the user interface and the memory and configured to execute the instructions to receive a configuration of a tubing usage limit via the user interface. The processor may be configured to operate the pump according to a program. The processor may be configured to measure a tubing usage during pump operation. The processor may be configured to generate an alert when the tubing usage reaches the tubing usage limit.
In another aspect, the present disclosure provides a method of controlling a pump by a pump controller. The method may include receiving a configuration of a tubing usage limit via a user interface. The method may include operating the pump according to a program. The method may include measuring a tubing usage during pump operation. The method may include generating an alert when the tubing usage reaches the tubing usage limit.
In another aspect, the present disclosure provides a pump controller for controlling a pump. The pump controller may include a memory storing computer-executable instructions and at least one processor coupled to the memory and configured to execute the instructions to receive a configuration of a tubing usage limit via a user interface. The processor may be configured to operate the pump according to a program. The processor may be configured to measure a tubing usage during pump operation. The processor may be configured to generate an alert when the tubing usage reaches the tubing usage limit.
These and other aspects of the present disclosure will become more fully understood upon a review of the detailed description, which follows.
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 tubing usage alarm built into a user interface of the pump and methods for controlling such a positive displacement pump. An operating life of tubing in a pump may vary greatly based on various operating parameters of the pump such as the tubing material, tubing size, operating speed, operating pressure, fluid being pumped. A cost of a catastrophic failure may also vary greatly in comparison to replacement costs for the tubing. For example, a pump that maintains a level of a non-reactive chemical may merely require replacement of the tubing if the tubing ruptures. There may be little chance of damage to other equipment. In contrast, a pump that transports a caustic fluid may have the potential to cause injury or damage equipment if the pump ruptures. Accordingly, even if the pump with the caustic fluid has the same expected tubing life as the pump with the non-reactive chemical, an operator may want to replace the tubing earlier to avoid the risk of a catastrophic failure. As another example, the fluid being pumped may be expensive or may be part of an expensive process or experiment such that a catastrophic failure may result in costs beyond the specific operation of the pump.
In an aspect, because the uses of a pump are so varied and costs are unpredictable, a configurable usage limit may be desirable. Because the tubing limit may depend on actual usage of the pump, access to operation parameters of the pump may be necessary to determine when the tubing limit is reached. In an aspect, the user interface of a pump provides both user selectable configuration and access to operation parameters. The user interface may provide a tubing monitoring feature that provides an alert when tubing usage reaches a user defined usage limit. The user interface may receive a configuration of a tubing usage limit via the user interface. The user interface may operate the pump according to a program. The user interface may measure a tubing usage during pump operation. The user interface may display the tubing usage with respect to the user defined usage limit. The user interface may generate an alert when the tubing usage reaches the tubing usage limit.
The positive displacement pump 110 may include a pump controller that controls a motor of the positive displacement pump 110 according to a program. The positive displacement pump 110 and/or the external pump controller 160 may include a user interface. For example, the user interface may include a monitor such as a touch screen display for both input and output. In some implementations, the user interface includes a speaker for audio output and/or a microphone for audio input. In an aspect, the user interface may provide an alert when pump usage reaches a configured usage limit set by a pump operator via the user interface.
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 user interface controller 262 and a tubing sensor 272. The user interface controller 262 may control the local user interface 234. The user interface controller 262 may include a limit interface 264, a program interface 266, a usage monitor 268, and an alert component 270.
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 Internet Protocol (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 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). The display screen may be a touch-screen that receives user input. In another aspect, the local user interface 234 may include dedicated buttons and/or other selection features for navigating the menus. For example, the local user interface 234 may include directional buttons and/or a selection button. The local user interface 234 may generate commands to the processor 250 for processing by the pump controller 260. In an aspect, the local user interface 234 may be controlled via firmware executed by the processor 250. For example, the pump controller 260 may include a user interface controller 262. The firmware may be updated to add features or otherwise change the operation of the local user interface 234.
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. Although pump controller 260 is illustrated as being a component of the pump 110, in some implementations, the pump controller 260 may reside within the external pump controller 160. For example, executable instructions for the pump controller 260 may be stored in a memory of the external pump controller 160 and executed by a processor of the external pump controller 160.
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 user interface controller 262 for controlling the local user interface 234. The user interface controller 262 may include a limit interface 264 for receiving a configuration of a tubing usage limit via the user interface, a program interface 266 configured to operate the pup according to a program, a usage monitor 268 configured to measure a tubing usage during pump operation, and an alert component 270 configured to generate an alert when the tubing usage reaches the tubing usage limit. The pump controller 260 may optionally include a tubing sensor 272 configured to detect a change of pump tubing. For example, the tubing sensor 272 may be an open head sensor that generates a signal when the pump head 222 is open.
The user interface 300 may include an operation observation region 320. The operation observation region 320 may present information (e.g., operation parameters) about operation of the pump under the selected operation mode. The operation parameters may be generated by the pump controller 260 and provided to the program interface 266 for display on the user interface 300. For instance, the operation observation region 320 may indicate a cumulative volume button 322 and a batch total button 324 that each display a dispatched volume. The cumulative volume button 322 and the batch total button 324 may be selectable to reset the indicated volume. The operation observation region 320 may present other operation parameters that are not resettable. For example, the operation observation region 320 may display the on time, off time, and flow rate.
The user interface 300 may include control buttons such as a prime button 330 and a start button 332. The prime button 330 may cause the pump to operate for a sufficient time to fill the tubing 122 and 124 from the fluid source 120. In an aspect, operation of the pump caused by the prime button 330 may not count toward the operating parameters, for example, because fluid may not be dispensed to the fluid destination 130 during the priming operation. Operation of the pump caused by the prime button 330 may count toward a usage limit because such operation may cause wear on the tubing. The start button 332 may cause the pump 110 to operate according to the selected mode and operation parameters. The user interface may display the current operation parameters in the operation observation region 320 as the pump operates in response to the start button 332 being selected. In some implementations, the start button 332 may change to a stop button while the pump 110 is operating.
The user interface 300 may include management buttons such as a log out button 334 and an options button 336. The log out button 334 may allow a current user to log out and/or allow a new user to log in. The user interface 300 may implement controls based on the user that is logged in. The user interface 300 may log data based on the user that is logged in. The options button 336 may allow configuration of various options for the operation mode.
In an aspect, the user interface 300 may include a tubing monitor button 350. The tubing monitor button 350 may activate a tubing monitor feature. In an aspect, the tubing monitor button may open the user interface 400 of
The user interface 400 may include one or more limit buttons that allow the user to set a usage limit for one or more operation parameters. For example, the user interface may include an operating time button 420 that allows the user to set an operating time limit, a pump cycles button 430 that allows the user to set a limit on a number of pump cycles, and a volume button 440 that allows the user to set a limit on a fluid volume.
The user interface 400 may include control buttons such as a back button 450, an options button 460, and a confirm button 470. The back button 450 may cause the local user interface 234 to display the user interface 300. The options button 460 may present configurable options for the tubing monitor feature. For example, the options may include a display type, an alert type, an alert volume, or whether to stop operation. For instance, a display type may include graphical options for displaying the tubing usage such as a count-down display or a graphic such as a needle moving on a simulated dial. The alert types may include audio alerts, visual alerts, and remote alerts. For example, a remote alert may be configured to transmit an alert to a phone number, email address, or device connected via Bluetooth or other short range connection. The confirm button 470 may apply any changes made to the tubing monitor feature settings and return the local user interface to the user interface 300.
At block 516, the pump controller 260 may prompt a user to enter a monitor configuration. For example, the pump controller 260 and/or the limit interface 264 may control the local user interface 234 to present the user interface 400. Control may proceed to block 518 where the pump controller 260 may receive a monitor configuration. For example, the user may enter a monitor configuration by setting a limit using one or more of the operating time button 420, the pump cycles button 430, or the volume button 440. In some implementations, multiple limits may be configured. For example, the user may configure a first operating time limit that only generates a visual alarm and a second operating time limit that generates an audio alarm and/or stops the pump. The multiple limits may include different types of limits such as a pump cycle limit and a volume limit. The user may confirm the monitor configuration by pressing the confirm button 470.
At block 520, the pump controller 260 may operate the pump according to the program selected by the user. The pump controller 260 may also measure usage of the tubing. For example, the pump controller 260 and/or the usage monitor 268 may accumulate one or more operation parameters. For instance, the operation parameters may correspond to one of the limits selected by the user. Control may proceed to block 522, where the pump controller 260 and/or the usage monitor 268 may determine whether a tubing usage limit has been reached. For example, the pump controller 260 and/or the usage monitor 268 may compare the configured usage limit to the corresponding accumulated operation parameter. If the tubing usage limit has been reached, control may proceed to block 524. Otherwise, control may proceed to block 526.
At block 524, the pump controller 260 may generate an alert. For example, the alert may include an audible and/or visual alarm at the pump 110. As another example, the alert may include a message transmitted to a device of the user (e.g., a mobile phone or computer). For example, the alert may be transmitted as a short message service (SMS) message, email, or notification.
At block 526, the pump controller 260 may determine whether the program is complete. For example, the pump controller 260 may determine whether an operation parameter configured for the program (e.g., an on time) has been reached. If the program is complete, control may return to block 512 to wait for a new program configuration. If the program is not complete, control may return to block 520 to continue operating the pump according to the program and monitoring usage.
At block 610, the method 600 may optionally include downloading processor executable instructions from an authenticated source. In an aspect, for example, the network interface 232 procedure may download processor executable instructions such as user interface controller 262 from an authenticated source. The authenticated source may be a manufacturer system. An address of the manufacturer system may be embedded into the network interface 232. The processor executable instructions may be a firmware update that adds the usage monitor feature to the pump controller 260.
At block 620, the method 600 may optionally include detecting a change of pump tubing.
For example, the tubing sensor 272 may detect the change of pump tubing. For example, the tubing sensor 272 may detect that a pump cover or pump head has been opened and closed, which may indicate that the tubing has been changed. In another aspect, the user interface controller 262 may receive an indication from the user that the tubing has changed (e.g., a change in a size of the tubing) for a volume dispense mode.
In block 630, the method 600 may optionally include determining a predicted movement time of the pump movement sub-cycle for a motor of prompting the user to input the configuration of the tubing usage limit via the user interface. In an aspect, for example, the user interface controller 262 may prompt the user to input the configuration of the tubing usage limit via the user interface. For example, the limit interface 264 may generate the user interface 400 on the local user interface 234.
At block 640, the method 600 may include receiving a configuration of a tubing usage limit via the user interface. For example, the limit interface 264 may receive a configuration of a tubing usage limit (e.g., a time limit, cycle limit, or volume limit) via the user interface 400. For example, the user may press the operating time button 420, the pump cycles button 430, and/or the volume button 440, then enter a value to define the tubing usage limit.
At block 650, the method 600 may include operating the pump according to a program.
For example, the pump controller 260 may operate the pump 110 according to a program. In some implementations, the user may select the program via the user interface 300. In implementations where the pump controller 260 resides within an external pump controller 260, operating the pump according to the program may include sending commands to the pump 110 via the connection 114.
At block 660, the method 600 may include measuring a tubing usage during pump operation. For example, the usage monitor 268 may measure the tubing usage during pump operation. The tubing usage may include any operation parameter. The tubing usage may include usage during both a priming operation and operation according to a pump program. In implementations where the pump controller 260 resides within an external pump controller 260, measuring a tubing usage during pump operation may include receiving measurements from the pump 110 via the connection 114.
At block 670, the method 600 may include generating an alert when the tubing usage reaches the tubing usage limit. For example, the alert component 270 may generate the alert when the tubing usage reaches the tubing usage limit. For example, the alert component 270 may control a speaker of the local user interface 234 to play a sound or may control a display of the local user interface 234 to flash. In some implementations, the alert component 270 may transmit a message via the network interface 232.
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.
Computer system 700 includes one or more processors, such as processor 704. The processor 704 is connected to a communication infrastructure 706 (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 700 may include a display interface 702 that forwards graphics, text, and other data from the communication infrastructure 706 (or from a frame buffer not shown) for display on a display unit 730. Computer system 700 also includes a main memory 708, preferably random access memory (RAM), and may also include a secondary memory 710. The secondary memory 710 may include nonvolatile memory, for example, a hard disk drive 712, flash memory and/or a removable storage drive 714, representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive 714 reads from and/or writes to a removable storage unit 718 in a well-known manner. Removable storage unit 718, represents a USB memory drive, SD card, floppy disk, magnetic tape, optical disk, etc., which is read by and written to removable storage drive 714. As will be appreciated, the removable storage unit 718 includes a computer usable storage medium having stored therein computer software and/or data.
In alternative aspects, secondary memory 710 may include other similar devices for allowing computer programs or other instructions to be loaded into computer system 700. Such devices may include, for example, a removable storage unit 722 and an interface 720. 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 722 and interfaces 720, which allow software and data to be transferred from the removable storage unit 722 to computer system 700.
Computer system 700 may also include a communications interface 724. Communications interface 724 allows software and data to be transferred between computer system 700 and external devices. Examples of communications interface 724 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 724 are in the form of signals 728, which may be electronic, electromagnetic, optical or other signals capable of being received by communications interface 724. These signals 728 are provided to communications interface 724 via a communications path (e.g., channel) 726. This path 726 carries signals 728 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 714, a hard disk installed in hard disk drive 712, and signals 728. These computer program products provide software to the computer system 700. 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 708 and/or secondary memory 710. Computer programs may also be received via communications interface 724. Such computer programs, when executed, enable the computer system 700 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 704 to perform such features. Accordingly, such computer programs represent controllers of the computer system 700.
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 700 using removable storage drive 714, hard disk drive 712, or communications interface 720. The control logic (software), when executed by the processor 704, causes the processor 704 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.
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.
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.
