U.S. patent application number 15/409587 was filed with the patent office on 2017-08-03 for controller for pump system.
The applicant listed for this patent is Ramparts, LLC. Invention is credited to David Lee Dickman, Joshua Luke Ellis.
Application Number | 20170218943 15/409587 |
Document ID | / |
Family ID | 59385479 |
Filed Date | 2017-08-03 |
United States Patent
Application |
20170218943 |
Kind Code |
A1 |
Ellis; Joshua Luke ; et
al. |
August 3, 2017 |
CONTROLLER FOR PUMP SYSTEM
Abstract
A pump control system includes a pump operable via actuation of
an actuator that moves an actuating element to cause the pump to
generate an intake stroke and a discharge stroke to pump media
along a pipe or conduit. A sensor is disposed at the actuator and
is operable to sense the position of the actuating element during
operation of the actuator and pump. A controller is operable to
control the actuator. The controller, responsive to an output of
the sensor, determines the current position of the actuating
element and automatically controls the actuator to provide a
selected performance of the pump.
Inventors: |
Ellis; Joshua Luke; (Alto,
MI) ; Dickman; David Lee; (Kentwood, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ramparts, LLC |
Kentwood |
MI |
US |
|
|
Family ID: |
59385479 |
Appl. No.: |
15/409587 |
Filed: |
January 19, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62288542 |
Jan 29, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04B 43/06 20130101;
F04B 43/067 20130101; F04B 51/00 20130101; F04B 49/06 20130101;
F04B 49/12 20130101; F04B 2205/14 20130101; F04B 49/08 20130101;
F04B 53/16 20130101; F04B 2207/02 20130101 |
International
Class: |
F04B 49/06 20060101
F04B049/06; F04B 51/00 20060101 F04B051/00; F04B 53/16 20060101
F04B053/16; F04B 49/08 20060101 F04B049/08; F04B 43/067 20060101
F04B043/067; F04B 49/12 20060101 F04B049/12 |
Claims
1. A pump control system comprising: a pump operable via actuation
of an actuator that moves an actuating element to cause the pump to
generate an intake stroke and a discharge stroke to pump media
along a pipe or conduit; a sensor disposed at the actuator and
operable to sense the position of the actuating element during
operation of the actuator and pump; and a controller operable to
control the actuator, wherein the controller, responsive to an
output of the sensor, determines the current position of the
actuating element and automatically controls the actuator to
provide a selected performance of the pump.
2. The pump control system of claim 1, wherein the selected
performance comprises a selected stroke rate of the pump.
3. The pump control system of claim 1, wherein the selected
performance comprises a selected pump discharge pressure.
4. The pump control system of claim 1, wherein the actuator
comprises a pneumatic or hydraulic cylinder and the actuating
element comprises a piston that moves within the cylinder
responsive to pressurization of the cylinder.
5. The pump control system of claim 4, wherein the sensor comprises
an ultrasonic sensor disposed at an end region of the cylinder to
sense the location of the piston relative to the cylinder.
6. The pump control system of claim 4, wherein the pump comprises a
diaphragm pump and wherein the piston moves relative to the
cylinder to move a diaphragm element of the diaphragm pump.
7. The pump control system of claim 1, wherein the actuator
comprises a suction device that applies suction at the pump to draw
a diaphragm of the pump upward during an intake stroke of the
pump.
8. The pump control system of claim 1, wherein the controller is
operable to control the actuator to provide the selected
performance of the pump irrespective of changes in viscosity of the
media pumped by the pump.
9. The pump control system of claim 1, wherein the controller is
operable to control the actuator to provide the selected
performance of the pump irrespective of changes in pressure in the
pipe or conduit.
10. The pump control system of claim 1, wherein the controller is
operable to control a stroke rate of the pump irrespective of
changes in pressure in the pipe or conduit.
11. The pump control system of claim 1, wherein the controller is
operable to control a stroke rate of the pump irrespective of
changes in viscosity of the media pumped by the pump.
12. The pump control system of claim 1, wherein the controller
adjusts operation of the pump responsive to changes in pressure in
the pipe or conduit.
13. The pump control system of claim 1, wherein the controller
adjusts operation of the pump responsive to changes in viscosity of
the media pumped by the pump.
14. The pump control system of claim 1, wherein the controller is
operable to control the actuator to enhance efficiency of the
pump.
15. The pump control system of claim 1, wherein the controller
continuously determines the position of the actuating element
during operation of the actuator and pump.
16. The pump control system of claim 15, wherein the controller
determines and applies optimum operating suction and discharge
pressures of the pump.
17. The pump control system of claim 15, wherein the controller
controls the actuator to make the pump take a complete stroke
during operation of the pump.
18. The pump control system of claim 1, wherein, responsive to a
determination of a partial blockage condition of the pipe or
conduit, the controller switches the pump to a short stroke
mode.
19. The pump control system of claim 1, wherein the system
comprises a plurality of pumps and a sensor disposed at an actuator
of each of the pumps, and wherein the controller, responsive to the
outputs of the sensors, automatically controls the actuators to
provide selected performance of the pumps.
20. The pump control system of claim 19, wherein the controller is
operable to control the pumps such that each pump will stroke at
least partially out of phase with the other pumps.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims the filing benefits of U.S.
provisional application Ser. No. 62/288,542, filed Jan. 29, 2016,
which is hereby incorporated herein by reference in its
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of
pumps and more particularly to the field of diaphragm pumps that
are actuated to pump liquid through a pipe.
BACKGROUND OF THE INVENTION
[0003] It is known to provide a diaphragm pump that is operable to
pump liquid by movement of a diaphragm element to cause intake of
fluid (such as liquid or semi-solid media or the like) into the
pump and discharge of fluid from the pump. The movement of the
diaphragm element is caused by a piston and cylinder arrangement,
whereby vertical movement of the piston imparts vertical movement
of a center region of the diaphragm element. The actuation of the
piston/cylinder is set to provide a desired stroke rate or stroke
distance.
SUMMARY OF THE INVENTION
[0004] The present invention provides a pump control system for a
pump that generates alarms or alerts to inform a user of a required
operational change and/or that automatically controls the operation
of the piston/cylinder and pump so that the pump provides a desired
flow rate and/or stroke length and/or pressure irrespective of
changes in viscosity of the fluid (such as liquid or semi-solid
media or the like) being pumped or restrictions or blockages
occurring in the pipes. The pump and control system of the present
invention uses a single sensor, such as an ultrasonic sensor or
probe to sense the location of the piston and utilizes the sensor
data (output by the sensor to the controller) to determine optimum
operation of the pump to meet desired input parameters. The system
and its controller directly measure and adjust the piston and
diaphragm position to automatically control operation of the pump,
with minimal to no operator input required.
[0005] These and other objects, advantages, purposes and features
of the present invention will become apparent upon review of the
following specification in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a pump and control system in
accordance with the present invention;
[0007] FIG. 2 is a side elevation and partial sectional view of the
pump system of FIG. 1, showing the pump drawing the diaphragm
upward during an intake stroke of the pump;
[0008] FIG. 3 is another side elevation and partial sectional view
of the pump system, showing the pump pushing the diaphragm downward
during a discharge stroke of the pump;
[0009] FIG. 4 is a side elevation and partial sectional view of a
pump and sensor probe of the controller of the present invention,
shown disposed or installed at the top of the cylinder and operable
to sense the position of the piston rod during operation of the
cylinder and pump;
[0010] FIG. 5 is a plan view of a controller of the control system
of the present invention;
[0011] FIGS. 6-13 show various exemplary control screens of the
controller of FIG. 5;
[0012] FIG. 14 is a plan view of another controller of the control
system of the present invention; and
[0013] FIGS. 15-18 show various exemplary control screens of the
controller of FIG. 14.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring now to the drawings and the illustrative
embodiments depicted therein, a pump system 10 includes a
controller 12 for controlling operation of a pump 14 for pumping
fluid along a fluid line or pipe or conduit (FIG. 1). As shown in
FIGS. 2 and 3, the pump 14 comprises a diaphragm pump that includes
a diaphragm that moves responsive to actuation of an actuator 16,
such as a pressurized gas or fluid cylinder (such as, for example,
a pneumatic or hydraulic cylinder). The controller 12 is responsive
to a sensor 18 (such as an ultrasonic sensor or probe) that is
disposed or installed at the cylinder and senses the position of an
actuating element or piston rod of the actuator or pneumatic (or
hydraulic) cylinder 16, and controls the actuation of the actuator
or cylinder accordingly, as discussed below. The controller 12 thus
automatically controls the pump (or pumps) and can adjust the rate
and/or length of the stroke of the cylinder and pump to enhance or
optimize pump performance and/or to adjust the pump operation
responsive to changes in fluid viscosity or density or pressure or
the like, as also discussed below. The controller also or otherwise
generates an alert or alarm to inform or alert the user that a
required adjustment of one or more pump settings is required to
enhance or optimize pump performance and/or to adjust the pump
operation responsive to changes in fluid viscosity or density or
pressure or the like, as also discussed below.
[0015] The pump controller directly measures and adjusts the
diaphragm position with positive feedback. The controller can be
readily set up for an existing pump, such as by connecting the
control lines of the controller to the lines of the cylinder and
connecting the sensor or probe at the cylinder.
[0016] During operation, the controller cycle rate may be
responsive to an output signal (such as a 4-20 ma signal or the
like) from the sensor, and may provide full adjustable suction and
discharge pressures to match the system pressures. The system may
provide full emergency shutdown for maximum safety, and may provide
local and remote start/stop to facilitate easy pump operations.
Optionally, the controller and system may provide a diaphragm
monitor to determine the status of the diaphragm and to determine
if leaks occur at the diaphragm. Optionally, and desirably, the
controller may provide touch screen control to enhance the user's
ability to adjust operation of the controller and pump.
[0017] With the continuous measuring of the position of the piston
of the cylinder or actuator, and thus the position of the pump
diaphragm, the controller can be set to maintain full suction and
discharge strokes even with varying system conditions. The system
may not allow the diaphragm to stop at the bottom of the discharge
stroke. Thus, the pump is always full and never over pressurized,
thereby optimizing or maximizing pump performance and diaphragm
life.
[0018] In the illustrated embodiment, the controller uses an
ultrasonic probe or senor that can be disposed in (such as by being
pushed into) a hole at the top of the cylinder and that may send an
output signal to the controller. The controller processes the
signal to measure or determine the piston and diaphragm position
and rate or speed continuously. This allows the controller to
change the speed and timing of the pump diaphragm in real time.
[0019] The controller of the present invention provides automatic
control of the pump operation. When the pump solenoid valve is idle
(not energized), supply (fluid or gas or air) pressure is on the
bottom side of the pump air cylinder (with the diaphragm
accordingly being in the up or intake position as shown in FIG. 2)
and the pump controller measures the position using feedback from
the ultrasonic probe regarding the position. The controller
processes or determines the position of the diaphragm and shifts
the solenoid valve, diverting supply air to the top of the
diaphragm (FIG. 3) to drive the diaphragm down for the discharge
stroke. At the bottom of the stroke the solenoid is immediately
de-energized. When the solenoid valve is de-energized, the solenoid
valve shifts back to its idle position, the air pressure on the
diaphragm is exhausted to atmosphere, and the supply air pressure
returns to the bottom side of the air cylinder piston to lift the
diaphragm assembly for the upward or suction stroke.
[0020] The control of the present invention provides positive
stroke feedback (or control). For example, if the suction or
discharge pressure is too low, the controller may generate or
display a visual or audible alert or alarm at the controller or to
a remote location. The operator thus knows to adjust the pressure
at the cylinder to maintain a full stroke. The controller may
control a single pump (as shown in FIG. 1) or may control two or
more (such as four) pumps in sequence.
[0021] With reference to FIGS. 5-13, an embodiment of a smart pump
controller of the present invention is shown, with different touch
screen displays and user inputs or function keys (e.g., F1-F5) to
allow an operator to set the controller for the desired or
appropriate operation and control of the cylinder and pump,
depending on the particular application of the controller and pump
system. For example, FIG. 6 shows a startup screen that lists
optional screens to select.
[0022] The controller device or box comprises a small programmable
logic controller (PLC), an operator interface, and an optional
diaphragm moisture detector. The operator interface enables the
setting of pump operating parameters, as well as the monitoring,
documenting, and resetting of pump alarms. The total run time and
stroke count can also be monitored and reset through the operator
interface. Through the operator interface, the stroke rate can be
monitored and changed by an operator or user of the controller.
Optionally, and desirably, if the controller detects moisture in
the dry (upper) side of the diaphragm (such as responsive to a
moisture sensor or the like disposed at the dry side of the
diaphragm), the pump may be shut down and the controller may
generate a diaphragm failure alarm or alert (such as an audible
and/or visual alert).
[0023] As shown in FIG. 7, a first screen may allow the user to
turn the pump on or off, while also displaying the current or
actual pump rate, and optionally displaying remote operation of the
pump and/or if the pump is operating in the short stroke mode.
Another screen or input (FIG. 8) may allow the user to change the
targeted or desired pump rate (strokes per minute). Other control
screens or inputs may be provided to display various information,
such as total cycles and maintenance cycles (FIG. 9), short stroke
alarm or control and/or max stroke rate set point (FIG. 10), remote
operation control (FIG. 11), calibration settings and setting the
position of the piston at the top of the stroke (FIG. 12) and at
the bottom of the stroke (FIG. 13) and the like.
[0024] The controller of the present invention is designed to
maximize the pump system's efficiency with minimal operator input.
The controller can automatically adjust the discharge and suction
pressure independently to achieve the desired stroke rate for the
current system conditions. The pumping system will use only the
amount of air required to achieve the current desired stroke
rate.
[0025] As discussed above, the controller uses the ultrasonic probe
to actively monitor the position of the diaphragm of the pump or
pumps. This information is continuously used by the controller to
make adjustments to the pump's discharge and suction timers and
pressures. The user input touchscreen is designed to simplify
controller setup and pump system monitoring. By using an Ethernet
port or connection, the controller may be remotely accessed and
operated from a laptop, desktop, or smart phone. The controller is
responsive to the signal from the sensor or probe to set stroke
rate, and may also be responsive to a remote start/stop Input. If
the controller has a moisture detection option, connections for an
external moisture alarm switch may be provided.
[0026] Thus, the controller of the present invention is a device
used for all pump control and monitoring, as well as alarm
response. As shown in FIG. 1, all inputs and outputs are connected
to the controller. The programming is designed to automatically
adjust the pump stroke rate to achieve the operator's desired
stroke rate that is selected for the particular system and desired
flow of the fluid or media in the pipe or conduit. If the discharge
or suction regulated air pressure needs to be adjusted, the
controller may adjust the air pressure or may display a message on
the operator screen, so that the operator can adjust the air
pressure, until the desired air pressure is reached. The pressures
need to be set to the required pressure to move the pump in its
suction and discharge stroke. This assists the operator with
setting the suction and discharge air regulators for the current
pumping condition and not over consuming the air supply at the
plant or facility.
[0027] Optionally, the control may provide automatic control of the
pump (more than generating an alert). For example, a smart pump
control of the present invention can replace system pressure
transmitters, flow meters, density meters and/or other process
feedback instruments. The control thus may be an integral part of
the complete process control system. The alarm and display
functions may be transmitted remotely to a central control via a
wired link or a wireless communication connection. An example being
the touch screen display for such a controller (FIG. 14), with
example screens/inputs shown in FIGS. 15-18. For example, FIG. 15
shows a calibration input screen to provide for calibration of the
probe or sensor and/or the air regulators of the pump/system, while
FIG. 16 shows an input screen that allows a user to select the
desired function of the controller, such as to maintain a desired
stroke rate and/or maximum pressure or the like, and FIG. 17 shows
an input screen for maintenance of the pump or system, and FIG. 18
shows an input or operation screen that shows the current function
of the pump and system (so an operator can readily monitor the
operation of the pump system to make sure the system is operating
within the desired stroke rate and pressures).
[0028] The controller may automatically adjust the pressure if the
system determines that the pump does not have enough air pressure
or an excess of air pressure on either the suction or discharge
stroke. Optionally, instead of automatically adjusting or
increasing the pressure, the system may generate an alert or alarm
to indicate to an operator that the pressure needs to be adjusted
or increased. The controller thus functions to enhance or maximize
flow and reduce or minimize air usage.
[0029] Optionally, when the short stroke control feature is
activated, the pump can be used to feed a plate filter press, where
the pump may stall and continue to tap the press with a pressure
pulse to enhance or maximize flow and reduce or minimize air usage,
as well as increase filter cake density. Optionally, the system may
operate to hold a set system pressure at or near a constant
level.
[0030] The controller thus allows the short stroke mode to be
turned on or off. During operation, the pumps are always trying to
take a full stroke to maximize efficiency. The operator can set the
maximum discharge pressure that is desired. When the discharge
pressure created by the pumps is no longer enough to move the media
in a desired discharge time, the pump will short stroke or
"pulse."
[0031] The controller will control the pump(s) to short stroke
while maintaining the desired suction and discharge times but not
increasing the discharge pressure beyond the set maximum pressure.
The controller and pump(s) will exit the short stroke mode and
return to normal operation after they reach a predetermined number
(such as 10 or 20) full strokes or if they are stopped and
restarted. Optionally, if the pump(s) are stopped and restarted,
the discharge pressure will be reduced (such as by about 30
percent) upon restart and then automatically adjusted by the
controller for the discharge system conditions.
[0032] The controller of the present invention allows for and
adapts the pump system to changes in the liquid or media being
pumped and to changes in the system. For example, the control may
be set to maintain a set stroke rate, such that the control will
maintain the stroke rate even if the fluid viscosity, density
and/or other liquid or media characteristics change. The control,
responsive to the signal from the sensor or probe 18, will
automatically increase or decrease the suction or discharge
pressure as required by the pump and system to maintain the desired
stroke rate or the like.
[0033] In situations where the pump controller controls two or more
pumps in sequence (such as, for example, four pumps in sequence),
the controller may control the pumps such that each pump will
stroke out of phase with the other pumps, thereby reducing pressure
pulsations.
[0034] Thus, the controller of the present invention makes the pump
a true process system that can be used to pace a flow rate or
follow a pressure. The controller can hold the level of a reactor
or tank making the system an excellent reactor bottom pump. The
controller can handle system upset conditions with varying
conditions, and can automatically compensate for different products
in the same process system.
[0035] The controller of the present invention is also suitable for
use with suction lift pumps (where suction is applied to raise the
diaphragm during an intake stroke) and adjusts the suction
regulator to fully raise the diaphragm without slamming the piston
on the top of the cylinder. This can be tailored to the viscosity
and suction lift of the liquid being pumped and the system by
varying the suction. The controller will maintain the correct
internal pipe velocity to enhance or maximize performance, while
minimizing the air usage and increasing the efficiency of the pump
system.
[0036] Therefore, the controller and pump system of the present
invention provides a complete pump system that is tailored to the
particular application and desired pump outputs. The pump is easily
controlled over 0 to maximum flow of the pump. The controller's
operating parameters can be quickly modified or automatically
adjusted for upset conditions. The controller thus provides simple
and easy pressure and flow control.
[0037] The controller of the present invention thus continuously
measures the position and speed of the diaphragm on the suction and
discharge stroke, and gives direct feedback to the user of the
position. The controller uses the position/speed information to
calculate or determine the optimum operating suction and discharge
pressures for the pump, ensure that the pump always takes a
complete stroke, ensure that the diaphragm is never in an
unbalanced state during the discharge stroke, minimize the air flow
rate (SCFM) used by the pump, maximize the efficiency and
reliability of the pump. The controller automatically corrects for
system changes (such as changes in pressures, viscosity of the
pumped media, and/or density of the pumped media) without requiring
additional instrumentation (such as density meters or viscometers)
or process inputs. The controller does this without requiring user
input, other than initial set up of the controller, such that the
controller automates the pump and provides enhanced performance and
enhanced efficiency of the pump or pumps.
[0038] Changes and modifications in the specifically described
embodiments may be carried out without departing from the
principles of the present invention, which is intended to be
limited only by the scope of the appended claims as interpreted
according to the principles of patent law.
* * * * *