EP2246569B1 - Contrôleur de pompe - Google Patents

Contrôleur de pompe Download PDF

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Publication number
EP2246569B1
EP2246569B1 EP10160593.9A EP10160593A EP2246569B1 EP 2246569 B1 EP2246569 B1 EP 2246569B1 EP 10160593 A EP10160593 A EP 10160593A EP 2246569 B1 EP2246569 B1 EP 2246569B1
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Prior art keywords
pump
current
motor voltage
containing information
signal
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EP10160593.9A
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German (de)
English (en)
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EP2246569A2 (fr
EP2246569A3 (fr
Inventor
Thanh Tran Derrick
Thang Quoc Dang
Rufino Naval Jr.
David L. Phillips
Jignesh N. Pandya
Ujjaval D. Joshi
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Xylem IP Holdings LLC
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Xylem IP Holdings LLC
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B35/00—Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for
    • F04B35/04—Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for the means being electric
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06—Control using electricity
    • F04B49/065—Control using electricity and making use of computers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2203/00—Motor parameters
    • F04B2203/02—Motor parameters of rotating electric motors
    • F04B2203/0201—Current
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2203/00—Motor parameters
    • F04B2203/02—Motor parameters of rotating electric motors
    • F04B2203/0202—Voltage
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2203/00—Motor parameters
    • F04B2203/04—Motor parameters of linear electric motors
    • F04B2203/0401—Current
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2203/00—Motor parameters
    • F04B2203/04—Motor parameters of linear electric motors
    • F04B2203/0402—Voltage
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2205/00—Fluid parameters
    • F04B2205/04—Pressure in the outlet chamber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2205/00—Fluid parameters
    • F04B2205/05—Pressure after the pump outlet

Definitions

  • the present invention relates to a technique for controlling the operation of a pump, including providing a method of controlling the operation of a pump at a constant pressure using motor current as a sensing parameter and motor voltage as a controlling parameter.
  • the present invention relates to a method and apparatus using a pump control to keep an outlet pressure constant based at least partly on sensing motor current and a unique algorithm of tracking the V-I characteristics of a pump.
  • EP 0 226 858 A1 discloses aspects of a pump control.
  • Many pumps known in the art include a mechanical pressure switch, or semiconductor hall sensors, or load cells, or any other type of electronic pressure sensing device, that shuts off the pump when certain pressure (i.e., the shut-off pressure) is exceeded.
  • the pressure switch, hall sensor or load cell is typically positioned in physical communication with the fluid in the pump. When the pressure of the fluid exceeds the shut-off pressure, the force of the fluid moves the mechanical switch to open the pump's power circuit or generates corresponding electrical signal to trace the set pressure.
  • Mechanical switches have several limitations. For example, during the repeated opening and closing of the pump's power circuit, arcing and scorching often occurs between the contacts of the switch. The pressure cannot remain constant because of the non-repetitive and/or non-linear behavior. So relying totally on the pressure switch or sensor will always give an inconsistence control loop.
  • a new technique is provided using current sensing to control the pressure at a constant level without the direct sensing of the pressure and determining an output voltage signal for providing to the pump containing a correction term to the motor voltage based on a set current calibrated from a table at the motor voltage.
  • This new technique will help to reduce the dependency solely on the pressure switch or sensor and their non-linearity and other associated problems such as the non-repetitive behavior, as well as other known problems associated with being affected by electromagnetic interference (EMI), etc.
  • EMI electromagnetic interference
  • the present invention may take the form of apparatus, such as a pump controller, featuring one or more modules configured to respond to one or more input signals containing information about current provided from a pump; and also configured to provide one or more output signals containing information to control the pump to operate at a substantially constant pressure without the direct sensing of pump pressure.
  • apparatus such as a pump controller, featuring one or more modules configured to respond to one or more input signals containing information about current provided from a pump; and also configured to provide one or more output signals containing information to control the pump to operate at a substantially constant pressure without the direct sensing of pump pressure.
  • Embodiments of the present invention may also include one or more of the following features:
  • Either the one or more modules or the apparatus as a whole may be configured as a PID controller for controlling the operation of the pump.
  • the apparatus takes the form of a controller featuring one or more signal processing modules configured to respond to one or more input signals containing information about current provided from a pump; and configured to provide one or more output signals containing information to control the pump to operate at a substantially constant pressure without the direct sensing of pump pressure.
  • Embodiments of the controller may include one or more of the features described herein.
  • the controller may also form part of a pumping system or arrangement that includes the pump.
  • the present invention also takes the form of a method featuring steps for controlling the pump, including responding to one or more input signals containing information about current provided from a pump; and providing one or more output signals containing information to control the pump to operate at a substantially constant pressure without the direct sensing of pump pressure.
  • Embodiments of the method may include steps for implementing one or more of the features described herein.
  • the present invention may also take the form of a computer program product having a computer readable medium with a computer executable code embedded therein for implementing the steps of the method when run on a signaling processing device that forms part of such a pump controller like element 10.
  • the computer program product may take the form of a CD, a floppy disk, a memory stick, a memory card, as well as other types or kind of memory devices that may store such a computer executable code on such a computer readable medium now known.
  • FIG. 1a shows apparatus in the form of a pump controller generally indicated as 10 featuring one or more modules 12 and 14.
  • the one or more modules 12 is configured to respond to one or more input signals containing information about current provided from a pump (see element 30 ( Figure 4 ); and also configured to provide one or more output signals containing information to control the pump 30 ( Figure 4 ) to operate at a substantially constant pressure without the direct sensing of pump pressure.
  • Either the one or more modules 12 or the apparatus 10 as a whole is configured as, or form part of, a module (see element 40 ( Figure 4 )) having a PID controller 41 along with other components or modules 42, 44, 46, 48 described below for controlling the operation of the pump 30.
  • the module 40 includes, e..g., one or more signal processing modules configured to perform the signal processing for implementing the functionality of the present invention.
  • the PID controller 40 may also form part of a pumping system or arrangement generally indicated as 50 in Figure 4 for controlling the operation of the pump 30.
  • the one or more modules 14 may include other modules that may form part of the pump controller to implement other controller functionality that does not form part of the underlying invention, e.g., including input/output functionality for processing signaling to and from a pump/motor, a sensing device, etc., as well as functionality associated with other devices or components, e.g., including a random access memory (RAM) type device, a read only memory (ROM) type device, control and data bus type devices, etc.
  • RAM random access memory
  • ROM read only memory
  • the calibration table may form part of, e.g., a memory storage device.
  • the memory storage device itself may form part of the one or more modules 12, the one or more other modules 14, or some combination thereof.
  • Memory storage devices are known in the art, and the scope of the invention is not intended to be limitation to any particular type or kind thereof now known.
  • the present invention also takes the form of a method shown in Figure 1b having steps 22, 24 that form part of a flowchart generally indicated as 20 for controlling the pump 30 ( Figure 4 ), including responding to one or more input signals containing information about current provided from the pump 30, e.g. along signal path 42a ( Figure 4 ); and providing one or more output signals, e.g. along signal path 41a ( Figure 4 ), containing information to control the pump 30 to operate at a substantially constant pressure without the direct sensing of pump pressure.
  • Figure 2 is provided to show the general head-flow characteristics for a typical diaphragm pump. From the characteristics, the current and voltage are understood to be substantially unique for the head-flow desired. Another important outcome is that the pressure at the two different flow rates is understood not to substantially have the same voltage and current at any given time.
  • Figure 3 is provided to show a V-I characteristic at a constant pressure for a typical diaphragm pump, which forms the basis for the table or table look-up technique according to the present invention.
  • the V-I characteristics can be determined by varying the voltages applied to the pump for its entire operating range (e.g. from 8.5 V to 14.8V for +12V motor and without any control electronics, i.e. a variable speed drive (VSD)) and plotting the current by keeping the pressure constant which is the desired constant pressure at which the pump needs to be maintained when it is in its intended normal operation (e.g., 30 PSI).
  • VSD variable speed drive
  • V-I characteristics in Figure 3 that determine the table for a given pump are unique for that given pump since V-I characteristics substantially depend on the motor characteristics of that given pump, which typically vary from one motor when compared to another motor.
  • respective V-I characteristics will be sensed and determined for each pump and a respective table will be formulated for each pump that are unique for each pump, and used to control each pump.
  • any controller or control system may be implemented to control the pump at the constant pressure by looking up and following the above obtained trend line (V-I characteristics) using the table loop-up technique according to the present invention.
  • FIG. 4 shows a diagram of a control block for a pump system 50 having a simple yet effective approach according to an embodiment of the present invention.
  • the control block or module 40 includes devices, components or modules such as the PI(D) controller module 41, along with other components or modules 42, 44, 46, 48 for controlling the operation of the pump 30.
  • the module 42 senses current from the motor along signal path 42a, and provides a current sensing signal along signal path 42b containing information about the sensed motor current.
  • the module 44 is configured to respond to the current sensing signal along signal path 42b, to measure current at a motor voltage, and provide a measured current signal along signal path 44a containing information about the measured current at that motor voltage.
  • the one or more input signals containing information about current provided from the pump 30 includes the current sensing signal along signal path 42b.
  • the module 46 is configured to respond to a voltage output signal E along signal path 41a provided from the PI(D) controller module 41 to the pump 30 along signal path 41a for controlling the operation of the pump 30, to set current at a particular voltage (calibration), and provide a signal along signal path 46a containing information about the set current at the particular voltage (calibration).
  • the node module 48 is configured to respond to the signal along signal path 44a containing information about the measured current at the motor voltage and the signal along signal path 46a containing information about the set current at the particular voltage (calibration), and provide a signal e along signal path 48a to the PI(D) module 41 containing information about the two signals. Consistent with that described in further detail below, the signal e provided from the node module 48 to the PI(D) module 41 along signal path 48a contains information about an error between the set current and sensed actual motor current that will be used as input parameter for the PID controller 41.
  • the PI(D) module 41 is configured to respond to one or more input signals, including the signal e along signal path 48a that contains information about current provided from the pump 30, as well as voltage output signal E along signal path 41a provided from the PI(D) controller module 41 to the pump 30 along signal path 41a for controlling the operation of the pump 30. Consistent with that described in further detail below, the voltage signal E from the PI(D) module 41 to the pump 30 along signal path 41a will contain the correction term to the motor voltage to get the desired pressure.
  • the one or more output signals containing information to control the pump 30 ( Figure 4 ) to operate at the substantially constant pressure without the direct sensing of pump pressure includes the voltage output signal E along signal path 41a.
  • the voltage output signal E along signal path 41a for controlling the operation of the pump 30 is effectively corrected or modified based at least partly on the control feedback system shown in Figure 4 that depends on a relationship between the sensed motor current and the information contained in the table calibrated for the respective pump 30 so as to operate the respective pump 30 at the substantially constant pressure without the direct sensing of pump pressure.
  • Figure 5 shows a graph of current in relation to voltage having V-I characteristics for desired current indicated as D (shown as having a lighter colored function) and achieved current indicated as A (shown as having a darker colored function) at a constant pressure without the direct sensing of pump pressure for controlling the operation of a diaphragm pump according to some embodiments of the present invention.
  • the one or more modules 12 ( Figure 1 ) or 41 ( Figure 4 ) is configured to provide a correction term, e.g., in the form a modified voltage signal along signal path 41a, to control the pump so as to operate at the substantially constant pressure, such that the desired current D and achieved current A have similar values at a similar motor voltage as shown in the graph Figure 5 for controlling the operation of a diaphragm pump without the direct sensing of pump pressure, according to some embodiments of the present invention.
  • a correction term e.g., in the form a modified voltage signal along signal path 41a
  • This control implementation according to the present invention as described herein provides a highly accurate, seamless yet easy to implement control algorithm, which provides a piece-wise linear approach that is easy to calibrate (obtain the V-I characteristics) and has less computational burden on the controller.
  • V-I curve The reproduction of the V-I curve is done using the piece-wise linear method.
  • the curve is divided in number (ideally infinite) small linear lines.
  • the pump will sense the actual motor current and apply the voltage to the motor. The same voltage will be sent to the set current prediction logic to get the set current for the desired pressure at the present motor voltage. The sensed actual motor current will be compared with the set current (desired current at that voltage for desired pressure - from the calibration table). The error between the set current and sensed actual motor current will be used as input parameter for the PID controller. The PID controller will generate the correction term to the motor voltage (controller by duty cycle) to get the desire pressure. Next time the above steps are repeated at a constant and very fast rate.
  • the one or more output signals along signal path 41a may be provided to get the output that gives the constant desired pressure at the pump's output through the predictive algorithm approach according to the present invention.
  • the functionality of the modules 12, 41, 42, 44, 46 or 48 may be implemented using hardware, software, firmware, or a combination thereof.
  • the modules 12, 41, 42, 44, 46 or 48 would include one or more microprocessor-based architectures having a microprocessor, a random access memory (RAM), a read only memory (ROM), input/output devices and control, data and address buses connecting the same.
  • RAM random access memory
  • ROM read only memory
  • a person skilled in the art would be able to program such a microcontroller (or microprocessor)-based implementation to perform the functionality described herein without undue experimentation.
  • the scope of the invention is not intended to be limited to any particular implementation using technology now known.
  • VSD variable speed drive pump controller

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
  • Measuring Fluid Pressure (AREA)

Claims (6)

  1. Appareil incluant un contrôleur de pompe (10), comprenant:
    un module contrôleur de pompe configuré pour répondre à un signal d'entrée contenant des informations sur un courant fourni par une pompe (30) à une tension de moteur fournie à la pompe (30); et configuré pour déterminer un signal de tension de sortie (E) à fournir à la pompe (30) contenant un terme de correction de la tension du moteur sur la base d'au moins en partie d'une erreur entre le courant fourni par la pompe (30) à la tension du moteur et un courant de consigne étalonné à partir d'un tableau à la tension du moteur, de manière à contrôler la pompe (30) pour qu'elle fonctionne à une pression sensiblement constante sans détection directe de la pression de la pompe, dans lequel le module contrôleur de pompe comprend:
    un module de détection de courant (42) configuré pour:
    recevoir le signal d'entrée (42a) contenant des informations sur le courant à la tension du moteur, et
    fournir une détection de courant contenant des informations sur le courant détecté à la tension; et
    un module de mesure du courant (44) configuré pour:
    recevoir le signal de détection de courant (42b) contenant des informations sur le courant détecté à la tension du moteur, et
    fournir un signal de courant mesuré (44a) contenant des informations sur le courant mesuré à la tension du moteur; et dans lequel le module contrôleur de pompe comprend un module de courant de consigne (46) configuré pour:
    recevoir un signal de tension du moteur (41a) contenant des informations sur la tension du moteur, et
    fournir un signal de courant de consigne (46a) contenant des informations sur le courant de consigne étalonné à partir du tableau à la tension du moteur; et dans lequel le module contrôleur de pompe comprend un module de nœud (48) configuré pour:
    recevoir un signal de courant mesuré contenant des informations sur le courant mesuré à la tension du moteur,
    recevoir le signal de courant de consigne (46a) contenant des informations sur le courant de consigne étalonné à partir du tableau à la tension du moteur, et
    fournir un signal de correction d'erreur (e) contenant des informations sur une erreur entre le courant mesuré à la tension du moteur et le courant de consigne étalonné à partir du tableau à la tension du moteur; et dans lequel le module contrôleur de pompe comprend un module contrôleur PID (41) configuré pour:
    recevoir le signal de correction d'erreur (e) contenant des informations sur l'erreur entre le courant mesuré à la tension du moteur et le courant de consigne étalonné à partir du tableau à la tension du moteur,
    recevoir un signal de tension du moteur contenant des informations sur la tension du moteur, et
    fournir le signal de tension de sortie (E) pour contrôler la pompe (30) afin qu'elle fonctionne à la pression sensiblement constante sans détection directe de la pression de la pompe.
  2. Appareil selon la revendication 1, dans lequel le tableau est étalonné pour chaque pompe (30).
  3. Appareil selon l'une des revendications précédentes 1 ou 2, dans lequel la détermination est basée au moins en partie sur les caractéristiques liées à la tension et au courant en utilisant l'équation suivante: I = Vm + C ,
    Figure imgb0031
     où m = I 1 − I 2 / V 1 − V 2 ,
    Figure imgb0032
     C = V 1 * I 2 − V 2 * I 1 / VI − V 2 ,
    Figure imgb0033
    (VI, I1): Point bas de la courbe, et
    (V2, I2): Point haut de la courbe.
  4. Procédé de contrôle d'une pompe (30) comprenant:
    la réponse à un signal d'entrée contenant des informations sur un courant fourni par la pompe (30) à une tension du moteur fournie à la pompe (30); et
    la détermination d'un signal de tension de sortie (E) à fournir à la pompe (30) contenant un terme de correction de la tension du moteur sur la base d'au moins en partie d'une erreur entre le courant fourni par la pompe (30) à la tension du moteur et un courant de consigne étalonné à partir d'un tableau à la tension du moteur, de manière à contrôler la pompe (30) pour qu'elle fonctionne à une pression sensiblement constante sans détection directe de la pression de la pompe; et dans lequel le procédé comprend:
    la réception d'un signal de tension du moteur (41a) contenant des informations sur la tension du moteur, et
    la fourniture d'un signal de courant de consigne (46a) contenant des informations sur le courant de consigne étalonné à partir de la tension; et dans lequel le procédé comprend en outre:
    la réception du signal de courant mesuré (44a) contenant des informations sur le courant mesuré à la tension du moteur,
    la réception du signal de courant de consigne (46a) contenant des informations sur le courant de consigne étalonné à partir du tableau à la tension du moteur, et la fourniture d'un signal de correction d'erreur (e) contenant des informations sur l'erreur entre le courant mesuré à la tension du moteur et le courant de consigne étalonné à partir du tableau à la tension du moteur; et dans lequel le procédé comprend:
    la réception du signal de correction d'erreur (e) contenant des informations sur la correction d'erreur entre le courant mesuré à la tension du moteur et le courant de consigne étalonné à partir du tableau à la tension du moteur,
    la réception d'un signal de tension du moteur contenant des informations sur la tension du moteur, et
    la fourniture du signal de tension de sortie (E) pour contrôler la pompe (30) afin qu'elle fonctionne à la pression sensiblement constante sans détection directe de la pression de la pompe.
  5. Procédé selon la revendication 4, dans lequel le tableau est étalonné pour chaque pompe (30).
  6. Procédé selon l'une des revendications précédentes 4 ou 5, dans lequel le procédé consiste à déterminer les caractéristiques relatives à la tension et au courant avec l'équation suivante: I = Vm + C ,
    Figure imgb0034
     où m = I 1 − I 2 / V 1 − V 2 ,
    Figure imgb0035
     C = V 1 * I 2 − V 2 * I 1 / VI − V 2 ,
    Figure imgb0036
    (VI, I1): Point bas de la courbe, et
    (V2, I2): Point haut de la courbe.
EP10160593.9A 2009-04-21 2010-04-21 Contrôleur de pompe Active EP2246569B1 (fr)

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CN (1) CN101871447B (fr)
AU (1) AU2010201599B2 (fr)
MX (1) MX2010004368A (fr)

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JP2010255634A (ja) 2010-11-11
EP2246569A2 (fr) 2010-11-03
MX2010004368A (es) 2010-10-20
JP5479995B2 (ja) 2014-04-23
EP2246569A3 (fr) 2011-06-22
BRPI1002730A2 (pt) 2012-04-03
CN101871447B (zh) 2015-12-16
AU2010201599B2 (en) 2014-06-05
CN101871447A (zh) 2010-10-27
AU2010201599A1 (en) 2010-11-04

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