SI23685A - Device for controlling pump with multi sensor microprocessor controller - Google Patents

Abstract

The subject of the invention is a device for automatic regulation of the operation of the sensor microprocessor controller pump, which optimally regulates the operation of the pump. According to the invention, the device solves the aforementioned problems and, with the help of sensors, preferential sound, resolves the regulation as well as the occurrence of undesired noise. For optimal system operation, a microprocessor is required, which has a built-in algorithm for operation, preferably with a soft logic. The operation and conditions are controlled by various sensors, such as temperature, pressure and sound sensors, or other status sensors.

Description

Pump control unit with multiple sensor microprocessor controller

The invention relates to a device for regulating a water pump, which automatically regulates the supplied energy by means of a multi-sensor microprocessor controller. The invention belongs to class F 04B 49/06.

The pumps are assembled as shown in Figure 1 from the housing, rotor, stator, controller and axis on which the turbine is located. The pumps are used for the flow of water in the heating systems.

The principle of pump operation and regulation are generally known and described in detail in patents. The pumps operate in such a way that a certain water flow and pressure are established at a certain number of rotor turns. The characteristic of the operation is shown in the diagram of pressure, flow and energy efficiency.

There are several known solutions for regulating pump operation.

The principle of determining the pressure based on the flow rate (a specified number of turbine revolutions) is used to optimize the pump operation. The controller may be determined to operate on the basis of constant flow, constant pressure, or automatic operation, for example, reduction of revolutions in the night mode of operation or the like. In some cases, pressure sensors are used for better regulation, which allows better regulation by measuring differential pressure. State of the art pumps allow the pump to be controlled by measuring the frequency of voltage on the stator, which determines the number of turns. By measuring current consumption, however, the pressure in the system is indirectly determined.

The pumps are controlled using a microcontroller. For newer pumps, the controller is mounted on the housing. Although new pumps are energy efficient because they are classified into energy classes, there is still a big problem in this area. Pressure and flow control are not sufficient for optimal performance. The pumps can be installed in so many different systems that determining how to operate properly requires expert people and making the right choice. Even quality pumps can be inefficient when not properly installed.

Another problem is that the pumps can be installed in hard-to-reach parts of the devices and that access to adjust the settings is difficult. A problem is also the servicing of the system and the pumps, since they do not have a mechanism for detecting irregularities.

Problems are also described with the latest pumps. Most of the problems are related to the sound that occurs due to cavitation on the turbine, due to the air in the system due to resonance, due to excessive flow on the system elements or other causes.

The subject of the invention is a device for automatically regulating the pump operation of a sensor microprocessor controller, which optimally regulates the pump operation. According to the invention, the device solves the aforementioned problems and by means of sensors, preferentially sounds, resolves the regulation and also the occurrence of unwanted noise. Optimal operation of the system requires a microprocessor that has a built-in algorithm for operation, preferably with fuzzy logic. The operation and conditions are controlled by various sensors such as temperature, pressure and sound sensors or other state change sensors.

The principle of operation of the regulation and the implementation of the device will be explained in more detail on the basis of the example and pictures, of which:

Fig. 01 Schematic illustration of the installation of the parts of the device according to the invention on the pump and the pump cross-section Fig. 02 Displays the modes of pump operation Fig. 03 Flow chart, pressure and efficiency of the pump Fig. 04 Flow graph of the pump operation Fig. 05 Flow graph of the pump operation Fig. 06 Factor graph energy efficiency, figure 07 timing graph of sound at different pump operating modes figure 08 example of electronic controller knob figure 09 example of placement of movable pump button figure 10 simple fuzzy logic of the controller pictured mounting modes painted 2 power figure 3 data entry figure 14 button on the pump • · Figure 15 Pump insert Figure 16 Button Interface Figure 17 Example of a wireless network when operating a pump

An automatic microprocessor controller pump control unit is integrated into pump housing 1. The pump is integrated into the pipeline installation via the turbine section (2). In the turbine part, the most important element is the turbine wheel (3) rotated by the rotor. In most modern motors, a permanent magnet rotates on the rotor (4). To control the number of turns, the electrical and voltage parameters are processed in the electronic circuit board (6). The stator (9) changes the number of turns and thus the flow. According to the invention, a sensor part (5) and an electronic button (9) were added. For optimum system performance, a microprocessor is installed on the electronic circuit board, which has a built-in algorithm for operation, preferably with fuzzy logic. The operation and conditions are controlled by various sensors such as temperature, pressure and sound sensors or other state change sensors.

In a system where the pump is connected, most often it is a system of heating with pipes, radiators and other necessary elements, the pump has the task of circulating the medium. Each centrifugal pump has a similar performance characteristic as in the illustration

2. The pressure drop (12) and flow rate (13) shall be set for the specified system conditions. An example is shown by point (10) where the flow rate is reduced and thus the heat transfer increased and the point (11) where the flow rate is increased is the maximum heat flow. By changing the flow rate, the optimal heat transfer and thus the efficiency factor can be sought.

The graph in Figure 3 shows the relationship between flow (15) and pressure (14) in curve (17) and the associated efficiency curve (16). The characteristic shows the optimum flow to some point when the efficiency begins to fall. For easy understanding of changes in flow, pressure and efficiency, the same data are presented in Figures 4, 5 and 6 with respect to the time axis (18).

The device according to the invention uses the results of sound analysis experiments to improve the performance of the pump in the work system. Figure 7 shows an acoustic signal (20) for different modes of operation of the pump, where the maximum value is the maximum amplitude of the signal (19). Sound from pumps has been a disturbing factor so far, and in our io solution we use it to correct performance and preventively detect timely faults in the system. Because too much fluid velocity causes noise, this is also an easy way to control it.

Figure 8 shows one of the possible wireless button designs. The base (21) can be attached to a pump or a button component (22). The device may be powered by a battery (23) and attached to a pump with a magnet (24) as in this case.

9 shows a wireless module on a pump (25) connected to a microprocessor unit (26) by a separate control portion (27).

Fuzzy logic is especially suitable for management. An example with 6 inputs and two outputs is shown in Figure 10. Inputs (28) can be sound, temperature, and output can be number of turns (29) and power (30).

Figure 11 explains in more detail some of the possible ways of attaching the device button (31) to the base (33). One possible embodiment is with magnets. The magnet (32) may be in the housing of the device or the magnet (34) may be located on or below the base. The attraction of a magnet can also be realized with non-magnetic metal. In one embodiment, the magnet on the base, on the other hand, is the part attracted by the metal (iron) magnet of a certain size and shape. In another embodiment, a magnet is used in the housing, which is mounted on an iron base.

Another classically known method of attachment is the mechanical connection to the screw (36).

By means of a screw, a plastic part may also be attached to the base (35), which has wedges for the second dividing part on the handle. Such possible solutions are known and are not the subject of the invention.

In the following embodiment, the button is secured to the base with a special rubber teat (40) shaped to comprise a channel. Pressing your fingers on this channel (38) pushes the air out of the pouch. When released, the rubber shape generates a certain force due to subpressure, which, after the distress is released, creates a force that holds the button on the ground. These are not the only ways. In this case, the electronics are protected from water.

Similarly, the magnet-supported version is silicone rubber cylindrical shape 15 (42), which also protects the system from water.

For the operation of the device, it is very important that the user does not have to worry too much about the power supply to the microprocessor module. Since the device is in certain positions in the wireless mode, it is necessary to maximize the available energy with the operating mode. Some possible modes are shown in Figure 12. The basic mode of operation is the battery, which should be in normal mode for at least 6 months. Because batteries are extremely environmentally friendly, there are some battery-free modes shown in embodiments. Most often, the power module uses a capacitor or a digital energy saver instead of a battery for energy storage. These options do not preclude other storage methods.

It is known from previous descriptions that the methods of using the buttons are related to devices connected to the power supply. An example of an energy storage charging embodiment shown as a first example is by means of electromagnetic inductive charging via a coil. The coil (44) is located on the device and creates with the help of an electronic circuit an electromagnetic field which in the coil (45) in the housing of the device induces energy, which is then prepared for storage via the electronic circuit. For better energy transfer, ferrite cores can be used, and coils can also be used to transfer information between modules in different execution io cases.

Information between modules as well as the power supply may in some cases be made with connectors (46). In such a case, there is no need for wireless operation.

Because there is also enough heat on the pump, in one embodiment, in 15 cases, a peltie element (47) is used to power the module and fill the energy storage unit, which converts the thermal energy into electrical energy. In the same way, by adjusting different voltage levels, which is not the subject of the invention, a photovoltaic cell (48) can be filled at the knob.

It is very important for the user, when using the device, to see the position in which he has placed the button - device. Figure 13 explains this interaction as a confirmation of his wish. In the manual mode described in previous cases, the user sees a position in which a button is placed with a mark on the button and a position facing one of the symbols. In automatic control, this mode of interaction can be maintained. The manner in which the functions are selected is the object of the invention and represents the embodiment of a button position selector relative to the mounting ring. Four examples are discussed in detail, but not the only ones. In the first embodiment, contacts (50) are connected to the electronic board (49) on one side, which are connected to the electronics. By means of a selector (51) which rotates about its axis and has a contactor mounted on it, which connects the contacts (50) when it reaches a certain position. The shape of the slider (53) is such that, with the tab on the cylindrical shape of the button, it enters the channel (52). In this way, by turning the knob or by turning the cylindrical part around the knob, the desired positions can be determined to determine the desired control mode.

io Another embodiment is a potentiometer mode. A potentiometer (54) is attached to the electronic plate. In the center of the potentiometer is a part (55). By turning around the common axis, the user can select a particular control mode. In certain embodiments, both control modes are required. The interactive rendering method will be explained in detail below. A very interesting way to choose because of its contactlessness and therefore security is to operate the magnets. The reed relay switches on or off with a magnet. Only some possible use combinations are shown. The basic but not the only one according to the invention is that the electronics in the button have a relay (61) and a magnet (58) on the other part. Use in the opposite way is also possible. By rotating the magnet through the electronics, the positions are engaged. In a certain situation, the electronics can also be switched off and thus there is no stand by power consumption, which will be explained further in the description below. A little different way, one example example is with the three keys. Button (62) is to confirm the operation of keys (60) and (63) are plus + and minus - by which the settings can be changed digitally.

Figure 14 shows a derivative example of a button device according to the invention for the example of controlling a circulating pump by a centrifugal turbine. Sensors (63) are primarily used for sound sensors, as well as temperature sensors and pressures are desirable. In this case, the sensor part (65) is connected wirelessly behind the control knob (66), which is connected wirelessly to the pump.

To illustrate the possible connection to connectors or contacts (67), an example is in Fig. 15, when the transfer part (68) contacts the sensors (80) and (81) when mounted on the pump. There are many possible ways of realization and they are not excluded by listing our examples of implementation.

io It is very important for the user to know the position they have chosen. The first embodiment is illustrated by illuminating the symbols on the selector (83). An electronic LED (84) is placed on the electronic plate, which illuminates the symbol (86) in the part which leads as a light line. By rotating the knob (85) relative to the part (83), light moves in the symbols.

Figure 17 illustrates another advantage of using a button in wireless operation with circulation pumps (90). Pumps are used in certain systems in inaccessible locations and many can be used. By means of a button according to the invention, which uniquely connects to a device which is operated, transparent and easily accessible panels can be created - control cabinets (91) where simple operation (92) can simplify and optimize operation.

When talking about the important characteristics of a circulating pump in a heating system, the following parameters related to the pump must be considered:

• Power consumption (energy efficiency) in all operating conditions • Flow characteristics • Pressure characteristics

State of the art is a method described in patents and used with the latest generation of pumas. These pumps use energy-efficient induction motors. Typical for these engines is that their design makes it easy to control the speed and thus determine the flow. Most often, the control electronics have a power meter, which gives information about the pressure in the system. With this control, the pumps can adapt to certain pressure and flow conditions in the system. The principle of operation is to optimize the heating system on the basis of a given flow rate by selecting different predefined operating profiles.

System sizing shall take into account:

• system pressure called static pressure, which depends on the type of heating system. At low pressures, cavitation sounds. There is a particular problem at higher temperatures. Current systems with compensation vessels may experience instantaneous pressures as a result of the absorption of hot water dilatation.

• a pressure drop that compensates for pressure losses throughout the system. The pressure at the pump inlet itself is critical and must meet the minimum requirements, which of course causes the constraints that we do not want to optimize the system. At the same time, the hydraulic resistance of the system caused by the system elements must be taken into account. , such as closing valves on radiators and the like.

The pressure drop through the system is influenced by the flow, and for a double flow we have a fourfold increase in the pressure drop. Increasing the flow also increases the speed through the elements, thereby increasing the possibility of unfavorable sound.

The basic solutions are known and described and a selection of Q-p characteristics is used for optimization. Looking for the most favorable point of operation that is the same for the system and the pump. The assumption is that with reduced heating demand, the flow of valves will be reduced. This also changes the selected pump characteristic.

The heating system must balance itself by selecting operating parameters based on system pressures. For example, at differential pressure in a two-pipe system, the valves on the radiator balance the system.

Even state-of-the-art pumps have problems especially with the appearance of sound, which makes installation and maintenance very demanding, as indicated by the installation notes, see pump installation instructions. Common and not the only ones are:

• Bleed the system • Fill up to a certain pressure • Start the system, shut down and vent again • Measure parameters and fine-tune

An even bigger problem is the real optimization of the system that the user would have to do after installation, which very often occurs when the system is set up. If after the installation of the system we do not have enough energy on the radiators, a club with a sufficiently large source of energy is a problem in the choice of the pump performance. The problem is that the increased velocity resulting from the higher flow does not allow for a sufficiently large transfer of heat from the water. The high output temperature has a particularly negative effect on the thermal efficiency of the system. Reduced flow has a positive effect on efficiency. This is due to the exponential Q H curve in the radiators. Thus half the flow gives about 80% of the heat utilization.

The basis of regulation is a printed circuit board with a microprocessor and the necessary electronic elements to which the sensors S1 .... Sn and the selector button are connected.

Regulatory algorithms, especially fuzzy logic systems, are suitable for software support. The only quality optimization method is to monitor the system in all segments with the help of sensors. The task we are solving is to achieve maximum impact through optimal use of sensors and systems.

Possible sensors that can be used are sensors of pressure, flow, temperature, humidity, sound, pump power consumption, and the like.

When using sensors, care must be taken not to increase the cost of the system and the complexity of its use. Sensors can be installed outside the casing or inside the pump casing. The sensors can be wired or wirelessly connected.

As a standard, the pump already uses methods for determining the flow through the pump based on the frequency characteristic of the control signal, and determining the pressure known by measuring consumption on the stator determines the other characteristics in the system. The selectable operation is automatic, constant pressure, constant flow, night and the like.

• ·

The solutions for determining the performance of the pump itself are good enough and we will also use them to determine the flow and pressure at the pump. The pump design itself and the quality of the control offer an easy way to solve the control problem.

Without excluding cable connection, we choose a wireless sensor network.

The universal module has a multisensor module, which consists of a receive and transmit module, a power module and a sensor part. The standard module has a temperature, pressure and sound sensor. The transceiver module is primarily intended for sending data, for communicating with each other and for pairing sensors and a controller. The electronics are identical on the sensor and in the pump only on the pump the module is connected to the control module. Wireless control panel connection with a possible pump partThis detachable module, which can be separated from the pump and uniquely identified with a specific pump, enables simplified pump management even in complex systems and when pumps are mounted in difficult to reach locations.

Claims (5)

PATENT APPLICATIONS 1. Pump control device with multiple sensor microprocessor 5 controllers, characterized in that it is shaped like a button for user friendly use. Pump control device according to claim 1, characterized in that it automatically regulates the level of energy input based on the measured parameters by means of control logic. Pump control device according to claim 1, 15, characterized in that s also operates wirelessly with a special protocol. Pump control device according to claim 1, characterized in that 20 that the buttons are connected to the operation network. Pump control device according to claim 1, characterized in that it can have various sensors that enable the capture of data necessary for quality control of the processes. A pump control device according to claim 1, 5, characterized in that it consists of an electronic part, a housing and a control logic. 7. Pump control device according to claim 1, io characterized in that it also allows for pre-adjustable and in-process controlled regulation of the user's specific preferences. A pump control device according to claim 1, 15, characterized in that the operation control is manual and the user selects the operating mode by rotating the button. A pump control device according to claim 1, 20, characterized in that there is a position mark on the button 10. Pump control device according to claim 1, characterized in that 25 so that the button can be removed from position. 11. Pump control device according to claim 1, characterized in that it has a ring which can be fixed to the carrier or movable. A pump control device according to claim 1, characterized in that the operating ring is drawn or mounted on the ring based on constant flow, constant pressure or automatic operation. io 13. Pump control device according to claim 1, characterized in that the device regulates operation by means of sensors, preferentially sound 15. The pump control device according to claim 1, characterized in that it has a built-in algorithm for operation, preferably by fuzzy logic. 15. Pump control device according to claim 1, 20, characterized in that sound is used for performance correction and preventive for timely detection of system errors. 16. Pump control device according to claim 1, characterized in that Ida is used to control the most favorable operating point, which is the same for the system and the pump. 5 The pump control device according to claim 1, characterized in that it has a multisensor module, which consists of a receiving and transmitting module, a power module and a sensor part. io 18. Pump control device according to claim 1, characterized in that the electronics are identical on the sensor and in the pump only at the pump the module is connected to the control module. 15 19. Pump control device according to claim 1, characterized in that it can be separated from the pump and uniquely identified by a specific pump 20. Pump control device according to claim 1, 20, characterized in that the device is attached to the base by magnets. The magnet (34) can be in the housing of the device (31) or underneath. 21. Pump control device according to claim 1, characterized in that the fixing method is a mechanical connection to the screw. 22. Pump control device according to claim 1, 5, characterized by the fact that a screw or a plastic or metal part is attached to the base (35), which is then used for mounting another split part on the handle. 23. Pump control device according to claim 1, characterized in that the knob is attached to a pump with a special rubber nipple (40) configured to contain a duct for generating a vacuum. A pump control device according to claim 1, 15, characterized in that, by means of a rubber bellows (42), the device is protected from moisture. 25. Pump control device according to claim 1, characterized in that 20 that the battery is powered by 26. Pump control device according to claim 1, characterized in that a capacitor, digital energy storage or similar system is used for power supply. A pump control device according to claim 1, 5, characterized in that the energy storage charges are carried out by means of electromagnetic inductive charging via a coil. 28. Pump control device according to claim 1, io characterized in that the coils are also used for transmitting information 29. Pump control device according to claim 1, characterized in that 15 that the connectors (46) supply power and transmit information. Pump control device according to claim 1, characterized in that a peltie element (47) is used to fill the energy storage unit, which converts 20 thermal energy into electrical energy. 31. Pump control device according to claim 1, characterized in that a photovoltaic cell (48) is used to fill the energy storage device. 32. A pump control device according to claim 1, characterized in that it has a knob position selector and a mounting ring. Pump control device according to claim 1, characterized in that different settings are made by means of contacts (52) connected by the contactor (50) on the selector (53) io 34. Pump control device according to claim 1, characterized in that the position of the controller is determined by means of a potentiometer (54). A knob is mounted in the potentiometer part (55) to turn the knob. 35. Pump control device according to claim 1, characterized in that a potentiometer and a selector with a contactor are used to determine the data 20 36. Pump control device according to claim 1, characterized in that the position is selected by means of a magnet (58) and magnetic switches (61). 37. Pump control device according to claim 1, characterized in that the magnet is used to disconnect the circuit by means of a magnetic switch. A pump control device according to claim 1, 5, characterized in that the position is selected by a combination of keys (60,63 and 62) 39. Pump control device according to claim 1, characterized in that the knob is mounted on a circulating pump by a centrifugal turbine and the pump is controlled by sensors. 40. Pump control device according to claim 1, characterized in that 15 that sound is also used to control the pump's operation. 41. Pump control device according to claim 1, characterized in that the button is mounted on the pump and the two parts are electrically connected to the contacts (67) A pump control device according to claim 1, characterized in that important position information selected by the user is displayed by illuminating the symbols (86) on the selector (83) by means of an LED and a light line. 43. Pump control device according to claim 1, 5, characterized in that the buttons are placed on one panel in groups (91) and allow complete control systems to be operated easily.