US20190264677A1 - Automated pumping system and methods - Google Patents

Automated pumping system and methods Download PDF

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Publication number
US20190264677A1
US20190264677A1 US16/289,545 US201916289545A US2019264677A1 US 20190264677 A1 US20190264677 A1 US 20190264677A1 US 201916289545 A US201916289545 A US 201916289545A US 2019264677 A1 US2019264677 A1 US 2019264677A1
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United States
Prior art keywords
pump
fluid
engine
controller
sensor
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US16/289,545
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English (en)
Inventor
David G. Lake
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Clio Technology LLC
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Clio Technology LLC
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Priority to US16/289,545 priority Critical patent/US20190264677A1/en
Assigned to Clio Technology, LLC reassignment Clio Technology, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LAKE, DAVID G.
Publication of US20190264677A1 publication Critical patent/US20190264677A1/en
Priority to US17/956,285 priority patent/US20230279850A1/en
Abandoned legal-status Critical Current

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    • 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
    • F04B17/00—Pumps characterised by combination with, or adaptation to, specific driving engines or motors
    • F04B17/03—Pumps characterised by combination with, or adaptation to, specific driving engines or motors driven by electric motors
    • 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
    • F04B17/00—Pumps characterised by combination with, or adaptation to, specific driving engines or motors
    • F04B17/05—Pumps characterised by combination with, or adaptation to, specific driving engines or motors driven by internal-combustion engines
    • 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
    • F04B23/00—Pumping installations or systems
    • F04B23/02—Pumping installations or systems having reservoirs
    • 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
    • F04B49/04—Regulating by means of floats
    • 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
    • F04B49/10—Other safety measures
    • F04B49/103—Responsive to speed
    • 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
    • F04B49/20—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 by changing the driving speed
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D13/00—Pumping installations or systems
    • F04D13/02—Units comprising pumps and their driving means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
    • F04D15/0066—Control, e.g. regulation, of pumps, pumping installations or systems by changing the speed, e.g. of the driving engine
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
    • F04D15/02—Stopping of pumps, or operating valves, on occurrence of unwanted conditions
    • 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
    • F04B2207/00—External parameters
    • F04B2207/70—Warnings

Definitions

  • the present invention concerns a pump controller and fluid pumping systems. More particularly, some embodiments of the present invention concern a pump controller that can be coupled with a pump, pump fluid sensors, fluid level sensors, fuel sensors, and oil pressure sensors. Some embodiments of the present invention concern a pump controller for characterizing, operating, and exchanging information with connected devices which may use mathematical techniques, such as proportional-integral-derivative control. The present invention also concerns a pumping system for draining and filling fluid containers or reservoirs.
  • a pump controller which is easy to operate, adaptable, efficient, and can handle complex pumping situations. Furthermore, there is a need for a pump controller which can automate a fluid pumping system with little to no user interaction. Moreover, there exists a need for a pump controller which can interface with other devices and sensors to characterize and protect a pump and its internal components, while also maximizing the output and efficiency of the pump and pumping system.
  • the present invention concerns a controller for controlling a pump.
  • the controller may include one or more interfaces, ports, devices, or processors by which a user may operate the controller and by which the controller operates, or communicates with, connected devices.
  • the controller may include a processor, a memory device for storing processor instructions, a user interface, a pump interface, and a fluid sensor interface.
  • the controller may include a user interface which has a display, such as, but not limited to, a human-machine interface (“HMI”), human interface device (“HID”), or graphical user interface (“GUI”).
  • HMI human-machine interface
  • HID human interface device
  • GUI graphical user interface
  • One or more buttons, switches, and/or knobs, or the like, may be provided as a means by which the user can make selections shown on the user interface display or by which the user can turn on (or off) the controller, toggle between modes, configure the controller, or otherwise operate the controller.
  • One or more lights may also be provided within the user interface which, depending on the state of the light (i.e., on or off), may provide information about the current status or condition of the controller or any of its connected devices.
  • the user interface may include a touchscreen display, allowing the user to select an action by touching an area of the screen corresponding to the action.
  • the user interface may also have a transceiver and a remote user device (e.g., smartphone, tablet, laptop) which are operatively engaged with a computer network, allowing the user to remotely connect to, and operate, the controller.
  • the controller can connect to the engine controller of the pump by means of the pump interface. Using this interface, the controller may communicate with the engine controller in order to power, operate, and/or exchange information with the pump. For example, the user can use the controller to turn the pump on or off, adjust the engine speed, and/or retrieve data about the current status of the pump (e.g., oil pressure, coolant temperature, fuel level, voltage, etc.).
  • an emergency stop switch may be connected to the controller via the pump interface. When activated, the emergency stop switch suspends, or freezes, the currently active mode or program of the controller and immediately removes power to the pump engine to shut it down.
  • a pump controller may use pump data, received through the various sensor interfaces, to map a pump curve. For example, while a pump is running, the pump controller can store and plot current running parameters to determine the pump curve associated with the pump. The pump controller can also compare current running parameters to a pump curve to determine if a pump is running within the pump curve. The pump controller can display a warning message indicating if the pump is operating outside of the pump curve.
  • the controller can also connect to one or more fluid level sensors by means of the fluid sensor interface.
  • the controller may be adapted to exchange information with a fluid level sensor.
  • the controller may be connected to a float, which, depending on the state thereof (i.e., activated or inactivated), can provide information to the controller about a fluid level within a fluid container, such as a tank.
  • the controller may also be connected to a transducer, which can provide an indication of the current fluid level.
  • the controller can also connect to a fluid pressure sensor, which can provide fluid pressure readings at a given time and position.
  • the controller may be connected to fluid pressure sensors provided within the inlet and outlet of a volute of the pump in order to monitor inlet and outlet pressure (which may be indicative of operational issues within the pump, such as cavitation).
  • a pump controller may use pump data, received through the various sensor interfaces, to map a pump curve. For example, while a pump is running, the pump controller can store and plot current running parameters to determine the pump curve associated with the pump. The pump controller can also compare current running parameters to a pump curve to determine if a pump is running within the pump curve. The pump controller can display a warning message indicating if the pump is operating outside of the pump curve.
  • the controller of the present invention can interface with devices and sensors to form a system for controlling a pump.
  • the system may comprise a pump controller, a pump, and one or more sensors.
  • the pump controller may act as the central communication hub, through which information is received, processed, and transmitted. More specifically, the controller can send commands to the pump based on user input (e.g., by selecting a mode or program, or by setting parameters) or based on feedback from a fluid level or pump sensor.
  • the system may also include a remote connection, allowing a user to remotely access and operate the pump controller via a remote user device.
  • the system may include: a pump controller; a pump having an engine and electronic engine controller; one or more fluid level sensors; a fuel level sensor; inlet and outlet oil pressure sensors for detecting pressure in an oil line of the pump engine; and inlet and outlet fluid pressure sensors for detecting fluid pressure in the pump.
  • the system network may also include one or more floats and/or transducers.
  • the pump controller may include one or more programs, or modes of operation.
  • the controller may include a manual mode, an automatic mode, a diagnostics mode, and a configuration mode.
  • the user may configure the controller for use with a connected pump by selecting configuration mode on the user interface or by connecting a user device, such as a laptop, to the pump controller.
  • a user device such as a laptop
  • the user may enter characterization parameters for the connected devices (e.g., pump engine type), as well as operational parameters (e.g., engine throttle set point).
  • the controller may run the controller in manual mode or automatic mode.
  • the pump engine may be started by pressing a button or switch on the controller user interface. Once the engine is running, the user may adjust the engine throttle by adjusting the revolutions-per-minute (“RPM”) on the user interface.
  • RPM revolutions-per-minute
  • the pump engine may be started by the pump controller via a signal from a fluid level sensor. Once the engine is running, the pump may operate on a fixed throttle based on the RPM set by the user during configuration.
  • the engine throttle may be automatically adjusted, as fluid levels (or pressure) rise or fall, by the controller based on feedback received from a fluid level or pressure sensor. In this case, the throttle may be adjusted at a linear rate, relative to the fluid level or pressure (noting that RPM is proportional to fluid level or pressure).
  • the engine throttle may also be adjusted by proportional-integral-derivative (PID) control, based on feedback from one or more fluid level or pressure sensors.
  • PID proportional-integral-derivative
  • the system may be coupled with one or more containers (e.g., tanks, pits, reservoirs, or the like), which may comprise fluid.
  • containers e.g., tanks, pits, reservoirs, or the like
  • a user can drain fluid from a tank, or fill a tank with fluid, by turning the pump engine on using the pump controller. Once the fluid has reached a desired level, the user can turn the pump off using the pump controller.
  • the pump controller may start the pump engine upon receiving a signal from a fluid sensor.
  • the pump controller system may be coupled with a tank having a float which is connected to the pump controller.
  • the pump In a suction application (i.e., when the pump is configured to drain fluid from the tank), the pump may be turned on once the fluid level within the tank rises to the level (or set point) of the float. In a discharge application (i.e., when the pump is configured to fill the tank with fluid), the pump may be turned on once the fluid level within the tank lowers to the level of the float. The pump engine may then run according to a predefined duration, in which the pump turns off upon expiration of a set time limit, or until the float relay clears.
  • the pump controller system may be coupled with a tank having two floats which are connected to the pump controller.
  • the first float may be at a first position (e.g., near the top of the tank) and the second float may be at a second position, below the first float (e.g., near the bottom of the tank).
  • the pump may be turned on by one float and turned off by the other. For example, in a suction application, the pump may be turned on once the fluid level within the tank rises to the level of the first float. The pump engine may then run until the fluid level lowers to the level of the second float.
  • the pump controller system may be coupled with a tank having a fluid level transducer which is connected to the pump controller.
  • the transducer may be positioned at the top of the tank, such that the signal is directed toward the fluid surface.
  • the pump may be turned on and off by the transducer, depending on the predefined set points programmed to the controller by the user. For example, in a suction application, the pump may be turned on once the fluid level within the tank rises to a first set point. The pump engine may then run until the fluid level lowers to a second set point, at which point the controller shuts down the pump. While the pump is running (i.e., while the fluid is between the first and second set points), the engine may be throttled at a constant rate, linear rate, or using PID.
  • the pump controller system may be coupled with a tank having a transducer and one or more floats, each of which are connected to the pump controller.
  • the floats may provide the “on/off” signal to the controller, while the transducer provides feedback to the controller to dynamically adjust the pump engine speed.
  • the transducer may provide feedback for the engine throttle, as well as the “on” (“off”) signal to the controller.
  • the “off” (“on”) signal may be provided by a float.
  • the pump controller system may be coupled with one or more tanks which may include any number and combination of floats and transducers (or other types of fluid sensors).
  • a controller system may include digital and/or analog inputs. These inputs may provide information to the controller about the pump or a fluid tank.
  • a fuel level sensor may allow the user and controller to monitor fuel level and manually, or automatically, shut off the pump when the fuel is nearly depleted.
  • an emergency stop device (“e-stop”) may be coupled with the controller, allowing the user to immediately stop the pump engine by removing power to the controller.
  • the invention concerns a pump controller for controlling a pump having an engine and an engine controller.
  • the pump controller may include: a processor; a memory device for storing processor instructions; a user interface; a pump interface; and a fluid level sensor interface for communication with a fluid level sensor.
  • the pump interface may be used to communicate with the engine controller (for example, and without limitation an engine control unit).
  • the fluid level sensor interface may be used to communicate with a fluid level sensor (for example, and without limitation, a float in a tank).
  • the pump controller may receive, from the fluid level sensor through the fluid sensor interface, an indication of the level of a fluid in a fluid tank.
  • the pump controller may interface with a float or other sensor in a tank for determining whether to turn on or off the pump.
  • a user may interface with the pump controller directly at the pump controller location.
  • the user interface may include one or more touchscreens, buttons, switches, and/or lights.
  • the user may interface with the pump controller from a remote location via wired or wireless connection.
  • the pump controller may include: a transceiver operatively engaged to a computer network; and a remote user device operatively engaged to the computer network.
  • the computer network may be an open or closed network, and may be a cloud based server network on the internet.
  • the remote user device may be a remote desktop computer, or a wireless computing device (for example, and without limitation, a mobile phone, tablet, or computer).
  • the transceiver may include an antenna for wireless communication (including but not limited to cellular, point-to-point, microwave, short range communication such as near field communication under ISO/IEC standards, or one or more IEEE 802.xx standards, such as “WiFi” or “Bluetooth” communication).
  • the engine controller is an electronic engine controller (for example, and without limitation, an engine control unit (ECU) or engine control module (ECM)).
  • the pump controller may, through the pump interface, provide instructions to the engine controller and/or receive engine data from the engine controller.
  • the engine controller may include a motor and an armature attached to the motor. The armature may engaged and cooperate with a throttle assembly of the engine.
  • the pump controller may include a pump fluid sensor interface for communication with a pump fluid sensor.
  • the pump controller may receive, from the pump fluid sensor through the pump fluid sensor interface, an indication of the pressure of a fluid in the pump and/or an indication of the flow rate of a fluid in the pump via a fluid pressure sensor and/or a flow rate sensor, respectively.
  • the pump may include a volute (or “wet end” of the pump) and the fluid pressure sensor and/or flow rate sensor may be engaged to a fluid inlet and/or outlet of the volute.
  • the pump controller may include a fuel sensor interface for communication with a fuel level sensor.
  • the pump controller may receive, from the fuel level sensor through the fuel sensor interface, an indication of the level of fuel in a fuel tank.
  • the pump controller may include an oil pressure sensor interface for communication with an oil pressure sensor.
  • the pump controller may receive, from the oil pressure sensor through the oil pressure sensor interface, an indication of the pressure of oil in an oil line.
  • the oil line may be one that is engaged with an oil inlet and/or outlet of the engine of the pump.
  • the invention concerns a system for pumping a fluid with a pump having a volute, an engine and an electronic engine controller.
  • the system can include one or more fluid level sensors for detecting a level of the fluid in a fluid tank.
  • the fluid level sensors may be floats and/or transducers.
  • the transducer for detecting the level of the fluid in a fluid tank may be contact or non-contact level sensors.
  • the transducer may include a non-contact optical or ultrasonic level sensor for determining the distance from the sensor to the level of fluid in the fluid tank.
  • the transducer may include a contact capacitive sensor for determining, much like a float, when the level of fluid in the fluid tank is at the position where the sensor is mounted in the tank.
  • the transducer may include a submersible hydrostatic pressure sensor for determining the hydrostatic pressure on the bottom of the tank, which is reflective of the volume of fluid in the tank.
  • the system can also include: a fuel level sensor for detecting a level of fuel in a fuel tank; an inlet oil pressure sensor for detecting an inlet pressure of oil in an inlet oil line associated with the engine; an outlet oil pressure sensor for detecting an outlet pressure of the oil in an outlet oil line associated with the engine; and a pump fluid sensor for detecting a condition of the fluid in the volute of the pump.
  • the pump fluid sensor may comprise an inlet fluid pressure sensor for detecting an inlet pressure of the fluid in an inlet of the volute of the pump and/or an outlet fluid pressure sensor for detecting an outlet pressure of the fluid in an outlet of the volute of the pump.
  • the pump fluid sensor may comprise a flow rate sensor for detecting a flow rate of the fluid in the volute of the pump.
  • the pump controller may be operatively engaged with the engine controller, the fluid level sensors, the fuel level sensor, the inlet oil pressure sensor, the outlet oil pressure sensor, and the pump fluid sensor
  • the pump controller may include a processor, a memory device storing processor instructions, and a user interface.
  • the processor instructions when executed by the processor, may provide instructions to the engine controller.
  • the instructions may be in response to the level of fluid in the fluid tank, the level of the fuel, the inlet pressure of the oil, the outlet pressure of the oil, and the condition of the fluid in the volute.
  • the user interface may include a touchscreen device.
  • the user interface may include a transceiver and a remote user device.
  • the transceiver and the remote user device may be operatively engaged with a computer network.
  • the transceiver may, in some implementations, may be wireless and include an antenna.
  • the invention concerns a system for pumping a fluid.
  • the system may include a first fluid tank for containing the fluid, the first fluid tank having a tank port, and a first fluid level sensor for detecting the level of the fluid in the first fluid tank.
  • the fluid level sensor may include one or more floats or transducers.
  • the transducers may be contact or non-contact level sensors, and may include optical level sensors, ultrasonic level sensors, capacitive sensors, or hydrostatic pressure sensors.
  • the system may further include a fuel tank and a fuel level sensor for detecting the level of fuel in the fuel tank.
  • the system may further include an inlet and an outlet oil line, and an inlet and outlet oil pressure sensor for detecting a pressure of oil in the oil lines, respectively.
  • the system may further include a first fluid pressure sensor for detecting a first pressure of the fluid and a pump fluid flow rate sensor for detecting a flow rate of the fluid.
  • the pump may include: a volute having a first port engaged with the tank port of the first fluid tank and also being engaged with the pump fluid flow rate sensor; an engine engaged with the fuel line and the inlet and outlet oil lines; and an engine controller.
  • the pump controller may be engaged with the engine controller, the first fluid level sensor, the fuel level sensor, the inlet and outlet oil pressure sensors, the first fluid pressure sensor, and the pump fluid flow rate sensor.
  • the pump controller may provide instructions to the engine controller in response to the level of the fluid in the first fluid tank, the level of the fuel in the fuel tank, the pressure of the oil in the inlet oil line, the pressure of the oil in the outlet oil line, the first pressure of the fluid in the pump, the flow rate of the fluid in the pump, and a user interface of the pump controller.
  • the system may further include: a second fluid tank for containing the fluid, the second fluid tank comprising a tank port; a second fluid level sensor for detecting the level of the fluid in the second fluid tank; and a second fluid pressure sensor of detecting a second pressure of the fluid.
  • the volute may further include a second port engaged with the tank port of the second fluid tank and the second fluid pressure sensor.
  • the pump controller may further be engaged with the second fluid level sensor and the second fluid pressure sensor, and provide instructions to the engine controller in response to the level of the fluid in the second fluid tank and the second pressure of the fluid in the pump.
  • the invention concerns a method of controlling a pump having an engine and an electronic controller.
  • the method may include the steps of: characterizing the operation of a pump; performing a safety check of the pump; determining a level of a fluid in a fluid tank; and providing instructions to the electronic controller.
  • the method may further include the step of determining a target speed of the pump.
  • the method may further include the step of charging a battery.
  • characterization of the pump may include the steps of: providing instructions to the electronic engine controller to cause the engine to rotate at a first characterization speed; and, while the engine is rotating at the first characterization speed, detecting a first pump condition of the pump.
  • Detecting the first pump condition may include the steps of detecting an inlet fluid pressure of the fluid at a fluid inlet of a volute of the pump and/or detecting an outlet fluid pressure of the fluid at a fluid outlet of the volute of the pump.
  • Detecting the first pump condition may include the step of detecting a flow rate of the fluid in the volute of the pump.
  • characterization of the pump may further include the steps of: providing instructions to the electronic engine controller to cause the engine to rotate at a second characterization speed; and, while the engine is rotating at the second characterization speed, detecting a second pump condition of the pump.
  • Detecting the second pump condition may include the steps of detecting the inlet and/or outlet fluid pressures of the volute.
  • Detecting the second pump condition may include the step of detecting a flow rate of the fluid in the volute of the pump.
  • the instructions may be provided to the electronic engine controller by a pump controller having a processor, a memory device storing processor instructions thereon, and a user interface.
  • the instructions may cause the engine to rotate at a target speed.
  • the target may be determined from the level of the fluid in the tank, the first characterization speed, the first pump condition, the second characterization speed, and the second pump condition.
  • the safety check may include the steps of: detecting a pressure of oil in an inlet oil line engaged with the engine; detecting a pressure of oil in an outlet oil line engaged with the engine; and detecting the level of fuel in a fuel tank.
  • the safety check may include the step of receiving an engine condition of the engine from the electronic engine controller.
  • the engine condition could be one or more of the engine block temperature, a torque of the engine, a temperature of the oil in the engine, a pressure of the oil in the engine, a pressure of a coolant in the engine, a temperature of the coolant in the engine, a temperature of a fuel, an indication of the amount of the fuel that has been used, an indication of the rate at which the fuel is used, a temperature of an inlet air at an air inlet of the engine, a pressure of the inlet air, a temperature of an outlet air at an air outlet of the engine, a pressure of the outlet air, a temperature of air at an exhaust of the engine, the running hours of the engine, the total hours of the engine, and a fault code.
  • the battery may be charged by the steps of: determining whether the battery needs to be charged; opening a volute of the pump; and providing instructions to the electronic engine controller, the instructions causing the engine to rotate at a charging speed for a charging time.
  • FIG. 1 is a diagram illustrating an exemplary pump controller in accordance with some embodiments of the present invention.
  • FIG. 2 is a diagram illustrating an exemplary system for controlling a pump in accordance with some embodiments of the present invention.
  • FIG. 3 is a diagram illustrating an exemplary menu on a pump controller display in accordance with some embodiments of the present invention.
  • FIG. 4 is a diagram illustrating exemplary engine data on a pump controller display in accordance with some embodiments of the present invention.
  • FIG. 5 is a diagram illustrating an exemplary job setup interface on a pump controller display in accordance with some embodiments of the present invention.
  • FIG. 6 is a diagram illustrating an exemplary job configuration interface on a pump controller display in accordance with some embodiments of the present invention.
  • FIG. 7 is a diagram illustrating an exemplary engine startup interface on a pump controller display in accordance with some embodiments of the present invention.
  • FIG. 8 is a diagram illustrating exemplary diagnostics data on a pump controller display in accordance with some embodiments of the present invention.
  • FIG. 9 is a diagram illustrating an implementation of an exemplary system for pumping a fluid in accordance with some embodiments of the present invention.
  • FIG. 10 is a diagram illustrating an implementation of an exemplary system for pumping a fluid in accordance with some embodiments of the present invention.
  • FIG. 11 is a diagram illustrating an implementation of an exemplary system for pumping a fluid in accordance with some embodiments of the present invention.
  • FIG. 12 is a diagram illustrating an implementation of an exemplary system for pumping a fluid in accordance with some embodiments of the present invention.
  • FIG. 13 is a diagram illustrating an implementation of an exemplary system for pumping a fluid in accordance with some embodiments of the present invention.
  • FIG. 14 is a diagram illustrating an implementation of an exemplary system for pumping a fluid in accordance with some embodiments of the present invention.
  • FIG. 15 is a diagram illustrating an implementation of an exemplary system for pumping a fluid in accordance with some embodiments of the present invention.
  • FIG. 16 is a diagram illustrating an implementation of an exemplary system for pumping a fluid in accordance with some embodiments of the present invention.
  • FIG. 17 is a diagram illustrating an implementation of an exemplary system for pumping a fluid in accordance with some embodiments of the present invention.
  • FIG. 18 is a diagram illustrating an implementation of an exemplary system for pumping a fluid in accordance with some embodiments of the present invention.
  • FIG. 19 is a flowchart illustrating an exemplary process for characterizing the operation of a pump in accordance with some embodiments of the present invention.
  • FIG. 20 is a flowchart illustrating an exemplary process for setting an operational mode of a pump in accordance with some embodiments of the present invention.
  • FIG. 21 is a flowchart illustrating an exemplary process for implementing a password authentication procedure in accordance with some embodiments of the present invention.
  • FIG. 22 is a flowchart illustrating an exemplary process for setting a startup timer for a pump in accordance with some embodiments of the present invention.
  • FIG. 23 is a flowchart illustrating an exemplary process for executing the manual mode startup sequence pump in accordance with some embodiments of the present invention.
  • FIG. 24 is a flowchart illustrating an exemplary process for starting a pump engine in manual mode in accordance with some embodiments of the present invention.
  • FIG. 25 is a flowchart illustrating an exemplary process for executing the automatic mode startup sequence in accordance with some embodiments of the present invention.
  • FIG. 26 is a flowchart illustrating an exemplary process for executing the automatic mode shutdown sequence in accordance with some embodiments of the present invention.
  • FIG. 27 is a flowchart illustrating an exemplary process for executing the manual mode program in accordance with some embodiments of the present invention.
  • FIG. 28 is a flowchart illustrating an exemplary process for adjusting maximum and minimum engine speeds of a pump in accordance with some embodiments of the present invention.
  • FIG. 29 is a flowchart illustrating an exemplary process for executing automatic mode with a float system in accordance with some embodiments of the present invention.
  • FIG. 30 is a flowchart illustrating an exemplary process for executing the manual multi-state operation mode in accordance with some embodiments of the present invention.
  • FIG. 31 is a flowchart illustrating an exemplary process for executing the warm up and cool down procedure of a pump controller in accordance with some embodiments of the present invention.
  • FIG. 32 is a flowchart illustrating an exemplary process for executing the automatic mode program of a pump controller, with transducers, in accordance with some embodiments of the present invention.
  • FIG. 33 is a flowchart illustrating an exemplary process for configuring analog input, scaling, and unit data of pump controller in accordance with some embodiments of the present invention.
  • FIG. 34 is a flowchart illustrating an exemplary process for executing the automatic mode program of a pump controller, with a float and transducer, in accordance with some embodiments of the present invention.
  • FIG. 35 is a flowchart illustrating an exemplary process for executing the automatic mode program of a pump controller, using PID target control, in accordance with some embodiments of the present invention.
  • FIG. 36 is a flowchart illustrating an exemplary process for setting PID parameters for a pump controller in accordance with some embodiments of the present invention.
  • FIG. 37 is a flowchart illustrating an exemplary process for setting a pump scheduler program of a pump controller in accordance with some embodiments of the present invention.
  • FIGS. 38A-38AA are diagrams illustrating various exemplary interfaces for viewing, running, or editing operational modes, programs, menus, parameters, and data related to a pump controller, a pump, and various input sensors, which may displayed on the pump controller user interface display, in accordance with some embodiments of the present invention.
  • the present invention generally concerns a pump controller for controlling a pump, as well as systems, methods, and software for controlling a pump and for pumping a fluid.
  • the pump controller may include one or more interfaces, ports, devices, or processors by which a user may operate the controller and by which the controller operates, or communicates with, connected devices. More specifically, the controller may include a processor, a memory device for storing processor instructions, a user interface, a pump interface, and a fluid sensor interface. For example, as illustrated in FIG.
  • pump controller 100 may include one or more lights 110 , pump interface 121 , fluid level sensor interface 122 , fuel level sensor interface 123 , oil pressure sensor interface 124 , fluid pressure sensor interface 125 , transceiver 130 having antenna 131 , user interface 140 (with display 141 , one or more switches 142 , and knob 143 ), processor 150 , and memory device 160 for storing processor 150 instructions, and battery 170 .
  • lights 110 may provide information to a user about the current status or condition of controller 100 , or any of its connected devices, based on the current state of light(s) 110 (i.e., on or off, emitted color). For example, and without limitation, if light 110 is on and emitting a red color, it may indicate an issue with a connection between pump controller 100 and a fluid sensor. It is to be appreciated, however, that a pump controller can include any number of lights, or other audio or visual devices such as, but not limited to, a horn, which may serve as status indicators or warnings related to the pump controller or its connected devices.
  • a pump controller may be adapted to communicate with an electronic engine controller of a pump.
  • pump controller 100 can exchange information with a pump by means of pump interface 121 in order to power, operate, or otherwise control the pump. Through this interface, pump controller 100 can provide instructions to the electronic engine controller in order to start, stop, or adjust the throttle of the pump engine.
  • the pump controller may be adapted to communicate with an engine controller of a pump which may have an armature engaged with the throttle of the pump engine.
  • the pump controller can also be coupled with one or more fluid sensors, which may provide feedback to the pump controller regarding fluid level or fluid pressure.
  • controller 100 may be adapted to exchange information with a fluid level sensor by means of fluid level sensor interface 122 .
  • the fluid level sensor may provide feedback to controller 100 , which, depending on the signal, may cause controller 100 to turn the pump on or off, or to adjust the speed of the pump engine.
  • the pump controller may be connected to one or more floats which serve as feedback mechanisms for determining when, or at what fluid level within a fluid tank, the pump engine is to be turned on and off.
  • the controller may also be connected to one or more transducers, which, for example, can provide readings of a fluid level or pressure.
  • a transducer may serve as a feedback mechanism for determining the levels at which the pump engine is turned on and off. Additionally, feedback from a transducer can be used to determine throttle adjustment of the pump engine by the pump controller, thereby adjusting the speed of the pump.
  • a pump controller may also be adapted for remote operation. As further illustrated in FIG. 1 , pump controller 100 may be operatively engaged, via transceiver 130 , with computer network 900 , to which remote user device 800 may also be operatively engaged. Through computer network 900 , a user may operate pump controller 100 remotely via remote user device 800 .
  • a remote user device may include a smartphone, tablet, or laptop, or the like.
  • the user interface may include a display, buttons, switches, and/or knobs, which may provide a means by which the user can turn on (or off) the controller, toggle between modes, enter data, or otherwise operate the controller.
  • controller 100 may include display 141 , one or more switches 142 , and knob 143 .
  • Switches 142 and knob 143 may be used to select an option or field shown on display 141 .
  • Switches 142 and knob 143 may also be used to send a command to a connected pump, such as initiating the startup sequence to the pump engine.
  • a pump controller may be adapted to characterize a pump, which may provide a user with information pertaining to the health of the pump.
  • pump controller 100 may be further adapted to receive pump engine data from the engine controller by means of pump interface 121 .
  • a pump controller may also include fuel sensor and/or oil pressure sensor interfaces, through which the controller can communicate with a fuel level sensor and oil pressure sensor, respectively.
  • a fuel level sensor may be used to measure the level of fuel within a fuel tank associated with the pump engine.
  • An oil pressure sensor may be used to measure pressure within oil lines engaged with the oil inlet and/or outlet of the pump engine.
  • the pump controller may be adapted to automatically charge a pump battery.
  • pump controller 100 can receive information about battery 240 of pump 200 through pump interface 121 . Pump controller 100 can then determine if the voltage of battery 240 is low and if it needs charging. If battery 240 requires charging, pump controller 100 can turn on and run pump engine 220 at a predefined charge speed for a predefined duration of time. Once the set runtime expires, the pump controller will shut down the engine.
  • Pump controller 100 may also be adapted to receive data from one or more fluid sensors associated with a pump volute and connected via pump fluid sensor interface 125 .
  • fluid pressure sensors and/or fluid flow meters may be provided to measure fluid pressure or fluid flow, respectively, through an inlet or outlet of the pump volute.
  • the pump controller may be adapted to receive a wide variety of information regarding the status of a pump (e.g., oil pressure, fluid flow, fuel level, coolant temperature, voltage, etc.). This information can be used to protect and maintain pump health, either by built-in mechanisms within the pump controller, or by user action.
  • the pump controller may determine, by volute inlet and outlet flow rates measured by flow meters, that the pump is undergoing cavitation.
  • the pump controller may automatically shut down the pump engine.
  • the user may determine, based on the pump data, to manually shut down the engine.
  • a pump controller may be coupled with an emergency stop switch to immediately cut power to the controller and, thus, pump engine.
  • the pump data may be indicative of worn out or malfunctioning pump parts, which allows the user to determine if and when a part should be replaced—thus extending the life of the pump.
  • a pump controller can interface with a number of devices and sensors to form a system network for controlling a pump.
  • the pump controller may act as the central processor, receiving signals from one or more sensors and, based on sensor feedback or user input, providing commands to a pump.
  • system 5 may comprise: pump controller 100 ; pump 200 having engine control unit 210 , engine 220 , and volute 230 ; one or more fluid level sensors 300 ; one or more fuel level sensors 400 ; one or more oil pressure sensors 500 ; one or more fluid pressure sensors 600 ; and remote user device 800 .
  • information from pump 200 , fluid level sensors 300 , fuel level sensors 400 , oil pressure sensors 500 , and pump fluid sensors 600 may be received and processed by controller 100 .
  • Controller 100 may then transmit signals and commands to pump 200 to, for example, turn off or on, run in manual or automatic mode, and/or adjust engine speed.
  • system 5 may further include a wireless or wired connection to remote user device 800 , allowing a user to remotely, or externally, access and operate the pump controller from remote user device 800 .
  • a pump controller may include one or more programs, or primary modes of operation.
  • a pump controller may include diagnostics mode, automatic mode, manual mode, and configuration mode.
  • a user may configure the controller for use with a pump by selecting configuration mode on the user interface display, or by connecting an external user device, such as a laptop, to the pump controller.
  • the user may enter characterization parameters for the connected devices, as well as operational parameters.
  • the user may enter pump engine data, such as absolute max speed, idle speed, prime speed, prime duration, etc.
  • the user can also toggle between options, such as when specifying whether or not to enable a “low fuel shutdown” option (controller shuts down pump when fuel level is low).
  • a “low fuel shutdown” option controller shuts down pump when fuel level is low.
  • the user may configure connected sensors and specify the job type and operational parameters. For example, as illustrated in FIG. 5 , the user may specify the job type (i.e., drain or fill), the engine start/stop method, and the engine throttle control type (i.e., single speed, linear control, or PID control). The user may also have the option of specifying whether the connected pump is an agricultural pump and whether or not the pump is being used in a flooded suction (drain) application.
  • the job type i.e., drain or fill
  • the engine start/stop method i.e., single speed, linear control, or PID control
  • the engine throttle control type i.e., single speed, linear control, or PID control
  • the user may also enter fluid sensor information through configuration mode.
  • the user can set parameters related to a connected float and/or a connected transducer, as shown in FIG. 6 .
  • the user may specify whether a float has a normally open (“N/O”) or a normally closed (“N/C”) circuit.
  • the user may also specify transducer information such as displayed units, maximum and minimum RPM (engine speed limits during operation), fluid set point levels (i.e., levels at which the pump turns on or off), and the PID target (i.e., transducer target set point when in PID submode).
  • the controller Once the controller is properly configured, the user may run the controller in automatic mode.
  • the pump engine may be started by pressing a button or switch on the user interface. As shown in FIG. 7 , the user may press the engine start button for a number of seconds, as preconfigured or defined by the user. Upon expiration of the specified duration, the pump controller may attempt to start the pump engine. Once started, the pump engine will run at the speed set by default or as configured by the user. During any time while the pump is running, the user may adjust the pump engine throttle by modifying the RPM value displayed on the user interface. To shut down the pump engine, the user may press a corresponding button on the pump controller or on the display.
  • the pump engine may be started by the pump controller via a signal from a fluid sensor. For example, a connected float may be tripped by a fluid, or a connected transducer may detect that the fluid has reached a predefined set point, causing the pump controller to attempt to start the pump engine. If the pump engine does not start after a predefined maximum number of attempts, the start sequence may be aborted.
  • the pump may operate on either: a fixed throttle (single speed), based on the speed set by the user during configuration; linear throttling, based on predefined parameters and feedback from a transducer; or PID throttling, based one predefined parameters and feedback from a transducer.
  • the user can enter diagnostics mode. As shown in FIG. 8 , in diagnostics mode, the user can view pump engine data such as torque, load, oil pressure, coolant temperature, fuel information, etc. The user can also view inlet and outlet pressures of the pump volute, transducer feedback, and float status. Further exemplary information displayed on a pump controller user interface can be seen in FIGS. 38A -AA.
  • a pump controller and a pump may be coupled with one or more tanks, which may comprise fluid, for the purpose of pumping fluid into or out of a tank.
  • a pump controller may be coupled with a pump connected to a single tank.
  • a suction (drain) application an inlet of the pump may be engaged with an outlet of the tank.
  • a fill (discharge) application an outlet of the pump may be engaged with an inlet of the tank.
  • the pump may be connected to two tanks—one tank engaged with the pump inlet and the other tank engaged with the pump outlet.
  • fluid may be transferred between tanks when the pump is on (i.e., one tank drains, while the other tank fills).
  • a user can drain fluid from a tank, or fill a tank with fluid, by turning the pump engine on using the pump controller. Once the fluid reaches a desired level, the user can turn the pump off using the pump controller.
  • the pump controller may start the pump engine upon receiving a signal from a fluid sensor.
  • the pump controller and pump may be coupled with a tank having a float connected to the pump controller.
  • the pump In a suction application, the pump may be turned on once the fluid level within the tank rises to the level of the float and activates it.
  • the pump In a discharge application, the pump may be turned on once the fluid level within the tank lowers to the level of the float and activates it. If the float circuit is normally open, then the float is considered activated when the float circuit closes. If the float circuit is normally closed, then the float is considered activated when the float circuit opens.
  • a float may include a hysteresis function to delay the closing of the float circuit.
  • a float may have an activated range—that is, once activated, the float may stay activated until the fluid level rises above or lowers below the activated range. In this case, the pump may turn off after a fixed increase or decrease in fluid levels.
  • the pump controller and pump can be coupled with a tank having a transducer which is connected to the pump controller.
  • the transducer may be positioned at the top of the tank, such that the signal is directed toward the fluid surface, or, alternatively, the transducer may be positioned near the bottom of the tank, submerged in a fluid.
  • the pump may be turned on and off by the transducer, depending on the predefined set points programmed to the controller by the user. For example, in a suction application, the pump may be turned on once the fluid level within the tank rises to a first set point. The pump engine may then run until the fluid level lowers to a second set point, at which point the controller shuts down the pump.
  • a transducer can also be in used in controlling the pump engine throttle while the pump is running (i.e., while the fluid is between the first and second set points).
  • the pump controller calculates the engine throttle based on a linear correlation between a fluid level and pump engine RPM. To perform this calculation, the pump controller uses the ratios of the high fluid level set point to the low fluid level set point, and the maximum pump engine RPM to the minimum pump engine RPM (these parameters are predefined by the user).
  • the pump controller uses feedback from the transducer and uses PID to calculate throttle adjustment based on the target transducer value (e.g., fluid level).
  • the pump controller and pump may be coupled with a tank having one or more transducers and one or more floats, each of which are connected to the pump controller.
  • a float may provide the “on/off” signal to the controller, while a transducer may provide feedback to the controller to adjust the pump engine speed.
  • a transducer may provide feedback for the engine throttle, as well as the “on” (“off”) signal to the controller and the “off” (“on”) signal may be provided by a float.
  • the tank may have two or more transducers and no floats, where a first transducer provides the “on/off” signal and a second transducer provides feedback to the pump controller. It is to be appreciated, however, that a pump controller and pump may be coupled with one or more tanks which may include any number and combination of floats and transducers (or other types of fluid sensors).
  • FIGS. 9-18 exemplary implementations of a fluid pumping system are illustrated, in which pump controller 100 is coupled with pump 200 and one or more floats and/or transducers.
  • Pump 200 may be turned on by pump controller 100 upon receiving a signal from a float or transducer.
  • suction application FIGS. 9, 11, 13, 15, and 17
  • pump 200 is connected to tank 700 on the outlet side thereof.
  • tank outlet 780 When pump 200 is running, fluid is drawn out of tank 700 through tank outlet 780 and drawn into the pump through volute inlet 231 . The fluid is then discharged from pump 200 through volute outlet 232 .
  • a discharge (fill) application FIGS. 10, 12, 14, 16, and 18 )
  • pump 200 is connected to tank 700 on the inlet side thereof.
  • the exemplary fluid pumping systems described below include: a single float system ( FIGS. 9-10 ); a dual float system ( FIGS. 11-12 ); a single transducer system ( FIGS. 13-14 ); a single transducer and single float system ( FIGS. 15-16 ); and a single transducer and dual float system ( FIGS. 17-18 ).
  • pump controller 100 and pump 200 may be coupled with tank 700 for the purpose of draining fluid therefrom.
  • Tank 700 has a float 311 A near the top 710 of tank 700 at a depth 740 A.
  • Pump controller 100 starts the engine of pump 200 when the fluid level rises to depth 740 A and activates float 311 A.
  • Pump 200 runs until the fluid level lowers below depth 740 A and deactivates float 311 A. Pump 200 continues to run for a predefined duration of time and shuts down upon expiration thereof.
  • a user must turn on pump controller 100 and properly configure the controller for a single float suction program prior to use. Afterwards, the user selects automatic mode via the user interface to initiate the program. Once the fluid level within tank 700 rises to the level of float 311 A, the circuit of float 311 A becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Upon activation, a signal is sent to, and processed by, pump controller 100 . As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200 . Once pump 200 is running, the engine runs at a single speed predefined by the user through configuration mode of pump controller 100 .
  • Pump controller 100 then sends a signal to pump 200 to continue to run at the predefined engine speed for a predefined duration.
  • the predefined duration is set by the user in configuration mode of pump controller 100 by specifying the amount of time the engine runs after float 311 A is deactivated. Once this time period expires, pump controller 100 sends a signal to pump 200 to shut down the engine.
  • pump controller 100 and pump 200 may be coupled with tank 700 for the purpose of filling tank 700 with fluid.
  • Tank 700 has a float 313 B near the bottom 790 of tank 700 at depth 741 .
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level lowers to depth 741 and activates float 313 B. Pump 200 runs until the fluid level rises above depth 760 B and deactivates float 313 B. Pump 200 continues to run for a predefined duration of time and shuts down upon expiration thereof.
  • a user must turn on pump controller 100 and properly configure the controller for a single float discharge (drain) program prior to use. Afterwards, the user selects automatic mode via the user interface to initiate the program. Once the fluid level within tank 700 lowers to the level of float 313 B, the circuit of float 313 B becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Upon activation, a signal is sent to, and processed by, pump controller 100 . As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200 . Once pump 200 is running, the engine runs at a single speed predefined by the user through configuration mode of pump controller 100 .
  • Pump controller 100 then sends a signal to pump 200 to continue to run at the predefined engine speed for a predefined duration.
  • the predefined duration is set by the user in configuration mode of pump controller 100 by specifying the amount of time the engine runs after float 313 B is deactivated. Once this time period expires, pump controller 100 sends a signal to pump 200 to shut down the engine.
  • pump controller 100 and pump 200 may be coupled with tank 700 for the purpose of draining fluid therefrom.
  • Tank 700 has a float 311 C, near the top 710 of tank 700 at depth 740 C, and a float 313 C is near the bottom 790 of tank 700 at depth 760 C.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level rises to depth 740 C, activating floats 311 C and 313 C. Pump 200 continues to run until the fluid level lowers below depth 760 C, deactivating float 313 C.
  • a user must turn on pump controller 100 and properly configure the controller for a dual float suction program prior to use. Afterwards, the user selects automatic mode via the user interface to initiate the program. Once the fluid level within tank 700 rises to the level of float 311 C at depth 700 C, both the circuit of float 311 C and the circuit of float 313 C are activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Once floats 311 C and 313 C are activated, a signal is sent to, and processed by, pump controller 100 . As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200 .
  • pump 200 runs at a single speed predefined by the user through configuration mode of pump controller 100 .
  • the circuit becomes deactivated (circuit re-opens if float circuit is normally open; circuit re-closes if float circuit is normally closed).
  • Pump 200 continues to run until the fluid level lowers below the level of float 313 C, deactivating the circuit. Pump controller 100 then sends a signal to pump 200 to shut down the engine.
  • pump controller 100 and pump 200 may be coupled with tank 700 for the purpose of filling tank 700 with a fluid.
  • Tank 700 has a float 311 D, near the top 710 of tank 700 at depth 740 D, and a float 313 B near the bottom 790 of tank 700 at depth 760 D.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level lowers to depth 760 D and deactivates floats 311 D and 313 D. Pump 200 continues to run until the fluid level rises to depth 740 D, activating float 311 D.
  • a user must turn on pump controller 100 and properly configure the controller for a dual float discharge program prior to use. Afterwards, the user selects automatic mode via the user interface to initiate the program.
  • the fluid level within tank 700 lowers to below depth 760 D, below floats 311 D and 313 D, both the circuit of float 311 D and the circuit of float 313 D are deactivated (circuit opens if float circuit is normally open; circuit closes if float circuit is normally closed).
  • floats 311 D and 313 D are deactivated, a signal is sent to, and processed by, pump controller 100 . As a result, pump controller 100 sends a signal to pump 200 to start the engine of pump 200 .
  • pump 200 runs at a single speed predefined by the user through configuration mode of pump controller 100 .
  • the circuits of floats 311 D and 313 D become activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed).
  • pump controller 100 sends a signal to pump 200 to shut down the engine.
  • pump controller 100 and pump 200 may be coupled with tank 700 for the purpose of draining fluid therefrom.
  • Tank 700 has a transducer 320 E, at the top 710 of tank 700 .
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level exceeds high setpoint 745 E. Pump 200 continues to run until the fluid level lowers to low setpoint 765 E.
  • a user must turn on pump controller 100 and properly configure the controller for a transducer feedback suction program prior to use. If engine throttling is desired, the user must also configure the controller for linear and PID throttling submodes. Afterwards, the user selects automatic mode via the user interface to initiate the program. While the program is running, transducer 320 E provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320 E to the fluid surface). Once the fluid level within tank 700 rises to a point where transducer 320 E detects that the fluid level is above high setpoint 745 E, a signal is sent to, and processed by, pump controller 100 to start the pump engine.
  • the engine of pump 200 will run at a single speed until transducer 320 E detects that the fluid level has reached low setpoint 765 E. At this point, based on the feedback from transducer 320 E, pump controller 100 sends a signal to pump 200 to shut down.
  • pump controller 200 determines the instantaneous fluid level from transducer 320 E and then uses this value to calculate the engine throttle adjustment, based on the high setpoint and low setpoint, and the maximum and minimum speeds of the engine (predefined by the user). As the fluid level continues to lower, pump controller 100 continues to adjust the engine throttle in predefined time or distance increments until transducer 320 E detects that the fluid level has reached low setpoint 765 E. At this point, based on feedback from transducer 320 E, pump controller 100 sends a signal to pump 200 to shut down.
  • the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to a fluid level corresponding to depth 750 E, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320 E detects that the fluid level is below depth 750 E. If transducer 320 E detects that the fluid level is above depth 750 E, pump controller 200 will send a signal to pump 200 to increase the engine speed. Pump 200 will continue to run as long as the fluid level is above the low setpoint.
  • pump controller 100 and pump 200 may be coupled with tank 700 for the purpose of filling tank 700 with a fluid.
  • Tank 700 has a transducer 320 F, at the top 710 of tank 700 .
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level drops below low setpoint 765 F. Pump 200 continues to run until the fluid level rises to high setpoint 745 F.
  • a user must turn on pump controller 100 and properly configure the controller for a transducer feedback discharge program prior to use. If engine throttling is desired, the user must also configure the controller for linear and PID throttling submodes. Afterwards, the user selects automatic mode via the user interface to initiate the program. While the program is running, transducer 320 F provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320 F to the fluid surface). Once the fluid level within tank 700 lowers to a point where transducer 320 F detects that the fluid level is below low setpoint 765 F, a signal is sent to, and processed by, pump controller 100 to start the pump engine.
  • transducer 320 F detects that the fluid level has reached high setpoint 745 F.
  • pump controller 100 sends a signal to pump 200 to shut down.
  • pump controller 100 determines the instantaneous fluid level from transducer 320 F and then uses this value to calculate the engine throttle adjustment, based on the high setpoint, the low setpoint, and the maximum and minimum speeds of the engine (predefined by the user). As the fluid level continues to rise, pump controller 100 continues to adjust the engine throttle in predefined time or distance increments until transducer 320 F detects that the fluid level has reached high setpoint 745 F. At this point, based on feedback from transducer 320 F, pump controller 100 sends a signal to pump 200 to shut down.
  • the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to value corresponding to depth 750 F, pump controller 100 will send a signal to pump 200 to increase the engine speed (calculated via the PID algorithm) if transducer 320 F detects that the fluid level is below depth 750 F. If transducer 320 F detects that the fluid level is above depth 750 F, pump controller 100 will send a signal to pump 200 to decrease the engine speed. Pump 200 will continue to run as long as the fluid level is below the high setpoint.
  • pump controller 100 and pump 200 may be coupled with tank 700 for the purpose of draining fluid therefrom.
  • Tank 700 has a transducer 320 G, at the top 710 of tank 700 , and a float 314 near the top 710 of tank 700 at depth 740 G.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level rises to depth 740 G and activates float 311 G.
  • the speed of engine of pump 200 is adjusted at a linear rate, or according a PID algorithm, depending on the submode. Pump 200 continues to run until the float 311 G is deactivated.
  • a user must turn on pump controller 100 and properly configure the controller for a transducer feedback suction program prior to use.
  • the user must also configure the controller for linear or PID throttling submodes.
  • the user selects automatic mode via the user interface to initiate the program.
  • transducer 320 G provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320 G to the fluid surface).
  • the circuit of float 311 G becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed).
  • a signal is sent to, and processed by, pump controller 100 .
  • pump controller 100 sends a signal to pump 200 to start the engine of pump 200 .
  • the engine speed is adjusted at a linear rate (if set to linear throttle submode) based on high and low setpoints, and maximum and minimum engine speeds (analogous to the procedure described previously).
  • the circuit becomes deactivated (circuit re-opens if float circuit is normally open; circuit re-closes if float circuit is normally closed).
  • Pump controller 100 then sends a signal to pump 200 to shut down.
  • the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to depth 750 G, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320 G detects that the fluid level is below depth 750 G. If transducer 320 G detects that the fluid level is above depth 750 G, pump controller 200 will send a signal to pump 200 to increase the engine speed. Pump 200 will continue to run as long as float 311 G is activated.
  • pump controller 100 and pump 200 may be coupled with tank 700 for the purpose of filling tank 700 with a fluid.
  • Tank 700 has a transducer 320 H, at the top 710 of tank 700 , and a float 315 near the bottom 790 of tank 700 at depth 760 H.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level lowers to depth 760 H and deactivates float 313 H.
  • the speed of engine of pump 200 is adjusted at a linear rate, or according a PID algorithm, depending on the submode, based on feedback from transducer 320 H.
  • Pump 200 continues to run until the float 313 H is activated.
  • a user must turn on pump controller 100 and properly configure the controller for a transducer feedback suction program prior to use.
  • the user must also configure the controller for linear or PID throttling submodes.
  • the user selects automatic mode via the user interface to initiate the program.
  • transducer 320 H provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320 H to the fluid surface).
  • the circuit of float 313 H becomes deactivated (circuit opens if float circuit is normally open; circuit closes if float circuit is normally closed).
  • a signal is sent to, and processed by, pump controller 100 .
  • pump controller 100 sends a signal to pump 200 to start the engine of pump 200 .
  • the engine speed is adjusted at a linear rate (if set to linear throttle submode) based on high and low setpoints, and maximum and minimum engine speeds (analogous to the procedure described previously).
  • the circuit becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Pump controller 100 then sends a signal to pump 200 to shut down.
  • the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to depth 750 H, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320 H detects that the fluid level is above depth 750 H. If transducer 320 H detects that the fluid level is below depth 750 H, pump controller 100 will send a signal to pump 200 to increase the engine speed. Pump 200 will continue to run as long as float 313 H is deactivated.
  • pump controller 100 and pump 200 may be coupled with tank 700 for the purpose of draining fluid therefrom.
  • Tank 700 has a transducer 320 I at the top 710 of tank 700 , a first float 316 A near the top 710 of tank 700 at depth 740 I, and a second float 313 I near the bottom 790 of tank 700 at depth 760 I.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level rises to depth 740 I, activating floats 311 I and 313 I.
  • the speed of engine of pump 200 is adjusted at a linear rate, or according a PID algorithm, depending on the submode, based on feedback from transducer 320 I.
  • Pump 200 continues to run until second float 313 I is deactivated.
  • a user must turn on pump controller 100 and properly configure the controller for a transducer feedback suction program prior to use.
  • the user must also configure the controller for linear or PID throttling submodes.
  • the user selects automatic mode via the user interface to initiate the program.
  • transducer 320 I provides real-time feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320 I to the fluid surface).
  • the circuit of second float 313 I becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed).
  • the circuit of first float 311 I becomes activated.
  • pump controller 100 sends a signal to pump 200 to start the engine of pump 200 .
  • the engine speed is adjusted at a linear rate using transducer 320 I feedback (if set to linear throttle submode) based on high and low setpoints, and maximum and minimum engine speeds (analogous to the procedure described previously).
  • the circuit becomes deactivated (circuit re-opens if float circuit is normally open; circuit re-closes if float circuit is normally closed).
  • the circuit becomes deactivated. Pump controller 100 then sends a signal to pump 200 to shut down.
  • the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to a value corresponding to depth 750 I, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320 I detects that the fluid level is below depth 750 I. If transducer 320 I detects that the fluid level is above depth 750 I, pump controller 100 will send a signal to pump 200 to increase the engine speed. Pump 200 will continue to run as long as second float 313 I is activated.
  • pump controller 100 and pump 200 may be coupled with tank 700 for the purpose of filling tank 700 with a fluid.
  • Tank 700 has a transducer 320 I at the top 710 of tank 700 , a first float 311 J near the top 710 of tank 700 at depth 740 I, and a second float 313 I near the bottom 790 of tank 700 at depth 760 J.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level lowers to depth 760 I, deactivating floats 311 J and 313 I.
  • the speed of engine of pump 200 is adjusted at a linear rate, or according a PID algorithm, depending on the submode, based on feedback from transducer 320 J. Pump 200 continues to run until first float 311 J is activated.
  • a user must turn on pump controller 100 and properly configure the controller for a transducer feedback suction program prior to use.
  • the user must also configure the controller for linear or PID throttling submodes.
  • the user selects automatic mode via the user interface to initiate the program.
  • transducer 320 I provides real-time feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320 I to the fluid surface).
  • the circuit of first float 311 I becomes deactivated (circuit opens if float circuit is normally open; circuit closes if float circuit is normally closed).
  • the speed of the engine of pump 200 will be determined by a PID algorithm. For example, if the PID setpoint is set to depth 750 J, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320 J detects that the fluid level is above depth 750 J. If transducer 320 J detects that the fluid level is below depth 750 J, pump controller 100 will send a signal to pump 200 to increase the engine speed. Pump 200 will continue to run as long as first float 311 J is deactivated.
  • FIG. 19 illustrates an exemplary process 19000 for characterizing the operation of a pump, comprising the steps:
  • FIG. 20 illustrates an exemplary process 20000 for setting an operational mode of a pump, comprising the steps:
  • FIG. 21 illustrates an exemplary process 21000 of implementing a password authentication procedure, comprising the steps:
  • FIG. 22 illustrates an exemplary process 22000 for changing a startup timer, comprising the steps:
  • FIG. 23 illustrates an exemplary process 23000 of executing a manual mode startup sequence, comprising the steps:
  • FIG. 24 illustrates an exemplary process 24000 for starting a pump engine in manual mode, comprising the steps:
  • FIG. 25 illustrates an exemplary process 25000 of executing an automatic mode startup sequence, comprising the steps:
  • FIG. 26 illustrates an exemplary process 26000 for executing the shutdown of automatic mode, comprising the steps:
  • FIG. 27 illustrates an exemplary process 27000 for executing a manual mode program, comprising the steps:
  • FIG. 28 illustrates an exemplary process 28000 of setting maximum and minimum engine speed values, comprising the steps:
  • FIG. 29 illustrates an exemplary process 29000 for executing automatic mode with a float system, comprising the steps:
  • FIG. 30 illustrates an exemplary process 30000 for executing manual multi-state operation mode, comprising the steps:
  • FIG. 31 illustrates an exemplary process 31000 for executing a warm up and cool down procedure, comprising the steps:
  • FIG. 32 illustrates an exemplary process 32000 for executing automatic mode with one or more transducers, comprising the steps:
  • FIG. 33 illustrates an exemplary process 33000 for setting analog inputs, scaling, and units, comprising the steps:
  • FIG. 34 illustrates an exemplary process 34000 for executing automatic mode with a float and transducer using linear throttling, comprising the steps:
  • FIG. 35 illustrates an exemplary process 35000 for executing automatic mode with PID control is illustrated, comprising the steps:
  • FIG. 36 illustrates an exemplary process 36000 for changing PID parameters, comprising the steps:
  • FIG. 37 illustrates and exemplary process 37000 for setting a pump scheduler program, comprising the steps:
  • FIGS. 38A -AA various diagrams are shown which illustrate exemplary interfaces for viewing, running, or editing modes, programs, menus, parameters, and data related to a pump controller, a pump, and various input sensors, which can be displayed on the pump controller user interface display. For example, as illustrated in FIGS. 38A -AA, various diagrams are shown which illustrate exemplary interfaces for viewing, running, or editing modes, programs, menus, parameters, and data related to a pump controller, a pump, and various input sensors, which can be displayed on the pump controller user interface display. For example, as illustrated in FIGS.
  • a pump controller include a job setup interface for specifying (i) whether the connected pump is an agriculture pump, (ii) whether the job is for a flooded suction application, (iii) the type of job (drain or fill); the start/stop method (one float, two floats, or transducer), (iv) the throttle control type (constant speed, linear acceleration, or PID control), (v) the float type (normally open or normally closed), (vi) engine speed setpoint, (vii) PID setpoint, and (viii) transducer setpoints and units).
  • the pump controller may include one or more interfaces for displaying warning messages.
  • a pump controller may include interfaces which list warning messages, such as, but not limited to, low fuel warnings.
  • the interfaces may also include information regarding when the warning was issued and what device (or port) the warning corresponds to.
  • the user interface may also display editable thresholds for alarms and/or warning messages as seen, for example, in FIGS. 38S-T and 38 AA.
  • a pump controller user interface may include configuration interfaces for input devices, pump curve data, and network settings.
  • the user interface may display editable configuration parameters related to floats and/or transducers.
  • a user can also view and edit mathematical and algorithmic information, such as PID coefficients and pump curve polynomial coefficients.
  • a user may also view or edit network settings, such as internet protocol (“IP”), gateway, subnet mask, and broadcast addresses.
  • IP internet protocol

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
  • Control Of Non-Positive-Displacement Pumps (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
US16/289,545 2018-02-28 2019-02-28 Automated pumping system and methods Abandoned US20190264677A1 (en)

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US16/289,545 US20190264677A1 (en) 2018-02-28 2019-02-28 Automated pumping system and methods

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EP (1) EP3759350A4 (fr)
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DE3926911A1 (de) * 1989-08-16 1991-02-21 Bosch Gmbh Robert Elektromagnetischer drehsteller
US5765995A (en) * 1995-10-16 1998-06-16 Diesel Power Supply Co. Automated engine-powered pump control system
US6792966B2 (en) * 2000-10-03 2004-09-21 Federal-Mogul World Wide, Inc. Fuel transfer pump and control
US7758315B2 (en) * 2005-09-15 2010-07-20 Ansul Canada Limited Pump controller for controlling pumps connected in tandem
US8134469B2 (en) * 2010-10-27 2012-03-13 Ford Global Technologies, Llc Wireless fuel level sensor for a vehicle fuel tank
US20130105010A1 (en) * 2011-10-28 2013-05-02 Jnt Link, Llc Automatic fire pump control system and method
US9500193B2 (en) * 2014-02-24 2016-11-22 Sears Brand, L.L.C. Sump pump monitoring device and method
WO2016161479A1 (fr) * 2015-04-10 2016-10-13 Legra Engineering Pty Ltd Système de pompage
US10060379B2 (en) * 2015-09-04 2018-08-28 Ford Global Technologies, Llc Method for a hybrid vehicle

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US20230279850A1 (en) 2023-09-07
WO2019169190A1 (fr) 2019-09-06
CA3092457A1 (fr) 2019-09-06
EP3759350A4 (fr) 2022-06-01
AU2019228585A1 (en) 2020-09-24

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