WO2012121680A2

WO2012121680A2 - Pump control device with multiple sensors microprocessor controllers

Info

Publication number: WO2012121680A2
Application number: PCT/SI2012/000011
Authority: WO
Inventors: Tomaz SMRKOLJ; Albin Smrke
Original assignee: Strip's D.O.O.
Priority date: 2011-03-09
Filing date: 2012-03-08
Publication date: 2012-09-13
Also published as: EP2683943A2; SI23685A; WO2012121680A3

Abstract

The subject of the invention is a device for an automatic regulation of pump operation of a sensor microprocessor controller that optimally regulates the operation of a pump. The device of the invention solves the mentioned problems; by means of sensors, preferably of sound sensors, it solves regulation and also occurrence of undesired noises. An optimal operation of a system needs a microprocessor with a built-in operation algorithm, preferably with fuzzy logic. The operation and conditions are controlled by various sensors, such as temperature sensors, pressure sensors, sound sensors and other sensors of status change.

Description

PUMP CONTROL DEVICE WITH MULTIPLE SENSORS MICROPROCESSOR

CONTROLLERS

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

As shown in Figure 1 , pumps consist of a housing, a rotor, a stator, a controller and a shaft, on which a turbine is arranged. Pumps are used for water flow in heating systems.

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

Several solutions for regulating pump operations are known.

A principle of defining pressure on the basis of a flow (a certain number of turbine revolutions) is used to optimize operation of pumps. A controller can be used to set operation on the basis of a constant flow, constant pressure or automatic operation, such as reducing revolutions in a night mode or the like. In order to achieve a higher quality of regulation, pressure sensors can be used in certain cases. Such sensors provide for a better regulation due to the measurement of differential pressure. State of the art pumps provide control over pump operation by means of measurements of voltage frequency on a stator that dictates the number of revolutions. Measurement of current consumption indirectly determines the pressure in a system.

Pumps are controlled by means of microcontrollers. The latest pumps have a controller arranged on the housing. Although the new pumps are energy efficient, since they are grouped to energy classes, still many problems remain in this area. Regulation of pressure and flow is not sufficient for an optimal operation. Pumps may be arranged in many different systems and thus determining a proper mode of operation requires trained staff and proper selection. Even quality pumps may prove inefficient when not properly installed.

Another problem derives from the fact that pumps may be installed in heavily accessible parts of devices, which makes it very difficult to correct the settings. Servicing of the system and the pump is also difficult, as the pumps are not provided with a mechanism for detecting irregularities.

Problems are encountered also in the most modern pumps. A majority of problems refer to a sound that appears due to a cavitation on a turbine, due to the air within the system, due to resonance, due to too large flows on system elements or due to other reasons.

The subject of the invention is a device for an automatic regulation of pump operation of a sensor microprocessor controller that optimally regulates the operation of a pump.

The device of the invention solves the mentioned problems by way of sensors, preferably of sound sensors, that solve regulation and occurrence of undesired sounds. An optimal operation of a system needs a microprocessor with a built-in operation algorithm, preferably with fuzzy logic. Operation and conditions are controlled by various sensors, such as temperature sensors, pressure sensors and sound sensors as well as other sensors of status change.

The principle of operation of regulation and the device will be explained in more detail on the basis of an embodiment and drawings, representing in:

Figure 01 schematic view of arrangement of parts of the device of the invention onto a pump and a cross-section of the pump

Figure 02 modes of pump operation

Figure 03 graph of flow, pressure and efficiency in pump operation

Figure 04 time graph of flow in pump operation

Figure 05 time graph of pressure in pump operation

Figure 06 time graph of energy efficiency factor

Figure 07 time graph of sound in various modes of pump operation

Figure 08 embodiment of a regulator's electronic button

Figure 09 example of arrangement of a pump's slide button

Figure 10 simple controller's fuzzy logic

Figure 1 1 installation ways

Figure 12 power supply

Figure 13 data entry

Figure 14 button on the pump

Figure 15 insert on the pump

Figure 16 interactive interface on the button

Figure 17 example of wireless network in pump management A device for an automatic regulation of functioning of a pump of a sensor microprocessor controller is integrated onto a housing of a pump 1. The pump is mounted into a pipeline installation via turbine part (2). The most important element of the turbine part is a turbine wheel (3) rotated by a rotor. A permanent magnet (4) most often rotates on a rotor of modern engines. Parameters of electric current and voltage are processed in an electronic plate (6) in order to manage the number of revolutions. A stator (9) is used to change the number of revolutions and consequently the flow. The invention also added a sensor part (5) and an electronic button (9). In order for the system to function optimally, the electronic plate has a built-in microprocessor with an integrated operation algorithm, preferably with fuzzy logic. The functioning and conditions are controlled by various sensors, such as temperature sensors, pressure sensors and sound sensors as well as other sensors of status change.

In a system comprising a pump, most often a heating system with pipes, radiators and other necessary elements, the pump's function is to circulate the medium. Each centrifugal pump has a similar operation characteristic as shown in Figure 2. A relation of pressure (12) drop and flow (13) is set for certain conditions. An example is shown by a point (10), where the flow is reduced and the transfer of heat increased, and by a point (11), where the flow is increased, the highest heat transfer. By changing the flow an optimal transfer of heat can be searched for and thus the efficiency factor.

The graph in Figure 3 shows a relation of flow (15) and pressure (14) in a curve (17) and the corresponding efficiency curve (16). The characteristic shows an optimal flow up to a certain point, in which the efficiency starts to decline. For the sake of a more simple understanding of changes in flow, pressure and efficiency, the same data are presented in Figures 4, 5 and 6 in relation to a time axis (18).

The device of the invention makes use of results of sound analysis experiments in order to improve the operation of the pump in a work system. Figure 7 shows an audio signal (20) for various modes of pump operation, wherein the maximum value is the maximum signal amplitude (19). The sound in pumps used to be a disturbing factor, however, our solution uses it to correct the operation and to duly detect deficiencies in the system. As too high velocity of a liquid causes sound disturbances, this is a simple way of regulation.

Figure 8 shows one of possible constructions of a wireless button. A base (21) can be fastened to a pump or be a constituent part of a button (22). The device may be supplied from a battery (23) and fastened to the pump with a magnet (24) as in the presented example.

Figure 9 shows a wireless module on a pump (25) connected with a separate control element (27) with a microprocessor unit (26).

Fuzzy logic is especially suitable for control. An example with six inputs and two outputs is shown in Figure 10. Inputs (28) can be sound, temperature and outputs can be a number of revolutions (29) and power (30) for instance.

Figure 11 is a more detailed presentation of various possible ways of fastening the button - device (31) onto a base (33). One of possible variants of fastening is fastening with magnets. A magnet (32) can be within the housing of the device or a magnet (34) can be arranged on or below the base. Magnet attraction can also be implemented by a non-magnetic metal. One certain embodiment can have the magnet arranged on the base and on the other side there is a magnet attracted part, a metallic (iron) part of a certain size and shape. Another embodiment has a magnet within a housing arranged onto an iron base.

Another conventionally known fastening manner is a mechanical connection with a screw (36). A screw can be used to fasten a plastic part onto a base (35), said plastic part having wedges for another separable part on a handle. These possible solutions are known and are not the subject of the present invention.

In a further embodiment the button is fastened to the base by way of a special rubber suction member (40) provided with a groove. When the groove (38) is pressed with fingers, air is squeezed out from the suction member. When released, the rubber shape creates certain force due to underpressure, which creates a force holding the button on the base. These are not the only possible ways. In this case, electronics is protected against water.

A similar variant held by the magnet is a cylinder-shaped silicon rubber (42), which also protects the system against water.

It is very important for the operation of the device that a user does not have to care for the energy supplying the microprocessor module. As the device operates in a wireless mode of operation in certain positions, the available energy needs to be used as much as possible with the operation mode. A few possible ways are shown in Figure 21. The basic mode of operation is a battery, which must be at least 6 months of operation in a normal mode. Batteries are very environmentally unfriendly, so the embodiments show several ways of battery-free operation. Instead of a battery for storing energy the supply module is most often provided with a capacitor or a digital energy storage. These possibilities do not exclude other ways of storing.

It is known from earlier disclosures that the ways of using buttons depend on devices connected to power supply. The first embodiment of filling an energy storage element shows an example of filling by means of electromagnetic induction filling via coil. The coil (44) is arranged on the device and creates an electromagnetic field by way of electronic circuit, said electromagnetic field inducing energy in a coil (45) in the housing of the device, which is then prepared for storage via electronic circuit. To ensure a better energy transfer ferrite cores can be used, or the coils can also be used for a transfer of information between modules in various embodiments.

Information between modules and power supply can in certain cases be implemented by way of connectors (46). In such a case there is no need for wireless operation.

Since there is enough heat energy on the pump, a Peltier element (47) is used for supplying the module and filling the energy storage, which Peltier element converts heat energy into electric energy. The storage can also be filled with photovoltaic cells (48) on the button in the same way by adjusting various voltages to levels, which is not the subject of the present invention.

When using the device, it is very important for the user to see the position, into which the button - device was set. This interaction as a confirmation of a user's wish is shown in Figure 13. In a manual operation mode described in earlier examples, the user sees the position in which the button is set with the indicator on the button and the position turned towards one of the symbols. This way of interaction can be preserved in automatic control. The way how functions are selected is the subject of the present invention and represents the design of a selector of button position with regard to the selection ring. Four examples are presented in detail; however, these are not the only possible ways. In the first embodiment, the electronic plate (49) is provided at one side with contacts (50) connected with electronics and where with the selector 51 ), which is rotatable around its axis and have also contactor group which connected contacts (50), when reach the desired position. The shape of the slide button (53) is such that its nose on the cylindrical shape of the button fits into a groove (52). By rotating the button or by rotating the cylindrical part around the button the desired positions for defining the desired mode of regulation can be set.

A second embodiment is provided with a potentiometer. A potentiometer (54) is fastened to the electronic plate. A part (55) is arranged in the centre of the potentiometer. The user may select a certain mode of regulation by rotation about its common axis. Certain embodiments require both ways of regulation. The manner of interactive indication will be explained in more detail in the continuation. A control with magnets is a very interesting way of selection due to being contactless and thus safe. A reed relay switches on and off by means of a magnet. Only a few possible combinations of use are presented. The basic, yet not the only combination of the invention has a reed relay (61) in the button's electronic and a magnet (58) in the other part. A use in the opposite way is also possible. By rotating the magnet over electronics the positions get switched on. In a certain position also electronics can get switched off and there is no stand-by consumption, which will be explained in more detail in the continuation. A somewhat different way, which is one of the embodiments, is carried out by way of three push buttons. A push button (62) is intended to confirm operation and the push buttons (60) and (63) are plus + and minus -, by means of which the settings can be changed digitally.

Figure 14 shows an embodiment of the button - device of the invention for the case of regulating a circulation pump with a centrifugal turbine. Sensors (63) are primarily audio sensors, yet also temperature and pressure sensors are desired. The sensor part (65) has a wireless connection with the regulation button (66), which in turn has a wireless connection with the pump.

Figure 15 shows possible ways of connection with connectors or contacts (67), where a transfer part (68) establishes a contact with sensors (80) and (81) when arranged onto the pump. There are several possible ways of implementation, which are not excluded by our embodiments.

It is very important for the user to have the data about the selected position. A few ways are presented in Figure 16. The first embodiment shows the selected position by way of illuminated symbols on the selector (83). The electronic plate has a LED diode (84) that is oriented towards the part guiding a light beam over a symbol (86). When the button (85) is rotated with respect to the part (83) the light moves across symbols.

Figure 17 shows yet another advantage of use of the button in wireless operation of circulation pumps (90). Pumps in certain systems are used in inaccessible areas and there may be many of them. The button of the invention, which is uniquely connected with the device it controls, can create clear and easily accessible panels - control cabinets (91), wherein the operation can be simplified and optimised by following a simple scheme (92).

When talking about important characteristics of a circulation pump in a heating system, the following pump related parameters have to be taken into consideration:

• used power (energy efficiency) in all operating conditions

• flow characteristics • pressure characteristics.

State of the art is the way disclosed in patents and used in the latest generation of pumps. These pumps make use of energy efficient asynchronous engines. Typically, the construction of these engines provides for a simple regulation of the number of revolutions and consequently determines the flow. The control electronics usually includes a consumer power meter, which provides data on the pressure in the system. Pumps with such regulation can be adapted to certain conditions of pressure and flow in the system. The principle of operation is to optimise the heating system based on the given flow by selecting predefined operation profiles.

When dimensioning the system, the following needs to be taken into consideration:

• Pressure in the system called static pressure, which depends on the type of the heating system. In the case of small pressures sound due to cavitation occurs. A special problem appears at high temperatures. In systems with compensation vessels instantaneous increased pressures as a consequence of hot water dilatation may occur.

• Pressure drop, which compensates for the pressure losses in the entire system. The pressure at the entry to the pump is critical and must meet minimum requirements, which in turn requires limitations that are not desired in system optimisation. Simultaneously, the hydraulic resistance of the system caused by system elements needs to be taken into consideration. A majority of resistances is constant, yet also variables occur, such as closing of valves on radiators and the like. A drop in pressure through the system is influenced by the flow, double the flow, four-times higher drop in the pressure. An increased flow increases also the velocity through the elements and consequently increases a possibility of occurrence of an unpleasant sound.

Basic solutions are known and described and a selection of Q-p characteristics is used for optimisation. The most favourable point of operation is looked for, said point being equal for the system and the pump. It is assumed that a reduced need for heating will result in a reduced flow with valves. The selected characteristic of a pump is thus changed.

The heating system must be balanced by a selection of parameters of operation on the basis of pressures in the system. For instance, in case of differential pressure in a double-tube system, the system gets balanced with the valves on the radiator.

Even with most modern pumps we come across the occurrence of sound, which makes the setting and maintenance very demanding. This is included in warnings to be respected when assembling a pump. See instructions for pump assembly. Instructions are among others as follows:

• Bleed the system.

• Fill to reach a certain pressure.

· Start the system, switch it off and bleed it again.

• Measure parameters and perform fine calibration.

An even greater problem is proper optimisation of the system, which should be performed by the user after the installation and it appears very often when the system is established. If there is not sufficient energy in radiators after the system has been established despite a sufficient energy source, the problem lies in the operating characteristics of the pump. Usually, a higher flow does not have a great influence on the increase of heat effect. A problem is that increased velocity as a result of a higher flow does not allow a sufficient heat transfer from the water. High output temperature has a rather negative effect on thermal efficiency of the system. Reduced flow has a positive effect on efficiency. This is a consequence of an exponent curve of operation Q H in radiators. So half the flow gives approximately 80 % of heat yield.

The basis of regulation is a printed circuit board with a microprocessor and the necessary electronic elements. Sensors S1 ... Sn and the selection button are connected to said printed circuit board.

Algorithms for regulation and especially fuzzy logic systems are suitable for software support of operation. The only quality way of optimisation is that all segments of the system are monitored by means of sensors. The task to be solved is to achieve highest effect through an optimal use of sensors and systems.

Sensors, which can be used, are sensors of pressure, flow, temperature, air humidity, sound, pump's energy consumption and the like.

When sensors are used, one should be attentive not to increase the price of the system and the complexity of use. The sensors can be arranged outside of the housing or within the pump's housing. They can be connected through wires or wirelessly.

In standard pumps the flow through it is determined on the basis of frekvency charasteristics of the managing signal and the determination of the pressure is known with the measuring of the stator consumption which also determined the other characteristic of the system. The operation that can be selected is: automatic, constant pressure, constant flow, night mode and the like.

The solutions used to determine the characteristics of operation of a pump are good enough and will be used to determine the flow and pressure on the pump by us as well. The construction of the pump and the quality of regulation offer a simple solution to the problem of regulation.

Without excluding cable connections a wireless sensor network is selected. A universal module has a multi-sensor module comprising a receiving and a transmitting module, a supply module and a sensor part. The standard module has a temperature sensor, a pressure sensor and a sound sensor. The transceiver module is intended especially for sending data, for mutual communication and pairing of sensors and the controller. The electronics is the same on the sensor and in the pump, only that the module on the pump is connected to the control module.

Claims

PATENT CLAIMS

1. A device for regulating a pump with a multi-sensor microprocessor controller,

characterised in that

it is shaped like a user-friendly button.

2. A device for regulating a pump according to claim 1 ,

characterised in that

it automatically regulates the level of supplied energy based on the measured parameters by way of control logic.

3. A device for regulating a pump according to claim 1 ,

characterised in that

it operates wirelessly with a special protocol.

4. A device for regulating a pump according to claim 1 ,

characterised in that

the buttons are connection into an operation network.

5. A device for regulating a pump according to claim 1 ,

characterised in that

it may comprise various sensors allowing to gather data needed for a quality process management.

6. A device for regulating a pump according to claim 1 ,

characterised in that

it consists of an electronic part, a housing and control logic.

7. A device for regulating a pump according to claim 1 ,

characterised in that

it provides for a preset and process controlled regulation designed by user's wishes.

8. A device for regulating a pump according to claim 1 ,

characterised in that

operation is regulated manually and the user selects the mode of operation by rotating a button.

9. A device for regulating a pump according to claim 1 ,

characterised in that

the button has a position indicator.

10. A device for regulating a pump according to claim 1 ,

characterised in that

the button can be removed from the position.

11. A device for regulating a pump according to claim 1 ,

characterised in that it has a ring that may be fixed to a support or be movable.

12. A device for regulating a pump according to claim 1 ,

characterised in that

the ring is provided with marked or embedded indicators for operation on the basis of constant flow, constant pressure or automatic operation.

13. A device for regulating a pump according to claim 1 ,

characterised in that

the device regulates the operation by means of sensors, preferably of sound sensors.

14. A device for regulating a pump according to claim 1 ,

characterised in that

it has an integrated algorithm for operation, preferably with fuzzy logic.

15. A device for regulating a pump according to claim 1 ,

characterised in that

sound is used for correcting the operation and for due detection of errors in the system.

16. A device for regulating a pump according to claim 1 ,

characterised in that the most favourable point of operation is used for regulation, said point being the same for both the system and the pump.

17. A device for regulating a pump according to claim 1 ,

characterised in that

it has a multi-sensor module consisting of a receiving and transmitting module, a supply module and a sensor part.

18. A device for regulating a pump according to claim 1 ,

characterised in that

the electronics is the same on the sensor and in the pump, except that the module on the pump is connected to a control module.

19. A device for regulating a pump according to claim 1 ,

characterised in that

it may be detached from the pump and uniquely identified with a certain pump.

20. A device for regulating a pump according to claim 1 ,

characterised in that

the device is fastened to the base with magnets, wherein a magnet (34) can be within the housing of the device (31) or under the base.

21. A device for regulating a pump according to claim 1 , characterised in that

the fastening is carried out by a mechanical connection with a screw.

22. A device for regulating a pump according to claim 1 ,

characterised in that

a plastic or a metallic part is also fastened to the base (35) with a screw, said part serving for the mounting of another separable part on the handle.

23. A device for regulating a pump according to claim 1 ,

characterised in that

the button is fastened to the pump by way of a special rubber suction element (40) provided with a groove for the creation of underpressure.

24. A device for regulating a pump according to claim 1 ,

characterised in that

the device is protected against humidity by means of rubber bellows (42).

25. A device for regulating a pump according to claim 1 ,

characterised in that

power supply is a battery supply.

26. A device for regulating a pump according to claim 1 ,

characterised in that

a capacitor, a digital storage or a similar system is used for power supply.

27. A device for regulating a pump according to claim 1 ,

characterised in that

the energy storage is filled by means of electromagnetic induction filling via coil.

28. A device for regulating a pump according to claim 1 ,

characterised in that

coils are used for data transfer.

29. A device for regulating a pump according to claim 1 ,

characterised in that

connectors (46) are used for power supply and data transfer.

30. A device for regulating a pump according to claim 1 ,

characterised in that

a Peltier element (47) is used to fill the energy storage, said element converting heat energy into electric energy.

31 . A device for regulating a pump according to claim 1 ,

characterised in that

a photovoltaic cell (48) is used to fill the energy storage.

32. A device for regulating a pump according to claim 1 ,

characterised in that

is has a button position selector and a setting ring.

33. A device for regulating a pump according to claim 1 ,

characterised in that

various settings are selected by means of contacts (52) connected by contactor (50) on the selector (53).

34. A device for regulating a pump according to claim 1 ,

characterised in that

a position of the regulator is determined by means of a potentiometer (54) and part (55) is arranged within the potentiometer to rotate the button.

35. A device for regulating a pump according to claim 1 ,

characterised in that

a potentiometer and a selector with a contactor are used to determine data.

36. A device for regulating a pump according to claim 1 ,

characterised in that

a position is selected by means of a magnet (58) and magnet switches (61 ).

37. A device for regulating a pump according to claim 1 ,

characterised in that

a magnet is used to switch off the circuit by means of a magnet switch.

38. A device for regulating a pump according to claim 1 ,

characterised in that a position is selected by means of a combination of keys (60, 63 and 62).

39. A device for regulating a pump according to claim 1 ,

characterised in that

the button is arranged onto a circulation pump with a centrifugal turbine and sensors are used to regulate the pump's operation.

40. A device for regulating a pump according to claim 1 ,

characterised in that

sound is used for the regulation of the pump's operation as well.

41. A device for regulating a pump according to claim 1 ,

characterised in that

the button is arranged onto a pump and both parts are connected electrically with contacts (67).

42. A device for regulating a pump according to claim 1 ,

characterised in that

important data on the position selected by the user are shown by means of illumination of symbols (86) on the selector (83) with a LED diode and a light beam.

43. A device for regulating a pump according to claim 1 ,

characterised in that the buttons are arranged on one plate in groups (91) and a simple control of complete management systems is enabled.