WO2013090907A1 - Dynamic linear control methods and apparatus for variable speed pump control - Google Patents

Dynamic linear control methods and apparatus for variable speed pump control Download PDF

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Publication number
WO2013090907A1
WO2013090907A1 PCT/US2012/070138 US2012070138W WO2013090907A1 WO 2013090907 A1 WO2013090907 A1 WO 2013090907A1 US 2012070138 W US2012070138 W US 2012070138W WO 2013090907 A1 WO2013090907 A1 WO 2013090907A1
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WO
WIPO (PCT)
Prior art keywords
set point
control
flow rate
partly
adaptive
Prior art date
Application number
PCT/US2012/070138
Other languages
English (en)
French (fr)
Inventor
Andrew A. CHENG
James J. GU
Graham A. Scott
Original Assignee
Fluid Handling Llc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Fluid Handling Llc filed Critical Fluid Handling Llc
Priority to CA2856447A priority Critical patent/CA2856447C/en
Priority to RU2014121778A priority patent/RU2611071C2/ru
Priority to IN4206CHN2014 priority patent/IN2014CN04206A/en
Priority to CN201280061743.9A priority patent/CN104024965B/zh
Priority to EP12857590.9A priority patent/EP2791750B1/en
Publication of WO2013090907A1 publication Critical patent/WO2013090907A1/en

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Classifications

    • 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
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D7/00—Control of flow
    • G05D7/06—Control of flow characterised by the use of electric means
    • G05D7/0617—Control of flow characterised by the use of electric means specially adapted for fluid materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
    • Y02B30/70—Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Definitions

  • the present invention relates to a technique for controlling the operation of a pump; and more particularly, the present invention relates to a method and apparatus for controlling the speed of a pump, e.g., for domestic and commercial heating or cooling water systems.
  • Figure 1 (a) shows a secondary variable speed pump control hydronic heating and cooling system that is known in the art
  • Figure 1 (b) shows a water booster pumping system that is also known in the art.
  • hydronic pump control applications including pump controls for domestic and commercial heating and cooling water pumping or circulating systems, water booster pumping systems, and so forth, like those shown in Figures 1 (a) and (b) with their characteristics that may be dynamic and unknown in nature.
  • FIG. 1 (c) shows a graph having various functions plotted using known system curve equations, e.g., including a pump curve, an instant system curve, a constant control curve, an equivalent system curve (as designed), an adaptive control curve and a distribution loss curve.
  • a pressure set point, P * , with respect to a flow rate requested, Q * can be calculated and/or determined from the equation of (Q' ⁇ t)lc ⁇ t)f + b , where the adaptive control curve, v ( , may be obtained from the flow equation together with a moving average filter.
  • the adaptive control curve to obtain the pressure set point is much closer to the equivalent system curve which represents the minimum pressure needed to maintain the flow rate requested, consistent with that shown in Figure 1 (c). Because of this, pumping system operation energy may be saved using this adaptive approach.
  • the present invention provides an improvement on the adaptive control scheme set forth in the aforementioned U.S. patent application serial no. 12/982,286.
  • the present invention may take the form of apparatus, such as a pump controller, featuring a signal processor configured at least to: receive signaling containing information about a linear set point control curve based at least partly on an adaptive set point control curve related to fluid being pumped by a pump in a pumping system, and
  • the signal processor may be configured to provide a control signal containing information to control the pump based at least partly on the control set point determined.
  • the linear set point control curve is derived from the adaptive set point control curve with respect to system flow and pressure, including being derived by the signal processor.
  • the signal processor may be configured to determine the linear set point control curve based at least partly on the following equation:
  • b 0 is a pressure threshold
  • Q* is a flow rate at zone i and n is the total number of zones.
  • the signal processor may be configured to determine the system flow rate if zone temperature control parameters are used, based at least partly on the following equation:
  • T * is a temperature set point for zone i
  • ft.max is a maximum flow rate to obtain a maximum temperature
  • T i rmx is designated for a zone i
  • T outdoor is tne outdoor temperature, and a is a compensate coefficient.
  • the signal processor may be configured to determine a requested flow rate £> * (t) based at least partly on the following equation : , where r - b 0 / P 0 ,
  • Cv (t) MA ⁇ Q ⁇ t)l jP ⁇ t ) is the adaptive set point control curve
  • P 0 is a constant pressure set point.
  • the signal processor is configured to determine a pressure set point from the adaptive control curve directly based at least partly on the following equation:
  • the signal processor may be configured to determine the control set point based at least partly on the requested flow rate Q * and derived from the adaptive set point control curve.
  • the apparatus may further include, at least one memory including computer program code; and the at least one memory and computer program code are configured to, with at least one processor, cause the apparatus at least to:
  • control set point determines the control set point based at least partly on the signaling received.
  • the apparatus may include, or take the form of, a pump control or controller, including a PID control, having the one signal processor.
  • the present invention may takes the form of a method including steps for receiving in the signal processor signaling containing information about the linear set point control curve based at least partly on the adaptive set point control curve related to fluid being pumped by the pump in the pumping system, and determining in the signal processor the control set point based at least partly on the signaling received.
  • the present invention may also, e. g., take the form of a computer program product having a computer readable medium with a computer executable code embedded therein for implementing the method, e.g., when run on a signaling processing device that forms part of such a pump controller.
  • the computer program product may, e. g., take the form of a CD, a floppy disk, a memory stick, a memory card, as well as other types or kind of memory devices that may store such a computer executable code on such a computer readable medium either now known or later developed in the future.
  • One advantage of the present invention is that it can contribute to the overall reduction of energy consumption and operation costs, including, e.g., the secondary variable speed pump control hydronic heating and cooling system shown in Figure 1 (a) and the water booster pumping system shown in Figure 1 (b).
  • GPM graph of flow
  • FIG. 2 is a block diagram of apparatus according to some embodiments of the present invention.
  • Figure 3 is a graph of is a graph of system pressure in relation to flow (GPM) for implementing an adaptive control technique based on a linear set point curve derived from adaptive and constant control curves, according to some embodiments of the present invention.
  • GPM system pressure in relation to flow
  • Figure 4 is a graph of is a graph of system pressure in relation to flow (GPM) for implementing a linear adaptive control technique based on determining a request flow Q * , according to some embodiments of the present invention.
  • Figure 2 shows the present invention in the form of apparatus 10, such as a pump controller, featuring a signal processor 12 configured at least to receive signaling containing information about a linear set point control curve based at least partly on an adaptive set point control curve related to fluid being pumped by a pump in a pumping system, and determine a control set point based at least partly on the signaling received.
  • the signal processor 12 may also be configured to provide a control signal containing information to control the pump based at least partly on the control set point determined.
  • the apparatus 10 may include, or take the form of, a pump control or controller, including a PID control, having the signal processor 12.
  • Figure 3 shows a graph having various functions plotted using known system curve equations, e.g., including a pump curve, a constant control curve, a dynamic linear control curve, an equivalent system curve, an adaptive control curve and a distribution loss curve.
  • the control set point is obtained from, and based at least partly on, a linear set point curve derived from the adaptive and constant control curve.
  • the dynamic linear control curve may be derived from the adaptive control curve with respect to system flow and pressure, consistent with that shown in Figure 3.
  • the pressure set point P * may be obtained easily.
  • it makes an adaptive pump control means achievable for a system configuration without a need to have all zone flow rate signals available specially.
  • the set point curve with respect to a flow rate requested at any time t can be written as where P 0 is the constant pressure set point, is the maximum system flow rate, £?max is the maximum adaptive flow rate, b 0 is a pressure threshold, and
  • Cv (r) is the adaptive control curve, consistent with that set forth in the aforementioned U.S. patent application serial no. 12/982,286 . can be obtained directly through a moving average filter or through a moving peak detector, preferably upon the instant system characteristics.
  • the adaptive technique herein can be used to trace any varying or unknown system characteristics and to set up the control set point accordingly when the flow rate of Q' ( ⁇ ) is known.
  • the system flow rate can be expressed as the summation of each individual zone flow rate approximately as where g, (t) is the flow rate at zone i and n is the total number of zones.
  • T * is the temperature set point for zone i
  • Q I MAX is the maximum flow rate to obtain the maximum temperature T J MAX designated for zone i
  • T OUTDOOR is outdoor temperature
  • a is a compensate coefficient.
  • T * may be the water temperature set point leaving water heating or cooling exchanger coils or the temperature set point on the thermostat for circulator or control valve signals, respectively.
  • control curves and means for hydronic pumping systems set forth herein may include using such a dynamic linear set point curve in Fig. 3 and its corresponding expression in Eq. (1 ) with respect to system flow and pressure respectively.
  • the system flow rate at any time t can be expressed in forms of the summation of zone flow rates, Eq. (2), or zone temperatures, Eq. (3), which are requested and known.
  • Figure 4
  • Figure 4 shows a graph having various functions plotted using known system curve equations, e.g., including a pump curve, a constant control curve, a linear adaptive control curve, an instant system curve, an equivalent system curve, an adaptive control curve and a distribution loss curve.
  • the requested flow rate, Q' is calculated or determined specially.
  • the zone flow rate signals or zone temperature signals in Eqs. (2) and (3) are not always available or are too expensive to be obtained.
  • an alternative version of the linear adaptive control means is set forth consistent with that shown in Figure 4 schematically.
  • the system flow rate requested, Q' may be calculated and/or determined from the intersection of the instant system curve and the linear adaptive curve, while the pressure set point can then be obtained from the adaptive control curve based on the requested flow rate g * accordingly.
  • the adaptive control curve may be obtained from a moving average filter or a moving peak detector upon the flow informative equation.
  • Q ⁇ or C v (t) may be obtained by using a moving peak detector. Equation (5) together with (4) may be used to set up the control pressure set point in any hydronic system with zones flow rates regulated by control valves primarily, since the system characteristics is utilized to obtain the flow rate requested.
  • both the instant system pressure and flow rate may need to be known.
  • the system flow rate may not be always available.
  • one of those motor operation parameters such as speed, torque, power or current ratings, may be utilized to calculate the flow rate with a linear approximation alternatively.
  • a sensorless inverter which yields the system flow rate and pressure from motor speed and power based on pump and system calibration data may be used as well.
  • the certain amount of sensors monitoring and signaling, transmitting and wiring technologies may need to be provided.
  • the wireless sensor signals transmission technologies or sensorless pump control technologies may provide some optimal and better solutions.
  • control curves and means for hydronic pumping systems mentioned herein may include such using dynamic linear set point curves in Fig. 4 and its corresponding expressions in Eqs. (4) and (5) respectively.
  • the system flow rate requested may be calculated and/or determined by using Eqs.-(4) and (5), when the zone flow rate or zone temperature signals are not available.
  • one of the motor operation parameters including speed, torque, power or current ratings may be utilized to calculate the flow rate with a linear approximation alternatively.
  • a sensorless inverter which yields the system flow rate and pressure from motor speed and power based on pump and system calibration data may be used as well.
  • the linear adaptive control means according to the present invention, the pump operations energy can be saved significantly.
  • the methods are simple, feasible, and can be integrated easily into any pump control hydronic system including close loop heating and cooling control systems as well as open loop water booster pumping systems.
  • the functionality of the apparatus 10 may be implemented using hardware, software, firmware, or a combination thereof.
  • the apparatus 10 would include one or more microprocessor-based architectures having, e. g., at least one signal processor or microprocessor like element 12.
  • a person skilled in the art would be able to program such a
  • microcontroller or microprocessor-based implementation to perform the
  • processors 12 are not intended to be limited to any particular implementation using technology either now known or later developed in the future.
  • the scope of the invention is intended to include implementing the functionality of the processors 12 as stand-alone processor or processor module, as separate processor or processor modules, as well as some combination thereof.
  • the apparatus may also include other signal processor circuits or components 14, e.g. including random access memory (RAM) and/or read only memory (ROM) like element 14, input/output devices and control, and data and address buses connecting the same, and/or at least one input processor and at least one output processor .
  • RAM random access memory
  • ROM read only memory
  • control means for heating or cooling water systems as well as pressure booster systems may include the dynamic linear set point curves and means. With the new approaches, the control curve is much closer to the system curve and the operation energy cost on pump control may be reduced significantly.
  • the hydronic systems mentioned herein may include primary pumping systems, secondary pumping systems, water circulating systems, and pressure booster systems.
  • the systems mentioned herein may also consist of a single zone or multiple zones.
  • the systems mentioned above may incliide manual or automatic control valves, manual or automatic control circulators, or their combinations.
  • the input processing control signals for pumps control may include system pressure or differential pressure, zone pressures or differential pressures, system flow rate or zone flow rates.
  • the other input process signals may also include power, torque, motor speed, and so forth.
  • control signals generating and monitoring, transmitting and wiring technologies may include all conventional sensing and transmitting means that are used currently.
  • sensorless pump control technologies as well as wireless sensor signals transmission technologies may provide optimal and favorable solutions.
  • the pumps mentioned here for hydronic pumping systems may include a single pump, a group of parallel ganged pumps, a group of serial ganged pumps, or their combinations.
  • the pumps staging/destaging as well as alternating means may include all conventional means that are used currently.
  • an adaptive control curve SAMA, can be obtained from instant pressure and flow rate signals through an adaptive moving average filter based at least partly on a system flow equation in a self-calibrating manner as follows: where the function AMAF is an adaptive moving average filter function, and the parameters Q and ⁇ are instant system flow rate and differential pressure respectively.
  • the function AMAF is a 2D adaptive moving average filter with respect to an instant system flow rate percentage x and time t, respectively.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Control Of Non-Positive-Displacement Pumps (AREA)
  • Feedback Control In General (AREA)
  • Flow Control (AREA)
PCT/US2012/070138 2011-12-16 2012-12-17 Dynamic linear control methods and apparatus for variable speed pump control WO2013090907A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
CA2856447A CA2856447C (en) 2011-12-16 2012-12-17 Dynamic linear control methods and apparatus for variable speed pump control
RU2014121778A RU2611071C2 (ru) 2011-12-16 2012-12-17 Способ динамического линейного управления и устройство для управления насосом с переменной скоростью
IN4206CHN2014 IN2014CN04206A (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html) 2011-12-16 2012-12-17
CN201280061743.9A CN104024965B (zh) 2011-12-16 2012-12-17 用于可变速度泵控制的动态线性控制方法和装置
EP12857590.9A EP2791750B1 (en) 2011-12-16 2012-12-17 Dynamic linear control methods and apparatus for variable speed pump control

Applications Claiming Priority (2)

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US201161576737P 2011-12-16 2011-12-16
US61/576,737 2011-12-16

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US10048701B2 (en) 2018-08-14
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US20140005841A1 (en) 2014-01-02
CN104024965A (zh) 2014-09-03
CN104024965B (zh) 2018-02-13

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