WO2019169190A1 - Système et procédés de pompage automatisé - Google Patents

Système et procédés de pompage automatisé Download PDF

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Publication number
WO2019169190A1
WO2019169190A1 PCT/US2019/020135 US2019020135W WO2019169190A1 WO 2019169190 A1 WO2019169190 A1 WO 2019169190A1 US 2019020135 W US2019020135 W US 2019020135W WO 2019169190 A1 WO2019169190 A1 WO 2019169190A1
Authority
WO
WIPO (PCT)
Prior art keywords
pump
fluid
engine
controller
sensor
Prior art date
Application number
PCT/US2019/020135
Other languages
English (en)
Inventor
David G. Lake
Original Assignee
Clio Technology, 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 Clio Technology, LLC filed Critical Clio Technology, LLC
Priority to AU2019228585A priority Critical patent/AU2019228585A1/en
Priority to EP19761481.1A priority patent/EP3759350A4/fr
Priority to CA3092457A priority patent/CA3092457A1/fr
Publication of WO2019169190A1 publication Critical patent/WO2019169190A1/fr

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • 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. BACKGROUND ART
  • 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 In manual mode, the pump engine may be started by pressing a button or switch on the controller user interface.
  • 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.
  • 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.
  • 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 (ECET) 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.
  • controller 100 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.
  • controller 100 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 Before the user can operate the pump in automatic mode, 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
  • PID 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.
  • 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 ran 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 FIGGS. 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 740A.
  • Pump controller 100 starts the engine of pump 200 when the fluid level rises to depth 740A and activates float 311A.
  • Pump 200 runs until the fluid level lowers below depth 740A and deactivates float 311A. 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 311A 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 313B 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 313B.
  • Pump 200 runs until the fluid level rises above depth 760B and deactivates float 313B. 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 313B, the circuit of float 313B 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 313B 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 311C, near the top 710 of tank 700 at depth 740C, and a float 313C is near the bottom 790 of tank 700 at depth 760C.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level rises to depth 740C, activating floats 311C and 313C. Pump 200 continues to run until the fluid level lowers below depth 760C, deactivating float 313C.
  • 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 311C at depth 700C, both the circuit of float 311C and the circuit of float 313C are activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed). Once floats 311C and 313C 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 313C, 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 311D, near the top 710 of tank 700 at depth 740D, and a float 313B near the bottom 790 of tank 700 at depth 760D.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level lowers to depth 760D and deactivates floats 311D and 313D. Pump 200 continues to run until the fluid level rises to depth 740D, activating float 311D.
  • 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. Once the fluid level within tank 700 lowers to below depth 760D, below floats 311D and 313D, both the circuit of float 311D and the circuit of float 313D are deactivated (circuit opens if float circuit is normally open; circuit closes if float circuit is normally closed). Once floats 311D and 313D 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 311D and 313D 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 320E, at the top 710 of tank 700.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level exceeds high setpoint 745E. Pump 200 continues to run until the fluid level lowers to low setpoint 765E.
  • a user To execute the above-described implementation, 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 320E provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320E to the fluid surface). Once the fluid level within tank 700 rises to a point where transducer 320E detects that the fluid level is above high setpoint 745E, 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 320E detects that the fluid level has reached low setpoint 765E. At this point, based on the feedback from transducer 320E, pump controller 100 sends a signal to pump 200 to shut down.
  • pump controller 200 determines the instantaneous fluid level from transducer 320E 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 320E detects that the fluid level has reached low setpoint 765E. At this point, based on feedback from transducer 320E, 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 750E, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320E detects that the fluid level is below depth 750E. If transducer 320E detects that the fluid level is above depth 750E, 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 320F, 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 765F. Pump 200 continues to run until the fluid level rises to high setpoint 745F.
  • 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 320F provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320F to the fluid surface). Once the fluid level within tank 700 lowers to a point where transducer 320F detects that the fluid level is below low setpoint 765F, 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 320F detects that the fluid level has reached high setpoint 745F. At this point, based on the feedback from transducer 320F, pump controller 100 sends a signal to pump 200 to shut down.
  • pump controller 100 determines the instantaneous fluid level from transducer 320F 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 320F detects that the fluid level has reached high setpoint 745F. At this point, based on feedback from transducer 320F, 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 750F, pump controller 100 will send a signal to pump 200 to increase the engine speed (calculated via the PID algorithm) if transducer 320F detects that the fluid level is below depth 750F. If transducer 320F detects that the fluid level is above depth 750F, 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 320G, at the top 710 of tank 700, and a float 314 near the top 710 of tank 700 at depth 740G.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level rises to depth 740G and activates float 311G.
  • 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 311G is deactivated.
  • a user To execute the above-described implementation, 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. Afterwards, the user selects automatic mode via the user interface to initiate the program. While the program is running, transducer 320G provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320G to the fluid surface). When the fluid level reaches depth 740G, the circuit of float 311G 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.
  • 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 750G, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320G detects that the fluid level is below depth 750G. If transducer 320G detects that the fluid level is above depth 750G, 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 3 l lG 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 320H, at the top 710 of tank 700, and a float 315 near the bottom 790 of tank 700 at depth 760H.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level lowers to depth 760H and deactivates float 313H.
  • 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 320H. Pump 200 continues to run until the float 313H is activated.
  • transducer 320H provides feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320H to the fluid surface).
  • the circuit of float 313H 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 750H, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320H detects that the fluid level is above depth 750H. If transducer 320H detects that the fluid level is below depth 750H, 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 313H 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 3201 at the top 710 of tank 700, a first float 316A near the top 710 of tank 700 at depth 7401, and a second float 3131 near the bottom 790 of tank 700 at depth 7601.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level rises to depth 7401, activating floats 3111 and 3131.
  • 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 3201. Pump 200 continues to run until second float 3131 is deactivated.
  • transducer 3201 provides real-time feedback to pump controller 100 as to the value of the fluid level (measured from transducer 3201 to the fluid surface).
  • the circuit of second float 3131 becomes activated (circuit closes if float circuit is normally open; circuit opens if float circuit is normally closed).
  • the circuit of first float 3111 becomes activated.
  • 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 using transducer 3201 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).
  • transducer 3201 feedback if set to linear throttle submode
  • 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 7501, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 3201 detects that the fluid level is below depth 7501. If transducer 3201 detects that the fluid level is above depth 7501, 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 3131 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 320J at the top 710 of tank 700, a first float 311J near the top 710 of tank 700 at depth 740J, and a second float 313J near the bottom 790 of tank 700 at depth 760J.
  • Pump controller 100 starts the pump engine of pump 200 when the fluid level lowers to depth 760J, deactivating floats 311J and 313J.
  • 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 320J. Pump 200 continues to run until first float 311 J is activated.
  • transducer 320J provides real-time feedback to pump controller 100 as to the value of the fluid level (measured from transducer 320J to the fluid surface).
  • the circuit of first float 311J becomes deactivated (circuit opens if float circuit is normally open; circuit closes if float circuit is normally closed).
  • the circuit of second float 313J becomes deactivated.
  • 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 320J 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 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 750J, pump controller 100 will send a signal to pump 200 to decrease the engine speed if transducer 320J detects that the fluid level is above depth 750J. If transducer 320J detects that the fluid level is below depth 750J, 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:
  • Step 19001 Start selected mode, option, or program
  • Step 19002 Check if pump is running; if“yes,” proceed to Step 19003
  • Step 19003 Map pump curve to table
  • Step 19004 Plot current running parameters of pump to pump curve
  • Step 19005 Check if pump is running within pump curve; if“yes,” return to Step 19003; if“no,” proceed to step 19006
  • Step 19006 Display warning indicating pump is operating outside of pump curve
  • Step 19007 Display option to override; if not selected, return to Step 19003; if selected, proceed to Step 19008
  • Step 19008 Display command to enter user ID
  • FIG. 20 illustrates an exemplary process 20000 for setting an operational mode of a pump, comprising the steps:
  • Step 20001 Start selected mode, option, or program
  • Step 20002 Display level 0 menu options (modes which require no password to access)
  • Step 20003 Determine selected level 0 menu option from options 20003 A-G; if configuration mode, 20003G, is selected, proceed to Step 20004; if one of options 20003A-F is selected, proceed to initiate the selected level 0 menu option
  • Step 20004 Request level 1 password; if password is incorrect, return to Step 20002; if password is correct, proceed to Step 20005
  • Step 20005 Display level 1 menu options (modes which require level 1 password authentication)
  • Step 20006 Determine selected menu option from options 20006 A-G; if next page of configuration mode, 20006G, is selected, proceed to Step 20007; if one of options 20006A-F is selected, proceed to initiate the selected level 1 menu option
  • Step 20007 Display level 2 menu options (modes which require level 2 password authentication)
  • Step 20008 Determine selected menu option from options 20008 A-G; if diagnostics mode, 20008G, is selected, proceed to Step 20009; if one of options 20008A-F is selected, proceed to initiate the selected level 2 menu option
  • Step 20009 Request level 2 password; if password is incorrect, return to Step 20007; if password is correct, proceed to step 20010
  • Step 20010 Display diagnostics
  • Step 20011 Determine selected menu option from options 20011 A-G
  • FIG. 21 illustrates an exemplary process 21000 of implementing a password authentication procedure, comprising the steps:
  • Step 21001 Start selected mode, option, or program
  • Step 21002 Request password
  • Step 21003 Determine if password is correct; if password is correct, proceed to Step 20014; if password is incorrect, proceed to Step 21024
  • Step 21014 Notify user of accepted password
  • Step 21024 Determine if the number of password attempts is less than, or equal to, 3; if number of password attempts is less than, or equal to 3, proceed to Step 21025; if number of password attempts exceeds 3, proceed to Step 21035
  • Step 21015 Continue with currently selected mode, option, or program Step 21025: Notify user of denial of access
  • Step 21035 Notify user of incorrect password; return to step 21002
  • Step 21026 Return to beginning of currently selected mode, option, or program
  • FIG. 22 illustrates an exemplary process 22000 for changing a startup timer, comprising the steps:
  • Step 22001 Start selected mode, option, or program
  • Step 22002 Display options to change startup timer in manual mode or automatic mode
  • Step 22003 Determine if option to change startup timer in manual mode is selected, or if option to change startup timer in automatic mode is selected; if the former option is selected, proceed to step 22014; if the latter option is selected, proceed to step 22024; if neither option is selected and the exit key is pressed, proceed to step 22004
  • Step 22004 Return to beginning of selected mode, option, or program Step 22014: Display editable manual startup timer
  • Step 22024 Display editable automatic startup timer
  • Step 22015 User enters manual startup timer
  • Step 22025 User enters automatic startup timer
  • Step 22016 Save entered information to memory; return to Step 22003
  • Step 22026 Save entered information to memory; return to Step 22003
  • FIG. 23 illustrates an exemplary process 23000 of executing a manual mode startup sequence, comprising the steps:
  • Step 23001 Start selected mode, option, or program
  • Step 23002 Determine if manual mode is selected; if manual mode is selected, proceed to Step 23003; if manual mode is not selected, proceed with currently selected mode, option, or program
  • Step 23003 Display startup icon for 3 seconds
  • Step 23004 Determine if oil level is low; if oil level is not low, proceed to step 23015; if oil level is low, proceed to step 23025
  • Step 23015 Determine if battery voltage is low; if battery voltage is not low, proceed to Step 23016; if battery voltage is low; proceed to Step 23026
  • Step 23025 Display oil level warning message
  • Step 23016 Determine if fuel level is low; if fuel level is not low, proceed to Step 23017; if fuel level is low, proceed to Step 23027
  • Step 23026 Display low voltage warning message and display current voltage value
  • Step 23017 Determine if coolant level is low; if coolant level is not low, proceed to Step 23018; if coolant level is low, proceed to Step 23028
  • Step 23027 Display fuel level warning message
  • Step 23018 Display manual crank option
  • Step 23028 Display low coolant warning message
  • FIG. 24 illustrates an exemplary process 24000 for starting a pump engine in manual mode, comprising the steps:
  • Step 24001 Start selected mode, option, or program
  • Step 24002 Determine if engine crank option is selected; if engine crank option is selected, proceed to Step 24003; if engine crank option is not selected, proceed with currently selected mode, option, or program
  • Step 24003 Start 10-second timer
  • Step 24004 Display countdown timer
  • Step 24005 Determine if timer is at or above 10 seconds; if timer is at or above 10 seconds, proceed to step 24016; if timer is below 10 seconds, proceed to step 24036
  • Step 24016 Display option to crank engine
  • Step 24036 Display“please wait” message; return to Step 24005
  • Step 24017 Determine if user selected option to crank engine; if user selected option to crank engine, proceed to Step 24018; if user did not select option to crank engine, return to Step 24016
  • Step 24018 Crank engine for 10 seconds
  • Step 24019 Start 10-second timer
  • Step 24020 Display countdown timer
  • Step 24021 Run engine at idle
  • Step 24022 Determine if timer is at or above 10 seconds; if timer is at or above 10 seconds, proceed to Step 24023; if timer is below 10 seconds, return to step 24021.
  • Step 24023 Increase engine speed to 1000 RPM
  • Step 24024 Display lO-second timer
  • Step 24025 Determine if timer is at or above 10 seconds; if timer is at or above 10 seconds, proceed to Step 24026; if timer is below 10 seconds, return to step 24024
  • Step 24026 Return to beginning of currently selected mode, option, or program
  • FIG. 25 illustrates an exemplary process 25000 of executing an automatic mode startup sequence, comprising the steps:
  • Step 25001 Start selected mode, option, or program
  • Step 25002 Determine if automatic mode is selected; if automatic mode is selected, proceed to Step 25003; if automatic mode is not selected, proceed with currently selected mode, option, or program
  • Step 25003 Display startup icon for 3 seconds
  • Step 25004 Activate audio/visual alarm for 30 seconds
  • Step 25005 Determine if oil level is low; if oil level is not low, proceed to Step 25016; if oil level is low, proceed to Step 25036
  • Step 25016 Determine if battery voltage is low; if battery voltage is not low, proceed to Step 25017; if battery voltage is low, proceed to Step 25037
  • Step 25036 Display low oil warning message; proceed to step 25016
  • Step 25017 Determine if fuel level is low; if fuel level is not low, proceed to Step 25018; if fuel level is low, proceed to Step 25038
  • Step 25037 Display low voltage warning message and display current voltage; proceed to Step 25017
  • Step 25038 Display low fuel warning message; proceed to Step 25018 Step 25019: Load warm up and cool down settings
  • Step 25039 Display low coolant level warning message; proceed to Step 25019
  • Step 25020 Crank engine
  • Step 25021 Display automatic start option and timers
  • Step 25022 Increase engine speed from 800 RPM to 1000 RPM in 10 seconds
  • Step 25023 Maintain engine speed for 10 seconds
  • Step 25024 Return to original mode, option, or program
  • FIG. 26 illustrates an exemplary process 26000 for executing the shutdown of automatic mode, comprising the steps:
  • Step 26001 Start mode, option, or program
  • Step 26002 Display shutdown message, engine speed, and timers
  • Step 26003 Reduce engine speed to 800 RPM over 10 seconds
  • Step 26004 Maintain engine speed for 5 seconds
  • Step 26005 Turn off engine
  • Step 26006 Return to original mode, option, or program
  • FIG. 27 illustrates an exemplary process 27000 for executing a manual mode program, comprising the steps:
  • Step 27001 Start selected mode, option, or program
  • Step 27002 Determine if manual mode is selected; if manual mode is selected, proceed to Step 27003; if manual mode is not selected, proceed with currently selected mode, option, or program
  • Step 27003 Display manual crank button; if user presses manual crank button, perform startup sequence; if user does not press manual crank button, continue to display button
  • Step 27004 Display manual mode interface and current engine speed
  • Step 27005 Determine if user adjusts engine speed; if user decreases displayed engine speed value, proceed to Step 27016; if user increases displayed engine speed value, proceed to Step 27036; if user selects“option” button, proceed to Step 27026
  • Step 27016 If user selected engine speed is greater than idle speed, lower engine speed in increments of 10 RPM until actual engine speed matches user selected engine speed
  • Step 27026 Request password; if entered password is incorrect, return to Step 27004; if entered password is correct, proceed to Step 27007
  • Step 27036 If user selected engine speed is less than maximum engine speed, increase engine speed in increments of 10 RPM until actual engine speed matches user selected engine speed
  • Step 27027 Display engine speed options
  • FIG. 28 illustrates an exemplary process 28000 of setting maximum and minimum engine speed values, comprising the steps:
  • Step 28001 Start selected mode, option, or program
  • Step 28002 Display option to change maximum or minimum engine speed
  • Step 28003 Determine if user has selected option to change maximum or minimum engine speed; if user presses exit button, proceed to Step 28004; if user has selected to change minimum engine speed, proceed to Step 28014; if user has selected to change maximum engine speed, proceed to Step 28024
  • Step 28004 Return to original mode, option, or program
  • Step 28014 Display option for user to enter minimum engine speed value
  • Step 28024 Display option for user to enter maximum engine speed value
  • Step 28015 User enters minimum engine speed value
  • Step 28025 User enters maximum engine speed value
  • Step 28016 Save entered value to memory
  • Step 28026 Save entered value to memory
  • FIG. 29 illustrates an exemplary process 29000 for executing automatic mode with a float system, comprising the steps:
  • Step 29001 Start selected mode, option, or program
  • Step 29002 Determine if automatic mode with floats is selected; if automatic mode with floats is selected, proceed to Step 29003; if automatic mode with floats is not selected, proceed with currently selected mode, option, or program
  • Step 29003 Display automatic mode with floats interface
  • Step 29004 Determine if one or two float are equipped; if one float is equipped, proceed to Step 29105; if two floats are equipped, proceed to Step 29205
  • Step 29105 Display message indicating one float mode is selected
  • Step 29205 Display message indicating two float mode is selected
  • Step 29106 Display option to set float type as normally open (NO) or normally closed (NC)
  • Step 29206 Display option to set first float type as normally open or normally closed
  • Step 29107 User selects NO or NC relay
  • Step 29207 User selects NO or NC relay
  • Step 29108 Save float data to memory
  • Step 29208 Save first float data to memory
  • Step 29109 User enters desired engine speed for when float is tripped; save speed data to memory
  • Step 29209 Display option to set second float type as normally open or normally closed
  • Step 29110 Adjust warm up and cool down procedure
  • Step 29210 User selects NO or NC relay
  • Step 29111 Display message indicating controller is operating in automatic mode with a single float
  • Step 29211 Save second float data to memory
  • Step 29112 Determine if float is tripped; if float is tripped, proceed to Step 29113; if float is untripped; return to Step 29111
  • Step 29212 User enters desired engine speed; save speed data to memory
  • Step 29113 Initiate automatic mode startup sequence
  • Step 29213 Adjust warm up and cool down procedure
  • Step 29114 Increase engine speed to stored value in memory
  • Step 29214 Display message indicating controller is operating in automatic mode with dual floats
  • Step 29115 Determine if float is tripped; if float is tripped, return to Step 29114; if float is untripped; proceed to Step 29116
  • Step 29215 Determine if first and second floats are tripped; if floats are tripped, proceed to Step 29216; if floats are untripped; return to Step 29114 Step 29116: Initiate automatic mode shutdown sequence
  • Step 29216 Initiate automatic mode startup sequence
  • Step 29217 Increase engine speed to stored value in memory
  • Step 29218 Determine if first float is tripped; if first float is tripped, return to Step 29217; if first float is untripped, proceed to Step 29219
  • Step 29219 Initiate automatic mode shutdown sequence
  • FIG. 30 illustrates an exemplary process 30000 for executing manual multi-state operation mode, comprising the steps:
  • Step 30001 Start selected mode, option, or program
  • Step 30002 Determine if manual multi-state operation mode is selected; if manual multi-state operation mode is selected, proceed to Step 30003; if manual multi-state operation mode is not selected, proceed with currently selected mode, option, or program
  • Step 30003 Display manual multi-state operation mode interface
  • Step 30004 Display options for number of engine speeds
  • Step 30005 Determine number of engine speeds selected; if one engine speed is selected, proceed to Step 30106; if two engine speeds are selected, proceed to Step 30206; if three engine speeds are selected, proceed to Step 30306; if four engine speeds are selected, proceed to Step 30406; if five engine speeds are selected, proceed to Step 30506
  • Step 30106 Display option to enter first speed
  • Step 30206 Display option to enter first speed
  • Step 30306 Display option to enter first speed
  • Step 30406 Display option to enter first speed
  • Step 30506 Display option to enter first speed
  • Step 30107 User enters first speed; save data to memory
  • Step 30207 User enters first speed; save data to memory
  • Step 30307 User enters first speed; save data to memory
  • Step 30407 User enters first speed; save data to memory
  • Step 30507 User enters first speed; save data to memory
  • Step 30208 Display option to enter second speed
  • Step 30308 Display option to enter second speed
  • Step 30408 Display option to enter second speed
  • Step 30508 Display option to enter second speed
  • Step 30209 User enters second speed; save data to memory
  • Step 30309 User enters second speed; save data to memory
  • Step 30409 User enters second speed; save data to memory
  • Step 30509 User enters second speed; save data to memory
  • Step 30310 Display option to enter third speed
  • Step 30410 Display option to enter third speed
  • Step 30510 Display option to enter third speed
  • Step 30311 User enters third speed; save data to memory
  • Step 30411 User enters third speed; save data to memory
  • Step 30511 User enters third speed; save data to memory
  • Step 30412 Display option to enter fourth speed
  • Step 30512 Display option to enter fourth speed
  • Step 30413 User enters fourth speed; save data to memory
  • Step 30513 User enters fourth speed; save data to memory
  • Step 30514 Display option to enter fifth speed
  • Step 30515 User enters fifth speed; save data to memory
  • Step 30016 Display option to select input type
  • Step 30017 Determine which input type is selected; if analog input type is selected, proceed to Step 30618; if digital input type is selected, proceed to Step 30718; if relay input type is selected, proceed to Step 30818
  • Step 30618 Determine type of analog input (0-20ma, 0-1 Ov, or 4-20ma)
  • Step 30718 Determine type of digital input (high side or low side)
  • Step 30818 Determine type of relay input (normally open or normally closed)
  • Step 30619 Store data to memory
  • Step 30719 Store data to memory
  • Step 30819 Store data to memory
  • Step 30020 Display input type and inputs to be used
  • Step 30021 Initiate engine crank sequence
  • Step 30022 Run engine at idle speed
  • Step 30023 Display manual multi-state operation mode interface
  • Step 30024 Detect feedback from input; if feedback signal indicates engine speed is to be decreased, proceed to Step 30025A; if feedback signal indicates engine speed is to be increased, proceed to Step 30025B
  • Step 30025A If current engine speed is greater than idle speed, decrease engine speed to next lowest selected speed or idle
  • Step 30025B If current engine speed is less than maximum engine speed, increase engine speed to next highest selected speed
  • FIG. 31 illustrates an exemplary process 31000 for executing a warm up and cool down procedure, comprising the steps:
  • Step 31001 Start selected mode, option, or program
  • Step 31002 Display option to change warm up and cool down procedure
  • Step 31003 Display option to change warm up procedure or cool down procedure, or to select default parameters; if exit button is pressed, proceed to Step 31004; if option to change warm up procedure is selected, proceed to Step 31104; if option to change cool down procedure is selected, proceed to Step 31204; if option to select default parameters is selected, proceed to Step 31304
  • Step 31004 Determine if all setpoints are set; if setpoints are not all set, proceed to Step 31005 A; if all setpoints are set, proceed to Step 31005B
  • Step 31104 Display option to change warm up engine speed
  • Step 31204 Display option to change cool down engine speed
  • Step 31304 Display message indicating default parameters are loading
  • Step 31005A Display message to load default parameters or enter data manually; return to Step 31002
  • Step 31005B Return to original mode, option, or program
  • Step 31105 User enters warm up speed
  • Step 31205 User enters cool down speed
  • Step 31305 Load default parameters
  • Step 31106 Save entered data to memory
  • Step 31206 Save entered data to memory
  • Step 31107 Display option to change warm up timer
  • Step 31207 Display option to change cool down timer
  • Step 31108 User enters warm up timer value
  • Step 31208 User enters cool down timer value
  • Step 31109 Save entered data to memory
  • Step 31209 Save entered data to memory
  • Step 31110 Display option to change warm up ramp time
  • Step 31210 Display option to change cool down ramp time
  • Step 31111 User enters warm up ramp time
  • Step 31211 User enters cool down ramp time
  • Step 31112 Save entered data to memory
  • Step 31212 Save entered data to memory
  • FIG. 32 illustrates an exemplary process 32000 for executing automatic mode with one or more transducers, comprising the steps:
  • Step 32001 Start selected mode, option, or program
  • Step 32002 Determine if automatic mode with transducers is selected; if automatic mode with transducers is selected, proceed to Step 32003; if automatic mode with transducers is not selected, proceed with currently selected mode, option, or program
  • Step 32003 Display automatic mode with transducers interface
  • Step 32004 Adjust analog input, scaling, and units
  • Step 32005 Change warm up and cool down procedure
  • Step 32006 Display option to adjust engine running speed
  • Step 32007 User enters engine running speed; data stored to memory
  • Step 32008 Display option to specify setpoint for engine to run
  • Step 32009 Set setpoint as engine start setpoint
  • Step 32010 Display option to specify setpoint for engine shutdown
  • Step 32011 Set setpoint as setpoint for engine shutdown
  • Step 32012 Display that controller is operating in automatic mode with transducers
  • Step 32013 Determine if current measured value from transducers is greater than or equal to the start setpoint; if current measured value from transducers is greater than or equal to the start setpoint, proceed to Step 32014; if current measured value from transducers is less than the start setpoint, return to Step 32012
  • Step 32014 Initiate automatic mode startup sequence
  • Step 32015 Increase engine speed to stored speed value
  • Step 32016 Determine if current measured value from transducers is less than the shutdown setpoint; if current measured value from transducers is less than the shutdown setpoint, proceed to Step 32017; if current measured value from transducers is equal to, or greater than, the shutdown setpoint, return to Step 32015
  • Step 32017 Initiate automatic mode shutdown sequence; return to Step 32012
  • FIG. 33 illustrates an exemplary process 33000 for setting analog inputs, scaling, and units, comprising the steps:
  • Step 33001 Start selected mode, option, or program
  • Step 33001 Display option to change analog inputs, scaling, units, or failure response
  • Step 33002 Determine if option to change analog inputs, scaling, or units has been selected
  • Step 33003 Determine what option has been selected; if exit button has been pressed, proceed to Step 33004; if option to change analog inputs has been selected, proceed to Step 33014; if option to change scaling has been selected, proceed to Step 33024; if option to change units has been selected, proceed to Step 33034
  • Step 33004 Determine if all settings have been entered; if not all settings are entered, proceed to Step 33005 A; if all settings are entered, proceed to Step 33005B
  • Step 33014 Display option to change analog input
  • Step 33024 Display option to change scaling
  • Step 33034 Display option to change units
  • Step 33005A Display message to fill in settings
  • Step 33005B Return to original mode, option, or program
  • Step 33015 User enters analog input data
  • Step 33025 User enters scaling data
  • Step 33035 User enters unit data
  • Step 33016 Save data to memory
  • Step 33026 Save data to memory
  • Step 33036 Save data to memory
  • FIG. 34 illustrates an exemplary process 34000 for executing automatic mode with a float and transducer using linear throttling, comprising the steps:
  • Step 34001 Start selected mode, option, or program
  • Step 34002 Determine if automatic mode with float and transducer and linear throttling is selected; if automatic mode with float and transducer and linear throttling is selected, proceed to Step 34003; if automatic mode with float and transducer and linear throttling is not selected, proceed with currently selected mode, option, or program
  • Step 34003 Display automatic mode with float and transducer and linear throttling interface
  • Step 34004 Display option to select float or analog input
  • Step 34005 Determine if float or analog setpoint is selected; if analog setpoint is selected, proceed to Step 34106; if float is selected, proceed to Step 34206
  • Step 34106 Load analog input, scaling, and unit data
  • Step 34206 Display option to specify whether float relay is normally open or normally closed
  • Step 34107 Display option to specify setpoint value (unit based one loaded data)
  • Step 34207 User enters float relay information; designate and display relay to be used
  • Step 34108 User enters setpoint value
  • Step 34208 Load analog input, scaling, and unit data
  • Step 34109 Display option for user to select direct (signal increases, engine speed increases) or inverse (signal increases, engine speed decreases)
  • Step 34209 Display option for user to select direct or inverse
  • Step 34110 User selects option; selection stored to memory
  • Step 34210 User selects option; selection stored to memory
  • Step 34111 Adjust warm up and cool down procedure
  • Step 34211 Adjust warm up and cool down procedure
  • Step 34112 Display current operating mode
  • Step 34212 Display current operating mode
  • Step 34113 Determine if measured signal if greater than or equal to the setpoint; if measured signal if greater than or equal to the setpoint, proceed to Step 34114; if measured signal is less than the setpoint, return to Step 34112
  • Step 34213 Determine if float is tripped; if float is tripped, proceed to Step 34214; if float is untripped, return to Step 34212
  • Step 34114 Initiate automatic startup mode
  • Step 34214 Initiate automatic startup mode
  • Step 34115 Increase engine speed to warm up speed
  • Step 34215 Increase engine speed to warm up speed
  • Step 34116 Increase engine speed based on input signal, or based one last speed if no signal is received
  • Step 34216 Increase engine speed based on input signal
  • Step 34117 Determine if analog signal is being received; if analog signal is being received, proceed to Step 34118; if analog signal is not being received, return to Step 34116
  • Step 34217 Determine if float is untripped; if float is untripped, proceed to Step 34218, if float is tripped, return to Step 34216
  • Step 34118 Determine if measured signal is less than setpoint, if measured signal is less than setpoint, proceed to Step 34119; if measured signal equal to, or greater than, setpoint, return to Step 34116
  • Step 34218 Initiate automatic mode shutdown
  • Step 34119 Initiate automatic mode shutdown
  • FIG. 35 illustrates an exemplary process 35000 for executing automatic mode with PID control is illustrated, comprising the steps:
  • Step 35001 Start selected mode, option, or program
  • Step 35002 Determine if automatic mode with PID control is selected; if automatic mode with PID control is selected, proceed to Step 35003; if automatic mode with PID control is not selected, continue with currently selected mode, option, or program
  • Step 35003 Display automatic mode with PID control interface
  • Step 35004 Adjust analog input, scaling, and units
  • Step 35005 Load warm up and cool down procedures
  • Step 35006 Adjust PID settings
  • Step 35007 Display option to specify engine start by float or by transducer
  • Step 35008 Determine method selected; if float selected, proceed to Step 35109; if transducer selected, proceed to Step 35209
  • Step 35109 Display selected method
  • Step 35209 Display option to specify setpoint for turning engine on
  • Step 35110 Display option to specify if float relay is normally open or normally closed
  • Step 35210 User enters setpoint value
  • Step 35111 User selects relay type
  • Step 35211 Display option to specify setpoint for turning engine off
  • Step 35112 Store selection in memory
  • Step 35212 User enters setpoint value
  • Step 35113 Display option for PID target setpoint
  • Step 35213 Display option for PID target setpoint
  • Step 35114 User enters PID target setpoint value
  • Step 35214 User enters PID target setpoint value
  • Step 35115 Display current operating mode
  • Step 35215 Display current operating mode
  • Step 35116 Determine if float is tripped; if float is tripped, proceed to Step 35117; if float is untripped, return to Step 35115
  • Step 35216 Determine if measured value from transducer is greater than or equal to the start setpoint; if measured value from transducer is greater than or equal to the start setpoint, proceed to Step 35217; if measured value from transducer is less than the start setpoint, return to Step 35215
  • Step 35117 Initiate automatic startup sequence
  • Step 35217 Initiate automatic startup sequence
  • Step 35118 Increase engine speed to warm up speed
  • Step 35218 Increase engine speed to warm up speed
  • Step 35119 Increase engine speed and run at speed determined by PID feedback to reach target setpoint
  • Step 35219 Increase engine speed and run at speed determined by PID feedback to reach target setpoint
  • Step 35120 Determine if float is untripped; if float is untripped, proceed to Step 35121; if float is tripped, return to Step 35119
  • Step 35220 Determine if signal if being received from transducer; if signal is being received from transducer, proceed to Step 35221; if signal is not being received from transducer, return to Step 35219
  • Step 35121 Initiate shutdown sequence
  • Step 35221 Determine if measured signal from transducer is greater than stop setpoint; if measured signal from transducer is greater than stop setpoint, proceed to Step 35222; if measured signal from transducer less than, or equal to, stop setpoint, return to Step 35219
  • FIG. 36 illustrates an exemplary process 36000 for changing PID parameters, comprising the steps:
  • Step 36001 Start selected mode, option, or program
  • Step 36002 Display option to change proportional, integral, or derivative numbers, or to select default parameters
  • Step 36003 Determine option selected; if exit button is pressed, proceed to Step 36004; if option to change proportional number is selected, proceed to Step 36014; if option to change integral number is selected, proceed to Step 36024; if option to change derivate number is selected, proceed to Step 36034; if option to select default parameters is selected, proceed to step 36044
  • Step 36004 Determine if all settings are filled in; if not all settings are filled in, proceed to Step 36005 A; if all settings are filled in, proceed to Step 36005B
  • Step 36014 Display option to display proportional number
  • Step 36024 Display option to display integral number
  • Step 36034 Display option to display derivative number
  • Step 36044 Display default PID settings
  • Step 36005A Display message to user to fill in settings
  • Step 36005B Return to original mode, option, or program
  • Step 36015 User enters proportional number
  • Step 36025 User enters integral number
  • Step 36035 User enters derivative number
  • Step 36045 Display option to load default PID settings
  • Step 36016 Store entered data to memory
  • Step 36026 Store entered data to memory
  • Step 36036 Store entered data to memory
  • Step 36046 Determine whether option to load default settings is selected; if option to load default settings is selected, proceed to Step 36047; if option to load default settings is not selected, return to Step 36002
  • Step 36047 Load default settings; save to memory
  • FIG. 37 illustrates and exemplary process 37000 for setting a pump scheduler program, comprising the steps: Step 37001 : Start selected mode, option, or program
  • Step 37002 Determine if scheduler mode is selected; if scheduler mode is selected, proceed to Step 37003; if scheduler mode is not selected, continue with currently selected mode, option, or program
  • Step 37003 Display scheduler mode interface
  • Step 37004 Display option for specifying number of schedules
  • Step 37005 Determine number of schedules selected; if one schedule is selected, proceed to Step 37106; if two schedules are selected, proceed to Step 37206; if three schedules are selected, proceed to Step 37306; if four schedules are selected, proceed to Step 37406; if five schedules are selected, proceed to Step 37506
  • Step 37106 Display option to enter first schedule
  • Step 37206 Display option to enter first schedule
  • Step 37306 Display option to enter first schedule
  • Step 37406 Display option to enter first schedule
  • Step 37506 Display option to enter first schedule
  • Step 37107 User enters first schedule; save data to memory
  • Step 37207 User enters first schedule; save data to memory
  • Step 37307 User enters first schedule; save data to memory
  • Step 37407 User enters first schedule; save data to memory
  • Step 37507 User enters first schedule; save data to memory
  • Step 37208 Display option to enter second schedule
  • Step 37308 Display option to enter second schedule
  • Step 37408 Display option to enter second schedule
  • Step 37508 Display option to enter second schedule
  • Step 37209 User enters second schedule; save data to memory
  • Step 37309 User enters second schedule; save data to memory
  • Step 37409 User enters second schedule; save data to memory
  • Step 37509 User enters second schedule; save data to memory
  • Step 37310 Display option to enter third schedule
  • Step 37410 Display option to enter third schedule
  • Step 37510 Display option to enter third schedule
  • Step 37311 User enters third schedule; save data to memory
  • Step 37411 User enters third schedule; save data to memory
  • Step 37511 User enters third schedule; save data to memory
  • Step 37412 Display option to enter fourth schedule
  • Step 37512 Display option to enter fourth schedule
  • Step 37413 User enters fourth schedule; save data to memory
  • Step 37513 User enters fourth schedule; save data to memory
  • Step 37514 Display option to enter fifth schedule
  • Step 37515 User enters fifth schedule; save data to memory
  • Step 37016 Display option to run program
  • Step 37017 Determine if option to run program is selected; if option to run program is selected, proceed to Step 37018; if option to run program is not selected, return to Step 37002
  • Step 37018 Display currently running program
  • Step 37019 Determine if scheduled start has been reached and if engine is off; if scheduled start has been reached and if engine is off, proceed to Step 37010; if scheduled start has not been reached and if engine is on, repeat Step 37009
  • Step 37020 Initiate startup sequence
  • Step 37021 Increase engine speed and run at idle
  • Step 37022 Determine if timer as expired; if timer has expired, proceed to Step 37023; if timer has not expired, return to Step 37021
  • Step 37023 Initiate shutdown sequence
  • 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.
  • 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.
  • 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.
  • 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 38AA.
  • 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

Landscapes

  • 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)

Abstract

Système de commande d'une pompe pouvant comprendre un capteur de niveau de fluide (300), un capteur de niveau de carburant (300), un ou plusieurs capteurs de pression d'huile (500), un capteur de fluide de pompe (600), et un dispositif de commande (100) de pompe. Le dispositif de commande (100) de pompe peut fournir des instructions de vitesse à une pompe (200) ayant une unité de commande (210) de moteur, un moteur (220) et une volute (230). Le dispositif de commande (100) de pompe peut comprendre une interface utilisateur (140) qui comprend un dispositif d'affichage (141) et peut également comprendre un émetteur-récepteur (130) qui est en prise fonctionnelle avec un dispositif utilisateur distant (800) par l'intermédiaire d'un réseau informatique (900). Un procédé de commande d'une pompe peut comprendre la caractérisation du fonctionnement de la pompe, la réalisation d'un contrôle de sécurité de la pompe, la détermination d'un niveau d'un fluide dans un réservoir, et la fourniture des instructions de vitesse à la pompe.
PCT/US2019/020135 2018-02-28 2019-02-28 Système et procédés de pompage automatisé WO2019169190A1 (fr)

Priority Applications (3)

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AU2019228585A AU2019228585A1 (en) 2018-02-28 2019-02-28 Automated pumping system and methods
EP19761481.1A EP3759350A4 (fr) 2018-02-28 2019-02-28 Système et procédés de pompage automatisé
CA3092457A CA3092457A1 (fr) 2018-02-28 2019-02-28 Systeme et procedes de pompage automatise

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US201862636579P 2018-02-28 2018-02-28
US62/636,579 2018-02-28

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US5765995A (en) * 1995-10-16 1998-06-16 Diesel Power Supply Co. Automated engine-powered pump control system
US20030056824A1 (en) * 2000-10-03 2003-03-27 Harvey Richard W. Fuel transfer pump and control
US20070056630A1 (en) * 2005-09-15 2007-03-15 Ansul Canada, Ltd. Pump controller for controlling pumps connected in tandem
US20120167676A1 (en) * 2010-10-27 2012-07-05 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
WO2016161479A1 (fr) * 2015-04-10 2016-10-13 Legra Engineering Pty Ltd Système de pompage

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DE3926911A1 (de) * 1989-08-16 1991-02-21 Bosch Gmbh Robert Elektromagnetischer drehsteller
US9500193B2 (en) * 2014-02-24 2016-11-22 Sears Brand, L.L.C. Sump pump monitoring device and method
US10060379B2 (en) * 2015-09-04 2018-08-28 Ford Global Technologies, Llc Method for a hybrid vehicle

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Publication number Priority date Publication date Assignee Title
US5765995A (en) * 1995-10-16 1998-06-16 Diesel Power Supply Co. Automated engine-powered pump control system
US20030056824A1 (en) * 2000-10-03 2003-03-27 Harvey Richard W. Fuel transfer pump and control
US20070056630A1 (en) * 2005-09-15 2007-03-15 Ansul Canada, Ltd. Pump controller for controlling pumps connected in tandem
US20120167676A1 (en) * 2010-10-27 2012-07-05 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
WO2016161479A1 (fr) * 2015-04-10 2016-10-13 Legra Engineering Pty Ltd Système de pompage

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EP3759350A1 (fr) 2021-01-06
AU2019228585A1 (en) 2020-09-24
US20230279850A1 (en) 2023-09-07
CA3092457A1 (fr) 2019-09-06
US20190264677A1 (en) 2019-08-29
EP3759350A4 (fr) 2022-06-01

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