WO2024056395A1 - Système de commande de pompe et procédé de commande d'une pompe à étalonnage automatique de modèle de pompe - Google Patents

Système de commande de pompe et procédé de commande d'une pompe à étalonnage automatique de modèle de pompe Download PDF

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Publication number
WO2024056395A1
WO2024056395A1 PCT/EP2023/073929 EP2023073929W WO2024056395A1 WO 2024056395 A1 WO2024056395 A1 WO 2024056395A1 EP 2023073929 W EP2023073929 W EP 2023073929W WO 2024056395 A1 WO2024056395 A1 WO 2024056395A1
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Prior art keywords
operating value
model function
pump
value model
max
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PCT/EP2023/073929
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English (en)
Inventor
Torben Nielsen
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Grundfos Holding A/S
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Application filed by Grundfos Holding A/S filed Critical Grundfos Holding A/S
Publication of WO2024056395A1 publication Critical patent/WO2024056395A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
    • F04D15/0088—Testing machines
    • 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
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2260/00—Function
    • F05D2260/81—Modelling or simulation

Definitions

  • Pumps may be used as circulator pumps for circulating water or another liquid through a pipe system, e.g. a heating or cooling system.
  • circulator pumps may be operated in different operating modes. For example, a circulator pump may be operated to provide a constant output pressure, i.e. in constant pressure mode.
  • Another oper- ating mode is typically “proportional pressure mode”, wherein the op- erating points of the circulator pump follow a linear line in a pressure- flow-diagram, a so-called pq-diagram. It is a general goal of pump controlling to control the pump in such a way that the pump runs pre- cisely at a desired operating point, e.g. in the pq-diagram. Usually, the output pressure P and the flow q are measured and the measured val- ues are fed back in a closed-loop control, so that the pump runs at the desired operating point. [03] However, flow sensors are expensive and often not available for pump control.
  • pump control systems and methods use the affinity laws to estimate the current operating point based on other operating val- ues, e.g. the actual power consumption P, the motor current I and/or motor speed of the pump ⁇ .
  • Using such operating values for an indirect estimation of the operating point requires a precise model of the pump characteristic, e.g. a model function in the Pq-diagram.
  • Pump manufacturers typically determine the pump characteris- tics in a laboratory and/or field tests for certain pump types and pro- vide data sets with a plurality of model parameter sets indicative of operating value model functions that describe the pump characteris- tics of a certain model type.
  • a certain pump type comes in a plurality of variants and a large amount of combinations of customised options.
  • the true pump characteristics may differ slightly among the plurality of variants, whereas the same model function is used by the pump control system to describe the pump characteristic. So, the true pump characteristic may differ from the assumed modelled pump characteristic. Manufac- turing tolerances add further differences between the actual pump characteristic and the assumed model pump characteristic. The true pump characteristic may even depend on the pipe system that the pump is connected to, so that there is an inherent uncertainty about the modelled pump characteristic that a pump manufacturer is able to provide with a pump control system.
  • the pump char- acteristic may change dynamically over time due to wear and tear of mechanical and/or electrical components, so that an older pump be- haves differently than a brand new pump.
  • US 7,945,411 B1, DE 10 2009 050 083 B4, US 9,897,084 B1 and US 9,470,217 B1 describe control systems, wherein either the pump is forced to run at a known fix operation point for calibration, or wherein an actual flow is measured or estimated to determine the actual oper- ating point.
  • a pump control system comprising: - a storage element having stored a plurality of model parameter sets for a plurality of pump speeds, wherein each model param- eter set is indicative of an operating value model function corre- sponding to a pump speed; - control electronics configured to command the pump to run at a set pump speed based on the operating the value model function corresponding to the set pump speed, wherein a corre- sponding model parameter set of the stored model parameter sets is retrieved from the storage element; and - model updating electronics, wherein the model updating elec- tronics are configured to: - determine an actual operating value at the set speed; - compare the actual operating value with a maximum of the operating value model function and/or a minimum of the oper- ating value model function; and - automatically determine an updated model parameter set if the actual operating value is higher than the maximum of the oper- ating value model function or if the operating value is lower than
  • the operating value may be the power consumption of the pump, a motor current, or another electrical performance value that is readily available to be determined. It should be noted that the updat- ing or calibrating of the model parameter set does not require a meas- ured flow value or an estimated flow value. Furthermore, the pump is not forced to run at a fixed known operating point. The updating or calibrating of the model parameter sets may be performed dynamical- ly and automatically during normal pump operation. The updating or calibrating can be performed continuously, regularly and/or sporadi- cally over the lifetime of the pump. [10] The inventive idea uses the fact that normal operation of a circu- lator pump is often at or around a minimum or maximum operating val- ue.
  • the determined actual operating value is between a minimum and a maximum of the operating value model function, it may be im- possible to evaluate the model function without having a measured or estimated flow to determine the exact operation point. Outside of the operating value range, i.e. above a maximum of the operating value model function and below a minimum of the operating value model function, a deviation between the actual operating value and the op- erating value model function cannot be explained by the uncertainty in flow. In this case, it can be assumed that the operating value model function does not reflect the true pump characteristic. Therefore, the operating value model function is updated or calibrated if the actual operating value is higher than the maximum of the operating value model function and if the actual operating value is lower than the min- imum of the operating value model function.
  • the model updating electronics may be configured to shift or scale the operating value model function upward to the higher new operating value model function and/or to shift or scale the operating value model function downward to a lower new operating value model function.
  • the shape of the operating value model function may remain unamended.
  • the model updating electronics may be configured to apply a correc- tion function to tweak shape of the operating value model function. For example, in case of an upward updating, the model function may be lifted only in a predefined range about the maximum of the model function. Analogously, in case of a downward updating, the model function may be lowered in a predefined range about the minimum of the model function.
  • a shift amount and/or a scale factor may be applied, wherein the shift amount and/or the scale factor is a predetermined constant or depends in a predetermined way on set pump speed.
  • the updating logic is very simple and all pump speeds are given the same weight. If, how- ever, the accuracy of the model function is known to be better for cer- tain pump speeds, it may be advantageous to apply a shift amount and/or a scale factor that depends in a predetermined way on the set pump speed.
  • the shift amount and/or the scale factor may de- pend on a difference and/or ratio between the actual operating value and the maximum or the minimum, respectively, of the model function.
  • the operating value model function may be a model curve of the operating value in dependence of a pump flow within a predetermined flow range.
  • the model curve comprises a single well-defined minimum and maximum within the predetermined flow range.
  • the higher new operating value model function is at least in a subrange of the predetermined flow range higher than the previous operating value model function, and the lower new operating value model function may be at least in a subrange of the predeter- mined range lower than the previous operating model function.
  • the model function may not be automatically updated or cal- ibrated.
  • such calibration batch runs may be started when a new pump is installed and initially operat- ed for the first time.
  • such a calibration batch runs may be part of a regular maintenance action. It is preferred that the calibration batch runs are not automatically started, but start- ed manually by skilled personnel or user.
  • the model updating electronics may be further con- figured to: - determine a maximum actual operating value and/or a mini- mum actual operating value among the calibration batch runs, - compare the maximum actual operating value with the maxi- mum of the operating value model function and/or the mini- mum actual operating value with the minimum of the operating value model function; and - automatically update the operating value model function to a higher new operating value model function if the maximum ac- tual operating value is higher than the maximum of the operat- ing value model function, and/or automatically update the op- erating value model function to a lower new operating value model function if the minimum actual operating value is lower than the minimum of the operating value model function.
  • the calibration batch runs at different speeds are used to check if a maximum actual operating value is above a maxi- mum of the model function and whether a minimum actual operating value is below a minimum of the model function.
  • a broader range or area of operating points can be scanned to update or cali- brate the model parameter sets that are indicative of the model func- tions corresponding to the respective pump speeds.
  • the model updating electronics may be integrated into the control electronics that command the pump to run at a set pump speed based on the current operating value model function.
  • a pump assembly comprising a pump, an electric motor for driving the pump, and an electronics housing for housing motor control elec- tronics, wherein the above-mentioned pump control system is arranged within the electronics housing.
  • a method for controlling a pump comprises the following steps: - running a pump at a set pump speed based on an operating value model function corresponding to the set pump speed; - determining an actual operating value at the set pump speed; - comparing the actual operating value with a maximum of the operating value model function and/or a minimum of the oper- ating value model function; and - automatically updating the operating value model function to a higher new operating value model function if the actual operat- ing value is higher than the maximum of the operating value model function, and/or automatically updating the operating value model function to a lower new operating value model function if the actual operating value is lower than the minimum of the operating value model function.
  • updating the operating value model function to a higher new operating value model function may include shifting or scaling the operating value model function upward and/or updating the operating value model function to a lower new operating value model function may include shifting or scaling the operating value model function downward.
  • a shift amount and/or a scale factor may be applied, wherein the shift amount and/or the scale factor may be a predeter- mined constant or may depend in a predetermined way on the set pump speed.
  • a shift amount and/or a scale factor may be applied, wherein the shift amount and/or the scale factor depends on a differ- ence and/or ratio between an axial operating value and the maximum of the operating value model function or the minimum of the operating value model function.
  • the method may further comprise running the pump in a set of calibration batch runs at different pump speeds if the actual operation value is at or higher than the minimum of the operating value model function and if the actual operating value is at or lower than the maximum of the operating value model function.
  • the method may further comprise the following steps: - determining a maximum actual operating value and/or a mini- mum actual operating value among the calibration batch runs; - comparing the maximum actual operating value with the maxi- mum of the operating value model function and/or the mini- mum actual operating value with the minimum of the operating value model function; and - automatically updating the operating model function to a high- er new operating value model function if the maximum actual operating value is higher than the maximum of the operating value model function, and/or automatically updating the oper- ating value model function to a lower new operating value model function if the minimum actual operating value is lower than the minimum of the operating value model function.
  • the method disclosed herein may be implemented in form of compiled or uncompiled software code that is stored on a computer readable medium with instructions for executing the method. Alterna- tively, or in addition, the method may be executed by software in- stalled in electronics residing within an electronics housing of a pump assembly, or software running in a cloud-based system and/or a build- ing management system (BMS), e.g. in the pump control system dis- closed herein.
  • BMS build- ing management system
  • the pump control system and method described herein may be implemented and integrated in electronics residing within an electron- ics housing of a pump assembly, or in at least one central controller controlling a plurality of pumps, e.g. as part of a building management system (BMS).
  • a cloud computing environment may be particularly useful in case of geographically widely spread fluid distribution systems, such as a municipal water supply system or a district heating or cooling system.
  • Fig.1 shows a perspective view of a pump assembly according to the present disclosure
  • Fig.2 shows a Pq-diagram showing an example of pump char- acteristics of a pump assembly running at twelve different speeds
  • Fig.3 shows the pump characteristics as shown in figure 2 for four different pumps of the same pump type
  • Fig.4 shows a pump characteristic in a Pq-diagram for a single pump speed
  • Fig.5 shows a schematic diagram of a method for controlling a pump according to the present disclosure
  • Fig.6 shows a schematic diagram of further preferred steps of a method for controlling a pump according to the present disclosure.
  • FIG. 1 shows a pump assembly 1 according to the present dis- closure.
  • the hardware of the pump assembly 1 is here essentially identi- cal to the known pump type “Grundfos Magna350-60”.
  • the hardware comprises a pump housing 3 having an inlet flange 5 and an outlet flange 7.
  • the inlet flange 5 and the outlet flange 7 may be connected to a pipe system (not shown) for pumping water or another liquid through the pipe system.
  • the inlet flange 5 and the outlet flange 7 are arranged coaxially on an axis L that defines the predominant pump direction.
  • the pump assembly 1 further comprises an electric motor drive 9 for driving an impeller (not visible) residing within the pump hous- ing 3.
  • the motor rotor and the impeller rotate about a rotor axis R ex- tending perpendicular to the axis L.
  • the pump assembly 1 further com- prises an electronics housing 11 for housing motor control electronics.
  • the motor control electronics are configured to command the pump motor to run at a set pump speed.
  • a front face of the electronics hous- ing 11 comprises a human machine interface 13 comprising a display 15 and buttons 17 for outputting and inputting information, commands, settings, parameters and/or programs.
  • the pump assembly 1 may comprise automatic pump control algorithms to run automatically and/or may be set manually to run at a certain operating point by us- ing the human machine interface 13.
  • the pump control electronics within the electronics housing 11 is programmed in such a way that the pump assembly 1 comprises a new pump control system according to the present disclosure.
  • the pump control system of the pump assembly 1 comprises a storage element having stored a plurality of model parameter sets for a plurality of pump speeds, wherein each model parameter set is indicative of an operat- ing value model function corresponding to a pump speed. If the oper- ating value model function is very precise, the pump assembly 1 is able to run at a desired operating point without having a measured or esti- mated flow value.
  • the operating value could be the ac- tual power consumption of the pump assembly or a current drawn by the motor drive of the pump assembly 1.
  • an oper- ating value may be an output pressure measured by a pressure sensor.
  • the advantage of considering an actual power consumption or a mo- tor current as the modelled operating value is that these are readily available without a need for a pressure sensor.
  • the pump control system of the pump assembly 1 further com- prises control electronics configured to command the pump to run at a set pump speed based on the operating value model function corre- sponding to the set pump speed, wherein a corresponding model pa- rameter set of the stored model parameter sets is retrieved from the storage element.
  • the initial model parameter sets stored in the storage element when a new pump assembly 1 is commissioned may be de- termined for a pump type in laboratory tests or field tests using certain fitting and modelling procedures.
  • Figure 2 shows a result of such a fitting or modelling procedure to determine model parameter sets being indicative of operating value model functions.
  • the operating value is the power consumption P of the pump assembly 1, so that figure 2 shows a Pq-diagram, wherein the power consumption P of the pump assembly 1 is shown in dependence of the pumped flow q.
  • Figure 2 shows so-called “power curves” for twelve different pump speeds ⁇ 1 to ⁇ 12. There are numerous ways to fit the “power curve” to the data points as shown in figure 2.
  • Figure 2 actually shows two different model functions, wherein model function #2 is a fine-tuning of the model func- tion #1.
  • the model function may, for example, be a polynomial func- tion.
  • the model function may be described by a model parameter set that is initially determined by a simulation or a fitting procedure under laboratory or field test conditions.
  • Figure 3 shows how the power consumption model function P ⁇ (q) of figure 2 fits to four different pumps of the same pump type. As can be seen, manufacturing tolerances may lead to significant devia- tions between the data points and the model function P ⁇ (q). Such de- viations may also be due to pump variants of the same pump type or wear and tear after a certain amount of operating hours.
  • Figure 4 illustrates how a model function P ⁇ (q) is automatically updated or calibrated for each individual pump assembly 1 during normal operation of the pump assembly 1 in order to reduce the devia- tions between the true current pump characteristic and the assumed modelled pump characteristic.
  • Figure 4 shows a power curve for a sin- gle pump speed over a predetermined range of flows between a min- imum flow q min and a maximum flow q max .
  • the power curve in figure 4 has a well-defined minimum P min and a well-defined maximum P max .
  • Figure 4 shows three different operating areas A, B and C.
  • Operating area A includes all operating points with a power consumption below the minimum P min of the power consumption model function P ⁇ (q).
  • the operating area B includes all operating points with a power consump- tion between P min and P max .
  • Operating area C includes all operating points with a power consumption above the maximum P max of the power consumption model function P ⁇ (q).
  • the idea to improve the model function is now to lower the model function if the actual current- ly determined power consumption P is in the operating area A, i.e. be- low the minimum P min of the model function for the currently set pump speed ⁇ .
  • the rationale is here that the deviation between the actual determined power consumption P and the model function P ⁇ (q) can- not be due to the uncertainty in flow.
  • the model function is raised if the actual currently determined power consumption P is in the operating area C, i.e. above the maximum P max of the model func- tion P ⁇ (q).
  • the same rationale applies here that such a deviation can- not be explained by an uncertainty in flow.
  • the actual currently determined power consumption is in the operating area B, i.e.
  • FIG. 5 shows the applied method for controlling the pump as- sembly 1 in a flow diagram.
  • the pump is run at a set pump speed ⁇ based on an operating value model function P ⁇ (q) cor- responding to the currently stored model parameter sets.
  • an actual power consumption P of the pump assembly 1 is determined.
  • the actual power consumption P is then compared in fol- lowing steps 505a, b with the minimum P min of the power consumption model function P ⁇ (q) and/or with the maximum P max of the power con- sumption model function P ⁇ (q).
  • the compari- sons 505a,b could be performed in parallel or subsequently, wherein one comparison is obsolete if the other one is affirmative. However, both comparisons 505a,b are performed if the first one of the compari- sons is negative. If comparison 505a is affirmative, i.e.
  • the mod- el function P ⁇ (q) is lowered (step 507a) and new model parameter sets for the new lowered power consumption model function P ⁇ ,down (q) is stored at the storage element in order to subsequently run the pump based on the new lower power consumption model function P ⁇ ,down (q).
  • comparison 505b is affirmative, i.e. P > P max
  • the power consumption model function P ⁇ (q) is raised (step 507b) to a new higher power consumption model function P ⁇ ,up (q).
  • a new parameter set model parameter set indicative for the new higher power consumption model function P ⁇ ,down (q) is stored in the storage element in order to subsequently run the pump based on the new higher power consump- tion model function P ⁇ ,up (q). Only in case that both comparisons 505a and 505b are negative, i.e. the currently determined actual power consumption P is in the operating area B, i.e. between P min and P max , the power consumption model function P ⁇ (q) may remain unamended (step 509) for the time being.
  • Figure 6 shows further steps that could be manually triggered in case the pump assembly 1 is running in the operating area B of figure 4, i.e.
  • step 601 the pump assembly 1 could be run in a set of calibration batch runs at different speeds. Thereby, a larger part of the operating range can be scanned for deviations between the actual power con- sumption P and the power consumption model function P ⁇ (q).
  • step 603 a minimum actual power consumption P batch,min and/or a maximum actual power consumption P batch,max among the calibration batch runs is determined.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Positive-Displacement Pumps (AREA)

Abstract

La présente divulgation concerne un procédé de commande d'une pompe, le procédé comprenant les étapes suivantes consistant à : - faire fonctionner (501) une pompe à une vitesse de pompe définie (ω) sur la base d'une fonction de modèle de valeur de fonctionnement (Pω(q)) correspondant à la vitesse de pompe définie (ω) ; - déterminer (503) une valeur de fonctionnement réelle (P) à la vitesse de pompe définie (ω) ; - comparer (505a, 505b) la valeur de fonctionnement réelle (P) avec un maximum (Pmax) de la fonction de modèle de valeur de fonctionnement (Pω(q)) et/ou un minimum (Pmin) de la fonction de modèle de valeur de fonctionnement (Pω(q)) ; et - mettre à jour automatiquement (507b) la fonction de modèle de valeur de fonctionnement (Pω(q)) selon une nouvelle fonction de modèle de valeur de fonctionnement supérieure (Pω ,up(q)) si la valeur de fonctionnement réelle (P) est supérieure au maximum (Pmax) de la fonction de modèle de valeur de fonctionnement (Pω(q)), et/ou mettre à jour automatiquement (507a) la fonction de modèle de valeur de fonctionnement (Pω(q)) selon une nouvelle fonction de modèle de valeur de fonctionnement inférieure (Pω,down(q)) si la valeur de fonctionnement réelle (P) est inférieure au minimum (Pmin) de la fonction de modèle de valeur de fonctionnement (Pω(q)).
PCT/EP2023/073929 2022-09-13 2023-08-31 Système de commande de pompe et procédé de commande d'une pompe à étalonnage automatique de modèle de pompe WO2024056395A1 (fr)

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Citations (7)

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Publication number Priority date Publication date Assignee Title
JPS54203A (en) * 1977-06-03 1979-01-05 Hitachi Ltd Automatic chacteristic-curve correction type fluid conveyor system operation control method
DE102008027039B4 (de) * 2008-06-06 2011-04-14 Air-Regloplas Gmbh Temperiergerät mit Durchflussmessung
US7945411B2 (en) 2006-03-08 2011-05-17 Itt Manufacturing Enterprises, Inc Method for determining pump flow without the use of traditional sensors
US20140199183A1 (en) * 2014-03-27 2014-07-17 Smart Water Metering Inc. Method and device for measuring and controlling amount of liquid pumped
DE102009050083B4 (de) 2009-10-20 2016-08-18 Viessmann Werke Gmbh & Co Kg Verfahren zur Bestimmung eines Volumenstroms in einer mit einer Strömungsmaschine und mit einer Regelungseinheit versehenen, geschlossenen Strömungsanlage
US9897084B2 (en) 2013-07-25 2018-02-20 Fluid Handling Llc Sensorless adaptive pump control with self-calibration apparatus for hydronic pumping system
US20190187640A1 (en) * 2017-12-20 2019-06-20 Siemens Aktiengesellschaft Digital twin of centrifugal pump in pumping systems

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS54203A (en) * 1977-06-03 1979-01-05 Hitachi Ltd Automatic chacteristic-curve correction type fluid conveyor system operation control method
US7945411B2 (en) 2006-03-08 2011-05-17 Itt Manufacturing Enterprises, Inc Method for determining pump flow without the use of traditional sensors
DE102008027039B4 (de) * 2008-06-06 2011-04-14 Air-Regloplas Gmbh Temperiergerät mit Durchflussmessung
DE102009050083B4 (de) 2009-10-20 2016-08-18 Viessmann Werke Gmbh & Co Kg Verfahren zur Bestimmung eines Volumenstroms in einer mit einer Strömungsmaschine und mit einer Regelungseinheit versehenen, geschlossenen Strömungsanlage
US9897084B2 (en) 2013-07-25 2018-02-20 Fluid Handling Llc Sensorless adaptive pump control with self-calibration apparatus for hydronic pumping system
US20140199183A1 (en) * 2014-03-27 2014-07-17 Smart Water Metering Inc. Method and device for measuring and controlling amount of liquid pumped
US9470217B2 (en) 2014-03-27 2016-10-18 Mohsen Taravat Method and device for measuring and controlling amount of liquid pumped
US20190187640A1 (en) * 2017-12-20 2019-06-20 Siemens Aktiengesellschaft Digital twin of centrifugal pump in pumping systems

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