Lubrication and flushing of fluid seals used with reactive materials

Abstract

A pump system includes a housing, a lubricant system, and a control circuit. The housing includes a throat seal and a pump chamber defined by the housing. The lubricant system includes a lubricant pump, a lubricant passage defined within the housing of the main pump, and a lubricant circuit fluidly connecting the lubricant pump and the lubricant passage. The throat seal is disposed proximate to and between the pump chamber and the lubricant passage. The control circuit is configured to cause the lubricant pump to pump a purge volume of lubricant through the lubricant system, cause the lubricant pump to stop pumping for a first period of time after the lubricant pump has pumped the purge volume, and cause the lubricant pump to pump the purge volume of lubricant through the lubricant system after the first period of time.

Description

Technical Field

[0001] This disclosure relates to pump lubrication systems, and more specifically to control systems for pump lubrication systems. Background Technology

[0002] Positive displacement pumps (such as reciprocating pumps) are typically equipped with seals to reduce leakage from the pump chamber to the piston rod, protecting the piston rod and other pump components from deterioration or corrosion. To improve seal life, the pump may include lubricant passages to store lubricant for lubricating the seal. The lubricant held in the lubricant passages can be used to lubricate the seal during pump operation, reducing seal wear and thus extending seal life. The lubricant held in the lubricant passages may become contaminated by fluids in the pump chamber. Contaminated lubricant can be circulated outside the lubricant passages and replaced with fresh lubricant, thereby extending seal life. Summary of the Invention

[0003] According to one aspect of this disclosure, a pump system includes a housing, a lubricant system, and control circuitry. The housing includes a throat seal and a pump chamber defined by the housing. The lubricant system includes a lubricant pump, a lubricant passage defined within the housing of a main pump, and a lubricant circuit fluidly connecting the lubricant pump and the lubricant passage. The throat seal is disposed near and between the pump chamber and the lubricant passage. The control circuitry is configured to cause the lubricant pump to pump a cleaning volume of lubricant through the lubricant system, to stop pumping the lubricant pump after it has pumped a cleaning volume for a first time period, and to cause the lubricant pump to pump a cleaning volume of lubricant through the lubricant system after the first time period.

[0004] According to another aspect of this disclosure, a pump control system includes control circuitry and a main pump configured to pump fluid. The main pump includes a housing, a throat seal, and a pump chamber defined by the housing. The control circuitry is configured to: cause the main pump to pump fluid through the pump chamber; cause a lubricant pump to pump a cleaning volume of lubricant through a lubricant system; cause the lubricant pump to stop pumping for a first time period after it has pumped a cleaning volume; and cause the lubricant pump to pump a cleaning volume of lubricant through the lubricant system after the first time period. The lubricant system includes: a lubricant pump; a lubricant passage defined by the housing; and a lubricant circuit fluidly connecting the lubricant pump and the lubricant passage. The throat seal is disposed near the pump chamber and the lubricant passage, and between the pump chamber and the lubricant passage.

[0005] According to another aspect of this disclosure, a method of controlling a pump system includes: operating a lubricant pump to pump a cleaning volume of lubricant through a lubricant system; stopping the operation of the lubricant pump for a first time period after the lubricant pump has pumped the cleaning volume; and operating the lubricant pump after the first time period to pump a second cleaning volume of lubricant through the lubricant system. The lubricant system includes: a lubricant pump, a lubricant passage defined by a main pump housing, and a lubricant circuit fluidly connecting the lubricant pump and the lubricant passage. The main pump includes a throat seal and a pump chamber defined by a housing, the throat seal being disposed near the pump chamber and the lubricant passage and between the pump chamber and the lubricant passage.

[0006] The present invention also discloses the following aspects:

[0007] 1. A pump system, comprising:

[0008] A main pump, configured to pump fluid, comprising:

[0009] case;

[0010] The pump chamber defined by the housing; and

[0011] Throat seal;

[0012] Lubricant system, including:

[0013] Lubricant pump;

[0014] Lubricant passages defined within the housing of the main pump; and

[0015] A lubricant circuit that fluidly connects the lubricant pump and the lubricant passage.

[0016] Wherein, the throat seal is disposed near the pump chamber and the lubricant passage and between the pump chamber and the lubricant passage; and

[0017] Control circuit, the control circuit being configured to:

[0018] The lubricant pump delivers a cleaning volume of lubricant through the lubricant system;

[0019] After the lubricant pump has pumped the cleaning volume, the lubricant pump is stopped for a first time period; and

[0020] After the first time period, the lubricant pump pumps the cleaning volume of lubricant through the lubricant system.

[0021] 2. The pump system according to aspect 1, wherein the main pump is configured to pump a compound that reacts with water.

[0022] 3. The pump system according to aspect 1, wherein the lubricant system further includes a lubricant reservoir fluidly connected to the lubricant pump and the lubricant passage, such that operation of the lubricant pump causes lubricant to flow from the lubricant reservoir to the lubricant pump, from the lubricant pump to the lubricant passage, and from the lubricant passage to the lubricant reservoir.

[0023] 4. The pump system according to any one of aspects 1-3, wherein the cleaning volume is equal to the volume of the lubricant system.

[0024] 5. The pump system according to any one of aspects 1-3, wherein the first time period is selected to reduce lubricant pump wear.

[0025] 6. The pump system according to any one of aspects 1-3, wherein the first time period is 30 minutes.

[0026] 7. The pump system according to any one of aspects 1-3, wherein the lubricant pump is a peristaltic pump.

[0027] 8. The pump system according to any one of aspects 1-3, wherein the main pump is a reciprocating pump.

[0028] 9. The pump system according to any one of aspects 1-3, wherein the control circuit is configured to: pump the cleaning volume by operating the lubricant pump for a cleaning time, wherein the cleaning time is selected based on the flow rate of the lubricant pump.

[0029] 10. A pump control system, comprising:

[0030] A main pump, configured to pump fluid, comprising:

[0031] case;

[0032] The pump chamber defined by the housing; and

[0033] Throat seal;

[0034] Control circuit, the control circuit being configured to:

[0035] The main pump pumps fluid through the pump chamber;

[0036] A lubricant pump delivers a cleaning volume of lubricant through a lubricant system, wherein the lubricant system comprises:

[0037] The lubricant pump;

[0038] The lubricant channel defined by the housing; and

[0039] A lubricant circuit that fluidly connects the lubricant pump and the lubricant passage.

[0040] The throat seal is located near the pump chamber and the lubricant passage, and between the pump chamber and the lubricant passage;

[0041] After the lubricant pump has pumped the cleaning volume, the lubricant pump is stopped for a first time period; and

[0042] After the first time period, the lubricant pump pumps the cleaning volume of lubricant through the lubricant system.

[0043] 11. The pump control system according to aspect 10, wherein the cleaning volume is equal to the volume of the lubricant system.

[0044] 12. The pump control system according to aspect 10, wherein the first time period is selected to reduce lubricant pump wear.

[0045] 13. The pump control system according to any one of aspects 10-12, wherein the control circuit is further configured to:

[0046] The lubricant pump delivers lubricant at a first rate; and

[0047] The main pump is made to pump fluid at a second rate, wherein the first rate and the second rate are different.

[0048] 14. A method for controlling a pump system, the method comprising:

[0049] The lubricant pump is operated to pump a cleaning volume of lubricant through a lubricant system, wherein the lubricant system comprises:

[0050] The lubricant pump;

[0051] A lubricant passage defined by the housing of the main pump, the main pump comprising:

[0052] The pump chamber defined by the housing; and

[0053] A throat seal, wherein the throat seal is disposed near the pump chamber and the lubricant passage and between the pump chamber and the lubricant passage; and

[0054] A lubricant circuit that fluidly connects the lubricant pump and the lubricant passage;

[0055] After the lubricant pump has pumped the cleaning volume, the operation of the lubricant pump is stopped for a first time period; and

[0056] After the first time period, the lubricant pump is operated to pump a second cleaning volume of lubricant through the lubricant system.

[0057] 15. The method according to aspect 14, wherein operating the lubricant pump to pump a cleaning volume of lubricant through the lubricant system comprises: operating the lubricant pump for a cleaning time, wherein the cleaning time is selected based on the flow rate of the lubricant pump.

[0058] 16. The method according to aspect 14, wherein the cleaning volume is equal to the volume of the lubricant system.

[0059] 17. The method according to any one of aspects 14-16, further comprising: switching the lubricant pump to an idle mode after pumping the second cleaning volume.

[0060] 18. The method according to any one of aspects 14-16, wherein the first time period is selected to reduce wear on the lubricant pump.

[0061] 19. The method according to any one of aspects 14-16, wherein the main pump is configured to pump a compound that reacts with water. Attached Figure Description

[0062] Figure 1 This is a schematic cross-sectional view of an example of a lubricant system.

[0063] Figure 2 This is a schematic cross-sectional view of another example of a lubricant system.

[0064] Figure 3 This is a perspective view of an example of a proportional system.

[0065] Figure 4 It is used for control Figure 2 A schematic diagram illustrating an example of a control system for the operation of a lubricant system.

[0066] Figure 5 It is used for control Figure 2 A schematic diagram of another example of a control system for the operation of a lubricant system depicted in the diagram.

[0067] Figure 6 It is used for operation Figures 4-5 A diagram illustrating an example of a schedule for a control system.

[0068] Figure 7 It is an operation Figure 2 A flowchart illustrating an example of a method for a lubricant system. Detailed Implementation

[0069] This disclosure includes a lubricant system for a throat seal of a fluid pump. This disclosure also includes a control system for controlling the operation of the lubricant system and the fluid pump disclosed herein. The lubricant system and control system disclosed herein reduce undesirable agitation of the lubricant while ensuring sufficient lubricant flow to the throat seal of the fluid pump.

[0070] Figure 1 This is a cross-sectional view of a lubricant system 10, which is a prior art system for pumping lubricant. The lubricant system 10 is a closed lubrication system and includes a main pump 12, lubricant lines 14A and 14B, and a lubricant reservoir 16. The pump 12 is a reciprocating pump and includes a pump housing 18, a piston 20, a rod 22, a throat seal 24, and an attachment point 26. The pump housing 18 defines a pump chamber 28, a lubricant passage 30, and an inlet 32 ​​and an outlet 34. The lubricant passage 30 includes a first end 36 and a second end 38. The lubricant reservoir 16 includes check valves 40A and 40B.

[0071] The main pump 12 is configured to pump process fluid through pump chamber 28 using the reciprocating motion of piston 20 and rod 22. Rod 22 and piston 20 are disposed within pump housing 18, connected at attachment point 26, and centered on axis PP. In operation, an external motor attached to rod 22 causes piston 20 and rod 22 to reciprocate along pump axis PP, thereby generating fluid flow through pump chamber 28 of main pump 12. The process fluid pumped through pump chamber 28 of main pump 12 is typically a material other than lubricant. As piston 20 and rod 22 reciprocate along axis PP, the difference in diameter between piston 20 and rod 22 causes piston 20 to displace lubricant from lubricant passage 30, thereby generating pumping power. Thus, the reciprocating motion of piston 20 and rod 22 generates pumped process fluid through pump chamber 28 and pumps lubricant through lubricant system 10.

[0072] The lubricant passage 30 is a generally cylindrical chamber defined by the inner surface of the pump housing 18, centered on an axis PP and extending from a first end 36 to a second end 38. The lubricant passage surrounds a portion of the rod 22, a portion of the piston 20, and an attachment point 26. The lubricant passage stores lubricant for lubricating the throat seal 24, thereby preventing damage to the throat seal 24 from the reciprocating motion of the piston 20. The lubricant passage includes a first end 36 and a second end 38, which define the axial ends of the lubricant passage 30. The first end 36 is formed by the pump housing 18, and the second end 38 is formed by the throat seal 24. The piston 20 extends through the first end 36, and the throat seal 24 is disposed near the first end 36. The rod 22 extends through the second end 38, and the throat seal 24 is positioned opposite the second end 38.

[0073] The throat seal 24 is an annular seal centered on the axis PP and surrounding a portion of the piston 20, reducing the flow rate of process fluid pumped by the piston 20 from the pump chamber 28 into the lubricant passage 30. The lubricant passage 30 is an annular chamber centered on the axis PP, which holds the lubricant used to lubricate the throat seal 24. The throat seal 24 reduces, but does not prevent, the flow of process fluid from the pump chamber 28 into the lubricant passage 30. Therefore, during pump 12 operation, process fluid from the pump chamber 28 may migrate through the throat seal 24 and contaminate the lubricant retained in the lubricant passage 30. Lubricant contamination in the lubricant passage 30 may cause deterioration of the throat seal 24, the rod 22, or other components of the pump 12, thus adversely affecting the performance of the pump 12.

[0074] Lubricant reservoir 16 includes check valves 40A and 40B. The size of the lubricant reservoir is typically designed such that the volume of lubricant stored in lubricant reservoir 16 is significantly larger than the volume of lubricant retained in lubricant passage 30. This allows contaminated lubricant in the lubricant passage to be diluted in the lubricant retained in lubricant reservoir 16, thereby delaying the negative effects of lubricant contamination, which will be explained in more detail later.

[0075] Lubricant line 14A fluidly connects lubricant reservoir 16 to inlet 32 ​​of lubricant passage 30, and lubricant line 14B fluidly connects outlet 34 of lubricant passage 30 to lubricant reservoir 16. Therefore, lubricant can flow in a loop from lubricant reservoir 16 through lubricant line 14A and inlet 32 ​​to lubricant passage 30, and from lubricant passage 30 through outlet 34 and lubricant line 14B to lubricant reservoir 16.

[0076] During operation, when piston 20 moves out of lubricant passage 30 (i.e., when attachment point 26 moves toward the first end 36 of lubricant passage 30), lubricant is drawn into lubricant passage 30 from lubricant reservoir 16 through lubricant line 14A. As piston 20 reciprocates and moves into lubricant passage 30 (i.e., when attachment point 26 moves toward the second end 38 of lubricant passage 30), lubricant flows from lubricant passage 30 through lubricant line 14A to lubricant reservoir 16.

[0077] To force directional flow through the lubricant system 10, check valves 40A and 40B are included at the lubricant reservoir 16. Check valve 40A is a one-way valve configured to allow fluid from the lubricant reservoir 16 through lubricant line 14A to inlet 32 ​​and to prevent backflow from inlet 32 ​​of lubricant passage 30 through lubricant line 14A to the lubricant reservoir 16. Similarly, check valve 40B is a one-way valve configured to allow fluid from outlet 34 through lubricant line 14B to the lubricant reservoir 16 and to prevent backflow from the lubricant reservoir 16 through lubricant line 14B to outlet 34. Operation of check valves 40A and 40B causes lubricant to flow through the lubricant system 10 in the direction of arrow 42.

[0078] The effects of contamination in the lubricant channel 30 are reduced by the lubrication circulation of the lubrication system 10, which washes away contaminated lubricant from the throat seal 24 and dilutes it in the lubricant reservoir 16. The volume of lubricant stored in the lubricant reservoir 16 is typically significantly larger than the volume of lubricant held in the lubricant channel 30, such that the circulation of lubricant through the lubricant system 10 dilutes the contaminated lubricant from the lubricant channel 30 within the larger volume of lubricant held in the lubricant reservoir 16, thereby delaying the occurrence of adverse effects caused by lubricant contamination.

[0079] Figure 2 This is a cross-sectional view of a lubricant system 110, which is similar to lubricant system 10 and includes a main pump 112, a lubricant pump 113, lubricant lines 114A-C, a lubricant reservoir 16, and a controller 117. The main pump 112 is substantially the same as pump 113 and includes a pump housing 118, a throat seal 124, and a rod 22. The pump housing 118 defines a pump chamber 128 (e.g., ...). Figure 3 (As shown), lubricant channel 130, inlet 132, and outlet 134. To improve... Figure 2 Clarity, in Figure 2 Piston 20 and attachment point 26 are not shown.

[0080] Unlike lubricant system 10, lubricant system 110 does not use the different areas of piston 20 and rod 22 to pump lubricant through lubricant system 110. Instead, lubricant system 110 uses lubricant pump 113 to pump lubricant, thus separating the flow of lubricant from the pumping action of main pump 112.

[0081] The main pump 112 is configured to pump process fluid through pump chamber 128 using the reciprocating motion of piston 20 and rod 22. In operation, an external motor attached to rod 22 causes piston 20 and rod 22 to reciprocate along pump axis P'-P', generating fluid flow through pump chamber 28 of the main pump 112. The main pump 112 can be used in conjunction with another main pump to pump one component of a multi-component spray coating material, such as... Figure 3 A more detailed discussion follows.

[0082] Lubricant channel 130 is generally similar to lubricant channel 30, as previously discussed. Figure 1 Described. Lubricant channel 130 stores lubricant for lubricating throat seal 124. It is a generally cylindrical chamber defined by the inner surface of pump housing 118 and centered on axis P'-P'. Unlike lubricant channel 30, lubricant channel 130 only surrounds a portion of rod 22. Furthermore, throat seal 124 is generally similar to throat seal 24, as previously described. Figure 1 The description refers to a portion of the rod 22, but not a portion of the piston 20. The throat seal 124 is an annular seal centered on the axis PP, and its function is to reduce the flow of process fluid pumped by the piston 20 from the pump chamber 28 into the lubricant passage 130.

[0083] Since piston 20 does not need to reciprocate through lubricant passage 30 to generate a pumping action through lubricant system 110, the throat seal 124 is positioned around a portion of rod 22 rather than piston 20 to prevent additional, unwanted pumping action that could be generated by the reciprocating motion of piston 20 through lubricant passage 30. Therefore, the flow of lubricant through lubricant system 110 is entirely controlled by the operation of lubricant pump 113, which will be explained in more detail later. Positioning the throat seal 124 around a portion of rod 22 rather than piston 20 also allows lubricant passage 130 to have a smaller volume compared to lubricant passage 30, because the flow of lubricant through lubricant system 110 is driven by a separate lubricant pump 113, rather than by the displacement of lubricant in lubricant passage 130 by piston 20.

[0084] Lubricant line 114A is fluidly connected to lubricant reservoir 16 and lubricant pump; lubricant line 114B is fluidly connected to lubricant pump 113 and inlet 132 of lubricant channel 130; and lubricant line 114C is fluidly connected to outlet 34 of lubricant channel 130 and lubricant reservoir. Therefore, lubricant can flow in the loop from lubricant reservoir 16 through lubricant line 114A to lubricant pump 113, from lubricant pump 113 through lubricant line 114B and inlet 132 to lubricant channel 130, and from lubricant channel 130 through outlet 134 and lubricant line 114C to lubricant reservoir 16.

[0085] Lubricant pump 113 generates a pumping action and causes lubricant to flow from lubricant reservoir 16 to lubricant passage 130 and from lubricant passage 130 back to lubricant reservoir 16. In the depicted example, lubricant pump 113 is a peristaltic pump and is suitable to be driven by a fixed-speed electric motor. However, lubricant pump 113 can be any suitable pump used for pumping fluid through lubricant system 110. Similarly, lubricant pump 113 can also be driven by a variable-speed motor. Advantageously, including a separate lubricant pump 113 allows for control of lubricant flow independent of the operation of the main pump 12.

[0086] The operation of lubricant pump 113 is controlled by controller 117, which can be used to start, stop, or regulate the operation of lubricant pump 113 and the flow rate of lubricant required for a given application. Controller 117 can also be used to detect fault conditions and determine maintenance cycles based on the use of lubricant pump 113. Controller 117 can be connected to one or more temperature sensors (not shown) located at one or more locations in lubricant system 110 and can be configured to monitor the temperature of the lubricant while lubricant pump 113 is pumping lubricant. Similarly, controller 117 can be connected to one or more pressure sensors (not shown) located at one or more locations in lubricant system 110 and can be configured to monitor the pressure of the lubricant while lubricant pump 113 is pumping lubricant. Controller 117 can be further configured to detect leaks or blockages within lubricant system 110 based on measured pressure and to warn the operator when there is a leak in lubricant system 110 or when process fluid leaking from pump chamber 128 has caused a blockage. For example, controller 117 can be configured to compare the measured pressure with a baseline or reference pressure to determine whether there is a leak or blockage in the lubricant system 110.

[0087] The operation of the main pump 112 allows process fluid to flow through the pump chamber 128 without affecting the flow of lubricant through the lubricant passage 130. The operation of the lubricant pump 113 allows lubricant to flow from the lubricant reservoir through lubricant line 114A to the lubricant pump 113, from the lubricant pump 113 through lubricant line 114B to the inlet 132 of the lubricant passage 130, and from the outlet 134 of the lubricant passage through lubricant line 114C to the lubricant reservoir 16. To this extent, the operation of the lubricant pump 113 allows contaminated lubricant to be diluted from the lubricant passage 130 into the lubricant reservoir.

[0088] In the lubricant system 110, the operation of the lubricant pump 113 forces directional flow. To this extent, the lubricant system 110 does not require check valves 40A and 40B. Check valves 40A and 40B may fail during operation of the lubricant system 10, allowing backflow through the lubricant system 10. To this extent, the use of the lubricant pump 113 improves the reliability of the lubricant system 110 compared to conventional systems, such as the lubricant system 10 that relies on check valves to generate directional flow.

[0089] Although the lubricant system 110 has been discussed in relation to a lubricant pump for throat seals, the lubricant system 110 can be applied to any pump or valve seal. Similarly, the lubricant system 110 is not limited to seals of reciprocating or positive displacement pumps, and can be adapted to provide lubrication for seals of any pump system.

[0090] Lubricant system 110 provides superior performance compared to previous systems. Figure 1 The lubricant system 10 described has many advantages. In particular, the lubricant system 110 is decoupled and allows independent control of the flow of process fluid through pump chamber 128 and the flow of lubricant through lubricant passage 130. Independent control of lubricant pump 113 allows for pumping lubricant, for example, when main pump 112 is not in operation. Compared to conventional systems, lubricant system 110 thus allows for finer adjustment and more granular control of lubricant flow rate.

[0091] Figure 3 This is a perspective view of a proportioner system 200, which is an example of a multi-component dispensing system. The proportioner system 200 includes a lubricant system 110, which includes (a main pump 112, a lubricant pump 113, lubricant lines 114A-C, a lubricant reservoir 16, and a controller 117), a main pump 212, and a proportioner housing 218.

[0092] Main pump 212 has substantially the same components as main pump 112 and operates in substantially the same manner. In proportioner system 200, main pumps 112 and 212 are located on opposite sides of proportioner housing 218 and are configured to pump a first component material and a second component material, respectively. Main pumps 112 and 212 pump the first component material and the second component material, respectively, to an applicator (not shown) to form a sprayed material. Furthermore, main pumps 112 and 212 increase the pressure of the first component material and the second component material to the spray pressure, respectively. The first and second components are different materials selected to be combined to form a multi-component sprayed material with desired material properties, such as sprayed foam. Typically, mixing the first and second components causes a reaction that forms a multi-component sprayed material that can be sprayed by the applicator. The first and second components are mixed at the applicator, rather than upstream of proportioner system 200, to prevent undesirable reactions that could damage components of proportioner system 200.

[0093] The first component material can be a catalyst, such as isocyanate, and the second component material can be a resin material, such as polyol resin. In the example where isocyanate and polyol resin are used as the first and second component materials, respectively, the multi-component spraying material is polyurethane foam. Depending on the application requirements, other components can be used as the resin material. For example, for some applications, the resin material can be urethane or silicone resin. Similarly, other catalyst materials can be selected according to the application requirements.

[0094] Main pumps 112 and 212 receive a first component material and a second component material, respectively, from feed pumps that pump the first and second component materials from reservoirs (not shown) for each component. Main pumps 112 and 212 are mechanically connected such that the ratio of the first and second component materials is constant. Main pumps 112 and 212 can be driven by separate motors, or both can be driven by a single motor. Figure 3 In this design, both main pump 112 and main pump 212 are described as reciprocating pumps, but main pumps 112 and 212 can be any suitable type of pump used for distributing fluid component materials.

[0095] In the proportional system 200, the controller 117 also controls the operation of the main pump 112 and the main pump 212. The controller 117 may be further configured to measure and control the temperature and / or pressure of the first component material, the second component material, or the spraying material.

[0096] In the depicted example, the lubricant pump 113 and the lubricant reservoir 16 are arranged adjacent to each other and attached to the exterior of the proportioner housing 218 above the main pump 112. In other examples, the lubricant pump 113 and the lubricant reservoir 16 may be located at other positions on the proportioner housing 218, or may be located in other suitable positions such that the lubricant pump 113 and / or the lubricant reservoir 16 are not attached to the proportioner housing 218. The controller 117 is in Figure 3 The controller 117 is depicted as being mounted within the proportionalizer housing 218. In other examples, the controller 117 may be located in other locations, including external to the proportionalizer housing 218. Other components for operating the proportionalizer system 200 may also be located within the proportionalizer housing 218. For example, one or more motors for driving the operation of the main pumps 112 and 212 may be located within the proportionalizer housing 218.

[0097] Advantageously, the proportioner system 200 allows the reactive component materials to be pumped individually and combined downstream of the main pumps 112 and 212 to form a multi-component spray material. To this extent, the proportioner system 200 allows control of the ratio, temperature, and pressure of the fluid components pumped by the main pumps 112 and 212. Since the proportioner system 200 includes a lubricant system 110, the proportioner system 200 also has the previously mentioned... Figure 2 The advantages of the discussion are summarized below.

[0098] Figure 4 This is a schematic diagram of the control system 400, which includes a controller 117, a lubricant pump 113, a lubricant reservoir 16, lubricant lines 114A-C, and a main pump 112. The controller 117 includes a control circuit 420, a memory 424, and a user interface 428.

[0099] Control circuitry 420 is configured to control the operation of lubricant pump 113 and main pump 112 by executing instructions stored in memory 424. Control circuitry 420 may include one or more of a microprocessor, controller, digital signal processor (DSP), application-specific integrated circuit (ASIC), field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry. Control circuitry 420 may be wholly or partially mounted on one or more boards. Control circuitry 420 may be of any type suitable for operation according to the techniques described herein. In some examples, control circuitry 420 may be implemented as multiple discrete circuit sub-components.

[0100] Memory 424 is configured to store instructions and / or programs executable by control circuitry 420 for controlling the operation of main pump 112 and lubricant pump 113, including selective operation of either main pump 112 or lubricant pump 113. In some examples, memory 424 may be described as a computer-readable storage medium. In some examples, the computer-readable storage medium may include a non-transitory medium. The term "non-transitory" may mean that the storage medium does not embody a carrier wave or propagating signal. In some examples, the non-transitory storage medium may store data that can change over time (e.g., in RAM or cache). In some examples, memory 424 may include temporary memory, meaning that the primary purpose of the computer-readable memory is not long-term storage. In some examples, memory 424 may be described as volatile memory, meaning that the memory does not retain its stored contents when power to the controller is removed. Examples of volatile memory may include random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), and other forms of volatile memory. In some examples, memory 424 may be used to store program instructions for execution by one or more processors of the controller. For example, memory 424 may be used by software or an application executed by control circuitry 420 to temporarily store information during program execution. In some examples, memory 424 includes a non-volatile storage element. Examples of such a non-volatile storage element may include magnetic hard disks, optical disks, floppy disks, flash memory, or electrically programmable memory (EPROM) or electrically erasable programmable memory (EEPROM).

[0101] An operator can interact with controller 117 via user interface 428 to control the operation of main pump 112 and / or lubricant pump 113. User interface 428 can be an input / output device configured to provide and / or receive information from the operator. User interface 428 can be any form that enables the operator to interact with control circuitry 420. For example, control system 400 can implement a graphical user interface displayed on a display device of user interface 428 for presenting information to and / or receiving input from the operator. User interface 428 may include graphical navigation and control elements, such as graphical buttons or other graphical control elements presented on a display device. In some examples, user interface 428 includes physical navigation and control elements, such as physically actuated buttons or other physical navigation and control elements.

[0102] User interface 428 can be used to manually control the operation of main pump 112 and / or lubricant pump 113. Controller 117 can also be configured to automatically cause lubricant pump 113 to flow lubricant through lubricant system 110. Memory 424 can be encoded with instructions that allow controller 117 to automatically control the operation of main pump 112 and / or lubricant pump 113.

[0103] In some examples, controller 117 is two separate controllers, each controlling one of the main pump 112 and lubricant pump 113. Figure 5 This is a schematic diagram of control system 450. Although control system 450 is generally similar to control system 400 and includes the same components, it also includes a separate controller 467 for controlling the operation of lubricant pump 113. Controller 467 can perform essentially the same functions as controller 117 and includes control circuitry 470, memory 474, and user interface 478, which are generally similar to those described above. Figure 4 The control circuit 420, memory 424, and user interface 428 are described.

[0104] In control system 450, controller 117 controls only the operation of main pump 112. Similarly, controller 467 controls only the operation of lubricant pump 113. Using separate controllers 117 and 467 to control lubricant pump 113 and main pump 12 allows lubrication system 110 to be installed on existing pumping systems without reconfiguring the controller operating the main pump, thus allowing lubrication system 110 to be used on a variety of existing pumping systems. In some of these examples, controller 467 lacks memory 474 and control circuitry 470 is a timer circuit lacking a microprocessor. Using a simple timing circuit to control the operation of the lubricant pump reduces the costs associated with installing lubrication system 110 on existing equipment. In these examples, user interface 478 may be one or more physical switches, buttons, knobs, or dials.

[0105] The control system 400 has been described with reference to lubrication system 110 and pump 112. However, it should be understood that control system 400 or 450 can also be used to control the operation of other fluid pump systems not described herein.

[0106] Advantageously, both control systems 400 and 450 allow independent control of the main pump 112 and the lubricant pump 113', thus enabling independent control of the main pump 112 and the lubricant pump 113'. Furthermore, control systems 400 and 450 allow control of the main pump 112 and the lubricant pump 113 via operator input at user interfaces 428 and 478, via pre-programmed instructions stored in memories 424 and 474, or via a combination of operator input and pre-programmed instructions.

[0107] As previously mentioned Figure 3 As described, main pump 112 can pump a catalyst that reacts with a resin material pumped by main pump 212 to form a multi-component spray foam. Some catalyst materials are moisture-sensitive and can form crystals, particles, and other hard byproducts when exposed to moisture. For example, isocyanates are known to form hard crystalline byproducts when exposed to moisture. Although the lubricant circulating through lubricant system 110 is typically an oil or another hydrocarbon, sufficient moisture may be present in the lubricant to cause moisture-sensitive materials flowing through throat seal 124 into lubricant passage 130 to form hard byproducts.

[0108] Hard byproducts formed from moisture-sensitive materials can damage throat seal 124 and other components of main pump 112. Operation of lubricant pump 113 removes hard byproducts and moisture-sensitive materials from lubricant passage 130 and dilutes them in lubricant reservoir 16. However, operation of lubricant pump 113 also agitates the lubricant flowing through lubricant system 110, introducing air into the lubricant. Moisture in the air can accelerate the rate at which moisture-sensitive materials form hard, harmful byproducts.

[0109] Advantageously, the lubricant pump 113 can be operated intermittently to remove moisture-sensitive material from the lubricant channel 130 while reducing the agitation of the lubricant, thereby reducing the rate at which moisture-sensitive material suspended in the lubricant forms undesirable hard byproducts. Figure 6 This is a schematic diagram of a pump operation schedule 500, which control circuits 420 and 470 can use to minimize the formation of unwanted hard byproducts by intermittently operating the lubricant pump 113. The pump operation schedule 500 includes bars 510, 520, 530, and a time axis 540.

[0110] Pump operation schedule 500 describes the operation schedule of the main pump 112 and the lubricant pump 113 of the proportioner system 200. Specifically, bar 510 indicates the time the proportioner system 200 is energized, bar 520 indicates the operation time of the main pump 112, and bar 530 indicates the operation time of the lubricant pump 113. The lengths of bars 510, 520, and 530 along the time axis 540 represent the relative operation times of the proportioner system 200, the main pump 112, and the lubricant pump 113, respectively. As shown in bar 520, the main pump 112 has a continuous operation period. Conversely, bar 530 shows that the lubricant pump 113 has several intermittent operation periods.

[0111] The length of the operating period of lubricant pump 113 (as indicated by bar 530) is the length of time required for lubricant pump 113 to pump a cleaning volume of lubricant at a given pump rate. The cleaning volume is equal to the volume of lubricant channel 130, inlet 132, outlet 134, and lubricant line 114B, such that the pumped cleaning volume completely replaces the contaminated lubricant in lubricant channel 130 with fresh lubricant from lubricant reservoir 16. Advantageously, operating lubricant pump 113 only for the time required to pump a cleaning volume of lubricant minimizes agitation of the lubricant in lubricant channel 130 while still allowing lubricant pump 113 to completely flush contaminated lubricant out of lubricant channel 130. However, in other examples, the operating period of lubricant pump 113 can be long enough that lubricant pump 113 can pump multiple cleaning volumes of lubricant during the operating period. For example, the operating period of lubricant pump 113 can be selected such that lubricant pump 113 pumps 1.5, 2, or 3 cleaning volumes during the operating period.

[0112] Between operating periods, the lubricant pump 113 is inactive. The length of the inactive period between operating periods is chosen such that the lubricant pump 113 operates frequently enough to reduce the accumulation of unwanted contaminants in the lubricant channels, and infrequently enough to minimize lubricant agitation, thereby preventing the formation of unwanted hard byproducts. To this extent, the length of the inactive period depends on the flow rate of the first component material through the throat seal 124 and the formation rate of unwanted hard byproducts in the lubricant channels 130, as well as other relevant parameters. If the first component material is isocyanate, the length of the inactive period may be, for example, 30 minutes. The length of the inactive period may be constant or may vary based on operational needs.

[0113] exist Figure 6 In the example of the pump operation schedule 500 shown, lubricant pump 113 is active during an operation period prior to the operation of main pump 112. This initial operation period serves as an initial cleaning of the lubricant passage 130 and removes contaminant particles (e.g., dust, first component material, etc.) that have accumulated in the lubricant passage 130 while the proportioner system 200 is inactive. While main pump 112 is operating, lubricant pump 113 operates intermittently during operation periods offset from the inactive periods. After main pump 112 has stopped operating, lubricant pump 113 is active during another operation period before the proportioner system 200 is de-energized. This final operation period serves as a final cleaning of the lubricant passage 130 before the proportioner system 200 is set to an inactive state.

[0114] The operation schedule 500 can be pre-programmed and stored in memories 424, 474 for use by control circuits 420, 470. Alternatively, control circuits 420, 470 can be configured to automatically create the operation schedule 500 during operation of the proportional system 200 based on the volume of the lubricant channel, pump rate, desired length of inactive periods, and operator or application preferences for initial and final lubricant cleaning.

[0115] An operator can interact with user interfaces 428, 478 to program or adjust one or more elements of the operation schedule 500. Control circuits 420, 470 can be configured to automatically adjust other elements of the operation schedule 500 based on operator input. For example, control circuits 420, 470 can be configured to automatically cause lubricant pump 113 to perform an initial cleaning of lubricant passage 130 after the proportional system 200 is powered on. Control circuits 420, 470 can be configured to idle main pump 112 and lubricant pump 113 until an operator input instructing main pump 112 to operate is received at user interface 428. Then, control circuits 420, 470 can operate main pump 112 and lubricant pump 113 according to the operation schedule 500 until an input instructing main pump 112 to idle is received at user interface 428. Then, control circuits 420, 470 can automatically cause lubricant pump 113 to perform a final cleaning of lubricant passage 130 before the proportional system 200 is powered off.

[0116] The operation schedule 500 offers significant advantages. Specifically, control circuits 420 and 470 can use the operation schedule 500 to operate the lubricant pump 113 intermittently. As described above, intermittent operation of the lubricant pump 113 allows for optimal reduction of both lubricant agitation and contaminant buildup in the lubricant passage 130. Reducing lubricant agitation is particularly advantageous when using the main pump 112 to pump moisture-sensitive materials such as isocyanates. Control circuits 420 and 470 can further utilize the operation schedule 500 to perform an initial lubricant flushing of the lubricant pump 113 before the main pump 112 operates and a final lubricant flushing after the main pump 112 is idle.

[0117] Figure 7 This is a flowchart depicting method 600, which can be used to intermittently operate lubricant pump 113. Method 600 has successive steps 602-612, including: pumping an initial cleaning volume of lubricant using the lubricant pump (step 602), pumping process fluid using the main pump (step 604), pumping a cleaning volume of lubricant using the lubricant pump (step 606), allowing the lubricant pump to idle for an inactive period of time (step 608), determining whether the main pump is still operating (step 610), and pumping a final cleaning volume of lubricant using the lubricant pump (step 612).

[0118] In step 602, an initial cleaning volume of lubricant is pumped using a lubricant pump. The lubricant pump is configured to pump the cleaning volume of lubricant to clean and replace the lubricant stored in the lubricant passage of the main pump. The lubricant pump and the main pump are separate pumps and may be, for example, lubricant pump 113 and main pump 112, respectively. The main pump may be a positive displacement pump, such as a reciprocating pump. The lubricant pump may also be a positive displacement pump, such as a peristaltic pump. A lubricant passage is formed within the housing of the main pump and is separated from the pump chamber of the main pump by a throat seal. The throat seal reduces unwanted flow of process fluid or material from the pump chamber of the main pump toward, for example, a piston rod or other pump components. The lubricant passage stores lubricant for lubricating the throat seal. The lubricant passage may be, for example, lubricant passage 130, and the throat seal may be, for example, throat seal 124.

[0119] A lubricant pump, lubricant channel, and lubricant reservoir form a lubricant system for circulating lubricant. Fresh lubricant is pumped from the lubricant reservoir, and lubricant from the lubricant channel flows to and is diluted in the lubricant reservoir. The dilution of lubricant from the lubricant channel in the lubricant reservoir delays the negative impact of contamination of the lubricant by the materials or process fluids pumped by the main pump. The lubricant pump, lubricant reservoir, and lubricant channel are fluidly connected such that the pumping action of the lubricant pump causes the lubricant to flow in loops from the lubricant reservoir to the lubricant channel and from the lubricant channel to the lubricant reservoir. The rinsing volume is at least equal to the volume of the lubricant channel. Advantageously, as described above, selecting a rinsing volume equal to the lubricant channel minimizes unnecessary lubricant agitation.

[0120] The initial cleaning volume pumped in step 602 is used to remove lubricant that may have been contaminated by, for example, dust that may have accumulated when the main pump is not in operation, or by materials pumped by the main pump.

[0121] In step 604, the process fluid is pumped using the main pump. Step 604 is typically performed after the initial cleaning in step 602, ensuring that the lubricant in the lubricant channels has been completely replaced before the main pump is operated. The process fluid pumped by the main pump can be, for example, a moisture-sensitive material that, when agitated or exposed to moisture, forms undesirable hard byproducts.

[0122] In step 606, the lubricant pump is operated to pump a volume of lubricant for cleaning. Method 600 may proceed to step 606 immediately after step 604, or after a period equal to the inactivity period (discussed with respect to step 608) following step 602. In step 608, the lubricant pump idles for the inactivity period. The length of the inactivity period depends on the flow rate of the process fluid or material pumped by the main pump through the throat seal and the rate of formation of unwanted hard byproducts in the lubricant passages, among other relevant parameters.

[0123] In step 608, after the pump has been idle for an inactive period, method 600 proceeds to step 610. In step 610, the control circuit determines whether the main pump is still operating. If the pump is still operating, the control circuit proceeds to step 606. Thus, method 600 repeats steps 606 and 608 while the main pump is operating, ensuring that the lubricant in the lubricant pump is periodically flushed during the main pump's operating period. If the main pump is not operating, method 600 proceeds to step 612. In step 612, the lubricant pump pumps another flush volume of lubricant through the lubricant system, flushing any contaminated lubricant from the lubricant channels after the previous iteration in step 606.

[0124] Advantageously, method 600 can be executed by control circuitry to operate the lubricant pump intermittently. As described above, intermittent operation of the lubricant pump allows for optimal reduction of both lubricant agitation and contaminant buildup in the lubricant passages of the main pump. Also as described above, reducing lubricant agitation is particularly advantageous when the main pump is used to pump moisture-sensitive materials. Method 600 can also be used by control circuitry to cause the lubricant pump to perform an initial lubricant flush before the main pump operates and a final lubricant flush after the main pump is idle.

[0125] Although the invention has been described with reference to one or more exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from the scope of the invention. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of the invention without departing from its essential scope. Therefore, it is intended that the invention be limited to the specific embodiments disclosed, but rather that the invention encompass all embodiments falling within the scope of the appended claims.

Claims

1. A pump system, comprising: A main pump, configured to pump fluid, comprising: case; The pump chamber defined by the housing; and Throat seal; Lubricant system, including: Lubricant pump; Lubricant passages defined within the housing of the main pump; and A lubricant circuit that fluidly connects the lubricant pump and the lubricant passage. Wherein, the throat seal is disposed near the pump chamber and the lubricant passage and between the pump chamber and the lubricant passage; and Control circuit, the control circuit being configured to: After the lubricant system is energized and before the main pump is operated, the lubricant pump pumps an initial cleaning volume of lubricant through the lubricant system; After the lubricant pump has pumped the initial cleaning volume, the lubricant pump is stopped for a first time period; and After the first time period and during the operation of the main pump, the lubricant pump is used to pump at least a first cleaning volume of lubricant through the lubricant system.

2. The pump system according to claim 1, wherein, The main pump is configured to pump compounds that react with water.

3. The pump system according to claim 1, wherein, The lubricant system further includes a lubricant reservoir fluidly connected to the lubricant pump and the lubricant passage, such that operation of the lubricant pump causes lubricant to flow from the lubricant reservoir to the lubricant pump, from the lubricant pump to the lubricant passage, and from the lubricant passage to the lubricant reservoir.

4. The pump system according to any one of claims 1-3, wherein, The first cleaning volume is at least equal to the volume of the lubricant channel.

5. The pump system according to any one of claims 1-3, wherein, The first time period is selected to reduce wear on the lubricant pump.

6. The pump system according to any one of claims 1-3, wherein, The first time period is 30 minutes.

7. The pump system according to any one of claims 1-3, wherein, The lubricant pump is a peristaltic pump.

8. The pump system according to any one of claims 1-3, wherein, The main pump is a reciprocating pump.

9. The pump system according to any one of claims 1-3, wherein, The control circuit is configured to pump the first cleaning volume by operating the lubricant pump for a cleaning time for the first cleaning volume, wherein the cleaning time for the first cleaning volume is selected based on the flow rate of the lubricant pump.

10. A pump control system, comprising: A main pump, configured to pump fluid, comprising: case; The pump chamber defined by the housing; and Throat seal; Control circuit, the control circuit being configured to: The main pump pumps fluid through the pump chamber; After the lubricant system is energized and before the main pump is operated, the lubricant pump pumps an initial cleaning volume of lubricant through the lubricant system, wherein the lubricant system comprises: The lubricant pump; The lubricant channel defined by the housing; and A lubricant circuit that fluidly connects the lubricant pump and the lubricant passage. The throat seal is located near the pump chamber and the lubricant passage, and between the pump chamber and the lubricant passage; After the lubricant pump has pumped the initial cleaning volume, the lubricant pump is stopped for a first time period; and After the first time period and during the operation of the main pump, the lubricant pump is used to pump at least a first cleaning volume of lubricant through the lubricant system.

11. The pump control system according to claim 10, wherein, The first cleaning volume is at least equal to the volume of the lubricant channel.

12. The pump control system according to claim 10, wherein, The first time period is selected to reduce wear on the lubricant pump.

13. The pump control system according to any one of claims 10-12, wherein, The control circuit is also configured to: The lubricant pump delivers lubricant at a first rate; and The main pump is made to pump fluid at a second rate, wherein the first rate and the second rate are different.

14. A method for controlling a pump system, the method comprising: After the lubricant system is energized and before the main pump is operated, the lubricant pump of the lubricant system is operated to pump an initial cleaning volume of lubricant through the lubricant system, wherein the lubricant system comprises: The lubricant pump; A lubricant passage defined by the housing of the main pump, the main pump comprising: The pump chamber defined by the housing; and A throat seal, wherein the throat seal is disposed near the pump chamber and the lubricant passage and between the pump chamber and the lubricant passage; and A lubricant circuit that fluidly connects the lubricant pump and the lubricant passage; After the lubricant pump has pumped the initial cleaning volume, the operation of the lubricant pump is stopped for a first time period; and After the first time period and during the operation of the main pump, the lubricant pump is operated to pump at least a first cleaning volume of lubricant through the lubricant system.

15. The method according to claim 14, wherein, Operating the lubricant pump to pump the first cleaning volume of lubricant through the lubricant system includes: operating the lubricant pump for a cleaning time for the first cleaning volume, wherein the cleaning time for the first cleaning volume is selected based on the flow rate of the lubricant pump.

16. The method of claim 14, wherein, The first cleaning volume is at least equal to the volume of the lubricant channel.

17. The method according to any one of claims 14-16, further comprising: After pumping the first cleaning volume, the lubricant pump is switched to idle mode.

18. The method according to any one of claims 14-16, wherein, The first time period is selected to reduce wear on the lubricant pump.

19. The method according to any one of claims 14-16, wherein, The main pump is configured to pump compounds that react with water.

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