Dual-body variable duty cycle performance optimization pump unit

Abstract

The invention relates to a pump unit. The pump unit is a dual pump unit having a pair of pumps that provides parallel hydraulic paths and is configured to operate simultaneously in opposite rotational directions. A dual pump unit has a sealed housing including a suction flange, two volutes in a hydraulically parallel configuration, and a discharge flange. Pairs of pumps are located in respective volutes of the housing, and in an example, radially in-line and horizontally in-line. The housing may include a flat bottom. Each pump may include a touch screen for configuring the respective pump. The pumps are controllable to collectively provide an output to a load source with a circulating medium.

Description

This application is a divisional application of the invention patent application filed on May 29, 2017, with international application number PCT / CA2017 / 050648, which entered the national phase and is entitled "Dual-body Variable Duty Cycle Performance Optimization Pump Unit" with application number 201780083124.2. Cross-reference to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 62 / 451,219, filed January 27, 2017, the contents of which are incorporated herein by reference. Technical Field

[0002] Some example embodiments relate to circulation devices, and at least some example embodiments specifically relate to variable control smart pumps. Background Technology

[0003] Pumps can be used in a variety of applications, including industrial processes, which involve using inputs (such as cold water, fuel, air, etc.) to output products (such as hot water, air), heating, ventilation and air conditioning (HVAC) systems, and water supply.

[0004] Some pump units are designed to have two pumps in one unit, sometimes referred to as twin heads or dual heads. In some such units, the two pumps are designed to rotate in the same direction of rotation. However, this can lead to asymmetries in the physical design and in the flow profile.

[0005] Some pump systems require keypad or keyboard input for setup, configuration, and maintenance, which can be prone to sealing problems. Other pump systems may require a separate mobile handheld device for setup, configuration, and maintenance.

[0006] Given the specific implementation, additional difficulties of the existing system can be understood, as described below. Summary of the Invention

[0007] Example embodiments relate to pumps, boosters and fans, centrifuges, and related systems. According to some aspects, an intelligent multi-cycle pump unit is provided, which has multiple pumps and coordinated control of these pumps.

[0008] Example embodiments include a dual-pump unit with paired pumps that provides parallel hydraulic paths operating simultaneously in opposite directions of rotation.

[0009] An example embodiment is a pump unit comprising: a housing including a suction flange and a discharge flange; a first pump impeller within the housing; a second pump impeller within the housing, and providing a parallel hydraulic path to the first pump impeller; wherein the first pump impeller is configured to rotate simultaneously in a direction of rotation opposite to that of the second pump impeller.

[0010] Another example embodiment is a pump unit comprising: a housing including a suction flange and a discharge flange; a first pump within the housing; a second pump within the housing, and providing a parallel hydraulic path to the impeller of the first pump; a first touchscreen mounted on the housing for inputting and / or outputting data in association with the first pump; and a second touchscreen mounted on the housing for inputting and / or outputting data in association with the second pump.

[0011] Another example embodiment is a pump unit housing, comprising: a housing including a suction flange and a discharge flange; and a suction compartment defined by the housing having a flat bottom and being hydraulically fed from the suction flange.

[0012] Another example embodiment is a method for operating a multi-pump unit, the pump unit including a housing with a suction flange and a discharge flange, a first pump impeller within the housing, and a second pump impeller within the housing, and providing a parallel hydraulic path to the first pump impeller. The method includes: rotating the first pump impeller in a rotational direction to achieve flow between the suction flange and the discharge flange; and simultaneously rotating the second pump impeller in an opposite rotational direction to achieve flow between the suction flange and the discharge flange.

[0013] Another example embodiment is an integrated pump unit, including: a housing; a pump within the housing; a controller for controlling the operation of the pump; and a touchscreen configured for inputting and / or outputting communications to the controller.

[0014] Another example embodiment is a non-transitory computer-readable medium having instructions stored thereon that are executable by one or more processors for performing the described method. Attached Figure Description

[0015] The embodiments will now be described by way of example only with reference to the accompanying drawings, in which:

[0016] Figure 1 An example block diagram of a circulation system is shown, illustrating an intelligent dual-control pump unit that can be applied to example embodiments;

[0017] Figure 2 An exemplary operating range of a variable speed control pump is shown;

[0018] Figure 3 A schematic diagram illustrating the internal sensor control of a variable speed control pump is shown.

[0019] Figure 4 An example load profile of a system such as a building is shown;

[0020] Figure 5 An example detailed block diagram of a control device according to an example embodiment is shown;

[0021] Figure 6 A control system for coordinated control of an apparatus according to an example embodiment is shown;

[0022] Figure 7 Another control system for coordinated control of a device is shown according to another example embodiment;

[0023] Figure 8 A flowchart of an example method for coordinated control of a device according to an example embodiment is shown;

[0024] Figure 9 shows a schematic top view of an example prior art twin head pump design, illustrating the same rotational orientation configuration;

[0025] Figure 10A A schematic top view of an intelligent dual-pump unit according to an example embodiment is shown, the intelligent dual-pump unit having two pumps in a counter-rotating configuration, and the operation of the dual pumps is illustrated.

[0026] Figure 10B An example embodiment is shown. Figure 10A A schematic top view of the intelligent dual-pump unit, showing single-pump operation;

[0027] Figure 10C An example embodiment is shown. Figure 10A A schematic top view of the intelligent dual-pump unit, showing it not in operation;

[0028] Figure 11 It shows Figure 10A The velocity streamline diagram of one of the pumps in the intelligent dual-pump unit, and the other pump has a roughly the same streamline in the opposite direction;

[0029] Figure 12 The pump curve is shown, which illustrates, as Figure 10A The intelligent dual-pump unit in dual operation is relative to, for example, Figure 10B The dual-pump unit is in single-operation mode;

[0030] Figure 13A A front perspective view of an example intelligent dual-pump unit in a disjoint configuration according to an example embodiment is shown;

[0031] Figure 13B It shows Figure 13A A rear-view stereoscopic view of the intelligent dual-pump unit;

[0032] Figure 13C It shows Figure 13A A bottom-view 3D view of the intelligent dual-pump unit;

[0033] Figure 14A A front perspective view of an example intelligent dual-pump unit in a closed-loop configuration according to an example embodiment is shown;

[0034] Figure 14B It shows Figure 14A A rear-view stereoscopic view of an example intelligent dual-pump unit;

[0035] Figure 15 A flowchart of a method for operating a multi-pump unit according to an example embodiment is shown;

[0036] Figure 16A , 16B Figures 16C and 16D show screenshots of a touchscreen controlling a pump according to some example embodiments;

[0037] Figure 17A A front perspective view of a pump unit with a vertical inline pump having a closed connection is shown.

[0038] Figure 17B It shows Figure 17A The rear-view perspective view of the pump unit shown;

[0039] Figure 17C It shows Figure 17A The front view of the pump unit shown;

[0040] Figure 17D It shows Figure 17A The rear view of the pump unit shown;

[0041] Figure 17E It shows Figure 17A The left side view of the pump unit shown;

[0042] Figure 17F It shows Figure 17A The right-side view of the pump unit shown;

[0043] Figure 17G It shows Figure 17A A top view of the pump unit shown;

[0044] Figure 17H It shows Figure 17A The pump unit shown is shown in a bottom view.

[0045] Figure 18A A front perspective view of a pump unit with a vertical inline pump having a detachable connection is shown.

[0046] Figure 18B It shows Figure 18A The rear-view perspective view of the pump unit shown;

[0047] Figure 18C It shows Figure 18A The front view of the pump unit shown;

[0048] Figure 18D It shows Figure 18A The rear view of the pump unit shown;

[0049] Figure 18E It shows Figure 18A The left side view of the pump unit shown;

[0050] Figure 18F It shows Figure 18A The right-side view of the pump unit shown;

[0051] Figure 18G It shows Figure 18A A top view of the pump unit shown; and

[0052] Figure 18H It shows Figure 18A The pump unit shown is shown in a bottom view.

[0053] The same reference numerals may be used throughout the drawings to denote the same elements and features. Detailed Implementation

[0054] In some example embodiments, an intelligent multi-pump unit is provided for an operable system such as a flow control system or a temperature control system. The example embodiments relate to a "process" in an industrial sense, meaning a process that uses inputs (e.g., cold water, fuel, air, etc.) to output products (e.g., hot water, air).

[0055] Example embodiments include a dual-pump unit with paired pumps that provides parallel hydraulic paths operating simultaneously in opposite directions of rotation.

[0056] Example embodiments include a dual-pump unit having a housing including a suction flange and a discharge flange, and a pair of pumps radially aligned and providing parallel hydraulic paths within the housing, the pair of pumps operating simultaneously in opposite directions of rotation.

[0057] Example embodiments include a dual-pump unit having a pair of pumps that provide parallel hydraulic paths, wherein each pump includes a touchscreen for configuring the respective pump.

[0058] An example embodiment includes a pump unit housing, a first suction compartment and a second suction compartment. The pump unit housing has a suction flange and a discharge flange. The first suction compartment is defined by the housing, has a first flat bottom and is hydraulically fed from the suction flange. The second suction compartment is defined by the housing, has a second flat bottom and is hydraulically fed from the suction flange and provides a parallel hydraulic path to the first suction compartment.

[0059] Example embodiments include a dual-pump unit that coordinates the operation of multiple sensorless pumps thereon. For instance, in some embodiments, the system may be configured to operate without external sensors to collectively control output characteristics (variables) to supply the load.

[0060] Figure 9 illustrates a prior art pump unit that incorporates two pumps within a single unit. As shown in Figure 9, the two pumps are designed to rotate in the same direction. However, this can lead to asymmetries in the physical design and the flow profile.

[0061] refer to Figure 1 The diagram illustrates a circulation system 100 applicable to an example embodiment, featuring an intelligent dual-pump unit 101, which itself includes intelligent variable-speed circulation devices such as control pumps 102a, 102b (collectively or individually referred to as 102). The circulation system 100 can relate to a building 104 (as shown), a campus (multiple buildings), a vehicle, or other suitable infrastructure or load. Each control pump 102 may include one or more corresponding pump units 106a, 106b (collectively or individually referred to as 106) and control units 108a, 108b (collectively or individually referred to as 108) for controlling the operation of each pump unit 106. The specific circulation medium may vary depending on the specific application and may include, for example, ethylene glycol, water, air, and the like.

[0062] like Figure 1 As shown, the circulation system 100 may include one or more loads 110a, 110b, 110c, 110d, where each load may be based on varying usage requirements such as HVAC, piping, etc. Each 2-way valve 112a, 112b, 112c, 112d can be used to manage the flow rate to each corresponding load 110a, 110b, 110c, 110d. As the pressure differential across the load decreases, the control device 108 responds to the change by increasing the pump speed of the pump device 106 to maintain or reach the pressure setpoint. If the pressure differential across the load increases, the control device 108 responds to the change by decreasing the pump speed of the pump device 106 to maintain or reach the pressure setpoint. In some example embodiments, the control valves 112a, 112b, 112c, 112d may include taps or stopcocks for controlling the flow to the piping system. In some example embodiments, the pressure setpoint may be fixed, continuous or periodically calculated, externally determined, or otherwise specified.

[0063] The control device 108 for each control pump 102 may include internal detectors or sensors, commonly referred to in the art as a "sensorless" control pump because no external sensors are required. The internal detector may be configured to self-detect, for example, device characteristics (device variables), such as the power and speed of the pump device 106. In some example embodiments, external sensors are used to detect local head output and flow output (H, F). Other input variables may be detected. The pump speed of the pump device 106 may be varied to achieve the pressure and flow setpoints of the pump device 106 based on the input variables.

[0064] Still referencing Figure 1 The output characteristics of each control device 102 are controlled to reach a pressure setpoint, for example, at a combined output characteristic 114 shown at a load point on building 104. Output characteristic 114 represents the sum or aggregate of the individual output characteristics of all controlled pumps 102 at the load (in this case, flow rate and pressure). In an example embodiment, an external sensor (not shown) may be placed at the location of output characteristic 114 and associated controls may be used to control or change the pump speed of pump device 106 to reach the pressure setpoint based on the flow rate detected by the external sensor. In another example embodiment, output characteristic 114 is alternatively inferred or correlated from self-testing device characteristics such as the power and speed of pump device 106 and / or other input variables. As shown, output characteristic 114 is located at the most extreme load location at the height (or end of the line) of building 104, and in other example embodiments, it may be located at other locations such as the middle of building 104, two-thirds of the way from the top of building 104 or below that line, or at the furthest building on campus.

[0065] One or more controllers 116 (e.g., processors) may be used to coordinate the output flow of the control pump 102. As shown, the control pump 102 may be arranged in parallel with respect to the flow path to supply shared loads 110a, 110b, 110c, 110d.

[0066] In some examples, circulation system 100 may be a cooling circulation system (“chiller”). The chiller may include a section 118 in thermal communication with a secondary circulation system for building 104. Control valves 112a, 112b, 112c, 112d manage the flow rate to cooling coils (e.g., loads 110a, 110b, 110c, 110d). Each 2-way valve 112a, 112b, 112c, 112d may be used to manage the flow rate to each corresponding load 110a, 110b, 110c, 110d. As valves 112a, 112b, 112c, 112d open, the differential pressure across the valves decreases. Control device 108 responds to this change by increasing the pump speed of pump device 106 to achieve a specified output setpoint. If control valves 112a, 112b, 112c, and 112d are closed, the differential pressure across the valves increases, and control device 108 responds to this change by reducing the pump speed of pump device 106 to reach the specified output setpoint.

[0067] In some other examples, circulation system 100 may be a heating circulation system (“heating unit”). The heater unit may include a section 118 in thermal communication with a secondary circulation system for building 104. In such an example, control valves 112a, 112b, 112c, 112d manage the flow rate to the heating elements (e.g., loads 110a, 110b, 110c, 110d). Control device 108 responds to changes in the heating elements by increasing or decreasing the pump speed of pump device 106 to achieve a specified output setpoint.

[0068] Each pump unit 106 may employ a pump of various types with variable speed control. Figure 10A Figures 10B and 10C show schematic top views of an intelligent dual-pump unit 101 according to an example embodiment, having two control pumps 102a and 102b in an opposing rotational configuration. Pump unit 101 includes a first pump impeller 122a and a second pump impeller 122b. The pump impellers 122a and 122b are connected in parallel, meaning they are configured to achieve separate parallel hydraulic flow paths within pump unit 101. In the example embodiment, pump impellers 122a and 122b are radially aligned (opposite to axial alignment). In the example embodiment, pump impellers 122a and 122b are horizontally aligned, for example, they are horizontally aligned during pre-installation, installation, and use. Thicker arrows indicate streamlines of the circulating medium.

[0069] The intelligent dual-pump unit 101 includes a sealed housing housing a pump assembly 106, which includes a suction flange 124 for connection to a line for receiving circulating media and a discharge flange 126 for connection to a line for discharging circulating media. Each control pump 102a, 102b includes a corresponding suction compartment 128a, 128b. Corresponding volutes 130a, 130b fed from the corresponding suction compartments 128a, 128b house corresponding pump impellers 122a, 122b. Corresponding variable motors (not shown) can be variably controlled from control devices 108a, 108b to rotate at variable speeds. Each control pump 102a, 102b may also include corresponding touchscreens 120a, 12b for interaction, input, and / or output between the user and the corresponding control devices 108a, 108b. Pump impellers 122a, 122b are operatively coupled to motors and rotate based on the speed of the motors to circulate the circulating media. In an example embodiment, the first control device 108a and the second control device 108b are configured to control the corresponding pump impellers 122a, 122b within a range of 0% to 100% of the motor speed. The control of pumps 122a, 122b can be symmetrical or asymmetrical. In other example embodiments, depending on the desired or system operating range, other suitable ranges may be narrower than 0% to 100%.

[0070] Depending on the type of pump assembly 106, each control pump 102a, 102b may also include additional suitable operating elements or features. Each volute 130a, 130b may be configured to receive circulating medium pumped by the corresponding pump impeller 122a, 122b, slowing the fluid flow rate. Each volute 130a, 130b may include a curved funnel portion whose area increases with approach to the discharge flange 126.

[0071] In the example embodiment, the housing of pump unit 101 is substantially symmetrical in shape and size. This facilitates ease of design and manufacture. It also facilitates balance and centralization of the center of gravity during operation. Furthermore, for example, each control pump 102a, 102b can be controlled to operate simultaneously. Pump impellers 122a, 122b are coordinated so that the combined output reaches the setpoint. In the example embodiment, control pumps 102a, 102b are controlled at the same motor speed. When the housing is substantially symmetrical, the same motor speed results in each of the control pumps 102a, 102b making a substantially equal contribution to the circulating medium.

[0072] Figure 11 A velocity streamline diagram 1100 of one of the control pumps 102b is shown. It can be understood that the other control pump 102a has a streamline that is opposite and substantially the same. Therefore, for example, since control pumps 102a and 102b can have the same output variables as those operating with the same device variables, symmetrical and predictable performance of each control pump 102a and 102b can be more easily achieved. When the motors of control pumps 102a and 102b operate at the same speed, this results in the same flow contribution from each control pump 102a and 102b to achieve, for example, the output pressure setpoint. Brief reference. Figure 1 If an external sensor is placed at output characteristic 114, the motor speeds of each control pump 102a, 102b can be increased equally until the desired output pressure setpoint at output characteristic 114 is reached. This contrasts with the prior art system shown in Figure 9, which can have asymmetrical operation. The prior art system in Figure 9 may require additional calibration to determine individual contributions and requires different motor speeds to achieve the same output variable.

[0073] Now refer to Figure 10A , 10B The valve 140 of the pump unit 101 is described in 10C. Figure 10A Concurrent dual-pump operation according to an example embodiment is shown. Figure 10B The operation of a single pump according to an example embodiment is shown. Figure 10CThe pump is shown not operating according to an example embodiment. The valve 140 is configured as a back-pressure activated flow prevention valve device, which has a physical design capable of parallel operation, dual operation (symmetric or asymmetrical), and single pump operation.

[0074] The valve 140 includes a spring hinge 142, a first leaf 144a, and a second leaf 144b connected to the spring hinge. The spring hinge 142 is configured and biased such that each leaf 144a, 144b is normally closed, as... Figure 10C As shown. This prevents backflow. (As indicated) Figure 10A As shown, when the two pumps 102a and 102b operate at the same speed, symmetrical operation can be achieved, causing each lobe 144a and 144b to open. Figure 10B As shown, when only one control pump 102 is running, the first flap 144a is closed, while the second flap 144b is fully open toward the first flap 144a. Therefore, the asymmetrical flow between control pumps 102a and 102b causes flaps 144a and 144b to open more or less. In another example embodiment, more than one spring hinge 142 can be used, for example, one corresponding spring hinge for each flap 144a and 144b. In another example embodiment, other types of valves are used.

[0075] In an example embodiment, the control pump impellers 122a and 122b rotate simultaneously at different speeds. In another example embodiment, the control pump impellers 122a and 122b rotate at speeds less than the maximum motor capacity (speed). Since the variable motor can achieve optimal efficiency below its maximum speed, energy efficiency can be obtained in some example embodiments. In another example embodiment, the pump impellers 122a and 122b can be controlled to distribute wear among the respective control pumps 102a and 102b. For example, if a control pump 102a is not in use for a period of time, subsequent use of that control pump 102a can be increased to distribute wear. In yet another operating mode in an example embodiment, the control devices 108a and 108b are also configured to operate the pump impellers 122a and 122b in an on-standby mode. For example, in this mode, a primary pump 108a can be designated as the primary pump source (“on”), while a secondary pump can be used as a backup (“standby”) when the primary pump is unavailable.

[0076] Figure 12 The pump curve 1200 is shown, which illustrates, as Figure 10A The intelligent dual-pump unit in dual operation is relative to, for example, Figure 10BThe dual-pump unit is operating in a single configuration. As can be seen in Figure 1200, when compared to a single pump 102b using the dual-pump unit 101, the effective head relative to the flow rate is roughly matched when both pumps 102a and 102b are running. In the dual-pump configuration, the pump motors do not need to operate at maximum speed, which can result in greater energy savings.

[0077] Now for a brief reference Figure 13A , 13B Figures 13C and 13C show further details of pump unit 101. The housing of pump unit 101 also includes motor housings 132a, 132b for accommodating corresponding controllers 108a, 108b and for accommodating corresponding variable pump motors (not shown). The housing of pump unit 101 also includes base housings 134b, 134b, which accommodate corresponding shafts (one or more) between the corresponding pump motors and the corresponding pump impellers 122a, 122b. Additional seals, elements, and components (not shown) may be accommodated in the motor housings 132a, 132b and / or the base housings 134a, 134b.

[0078] Figure 13C A bottom perspective view of the intelligent dual-pump unit 101 is shown, revealing its flat bottom. In an example embodiment, each suction compartment 128a, 128b includes corresponding outer flanges 138a, 138b, each outer flange 138a, 138b having a flat bottom. As shown, each outer flange 138a, 138b may have a “cross” shape defining the flat surface. For example, the two outer flanges 138a, 138b provide two flat contact areas, allowing the pump unit 101 to stand independently on the flat surface, for example, during setup and installation of the pump unit 101. When the pump unit 101 is vertically oriented, the flat bottoms of each outer flange 138a, 138b are horizontally aligned, such that they collectively provide a flat surface. For example, the flat bottom allows the pump unit 101 to stand upright during assembly, packaging, and / or installation processes. In the example embodiment, the outer flanges 138a, 138b are integrally formed and integral with the corresponding suction chambers 128a, 128b, for example during casting or molding.

[0079] Still referencing Figure 13A , 13BLike 13C, pump unit 101 can be configured as a vertically inline separated connection unit. Vertical inline can mean that the pump motor, shaft, and impellers 122a, 122b are generally arranged vertically in line. The connection between the pump motor and the corresponding pump impellers 122a, 122b can be separated into two separate shafts and also includes pump seals (not shown). In an example embodiment, the connection is axially separated, and a spacer-type rigid coupling allows maintenance of the seals without interfering with the pump impellers 122a, 122b and / or the pump motor. For example, each base housing 134a, 134b may include at least one corresponding removable cover 136a, 136b. As shown, there are front removable covers 136a, 136b and rear removable covers 137a, 137b. When the covers 136a, 136b, 137a, 137b are removed, for example, the seals (not shown) of each pump motor within the base housing 134a, 134b can be replaced without removing the corresponding pump motor.

[0080] Now for reference Figure 14A and 14B The figure illustrates a pump unit 101 in a closed-loop configuration according to an exemplary embodiment. The same reference numerals are used for ease of reference. A closed-loop connection refers to a single shaft for connecting the pump motor to the pump impellers 122a, 122b. The single shaft is housed in corresponding base housings 134a, 134b. Therefore, there are no removable covers 136a, 136b, 137a, 137b (e.g., on the corresponding base housings 134a, 134b) on the corresponding base housings 134a, 134b. Figure 13A (as shown in the diagram), because, for example, seal maintenance or other maintenance is not performed without removing the entire motor. On the other hand, for example, fewer parts and vertical space are required in a closed-loop configuration, and a single shaft can provide a stronger connection.

[0081] Figure 16A , 16B Figures 16C and 16D show screenshots of each (or any one of) of the touchscreens 120a and 120b controlling the pumps according to an example embodiment. The touchscreens 120a and 120b can be used to implement user interfaces such as inputs and / or outputs for the respective controllers 108a and 108b. In the example embodiment, as shown in the screenshots, the touchscreens 120a and 120b can be configured to facilitate the setup and / or commissioning of the respective controllers 108a and 108b controlling the pumps 102a and 102b.

[0082] Figure 15 A flowchart of a method 1500 for operating a dual-pump unit 101 according to an example embodiment is shown. Where applicable, aspects or events of method 1500 may be executed by at least one or all of controllers 108a, 108b, 116. Method 1500 may be automated, where manual control is not required.

[0083] At event 1502, method 1500 includes determining the desired output setpoint, for example, system 100 ( Figure 1 The pressure setpoint. In some example embodiments, the pressure setpoint may be fixed, continuously or periodically calculated, externally determined or otherwise specified.

[0084] At event 1504, method 1500 includes detecting inputs, including variables such as system variables or device variables for each device (e.g., each control pump 102a, 102b). At event 1506, method 1500 includes determining one or more output characteristics (output variables) for each device. This can be detected directly from or inferred from device characteristics (device variables). The corresponding one or more output characteristics can be calculated to determine the individual contribution of each device to the system load point. At event 1508, method 1500 includes determining the aggregate output characteristics (output variables) to the load from the individual one or more output characteristics. At event 1510, the method includes coordinating control of each device to operate a corresponding controllable element (e.g., pump impellers 122a, 122b) causing one or more device variables to reach a corresponding one or more output characteristics to reach a setpoint. This includes rotating the first pump impeller 122a in the rotational direction to achieve flow between the suction flange and the discharge flange, while simultaneously rotating the second pump impeller 122b in the opposite rotational direction to achieve flow between the suction flange and the discharge flange. Method 1500 can be repeated, for example, as indicated by the feedback loop.

[0085] In an example embodiment, pump impellers 122a and 122b can be controlled to rotate simultaneously at equal speeds. Due to the symmetrical housing of pump unit 101, equal motor speeds result in equal flow output contributions from each pump impeller 122a and 122b. Therefore, when each pump impeller 122a and 122b rotates at the same speed, the hydraulic characteristics of the housing and each pump impeller 122a and 122b provide the same net flow rate and head pressure. In this case, equal and opposite flow paths are generated from each pump impeller 122a and 122b. In an example embodiment, pump impellers 122a and 122b can be controlled to rotate simultaneously at different speeds. In an example embodiment, pump impellers 122a and 122b can be controlled to rotate at a speed less than the maximum speed of each corresponding motor.

[0086] Now referencing graph 200. Figure 2Graph 200 illustrates an example of a suitable operating range 202 for a variable speed device, in this example, a control pump 102. The operating range 202 is shown as a polygonal region or area on graph 200, defined by boundaries representing the suitable operating range. For example, a design point could be, for instance, at a point such as in output characteristic 114 (…). Figure 1 The maximum expected system load required by the system at point A(210) of building 104 at location ).

[0087] The design point, point A (210), can be estimated by the system designer based on the flow rate required for the system to operate effectively and the head / pressure loss required to pump the design flow rate through the system piping and fittings. Note that because pump head estimates may be overestimated, most systems will never reach the design pressure and will exceed the design flow rate and power. Other systems where the designer underestimates the required head will operate at pressures higher than the design point. In such cases, a characteristic of appropriately selecting one or more intelligent variable speed pumps is that they can be appropriately adjusted to deliver more flow rate and head into the system than the designer specified.

[0088] Design points can also be estimated for the operation of multiple controlled pumps 102, thereby distributing the resulting flow requirements among the controlled pumps 102. For example, for controlled pumps of equivalent type or performance, the total estimated required output characteristic 114 of the system or building 104 (e.g., the maximum flow rate at the required pressure design point to maintain that location of the load) can be evenly distributed among each controlled pump 102 to determine individual design points, taking into account losses or any nonlinear combined flow outputs. In other example embodiments, depending on the specific flow rate of each control pump 102 and taking into account losses or any nonlinear combined flow outputs, the total output characteristic (e.g., at least the flow rate) may not be equally distributed. Thus, for each individual control pump 102, a single design setpoint is determined, such as at point A (210).

[0089] Graph 200 includes axes that incorporate relevant parameters. For example, the square of the head is approximately proportional to the flow rate, and the flow rate is approximately proportional to the velocity. In the example shown, the horizontal axis, or x-axis 204, shows the flow rate in US gallons per minute (GPM) (which could be liters per minute), while the vertical axis, or y-axis 206, shows the head (H) in pounds per square inch (psi) (or feet per meter or pascals). The operating range 202 is a superimposed representation of the control pump 102 relative to those parameters on graph 200.

[0090] The relationship between parameters can be approximated by specific similarity laws, which can be influenced by volume, pressure, and braking horsepower (BHP) (e.g., in kilowatts). For example, for a change in impeller diameter at a constant speed: D1 / D2 = Q1 / Q2; H1 / H2 = D1 2 / D2 2 BHP1 / BHP2 = D1 3 / D2 3 For example, with a constant impeller diameter for changes in velocity: S1 / S2 = Q1 / Q2; H1 / H2 = S1 2 / S2 2 BHP1 / BHP2 = S1 3 / S2 3 Where: D = impeller diameter (Ins / mm); H = pump head (Ft / m); Q = pump capacity (gpm / lps); S = speed (rpm / rps); BHP = brake horsepower (shaft power - hp / kW).

[0091] Specifically, for Figure 200, at least some parameters exist at more than one run point or path for the system variables of the runnable system, which can provide a given output setpoint. As understood in the art, at least one system variable at the run point or path restricts the operation of another system variable at the run point or path.

[0092] The optimal efficiency point (BEP) curve 220 for controlling pump 102 is also shown. Partial efficiency curves, such as the 77% efficiency curve 238, are also shown. In some example embodiments, the upper boundary of the operating range 202 may also be further defined by the motor power curve 236 (e.g., maximum power or horsepower). In alternative embodiments, the boundary of the operating range 202 may also depend on the pump speed curve 234 (shown in Hz) rather than the strictly maximum motor power curve 236.

[0093] like Figure 2 As shown, one or more control curves 208 (one shown) can be defined and programmed for a smart variable speed device such as control pump 102. Depending on the detected changes in parameters (e.g., detected, internal, or inferred flow / load change detection), pump unit 106 can be kept running on control curve 208 based on instructions from control unit 108 (e.g., at higher or lower flow points). This control mode can also be referred to as secondary pressure control (QPC) because control curve 208 is a quadratic curve between two operating points (e.g., point A (210): maximum head and point C (214): minimum head). The “smart” device mentioned here includes control pump 102, which is capable of self-regulating the operation of pump unit 106 along control curve 208 according to specific needs or detected loads.

[0094] Other example control curves besides quadratic curves include constant pressure control and proportional pressure control (sometimes called linear control). Another specific control curve (not shown) can also be selected depending on the application; this control curve can be predetermined or calculated in real time.

[0095] Figure 4 An example load profile 400 for a system such as building 104 is shown, for example, a “design day” for projection or measurement. Load profile 400 shows a curve relating the percentage of operating hours to the percentage of heating / cooling load. For example, as shown, many example systems may need to operate at only 0% to 60% of load capacity for 90% or more of the time. In some examples, pump 102 may be selected to operate at or around 50% of peak load for optimal efficiency. Note that the ASHRAE 90.1 energy efficiency standard requires that the pump motor demand not exceed 30% of the design wattage when the control device operates at 50% of the design water flow (e.g., 70% energy saving at 50% of peak load). It should be understood that a “design day” may not be limited to 24 hours but can be determined as a shorter or longer system period, such as a month, a year, or many years.

[0096] Refer again Figure 2 It can be based on the load profile 400 ( Figure 4 Select or identify or calculate the individual points on control curve 208, shown as points A (210), B (212), and C (214). For example, the points on control curve 208 may be optimized for partial loads rather than 100% loads. For example, referring to point B (212), efficiency meets ASHRAE 90.1 (energy saving greater than 70%) at 50% flow. Point B (212) may be referred to as the optimal setpoint on control curve 208, which maximizes efficiency on control curve 208 for 50% load or the most frequent partial loads. Point A (210) represents a design point that can be used for selection purposes for a particular system and may represent the maximum expected load requirement for a given system. Note that in some example embodiments, efficiency may actually be higher for partial loads at point B relative to point A. For example, by default, point C (214) represents the minimum flow and head (Hmin) based on 40% of the full design head. Other examples may use different values ​​depending on system requirements. Control curve 208 may also include a coarser portion 216, as shown, representing a typical expected load range (e.g., at or around 90%–95% of the projected load range on the design date of the projection). Therefore, the operating range 202 can be optimized for partial load operation. In some example embodiments, this can be based on the system's load profile 400 (…). Figure 4 The control curve 208 can be recalculated or redefined automatically or manually. The thicker portion 216 of the curve can also be based on the load profile 400. Figure 4 The change of ) varies with control curve 208.

[0097] Figure 5 An example embodiment of a method for controlling a first control pump 102a is shown. Figure 1 A detailed block diagram of an example of a first control device 108a is shown. A second control device 108b may be constructed in a similar manner to the first control device 108a, having similar components. The first control device 108a may include one or more controllers 506a, such as a processor or microprocessor, which control the overall operation of the control pump 102a. The control device 108a may communicate with other external controllers 116 or other control devices (one shown, referred to as the second control device 108b) to coordinate the control of the pump 102a. Figure 1 The controlled total output characteristic 114 of the controller 506a. The controller 506a interacts with other device components, such as memory 508a, system software 512a stored in memory 508a for executing application programs, input subsystem 522a, output subsystem 520a, and communication subsystem 516a. Power supply 518a supplies power to the control device 108a. The second control device 108b may, where appropriate, have the same, more, or fewer blocks or modules as the first control device 108a. The second control device 108b interacts with components such as the second control pump 102b. Figure 1 The second device is associated with ).

[0098] The input subsystem 522a can receive input variables. Input variables may include, for example, sensor information or information from the device detector 304. Figure 3 Information. Other example inputs may also be used. Output subsystem 520a can control output variables, such as controlling one or more operable elements of pump 102a. For example, output subsystem 520a may be configured to at least control the speed of the motor (and impeller) of pump 102a to achieve desired output setpoints for head and flow rate (H, F). Other example output variables, operable elements, and device characteristics may also be controlled. Touchscreen 120a is a display screen that can be used to input commands based on direct pressure from the user on the screen. In an example embodiment, touchscreen 120a may be a color touchscreen. In an example embodiment, touchscreen 120a and controller 506a are integrated in the form of a computer tablet. In an example embodiment, the onboard processor of the computer tablet is used to perform at least some pump controller functions.

[0099] The communication subsystem 516a is configured to communicate directly or indirectly with another controller 116 and / or a second control device 108b. The communication subsystem 516a can also be configured for wireless communication. The communication subsystem 516a can also be configured to communicate directly with other devices, which may be wired and / or wireless. Examples of short-range communication are Bluetooth® or direct Wi-Fi. The communication subsystem 516a can be configured to communicate over networks such as a wireless local area network (WLAN), a wireless (Wi-Fi) network, a public terrestrial mobile network (PLMN), and / or the Internet. These communications can be used to coordinate the control of pump 102 ( Figure 1 The operation of ).

[0100] Memory 508a can also store other data, such as the load profile 400 for measurement of the "design date" or average annual load. Figure 4 The memory 508a can also store information related to the system or building 104. Figure 1 Other relevant information, such as altitude, flow rate, and other design conditions. In some example embodiments, memory 508a may also store performance information of some or all of the other devices 102 in order to determine the appropriate combination of outputs to achieve the desired setpoint.

[0101] One type of conventional pump device estimates local flow rate and / or pressure based on electrical variables provided by an electronically variable speed drive. This technique is commonly referred to in the art as a "sensorless pump" or "observable pump." Example implementations using a single pump are described in WO2005 / 064167, US7945411, US6592340, and DE19618462, which are incorporated herein by reference. A single device can then be controlled, but the estimated local pressure and flow rate are used to infer remote pressure instead of direct fluid measurements. This method saves on the cost of sensors and their wiring and installation; however, these references may be limited to the use of a single pump.

[0102] In an example embodiment, the intelligent dual-pump unit 101 can be configured to operate both pumps 102a, 102b using at least one internal sensor, without requiring external sensors, for example, in a “sensorless” manner. An example of a coordinated sensorless system is described in the applicant’s PCT patent application No. WO2014 / 089693, filed November 13, 2013, entitled “Co-Ordinated Sensorless Control System,” which is incorporated herein by reference.

[0103] Now for reference Figure 3The diagram 300 illustrates internal sensing control (sometimes referred to as “sensorless” control) of a control pump 102 within an operating range 202 according to an example embodiment. For example, no external or nearby sensors are required in such an example embodiment. An internal detector 304 or sensor can be used to self-test device characteristics, such as the power and speed (P, S) of the associated motor of the pump unit 106. The control unit 108 uses a program mapping 302 stored in its memory to map or correlate the detected power and speed (P, S) to the resulting output characteristics for a specific system or building 104, such as the head and flow rate (H, F) of the device 102. During operation, the control unit 108 uses the internal detector 304 to monitor the power and speed of the pump unit 106 and establish relevant head-flow conditions relative to system requirements. These relevant head-flow (H, F) conditions of the device 102 can be used to calculate the total output characteristics 114 of the device 102 at the load. Figure 1 The program mapping 302 can be used to map the power and speed of the control pump unit 106 to a control curve 208, where points on the control curve are used as desired unit setpoints. For example, refer to... Figure 1 As control valves 112a, 112b, 112c, and 112d open or close to regulate the flow rate to the cooling coils (e.g., loads 110a, 110b, 110c, and 110d), control device 108 automatically adjusts the pump speed to match the system pressure requirements at the current flow rate.

[0104] Note that the internal detector 304 used for self-testing device characteristics (device variables) contrasts with some systems that may use local pressure sensors and flow meters that only directly measure the pressure and flow rate across the control pump 102. In the example embodiment, these variables (local pressure sensors and flow meters) may not be considered device characteristics (device variables).

[0105] Another example embodiment of a sensorless variable-speed device is a compressor that estimates refrigerant flow rate and lift based on electrical variables provided by an electronically variable-speed drive. In example embodiments, the "sensorless" control system can be used in one or more cooling units within a controlled system, such as as part of a "chiller" or other cooling system. For example, the variable-speed device could be a cooling unit that includes a controllable variable-speed compressor. In some example embodiments, the self-testing characteristics of the cooling unit may include, for example, the compressor's power and / or speed. The resulting output characteristics may include variables such as temperature, humidity, flow rate, lift, and / or pressure.

[0106] Another example embodiment of a variable speed sensorless device is a fan, which estimates the airflow and the pressure it generates based on electrical variables provided by an electronically variable speed drive.

[0107] Another example embodiment of a sensorless device is a belt conveyor, which estimates its speed and the mass it carries based on electrical variables provided by an electronically variable speed drive.

[0108] Refer again Figure 5 In some example embodiments, control device 108a may be configured for "sensorless" operation. Input subsystem 522a may receive input variables. Input variables may include, for example, detector 304 ( Figure 3 This is used to detect device characteristics such as the power and speed (P, S) of a motor. Other example inputs may also be used. The output subsystem 520a can control output variables, such as controlling one or more operable elements of the pump 102a. For example, the output subsystem 520a can be configured to at least control the speed of the motor controlling the pump 102a in order to achieve a desired output setpoint for head and flow rate (H, F), for example, to operate the pump 102a on control curve 208. Figure 2 It can also control other example output variables, operable components, and device characteristics.

[0109] In some example embodiments, the control device 108a may store data in memory 508a, such as correlation data 510a. Correlation data 510a may include relevant information, for example, for correlation or inference between input variables and obtained output characteristics. Correlation data 510a may include, for example, program mapping 302 (… Figure 3 This can map power and speed to the flow rate and head obtained at pump 102, thereby generating the desired pressure setpoint at the load output. In other example embodiments, the relevant data 510a may be in the form of tables, models, equations, calculations, inference algorithms, or other suitable forms.

[0110] In some example embodiments, the relevant data 510a stores data such as the second control pump 102b ( Figure 1 (relevant information about some or all other devices 102.)

[0111] Still referencing Figure 5The control device 108a includes one or more application programs. In some example embodiments, the control device 108a includes an associated application 514a or an inference application that receives input variables (e.g., power and speed) and determines or infers the output characteristics (e.g., flow rate and head) obtained at pump 102a based on associated data 510a. In some example embodiments, the control device 108a includes a coordination module 515a that may be configured to receive the determined individual output characteristics from a second control device 108b and to logically coordinate each control device 108a, 108b, and provide commands or instructions to coordinately control each output subsystem 520a, 520b and the obtained output characteristics to achieve a specified output setpoint of output characteristic 114.

[0112] In some example embodiments, some or all of the relevant application 514a and / or coordination module 515a may alternatively be part of external controller 116.

[0113] In some example embodiments, in an example operating mode, control device 108a is configured to receive input variables from its input subsystem 522a and transmit information such as detection data (e.g., irrelevant measurement data) via communication subsystem 516a to another controller 116 or a second control device 108b for off-device processing, which then correlates the detection data with corresponding output characteristics. Off-device processing can also determine the aggregate output characteristics of all control devices 108a, 108b, such as the shared load output characteristic 114. Control device 108a can then receive instructions or commands via communication subsystem 516a regarding how to control output subsystem 520a, for example, to control local device characteristics or operable elements.

[0114] In some example embodiments, in another example operating mode, the control device 108a is configured to receive input variables of the second control device 108b as sensed data (e.g., irrelevant measurement data) from the second control device 108b or another controller 116 via the communication system 516a. The control device 108a may also sense its own input variables from the input subsystem 522a. Then, the relevant application 514a can be used to correlate the sensed data of all control devices 108a, 108b with their corresponding output characteristics. In some example embodiments, the coordination module 515a may determine the aggregate output characteristics of all control devices 108a, 108b, such as the output characteristics 114 of a common load. Then, the control device 108a can send instructions or commands to another controller 116 or the second control device 108b via the communication subsystem 516a regarding how the second control device 108b controls its output subsystem, e.g., to control its specific local device characteristics. The control device 108a can also control its own output subsystem 520a, e.g., to control its own device characteristics to the first control pump 102a( Figure 1 ).

[0115] In some other example embodiments, the control device 108a first maps the sensed data to output characteristics and sends the data as relevant data (e.g., inferred data). Similarly, the control device 108a can be configured to receive data as relevant data (e.g., inferred data) that has been mapped to output characteristics by the second control device 108b rather than just receiving the sensed data. Then the relevant data can be coordinated to control each control device 108a, 108b.

[0116] Referring again to Figure 1 , the speed of each control pump 102 can be controlled to achieve or maintain a constant inferred remote pressure by achieving or maintaining H = H1+(HD - H1)*(Q / QD)^2 (Equation 1 below), where H is the inferred local pressure, H1 is the remote pressure set point, HD is the local pressure under design conditions, Q is the inferred aggregate flow rate, and QD is the total flow rate under design conditions. In an example embodiment, when H < HD*(Q / QD)^2*(N + 〈0000356〉 + k) (Equation 2 below), the number of pumps in operation (N) increases, and if H > HD*(Q / QD)^2*(N - 〈0000356〉 - k2) (Equation 3 below) it decreases, where k and k2 are constants that ensure a dead zone near the sequencing threshold.

[0117] Now referring to Figure 8The diagram illustrates a flowchart of an example method 800 for coordinating the control of two or more control devices according to an example embodiment. Each of these devices includes a communication subsystem and is configured to self-detect one or more device characteristics that result in outputs having one or more output characteristics. At event 802, method 800 includes detecting inputs including one or more device characteristics of each device. At event 804, method 800 includes associating the detected one or more device characteristics with one or more output characteristics for each device at each corresponding device. The corresponding one or more output characteristics can then be calculated to determine their individual contributions to the system load point. At event 806, method 800 includes determining a total output characteristic to the load from the individual one or more output characteristics. At event 808, method 800 includes comparing the determined total output characteristic 114 with a setpoint, such as a pressure setpoint at the load. For example, it can be determined that one or more of the determined total output characteristics are greater than, less than, or appropriately maintained at the setpoint. For example, as described above, this control can be performed using Equation 1. At event 810, the method includes coordinating the control of each device to operate the corresponding one or more device characteristics to coordinate the corresponding one or more output characteristics to reach the setpoint. This may include responses to, for example, control curve 208 ( Figure 2 The method 800 can be used to increase, decrease, or maintain one or more corresponding device characteristics by using points on the device. Method 800 can be repeated, for example, as indicated by feedback loop 812. Method 800 can be automated, where manual control is not required.

[0118] In another example embodiment, method 800 may include a decision to turn one or more control pumps 102 on or off based on predetermined criteria. For example, as described above, equations 2 and 3 may be used to make the decision.

[0119] Although Figure 8 The method 800 shown is represented as a feedback loop 812, but in some other example embodiments, each event may represent a state-based operation or module rather than a time-series flow.

[0120] For example, refer to Figure 1 , Figure 8 Various events of method 800 can be executed individually or in combination by the first control device 108a, the second control device 108b and / or the external controller 116.

[0121] Now for reference Figure 6This illustration shows an example embodiment of a control system 600 for coordinating two or more sensorless control devices (two are shown), illustrated as a first control device 108a and a second control device 108b. The same reference numerals are used for ease of reference. As shown, each control device 108a, 108b may each include controllers 506a, 506b, input subsystems 522a, 522b, and output subsystems 520a, 520b, for example, to control at least one or more operable device components (not shown).

[0122] A coordination module 602 is shown, which may be part of at least one of the control devices 108a, 108b, or such as controller 116. Figure 1 A separate external device. Similarly, it is inferred that applications 514a, 514b may be part of at least one of control devices 108a, 108b, or such as controller 116 ( Figure 1 It is part of a separate device.

[0123] During operation, coordination module 602 coordinates control devices 108a and 108b to produce coordinated outputs. In the illustrated example embodiment, control devices 108a and 108b operate in parallel to meet specific needs or share load 114, and infer one or more values ​​of each device's output characteristic by inferring them indirectly from other measured input variables and / or device characteristics. This coordination is achieved by using inference applications 514a and 514b that receive measured inputs to calculate or infer the corresponding individual output characteristic (e.g., head and flow rate at each device) at each device 102. From those individual output characteristics, individual contributions from each device 102 to the load (individually to output characteristic 114) can be calculated based on system / building settings. From those individual contributions, coordination module 602 estimates one or more properties of the aggregated or combined output characteristic 114 at the system load of all control devices 108a and 108b. The coordination module 602 compares the setpoint of the combined output characteristics (typically a pressure variable) and then determines how and by what intensity the operable elements of each control device 108a, 108b should be controlled.

[0124] It should be understood that, depending on the specific property being calculated and taking into account the losses in the system, the aggregate or combined output characteristic 114 can be calculated as a linear or nonlinear combination of the individual output characteristics, where appropriate.

[0125] In some example embodiments, when the coordination module 602 is part of the first control device 108a, this can be considered a master-slave configuration, where the first control device 108a is the master device and the second control device 108b is the slave device. In another example embodiment, the coordination module 602 is embedded in more control devices 108a, 108b than actually needed for fail-safe redundancy.

[0126] Still referencing Figure 6 The controlled allocation of output subsystems 520a and 520b will now be described in more detail for some specific examples. In one example embodiment, for instance, when output subsystems 520a and 520b are associated with control device characteristics of equivalent type or performance, the device characteristics of each control pump 102 can be controlled to have equal device characteristics to allocate flow load requirements. In other example embodiments, unequal allocations may exist; for example, the first control pump 102a may have a higher device characteristic than the second control pump 102b. Figure 1 Higher flow rates. In another example embodiment, each control pump 102 can be controlled to optimally optimize the efficiency of the corresponding control pump 102 under partial load, for example, to maintain their respective control curves 208 ( Figure 2 ) or the optimal proximity point B(212) on their respective control curves 208.

[0127] Still referencing Figure 6 Under optimal system operating conditions, each of the control devices 108a and 108b is controlled by the coordination module 602 to operate according to their respective control curves 208. Figure 2 The pressure setpoint is maintained at output characteristic 114. This also allows each control pump 102 to be optimized for partial load operation. For example, each control pump 102 can be given a percentage flow allocation as an initial allocation (e.g., 50% can be allocated between each control unit 108a, 108b in this example) to determine or calculate the required initial setpoint (e.g., point A(210)). Figure 2 The percentage responsibility for the required flow rate of each control pump 102 can then be determined by dividing the percentage flow rate allocation by the inferred total output characteristic 114. Each control pump 102 can then be controlled along its control curve 208 to increase or decrease the operation of the motor or other operable elements to achieve the percentage responsibility for each required flow rate.

[0128] However, if it is determined that one of the control pumps (e.g., the first control pump 102a) is performing poorly or deviating from its control curve 208, the coordination module 602 may first attempt to control the first control pump 102a to operate on its control curve 208. However, if this is not possible (e.g., damage, poor performance, resulting in operation outside the operating range 202, or otherwise too far from the control curve 208, etc.), the remaining control pumps (e.g., 102b) can be controlled to increase their device characteristics on their respective control curves 208 so as to reach the pressure setpoint of the desired flow rate at the output characteristic 114 to compensate for at least some of the deficiencies of the first control pump 102a. Similarly, one of the control pumps 102 may be intentionally disabled (e.g., for maintenance, inspection, cost savings, overnight storage, etc.), with the remaining control pumps 102 controlled accordingly.

[0129] In other example embodiments, the allocation between output subsystems 520a and 520b can be dynamically adjusted over time to track and appropriately distribute wear among control pumps 102.

[0130] Now for reference Figure 7 This illustrates another example embodiment of a control system 700 for coordinating two or more sensorless control devices (two are shown), illustrated as a first control device 108a and a second control device 108b. The same reference numerals are used for ease of reference. In some example embodiments, this may be referred to as a peer system. In such example embodiments, an external controller 116 may not be required. In the illustrated example, each of the first control device 108a and the second control device 108b can control its own output subsystems 520a, 520b to achieve a coordinated combined system output 114. As shown, each coordination module 515a, 515b is configured to respectively consider inferred and / or measured values ​​from the two input subsystems 522a, 522b. For example, as shown, the first coordination module 515a can estimate one or more output characteristics of the combined output characteristic 114 from the individual inferred and / or measured values.

[0131] As shown in the figure, the first coordination module 515a receives inferred and / or measured values ​​and calculates individual output characteristics (e.g., head and flow rate) for each device 102. From those individual output characteristics, individual contributions from each device 102 to the load (individually to output characteristic 114) can be calculated based on system / building settings. The first coordination module 515a can then calculate or infer the aggregate output characteristic 114 at the load.

[0132] Then, the first coordination module 515a compares the inferred total output characteristic 114 with the setpoint of the output characteristic (typically the pressure variable setpoint) and determines the individual allocation contribution required by the first output subsystem 520a (e.g., in this example, calculating 50% of the required total contribution). The first output subsystem 520a is then controlled at a controlled intensity (e.g., increasing, decreasing, or maintaining the speed of the motor or other device characteristics) to further infer the obtained coordinated output characteristic through further measurements at the input subsystems 522a, 522b.

[0133] like Figure 7 As shown, the second coordination module 515b may be constructed similarly to the first coordination module 515a to take into account the input subsystems 522a, 522b to control the second output subsystem 520b. For example, each control pump 102 may initially be given a percentage flow allocation. Based on the total load output characteristic 114, each control pump 102 can then be controlled along its control curve 208 to increase or decrease the operation of the motor or other operable elements. The total load output characteristic 114 can be used to calculate the required flow rate for each control pump 102 and the corresponding motor speed (e.g., to maintain a percentage flow rate, such as 50% for each output subsystem 520a, 520b in this example). Therefore, the two coordination modules 515a, 515b operate together to coordinate their respective output subsystems 520a, 520b to achieve a selected output setpoint at the load output characteristic 114.

[0134] like Figure 7 As shown, note that in some example embodiments, each of the coordination modules 515a, 515b does not need to communicate with each other to function functionally in coordination. In other example embodiments not shown, the coordination modules 515a, 515b communicate with each other for additional coordination among themselves.

[0135] Now for reference Figure 17A , 17BImages 17C, 17D, 17E, 17F, 17G, and 17H illustrate a pump unit 1700 according to an exemplary embodiment. In the exemplary embodiment, pump unit 1700 illustrates a single controlled pump in a vertically in-line closed-loop configuration. Pump unit 1700 is an integrated unit where components are physically integrated together as a single unit. Pump unit 1700 includes a controller device 1708 (including a controller / processor) and a pump device 1706, which may employ various forms of pumps with variable speed control. Pump unit 1700 includes a pump impeller within a sealed housing housing 1706, which includes a suction flange 1724 for connection to a line for receiving circulating media and a discharge flange 1726 for connection to a line for discharging circulating media. Pump unit 1700 includes a suction compartment 1728. A volute 1730 is fed from suction compartment 1728 and serves to house the pump impeller. A corresponding variable motor (not shown) can be variably controlled from control device 1708 to rotate at a variable speed. Pump unit 1700 may also include a touchscreen 1720 for interaction, input, and / or output between the user and control device 1708. Pump impellers are operatively coupled to the motor and rotate based on the motor speed to circulate the circulating medium. In an example embodiment, control device 1708 is configured to control the corresponding pump impeller within a range of 0% to 100% of the motor speed. Volute 1730 may be configured to receive the circulating medium pumped by the corresponding pump impeller. Volute 1730 may include a curved funnel portion whose area increases near the discharge flange 1726. The housing of pump unit 1700 also includes a base housing 1734 that houses one or more shafts between the pump motor and the pump impeller.

[0136] Figure 17A and 17H The pump unit 1700 is shown to have a flat bottom feature. In an example embodiment, the suction compartment 1728 includes an outer flange 1738 with a flat bottom. As shown, the outer flange 1738 defines a flat surface. For example, the outer flange 1738 provides a flat contact area, allowing the pump unit 1700 to stand independently on the flat surface, for example, during the setup and installation of the pump unit 1700. For example, the flat bottom allows the pump unit 1700 to stand upright during assembly, packaging, and / or installation processes. In an example embodiment, the outer flange 1738 is integrally formed and integral with the corresponding suction compartment 1728, for example, during casting or molding.

[0137] Now for reference Figure 18A , 18BModels 18C, 18D, 18E, 18F, 18G, and 18H illustrate a pump unit 1800 according to an example embodiment. Pump unit 1800 is similar to pump unit 1700, but differs in that, according to the example embodiment, a single control pump is in a vertically inline, discretely coupled configuration. Pump unit 1800 may also include a touchscreen 1820 for user interaction, input, and / or output.

[0138] For pump unit 1800, the connection between the pump motor and the corresponding pump impeller can be split into two separate shafts and also includes pump seals (not shown). In the example embodiment, this connection is axially separated, and a spacer-type rigid coupling allows maintenance of the seals without interfering with the pump impeller and / or pump motor. For example, there may be a front removable cover 1836 and a rear removable cover 1837. When covers 1836, 1837 are removed, for example, the seals (not shown) of each pump motor within the base housing can be replaced without removing the corresponding pump motor.

[0139] In the example embodiment, example screenshots of touchscreens 1720 and 1820 are shown in... Figure 16A , 16B As shown in 16C and 16D. These screenshots illustrate example user sections that can be used in pump units 1700 and 1800 to facilitate the setup and / or commissioning of the corresponding control devices for the respective control pumps.

[0140] Although the example embodiments have been described primarily with respect to a single pump unit, in some example embodiments, multiple such pump units may be used in the system, for example, arranged in parallel. In some example embodiments, the pump units may be arranged in series, for example, for piping, boosters, or other such applications. In such example embodiments, the resulting output characteristics can still be coordinated. For example, the load output setpoint and output characteristics may be located at the ends of the series connection. In such example embodiments, the control of the output subsystem, device characteristics, and operable elements can still be performed in a coordinated manner. In some example embodiments, the pump units can be arranged in a combination of series and parallel connections.

[0141] Variations can be made in the example embodiments. Some example embodiments can be applied to any variable speed device and are not limited to variable speed controlled pumps. For example, some other embodiments may use different parameters or variables, and may use more than two parameters (e.g., three parameters on a three-dimensional graph). For example, speed (rpm) is also shown on the described control curve. Furthermore, temperature (Celsius / Fahrenheit) versus temperature load (joules or BTU / hour) may be a parameter or variable considered for use in the control curve, such as by a variable speed circulating fan. Some example embodiments can be applied to any device that depends on two or more related parameters. Some example embodiments may include a range of parameters or variables depending on factors such as liquid, temperature, viscosity, suction pressure, site height, and the number of pumps operating.

[0142] In the example embodiments, each illustrated block or module may represent software, hardware, or a combination of hardware and software, where appropriate. Furthermore, some blocks or modules may be combined in other example embodiments, and more or fewer blocks or modules may exist in other example embodiments. Additionally, in other embodiments, some blocks or modules may be divided into multiple sub-blocks or sub-modules.

[0143] While some current embodiments have been described in terms of method, those skilled in the art will understand that the current embodiments also relate to various devices, such as server devices that include components for performing at least some aspects and features of the described methods, which may be assisted by hardware components, software, or any combination of both or in any other way. Furthermore, articles of art used with devices such as pre-recorded storage devices or other similar non-transitory computer-readable media including program instructions recorded thereon, or computer data signals carrying computer-readable program instructions, can instruct the devices to facilitate the practice of the described methods. It should be understood that such devices, articles of art, and computer design signals are also within the scope of the current exemplary embodiments.

[0144] While some of the examples described above have been presented in a specific order, those skilled in the art will understand that some messages, steps, or processes may be performed in a different order, as long as changing the order of any given step does not prevent or impair the occurrence of subsequent steps. Furthermore, in other embodiments, some of the above-described messages or steps may be removed or combined, and in other embodiments, some of the above-described messages or steps may be divided into many sub-messages or sub-steps. Moreover, some or all of the steps of a dialogue may be repeated when needed. Elements described as methods or steps are similarly applicable to systems or subcomponents, and vice versa.

[0145] As used herein, the term "computer-readable medium" includes any medium that can store instructions, program steps, or the like for use by or execution by a computer or other computing device, including, but not limited to: magnetic media such as magnetic disks, disk drives, magnetic drums, magneto-optical disks, magnetic tapes, magnetic core memory, or the like; electronic storage such as any type of random access memory (RAM), including static RAM, dynamic RAM, synchronous dynamic RAM (SDRAM), read-only memory (ROM), any type of programmable read-only memory, including PROM, EPROM, EEPROM, FLASH, EAROM, so-called "solid-state disks," any other type of electronic storage including charge-connected devices (CCDs) or bubble memory, any type of portable electronic data carrying card, including compact flash memory, secure digital card (SD-CARD), memory stick, and the like; and optical media such as optical discs (CDs), digital versatile optical discs (DVDs), or Blu-ray discs.

[0146] Variations can be made to some of the example embodiments, which may include any of the above combinations and sub-combinations. The embodiments shown above are merely examples and are by no means intended to limit the scope of this disclosure. Variations of the innovations described herein will be apparent to those skilled in the art who will benefit from this disclosure, and these variations are within the scope of this disclosure. Specifically, one or more features of the above embodiments can be selected to produce alternative embodiments including combinations of features that may not have been described in detail above. Additionally, one or more features of the above embodiments can be selected and combined to produce alternative embodiments including combinations of features that may not have been described in detail above. After reading this disclosure in its entirety, features suitable for such combinations and sub-combinations will be apparent to those skilled in the art. The subject matter described herein is intended to cover and encompass all suitable technical variations.

Claims

1. A pump unit, comprising: The housing includes a first base housing, a second base housing, a first motor housing, a second motor housing, a suction flange, and a discharge flange; A first pump is located within the housing and is hydraulically fed from the suction flange; The first shaft is located within the first base housing. The first pair of removable covers are located on opposite sides of the first base housing for accessing the first shaft; A first motor, the first motor being located within a first motor housing; A second pump, located within the housing, is hydraulically fed from the suction flange and provides a parallel hydraulic path to the first pump, wherein the discharge flange is hydraulically fed by both the first and second pumps; The second shaft is located within the second base housing; The second pair of removable covers are located on opposite sides of the second base housing for accessing the second shaft; The second motor is located inside the second motor housing; A first touchscreen, attached to the first motor housing, is used for input and / or output associated with the first pump; A first controller is used to control the operation of the first touchscreen and the first pump; A second touchscreen, attached to the second motor housing, is used for inputs and / or outputs associated with the second pump; A second controller, used to control the operation of the second touchscreen and the second pump; and A valve, which hydraulically connects the first pump and the second pump to the discharge flange. The pump unit is a vertically aligned, separately connected unit. In the vertical orientation, the housing is generally vertically symmetrical and includes a flat bottom.

2. The pump unit as described in claim 1, characterized in that, The first controller and the second controller are configured to control the first pump and the second pump, respectively, within any symmetrical or asymmetrical range of parallel flow operation of the first pump and the second pump.

3. The pump unit as described in claim 1, characterized in that, The first controller and the second controller are configured to control the first pump and the second pump respectively within the range of 0% to 100% of the motor speed.

4. The pump unit as described in claim 1, characterized in that, The first touchscreen and / or the second touchscreen are configured to debug and / or set the first pump and / or the second pump, respectively.

5. The pump unit as described in claim 1, characterized in that, When the first pump and the second pump rotate at the same speed, the housing and the hydraulic characteristics of each pump provide the same net flow rate and head pressure.

6. The pump unit as claimed in claim 1, characterized in that, When the first pump and the second pump rotate at the same speed, the hydraulic characteristics of the housing and each pump provide the same but opposite rotational paths.

7. The pump unit as claimed in claim 1, characterized in that, It also includes a coordination module configured to deactivate the first motor or the second motor for maintenance or inspection, and to operate the other of the first motor or the second motor during the maintenance or inspection.

8. The pump unit as claimed in claim 1, characterized in that, The flat bottom includes two flat contact areas, which include a first outer flange and a second outer flange. When the pump unit is vertically oriented, the suction flange and the discharge flange are in a floating state and are above the first outer flange and the second outer flange.

9. The pump unit as claimed in claim 8, characterized in that, The first outer flange has a first flat surface, and when the pump unit is vertically oriented, the first outer flange extends to a position lower than the suction flange and the discharge flange; and The second outer flange has a second flat surface, and when the pump unit is vertically oriented, the second outer flange extends to a position lower than the suction flange and the discharge flange.

10. The pump unit as claimed in claim 9, characterized in that, When the pump unit is vertically oriented, the first outer flange and the second outer flange are horizontally aligned, such that the first outer flange and the second outer flange together provide the flat bottom.

11. The pump unit as claimed in claim 9, characterized in that, The first outer flange and the second outer flange each have a corresponding flat cross shape, and the corresponding flat cross shape together defines the flat bottom.

12. The pump unit as claimed in claim 1, characterized in that, It also includes a coordination module configured to coordinate the operation of the first motor and the second motor.

13. The pump unit as claimed in claim 12, characterized in that, The coordinated operation includes shutting down only one of the first motor or the second motor for inspection, while running the other of the first motor or the second motor.

14. The pump unit as claimed in claim 12, characterized in that, The coordinated operation includes shutting down only one of the first motor or the second motor for maintenance, while operating the other of the first motor or the second motor.

15. The pump unit as claimed in claim 14, characterized in that, The maintenance includes sealing maintenance of the first motor without removing the first pump, and is performed by opening one of the first pair of removable covers.

16. Use of the pump unit as claimed in claim 15, including opening the removable cover and performing maintenance on the seal.

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