Backpressure electric diaphragm pump with self-adaptive capacity

Abstract

A backpressure electric diaphragm pump with self-adaptive capacity comprises a pump body and a torque output control system. The pump body comprises a discharging end and a driving motor. The torque output control system comprises an initialization setting unit, a pressure monitoring unit, a torque calculation unit, a torque monitoring unit, a comparison unit, a delay unit and a torque control unit for outputting torque. The adjusted output torque of the driving motor is lower than the output torque threshold value. According to the backpressure electric diaphragm pump, the torque output control system is arranged to control the output torque of the driving motor, and when backpressure occurs and is true backpressure, the output torque of the driving motor is reduced, so that the situation that the driving motor or other elements such as a diaphragm and a connecting rod shaft in the pump body are damaged due to the fact that the output torque is too large is avoided, and the service life of the diaphragm pump is prolonged. Therefore, the pump body can be prevented from being damaged by backpressure while the operation efficiency is ensured, and the production cost rise caused by the damage of the pump body is reduced.

Description

Technical Field

[0001] This invention relates to the field of diaphragm pump technology, and in particular to a back pressure electric diaphragm pump with adaptive capability. Background Technology

[0002] A diaphragm pump is a special type of pump whose most significant characteristic is its ability to transport liquids by compressing and expanding a diaphragm. This type of pump typically consists of two diaphragms that alternately inflate and deflate on either side of the pump, thus performing the suction and transport of fluids. If the diaphragm pump has two inlets, it can even simultaneously transport two fluids, either separately or together.

[0003] Diaphragm pumps have a wide range of applications due to their unique operating principle. For example, in the chemical industry, diaphragm pumps can be used to transport corrosive liquids, or in the food industry to transport liquid foods. Furthermore, diaphragm pumps can also be used to transport viscous liquids, which is difficult for other types of pumps to do.

[0004] Diaphragm pumps are designed to adapt to various working environments and fluid types. Their robust design allows them to operate in harsh environments, such as extreme conditions involving high temperatures, low temperatures, and high pressures. Furthermore, their ability to handle a wide range of fluids makes diaphragm pumps an ideal choice for many applications. In summary, diaphragm pumps are efficient, reliable, and highly adaptable partners with broad application prospects in both industrial production and daily life.

[0005] However, when flow becomes obstructed at the outlet of the diaphragm pump, such as when the pipe connected to the pump's outlet becomes blocked, the pressure inside the pump will increase; this phenomenon is called back pressure. If back pressure is not addressed promptly, it can easily damage the diaphragm pump, such as rupturing the diaphragm or breaking the output shaft connected to it. Currently, to prevent back pressure, safety valves are typically installed on diaphragm pumps to control the pump's output pressure and protect the normal operation of the delivery pipeline. Although safety valves are widely used by customers due to their low cost, they still cannot fully protect the pump unit and pipeline system in the field. Furthermore, when the diaphragm pump is conveying special materials, pipeline blockages cannot prevent it from stopping, leading to damage to the pump's internal transmission structure due to overpressure. Summary of the Invention

[0006] In view of this, the present invention provides an adaptive back pressure electric diaphragm pump that can solve the above problems.

[0007] An adaptive back-pressure electric diaphragm pump includes a pump body and a torque output control system disposed on the pump body. The pump body includes a main body, a pair of discharge ends disposed on one side of the main body, and a drive motor connected to the main body. The torque output control system includes an initialization setting unit, a pressure monitoring unit for monitoring the pressure at the discharge ends, a torque calculation unit electrically connected to the pressure monitoring unit, a torque monitoring unit for monitoring the torque at the output end of the drive motor, a comparison unit electrically connected to both the torque calculation unit and the torque monitoring unit, a delay unit, and a torque control unit for controlling the output torque of the drive motor based on the torque value monitored by the torque monitoring unit. The initialization setting unit is used to set the output pressure threshold of the pump body in normal state, the output torque threshold of the drive motor in normal state, and the time length threshold for back pressure occurrence. The pressure monitoring unit is used to monitor the instantaneous pressure at the discharge ends. The torque calculation unit calculates the required torque value output by the drive motor based on the pressure value from the pressure monitoring unit. The torque monitoring unit is used to detect the instantaneous torque magnitude at the output end of the drive motor. The comparison unit compares the torque value measured by the torque monitoring unit with the torque value calculated by the torque calculation unit. The extension unit maintains the output pressure value at the discharge end for a specified duration when the difference between the torque value measured by the torque monitoring unit and the torque value calculated by the torque calculation unit is negative. The torque control unit adjusts the output power of the drive motor based on the torque value monitored by the torque monitoring unit when the duration is greater than or equal to a set threshold. The adjusted output torque of the drive motor is lower than the output torque threshold.

[0008] Furthermore, the pump body also includes a feed end disposed on the main body.

[0009] Furthermore, the torque calculation unit is electrically connected to the pressure monitoring unit to collect the instantaneous pressure value detected by the pressure monitoring unit.

[0010] Furthermore, the comparison unit calculates whether the difference between the torque value measured by the torque monitoring unit and the torque value calculated by the torque calculation unit is positive or negative.

[0011] Furthermore, when the difference between the torque value measured by the torque monitoring unit and the torque value calculated by the torque calculation unit is positive, the pump body is in normal working condition.

[0012] Furthermore, when the difference between the torque value measured by the torque monitoring unit and the torque value calculated by the torque calculation unit is negative, the pump body is in an abnormal working state.

[0013] Furthermore, the modified output power of the drive motor makes the output pressure value at the discharge end less than or equal to the set output pressure threshold.

[0014] Compared with existing technologies, the adaptive backpressure electric diaphragm pump provided by this invention controls the output torque of the drive motor by setting the torque output control system. When backpressure occurs and is a true backpressure, the output torque of the drive motor is reduced to avoid excessive output torque that could damage the drive motor or other components in the pump body, such as the diaphragm, connecting rod shaft, etc. Specifically, the torque output control system includes a pressure monitoring unit, a torque calculation unit, a comparison unit, a delay unit, and a torque control unit. When the pressure monitoring unit detects that the output pressure value at the discharge end is greater than the output pressure threshold, the torque calculation unit calculates the output torque value of the drive motor corresponding to the output pressure value. Simultaneously, the torque monitoring unit monitors the instantaneous torque of the drive motor. When the instantaneous torque is greater than the output torque threshold but less than the output torque calculated by the torque calculation unit, the delay unit performs a delay to determine whether the backpressure is a true or false backpressure. If the time for which the instantaneous torque is less than the output torque calculated by the torque calculation unit exceeds a set time threshold, it is considered true back pressure. In this case, the torque control unit adjusts the output torque of the drive motor, ensuring that the output torque is less than or equal to the output torque threshold. This prevents damage to the pump body due to back pressure while maintaining operating efficiency, reducing production costs caused by pump damage. Furthermore, the adjustment of the drive motor is automatic, making the adjustment and correction of back pressure adaptive and requiring no active user intervention. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of an adaptive back pressure electric diaphragm pump provided by the present invention.

[0016] Figure 2 for Figure 1 The schematic diagram of the torque output control system of an adaptive back pressure electric diaphragm pump. Detailed Implementation

[0017] The following provides a more detailed description of specific embodiments of the present invention. It should be understood that the description of the embodiments of the present invention herein is not intended to limit the scope of protection of the present invention.

[0018] like Figures 1 to 2 The diagram shown is a structural schematic of an adaptive back-pressure electric diaphragm pump provided by the present invention. The adaptive back-pressure electric diaphragm pump includes a pump body 10 and a torque output control system 20 disposed on the pump body 10. It is conceivable that the adaptive back-pressure electric diaphragm pump may also include other functional modules, such as mounting components, assembly components, electrical connection components, etc., but these are prior art and well known to those skilled in the art, and will not be described in detail here.

[0019] The pump body 10, being a diaphragm pump, is itself prior art. Therefore, the various functional components included in the pump body 10, such as the diaphragm, piston, connecting rod shaft, sealing ring, valve ball, plug, etc., should be known to those skilled in the art and will not be described in detail here. In this embodiment, only the functional components associated with the present invention will be briefly described. The pump body 10 includes a main body 11, an inlet end 12 disposed on one side of the main body 11, a pair of outlet ends 13 disposed on the other side of the main body 11, and a drive motor 14 connected to the main body 11. The main body 11 is used to perform the pumping function under the drive of the drive motor 14. As is well known, for performing the pumping function, the main body 11 should include a housing, a diaphragm housed within the housing, a cap, a connecting rod shaft, and sealing components, etc., which are prior art and will not be described in detail here. The inlet end 12 is used to draw up unpumped liquid, and therefore the inlet end 12 can be connected to a storage device. The discharge end 13 is used to discharge the liquid pumped by the main body 11. Therefore, the discharge end 13 is connected to a feeding device or external equipment, that is, the discharge end 13 delivers the pumped liquid to the feeding device or external equipment for use. It is understandable that when the feeding device or external equipment cannot process the pumped material in time, such as when blockage or fullness occurs, the pressure at the discharge end 13 will increase, and this pressure will be transmitted to the main body 11; this is the back pressure phenomenon. It is conceivable that if the main body 11 cannot handle this back pressure in a timely, correct, and effective manner, the diaphragm and connecting rod shaft inside the main body 11 will be affected, deformed, or even damaged, thereby damaging the entire diaphragm pump and causing certain losses to the entire production system. The drive motor 14 is used to drive the diaphragm of the main body 11 to move left and right in the cavity for the purpose of material suction and feeding. It is conceivable that an eccentric wheel is provided between the output end of the drive motor 14 and the connecting rod shaft of the main body 11. The eccentric wheel converts the rotational motion of the output of the drive motor 14 into a reciprocating motion in the left-right direction, thereby driving the diaphragm to move left and right within the cavity. Figure 1 In order to show more components, the cavity shell is not shown.

[0020] The torque output control system 20 includes an initialization setting unit 21, a pressure monitoring unit 22 for monitoring the pressure at the discharge end 13, a torque calculation unit 23 electrically connected to the pressure monitoring unit 22, a torque monitoring unit 24 for monitoring the torque at the output end of the drive motor 14, a comparison unit 25 electrically connected to both the torque calculation unit 23 and the torque monitoring unit 24, a delay unit 26, and a torque control unit 27 for controlling the output torque of the drive motor 14 based on the torque value monitored by the torque monitoring unit 24. It is conceivable that the torque output control system 20 also includes other hardware or software functional modules, such as processors, circuit boards, electrical connection components, and data processing programs, etc., which are technologies well known to those skilled in the art and will not be described in detail here.

[0021] It should be further noted that the above-mentioned functional modules of the torque output control system 20 can be executed by a computer program. Such a computer program should be able to be compiled by those skilled in the art after understanding the spirit of the present invention, and will not be described further here.

[0022] The initialization setting unit 21 is used to set the output pressure threshold of the discharge end 13 of the pump body 10 under normal conditions, the output torque threshold of the drive motor 14 under normal conditions, and the time length threshold for back pressure occurrence. The initialization setting unit 21 allows the user to control the working state of the pump body 10 according to actual needs. It is conceivable that the initialization setting unit 21 is connected to an input / output interface to facilitate user data input and real-time reading of the working state of the pump body 10, such as output pressure, the current torque value of the drive motor 14, and the current input voltage and current values. The output pressure threshold is the value at which the output pressure of the discharge end 13 cannot exceed the threshold when the pump body 10 is working normally; otherwise, back pressure will occur. The output torque threshold is the value at which the output torque value of the drive motor 14 should not exceed the threshold when the pump body 10 is working normally. If it exceeds the threshold, it indicates that the output pressure of the discharge end 13 has definitely exceeded the output pressure threshold, meaning that back pressure has definitely occurred and correction is needed. The time length threshold refers to the duration of back pressure occurrence, because sometimes the back pressure may be spurious, such as when fluctuations occur due to the use of external equipment. When spurious back pressure occurs, there is no need to correct the output torque of the drive motor 14, otherwise it will affect the working efficiency.

[0023] The pressure monitoring unit 22 is a prior art technology and can be a pressure sensor. A pressure sensor is a device or apparatus that can sense pressure signals and convert them into usable output electrical signals according to a certain rule. The pressure monitoring unit 22 can be installed on the discharge end 13 of the pump body 10 to monitor the instantaneous pressure of the discharge end 13. Simultaneously, the pressure monitoring unit 22 can be installed on the discharge end 13 of the pump body 10 so that the pressure monitoring unit 22 and the pump body 10 are integrated, facilitating sale and assembly with other equipment. When the pressure collected by the pressure monitoring unit 22 is greater than the output pressure value set by the initialization setting unit 21 under normal conditions, it is considered that a back pressure phenomenon may have occurred, that is, the external equipment connected to the discharge end 13 may be malfunctioning and unable to discharge the material output from the discharge end 13 in a timely manner. Intervention may be necessary in this case to avoid damage to the pump body 10. Here, "may" means that there may be accidental errors or malfunctions of the external equipment, which may quickly return to normal operation on its own. When the pressure collected by the pressure monitoring unit 22 is less than the output pressure value of the normal state set by the initialization setting unit 21, no intervention is required, because this may be before or after the end of operation, or when other equipment connected to the pump body 10 is malfunctioning, such as a sudden increase in usage.

[0024] The torque calculation unit 23 is electrically connected to the pressure monitoring unit 22 and collects the output pressure value returned by the pressure monitoring unit 22 in a timely manner. Based on the output pressure value of the pressure monitoring unit 22, it calculates the required torque value of the drive motor 14. It is understood that, in order to correlate the output pressure value with the output torque value of the drive motor 14, data collection and statistics should be performed after the pump body 10 is assembled and manufactured, and a corresponding database should be compiled so that each output pressure value corresponds to an output torque value. Furthermore, since the external devices connected to the pump body 10 are complex and not singular, the data in this database should be theoretical, not actually measured. Simultaneously, this database should be stored in a memory chip and executed by a computer program.

[0025] The torque monitoring unit 24 can be a monitor installed at the output end of the drive motor 14, specifically between the eccentric wheel and the connecting rod shaft at the output end of the drive motor 14, used to test the instantaneous torque at the output end of the drive motor 14. Alternatively, the torque monitoring unit 24 can also calculate the torque based on the input current of the drive motor 14; this is existing technology and will not be elaborated further. In practical applications, the output pressure value of the discharge end 13 fluctuates significantly because it is connected to external equipment and is greatly affected by it. Sometimes the output pressure value of the discharge end 13 exceeds the set value, but this does not necessarily indicate back pressure, and correction is not necessary. However, the changes in the output pressure value of the discharge end 13 are very timely, therefore monitoring of the output pressure value of the discharge end 13 is essential. The torque measured by the torque monitoring unit 24 at the output of the drive motor 14 is an instantaneous torque. This instantaneous torque value is usually a normal value because the output of the drive motor 14 is usually made of metal, while the diaphragm and sealing components of the pump body 10 are made of non-metal. Therefore, when back pressure occurs in the pump body 10, the diaphragm will expand first, but the torque at the output of the drive motor 14 will not increase until the diaphragm expands to a certain extent, which will force the torque at the output of the drive motor 14 to increase. At this time, back pressure has definitely occurred and needs to be corrected immediately. Therefore, when back pressure occurs, the increase in torque at the output of the drive motor 14 is relatively delayed.

[0026] The comparison unit 25 is used to compare the torque value measured by the torque monitoring unit 24 with the torque value calculated by the torque calculation unit 23, that is, to calculate whether the difference between the torque value measured by the torque monitoring unit 24 and the torque value calculated by the torque calculation unit 23 is positive or negative. Under normal conditions, the torque value calculated by the torque calculation unit 23 should be less than the torque value measured by the torque monitoring unit 24, because the pump body 10 experiences losses during operation, and the torque output by the drive motor 14 cannot be entirely converted into the pressure value of the discharge end 13. Therefore, when the torque value measured by the torque monitoring unit 24 is less than the torque value calculated by the torque calculation unit 23, an abnormality has definitely occurred, but this abnormality may be false, that is, it may be caused by accidental errors of external equipment. When the torque value measured by the torque monitoring unit 24 is greater than or equal to the torque value calculated by the torque calculation unit 23, the operating state of the pump body 10 should be normal.

[0027] The extension unit 26 is used to maintain the output pressure value of the discharge end 13 for a certain period of time when the torque value measured by the torque monitoring unit 24 is less than the torque value calculated by the torque calculation unit 23 (i.e., the difference is negative). If this time is greater than or equal to a set time threshold, it can be determined that back pressure has occurred, and the output torque of the drive motor 14 needs to be adjusted immediately; otherwise, a component of the pump body 10 may be damaged, causing unnecessary losses. If the time is less than or equal to the set time threshold, it can be considered that this is only due to fluctuations in external equipment, and there is no need to correct the output torque of the drive motor 14.

[0028] The torque control unit 27 is used to adjust or correct the output power of the drive motor 14 based on the torque value monitored by the torque monitoring unit 24 when the time length is greater than or equal to a set time length threshold. The corrected output torque of the drive motor 14 should be lower than the output torque threshold, that is, the corrected output power of the drive motor 14 should make the output pressure value of the discharge end 13 less than or equal to the set output pressure threshold. As long as the output pressure value of the discharge end 13 is less than or equal to the set output pressure threshold, the pump body 10 will not be damaged due to back pressure, regardless of whether the external equipment malfunctions.

[0029] Compared with existing technologies, the adaptive backpressure electric diaphragm pump provided by the present invention controls the output torque of the drive motor 14 by setting the torque output control system 20. When backpressure occurs and is a true backpressure, the output torque of the drive motor 14 is reduced to avoid excessive output torque that could damage the drive motor 14 or other components within the pump body 10, such as the diaphragm, connecting rod shaft, etc. Specifically, the torque output control system 20 includes the pressure monitoring unit 22, the torque calculation unit 23, the torque monitoring unit 24, the comparison unit 25, the delay unit 26, and the torque control unit 27. When the pressure monitoring unit 22 detects that the output pressure value at the discharge end 13 is greater than the output pressure threshold, the torque calculation unit 23 calculates the output torque value of the drive motor 14 corresponding to the output pressure value. Simultaneously, the torque monitoring unit 24 monitors the instantaneous torque of the drive motor 14. When the instantaneous torque is greater than the output torque threshold but less than the output torque calculated by the torque calculation unit 23, the delay unit 26 performs a delay to determine whether the back pressure is true or false. If the time for which the instantaneous torque is less than the output torque calculated by the torque calculation unit 23 exceeds a set time length threshold, it is considered true back pressure. At this time, the torque control unit 27 adjusts the output torque of the drive motor 14 so that the output torque is less than or equal to the output torque threshold. This ensures operating efficiency while avoiding damage to the pump body 10 due to back pressure, reducing the increase in production costs caused by damage to the pump body 10. Furthermore, the adjustment of the drive motor 14 is automatic, making the adjustment and correction of back pressure adaptive without requiring active user intervention.

[0030] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions or improvements within the spirit of the present invention are covered within the scope of the claims of the present invention.

Claims

1. A back-pressure electric diaphragm pump with adaptive capability, characterized in that: The adaptive back-pressure electric diaphragm pump includes a pump body and a torque output control system mounted on the pump body. The pump body includes a main body, a pair of discharge ends disposed on one side of the main body, and a drive motor connected to the main body. The torque output control system includes an initialization setting unit, a pressure monitoring unit for monitoring the pressure at the discharge ends, a torque calculation unit electrically connected to the pressure monitoring unit, a torque monitoring unit for monitoring the output torque of the drive motor, a comparison unit electrically connected to the torque calculation unit and the torque monitoring unit respectively, a delay unit, and a torque control unit for controlling the output torque of the drive motor based on the torque value monitored by the torque monitoring unit. The initialization setting unit is used to set the output pressure threshold of the pump body and the output torque threshold of the drive motor in normal conditions. The pressure monitoring unit monitors the instantaneous pressure at the discharge end, and the torque calculation unit calculates the required torque value of the drive motor based on the pressure value of the pressure monitoring unit. The torque monitoring unit detects the instantaneous torque at the output end of the drive motor. The comparison unit compares the torque value measured by the torque monitoring unit with the torque value calculated by the torque calculation unit. The extension unit maintains the output pressure value at the discharge end for a negative difference when the torque value measured by the torque monitoring unit is less than the torque value calculated by the torque calculation unit. The torque control unit adjusts the output power of the drive motor based on the torque value monitored by the torque monitoring unit when the time length is greater than or equal to a set time length threshold. The adjusted output torque of the drive motor is lower than the output torque threshold.

2. The adaptive back-pressure electric diaphragm pump as described in claim 1, characterized in that: The pump body also includes a feed end disposed on the main body.

3. The adaptive back-pressure electric diaphragm pump as described in claim 1, characterized in that: The torque calculation unit is electrically connected to the pressure monitoring unit to collect the real-time pressure value detected by the pressure monitoring unit.

4. The adaptive back-pressure electric diaphragm pump as described in claim 1, characterized in that: The comparison unit calculates whether the difference between the torque value measured by the torque monitoring unit and the torque value calculated by the torque calculation unit is positive or negative.

5. The adaptive back-pressure electric diaphragm pump as described in claim 1, characterized in that: When the difference between the torque value measured by the torque monitoring unit and the torque value calculated by the torque calculation unit is positive, the pump body is in normal working condition.

6. The adaptive back-pressure electric diaphragm pump as described in claim 1, characterized in that: When the difference between the torque value measured by the torque monitoring unit and the torque value calculated by the torque calculation unit is negative, the pump body is in an abnormal working state.

7. The adaptive back-pressure electric diaphragm pump as described in claim 1, characterized in that: The corrected output power of the drive motor makes the output pressure value at the discharge end less than or equal to the set output pressure threshold.

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