Pneumatic pump control system

Abstract

A pneumatic pump control system includes a pump chamber having an inlet check valve, a discharge tube with a discharge check valve, and an air valve selectively operable to vent air from the pump chamber or introduce pressurized air therein. Liquid enters the pump chamber during a filling phase as air is vented, and pressurized air is subsequently introduced to displace the liquid through the discharge tube. A float within the pump chamber rises and sinks with the liquid level, and a pressure sensor detects internal pressure conditions indicative of predetermined high and low liquid levels. A controller governs operation of the air valve based on the detected pressure conditions to initiate discharge and terminate pressurized air introduction upon completion of liquid evacuation. The system operates in a closed-loop manner based on internal pressure behavior thereby preventing air entrainment, avoiding over-discharge, and enabling repeatable pumping across varying operating conditions.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. provisional application No. 63 / 746,570 filed Jan. 17, 2025, which is hereby incorporated herein in its entirety by reference.TECHNICAL FIELD

[0002] The present invention relates to the field of pneumatic pumps, and, more particularly, to a pneumatic pump control system.BACKGROUND

[0003] Pneumatic pumps are devices that use compressed air to move fluids, including liquids and gases, from one location to another. Such pumps operate by converting the energy of compressed air into mechanical motion or pressure differentials that drive fluid movement through a pumping chamber and associated conduits. Pneumatic pumps are widely used across a variety of industrial and environmental applications due to their relative simplicity, reliability, and ability to handle a wide range of fluids, including corrosive, abrasive, or viscous substances. By avoiding electric motors within the fluid path, pneumatic pumps are often suitable for harsh or hazardous environments.

[0004] Pneumatic pumping systems are commonly deployed in wells and similar installations, including oil wells, water wells, landfill leachate wells, and other subsurface or confined liquid collection environments. In such applications, the pump is typically cycled repeatedly to remove accumulated liquid from a well or sump. Operation often involves alternating phases in which liquid enters a pump chamber and phases in which compressed air is introduced to force the liquid out through a discharge line.

[0005] However, conventional pneumatic pump systems often lack effective control mechanisms for determining when liquid has been fully evacuated from the pump chamber or the surrounding well. As a result, compressed air may continue to be introduced after liquid discharge is substantially complete. This condition can lead to air being forced into the discharge line, commonly referred to as over-discharge or air entrainment.

[0006] Introduction of air into the discharge line can adversely affect downstream equipment, reduce pumping efficiency, and increase wear on pump components. Continued introduction of compressed air after the pump chamber is empty may also subject internal components to unnecessary pressure cycling, contributing to premature failure and increased maintenance requirements. In well-based applications, these issues may be exacerbated by variable liquid inflow rates, changing hydrostatic head, and inconsistent operating conditions.

[0007] Existing pneumatic pump systems may rely on fixed timing intervals, manual observation, or direct liquid level sensors to control pump operation. Such approaches may be insufficiently responsive to changing conditions within the pump chamber or may require frequent adjustment, calibration, or exposure of sensing components to the pumped fluid. In practice, these limitations can make it difficult to reliably prevent over-discharge while maintaining efficient pump cycling across different installations and operating environments.

[0008] It is therefore desirable to provide a pneumatic pump control system that is capable of preventing air from entering the discharge pathway when liquid discharge is complete, while also avoiding over-discharge of the pump chamber. It is further desirable to provide a system that can reliably detect completion of a pumping cycle and signal or control termination of compressed air introduction without reliance on fixed timing or direct liquid level sensing. Such a system would improve operational reliability, reduce maintenance, and extend service life in well-based and similar pneumatic pumping applications.SUMMARY

[0009] The present disclosure relates to a pneumatic pump control system and associated method for transferring liquid from a well, sump, landfill, or similar environment using controlled introduction and venting of pressurized air. The system is configured to operate in a closed-loop manner based on internal pressure conditions and fluid dynamics rather than fixed timing intervals, thereby enabling repeatable and efficient pumping while preventing air entrainment and over-discharge.

[0010] In one aspect, a pneumatic pump control system comprises a pump chamber having a top end and a bottom end. An inlet check valve is in fluid communication with the bottom end of the pump chamber and is configured to permit liquid to enter the pump chamber when pressure within the pump chamber is relieved. An air valve is coupled to the top end of the pump chamber and is configured to be coupled to a pressurized air source, the air valve being selectively operable to vent air from the pump chamber or to introduce pressurized air into the pump chamber. A pump chamber valve is coupled to the bottom end of the pump chamber and is configured to open to fill the pump chamber with liquid and to close when liquid is discharged from the pump chamber. A discharge tube has a bottom end in fluid communication with the bottom end of the pump chamber and a top end in fluid communication with a discharge fitting. A pump chamber float is positioned around the discharge tube and is configured to rise and sink with a liquid level within the pump chamber to permit liquid to be pumped out of the pump chamber through the discharge tube until the pump chamber is empty. A discharge check valve is coupled to the top end of the discharge tube and is configured to permit liquid flow in a discharge direction while preventing backflow.

[0011] In certain embodiments of the pneumatic pump control system, the air valve is selectively operable to vent air from the pump chamber during a filling phase and to introduce pressurized air into the pump chamber during a discharge phase. The inlet check valve is configured to open when pressure within the pump chamber is relieved and to close in response to pressurization of the pump chamber. The discharge check valve is configured to prevent reverse flow of liquid or air into the pump chamber during operation. In some embodiments, the pump chamber float is configured to cooperate with internal geometry of the pump chamber to influence internal pressure conditions as the pump chamber approaches an empty state.

[0012] In another aspect, the pneumatic pump control system further includes a pressure sensor coupled to the pump chamber and configured to detect pressure conditions indicative of predetermined liquid levels within the pump chamber. A controller is coupled to the pressure sensor and the air valve, and is configured to govern operation of the air valve based on the detected pressure conditions. In particular embodiments, the controller is configured to terminate introduction of pressurized air into the pump chamber when a detected pressure condition indicates that the pump chamber has been substantially emptied of liquid, thereby preventing over-discharge and minimizing air entry into the discharge pathway.

[0013] In another aspect, a method of operating a pneumatic pump control system includes venting air from a pump chamber through an air valve to allow liquid to enter the pump chamber through an inlet check valve, permitting a liquid level within the pump chamber to rise until a predetermined high level is reached, and introducing pressurized air into the pump chamber through the air valve to displace liquid from the pump chamber through a discharge tube. The method further includes preventing liquid or air from flowing through the inlet check valve during pressurization of the pump chamber, detecting a predetermined low liquid level within the pump chamber based on internal pressure conditions, and terminating introduction of pressurized air when the predetermined low liquid level is detected.

[0014] In still another aspect, a pneumatic pump control system includes a pump chamber configured to alternately receive liquid and pressurized air, a ventable air valve coupled to the pump chamber, an inlet check valve configured to permit liquid entry into the pump chamber when the pump chamber is depressurized, and a discharge pathway including a discharge check valve configured to permit unidirectional liquid discharge. A pressure sensor is configured to detect internal pressure conditions within the pump chamber, and a controller coupled to the pressure sensor and the air valve is configured to determine pump operating states based on the internal pressure conditions and to control venting and pressurization of the pump chamber in response thereto.

[0015] In certain embodiments of the control architecture, the controller is configured to detect completion of a discharge cycle based on a pressure rate-of-change within the pump chamber, to store one or more configurable pressure thresholds corresponding to predetermined liquid levels, and to confirm detected operating states using multiple pressure-based criteria. In some embodiments, the controller controls operation of the air valve without reliance on fixed timing intervals and is configured to prevent introduction of pressurized air into the discharge pathway after liquid discharge from the pump chamber is complete.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The aspects and the attendant advantages of the embodiments described herein will become more readily apparent by reference to the following detailed description when taken in conjunction with the accompanying drawings wherein:

[0017] FIG. 1 is a schematic cross-sectional view of a pneumatic pump control system illustrating a pump chamber in a low-level state and ready to begin a filling phase;

[0018] FIG. 2 is a schematic cross-sectional view of the pneumatic pump control system showing liquid entering the pump chamber and a rising liquid level during the filling phase;

[0019] FIG. 3 is a schematic cross-sectional view of the pneumatic pump control system showing the pump chamber at a predetermined high liquid level and transitioning from the filling phase to a discharge phase; and

[0020] FIG. 4 is a schematic cross-sectional view of the pneumatic pump control system showing pressurized air being introduced into the pump chamber and displacing liquid from the pump chamber through a discharge tube during the discharge phase.DETAILED DESCRIPTION

[0021] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

[0022] Referring specifically to FIG. 1, the pneumatic pump control system 100 is shown in a low-level initialization state corresponding to completion of a discharge cycle and readiness to begin a subsequent pumping cycle. In this configuration, the pump chamber 102 contains little or no liquid and is maintained at a pressure condition substantially equalized with the surrounding environment. This low-level state is a defined operational condition used by the system 100 to establish a repeatable baseline from which controlled filling may be initiated.

[0023] The pump chamber 102 is mounted to the base 110, with the lower chamber 108 positioned beneath the pump chamber 102 and in fluid communication therewith through one or more orifices 112a, 112b formed in the base 110. The orifices 112a, 112b define a controlled fluid pathway that permits liquid transfer while also influencing internal pressure behavior during discharge and reset. This structural relationship allows the system 100 to regulate internal conditions without reliance on separate flow-restricting components.

[0024] In the FIG. 1 configuration, the discharge check valve 118 positioned proximate the discharge fitting 116 is seated, thereby isolating the discharge tube 114 from the pump chamber 102. This isolation prevents backflow of liquid and inhibits entry of air into the discharge tube 114 during the reset state. By maintaining discharge isolation during low-level conditions, the system 100 preserves directional flow integrity throughout repeated operating cycles.

[0025] The pump chamber float 124 is disposed within an interior volume 122 of the pump chamber 102 and is positioned adjacent the base 110, corresponding to a predetermined low liquid level. In this position, the float 124 does not merely indicate liquid absence, but cooperates with internal geometry of the pump chamber 102 and base 110 to influence air movement and pressure behavior. When the float 124 reaches its lowered position, further displacement of liquid and air is restricted in a predictable manner, producing a characteristic pressure condition within the pump chamber 102.

[0026] The air valve 120 coupled to the upper portion of the pump chamber 102 is maintained in an open or venting condition during the FIG. 1 state. By permitting air to exit the pump chamber 102, the air valve 120 establishes pressure equilibrium and prevents residual pressurization following discharge. The venting state is actively maintained by the controller 126 rather than being a passive consequence of cycle timing.

[0027] The inlet check valve 106 is positioned in an inlet fitting 104 to control liquid flow into the lower chamber 108 and pump chamber 102. In the FIG. 1 configuration, the inlet check valve 106 may remain seated in the absence of incoming liquid flow, yet is responsive to internal pressure conditions. When the pump chamber 102 is vented via the air valve 120, the inlet check valve 106 is free to open under hydrostatic pressure, thereby permitting liquid admission only when the system 100 has entered a controlled filling mode.

[0028] A pressure sensor or switch 111 is coupled to the pump chamber 102 and is configured to detect pressure conditions associated with the low-level reset state. In particular, the pressure sensor or switch 111 detects a pressure response that occurs when liquid discharge has substantially ceased and air flow becomes restricted as the float 124 reaches its lowered position. This pressure response provides a repeatable, indirect indication of discharge completion without requiring direct liquid level sensing.

[0029] The controller 126 receives signals from the pressure sensor or switch 111 and determines, based on those signals, that the pump chamber 102 has reached the predetermined low liquid level. Upon such determination, the controller 126 terminates introduction of compressed air and maintains the air valve 120 in the venting condition. This control action prevents over-discharge, avoids forcing pressurized air into the discharge tube 114, and conserves compressed air resources.

[0030] In certain embodiments, the controller 126 may require confirmation of the low-level condition using multiple criteria, such as satisfaction of a pressure threshold for a minimum duration or detection of a pressure rate-of-change consistent with discharge completion. This multi-parameter evaluation further stabilizes cycle termination and reduces sensitivity to transient pressure fluctuations.

[0031] The coordinated interaction among the pump chamber 102, base 110, float 124, pressure sensor or switch 111, and valves 106, 118, and 120 establishes a closed-loop pneumatic control arrangement in which system state is determined by internal pressure behavior rather than by fixed timing or manual adjustment. In this arrangement, the low-level condition shown in FIG. 1 is actively detected, verified, and maintained through structural and control cooperation.

[0032] By integrating mechanical float positioning with pressure-based detection and controller-driven valve actuation, the system 100 achieves a form of state awareness that allows the pump to reset automatically under varying hydrostatic conditions. Changes in installation depth, liquid density, or discharge head do not require recalibration of mechanical components, as the low-level state is derived from internal system behavior.

[0033] The FIG. 1 configuration therefore represents more than an absence of liquid within the pump chamber 102. It defines an operational state in which the system 100 is hydraulically isolated, pressure balanced, and logically prepared for transition to a subsequent filling phase. This state serves as a reference point that governs all subsequent cycle transitions.

[0034] In operation, repeated establishment of the FIG. 1 low-level state ensures that each pumping cycle begins from a known and verified condition. This repeatability reduces component wear, improves discharge consistency, and minimizes the likelihood of air entrainment into the discharge tube 114.

[0035] The use of pressure-derived state detection in cooperation with structural elements such as the float 124 and base 110 allows the system 100 to function without exposed liquid level sensors or continuous monitoring of liquid height. Instead, the system 100 derives operational state from inherent fluid-dynamic behavior within the pump chamber 102.

[0036] As a result, the FIG. 1 configuration reflects a system architecture in which individual components do not operate independently, but rather interact to produce controlled, repeatable behavior that would not be achieved through simple aggregation of known pneumatic elements.

[0037] The low-level initialization state illustrated in FIG. 1 thus forms a foundational control condition that enables the coordinated filling, discharge, and termination behaviors illustrated in FIGS. 2-4, and contributes to the overall efficiency, reliability, and adaptability of the pneumatic pump control system 100.

[0038] Referring now to FIG. 2, the pneumatic pump control system 100 is illustrated during a controlled filling phase that follows the low-level initialization state shown in FIG. 1. In this configuration, the system 100 has transitioned from the reset condition into a liquid admission mode in which liquid is permitted to enter the pump chamber 102 in a regulated and pressure-responsive manner.

[0039] In the FIG. 2 state, the air valve 120 remains open or is otherwise actuated to permit air to exit the pump chamber 102. As air is vented through the air valve 120, the internal pressure within the pump chamber 102 is reduced relative to the surrounding liquid environment. This pressure differential enables liquid to enter the system without the use of mechanical pumping elements or electrically driven impellers.

[0040] Liquid from the surrounding environment enters the system 100 through the inlet check valve 106, which transitions from a seated position to an open position in response to the reduced pressure within the pump chamber 102. The inlet check valve 106 permits liquid flow in a single direction into the lower chamber 108 while preventing reverse flow. In one embodiment, the inlet check valve 106 comprises a ball-type valve that is lifted from its seat by incoming liquid and permitted to move in a wobbling or floating motion as liquid flows into the lower chamber 108.

[0041] From the lower chamber 108, liquid flows upward through the orifices 112a, 112b formed in the base 110 and into the pump chamber 102. The size, number, and placement of the orifices 112a, 112b are selected to regulate liquid flow rate and promote uniform filling of the pump chamber 102. During the FIG. 2 filling phase, the discharge check valve 118 remains seated, thereby isolating the discharge tube 114 and preventing premature discharge or air entry into the discharge pathway.

[0042] As liquid continues to enter the pump chamber 102, the liquid level rises and causes the pump chamber float 124 to move upward from its lowered position. The float 124 rises in response to buoyant forces generated by the increasing liquid level and provides a physical indication of the filling state of the pump chamber 102. In certain embodiments, the float 124 is shaped or guided to move in a substantially vertical path within the pump chamber 102 to provide consistent and repeatable positional behavior.

[0043] During the filling phase shown in FIG. 2, the pressure sensor or switch 111 monitors internal pressure conditions within the pump chamber 102. Because the air valve 120 remains open, pressure within the pump chamber 102 remains relatively low and stable as liquid displaces air. The pressure sensor or switch 111 may provide continuous or periodic signals to the controller 126 indicative of the filling state, although the controller 126 does not yet initiate pressurization at this stage.

[0044] The controller 126 maintains the air valve 120 in the venting condition throughout the FIG. 2 filling phase and prevents introduction of compressed air into the pump chamber 102. This active control ensures that liquid entry occurs solely under hydrostatic pressure and prevents premature closure of the inlet check valve 106. The filling process thus continues in a passive yet controlled manner until a predetermined high liquid level is reached.

[0045] The coordinated interaction of the air valve 120, inlet check valve 106, and discharge check valve 118 during the FIG. 2 state establishes a unidirectional liquid flow path into the pump chamber 102 while maintaining isolation of the discharge tube 114. This coordination prevents mixing of air and liquid within the discharge pathway and ensures that liquid accumulation within the pump chamber 102 occurs without air entrainment.

[0046] In certain embodiments, the controller 126 may utilize pressure trends detected by the pressure sensor or switch 111, in combination with elapsed time or known system parameters, to confirm that the system 100 is operating within expected filling conditions. Such confirmation may be used to detect abnormal conditions, such as restricted inlet flow or insufficient liquid supply, prior to initiating a discharge cycle.

[0047] The FIG. 2 configuration therefore represents a controlled filling mode in which liquid is admitted into the pump chamber 102 based on internal pressure conditions rather than mechanical pumping action or fixed timing intervals. By permitting air to escape freely through the air valve 120 and allowing the inlet check valve 106 to respond automatically to pressure differentials, the system 100 achieves efficient and adaptive filling across varying liquid depths and environmental conditions.

[0048] As liquid continues to enter the pump chamber 102 and the pump chamber float 124 rises toward an upper position, the system 100 approaches a transition point at which a predetermined high liquid level is detected. This transition point, illustrated more fully in FIG. 3, marks the end of the filling phase and the beginning of a controlled discharge phase initiated by the controller 126.

[0049] Referring now to FIG. 3, the pneumatic pump control system 100 is illustrated at or near completion of a filling phase, in which the liquid level within the pump chamber 102 has risen to a predetermined high level. In this condition, the pump chamber 102 contains a substantial volume of liquid, and the pump chamber float 124 has moved upward within the pump chamber 102 in response to buoyant forces generated by the rising liquid level. FIG. 3 thus represents a transition-ready state in which the system 100 is configured to switch from admitting liquid into the pump chamber 102 to pneumatically displacing liquid out of the pump chamber 102.

[0050] In the FIG. 3 configuration, the air valve 120 remains open or venting at least until the controller 126 determines that the predetermined high level has been reached. As liquid accumulates, displaced air exits through the air valve 120, maintaining the pump chamber 102 at a relatively low pressure during filling. The inlet check valve 106 remains responsive to hydrostatic pressure and, during the later portion of the filling phase, may continue to permit liquid entry into the lower chamber 108 and upward through the orifices 112a, 112b into the pump chamber 102.

[0051] The predetermined high level may be determined in multiple ways consistent with the system 100. In one embodiment, the pressure sensor or switch 111 coupled to the pump chamber 102 detects a pressure condition associated with nearing or reaching the high-level fill state. For example, as the pump chamber 102 approaches a filled condition, the rate of air expulsion through the air valve 120 may change and a characteristic pressure response may be detected by the pressure sensor or switch 111. In another embodiment, the pump chamber float 124 is positioned at a height corresponding to the predetermined high level and is configured to cooperate with a mechanical switch, magnetic sensor, or other detector coupled to the controller 126. In still other embodiments, the high-level condition is determined by the controller 126 based on combinations of sensed pressure, pressure rate-of-change, elapsed time, and known system parameters.

[0052] In certain implementations, the controller 126 uses signals from the pressure sensor or switch 111 to determine that the pump chamber 102 has reached the predetermined high liquid level and is prepared to enter a discharge phase. Upon this determination, the controller 126 actuates the air valve 120 to terminate venting and to initiate introduction of compressed air into the pump chamber 102. This transition may be performed by changing the state of the air valve 120 from an exhaust state to a pressurizing state, or by closing a vent pathway and opening a supply pathway, depending on valve configuration.

[0053] As compressed air begins to enter the pump chamber 102 through the air valve 120, the internal pressure within the pump chamber 102 increases. This pressure increase causes the inlet check valve 106 to move to a seated or closed position, thereby preventing liquid from flowing back outward through the inlet and preventing compressed air from escaping through the inlet pathway. In this manner, the inlet check valve 106 cooperates with the air valve 120 and the controller 126 to isolate the pump chamber 102 from the surrounding environment during the discharge phase.

[0054] With the inlet check valve 106 closed, continued introduction of compressed air into the pump chamber 102 produces a pressure-driven displacement of liquid within the pump chamber 102. Liquid is forced downward through the orifices 112a, 112b in the base 110 and into the discharge pathway defined by the discharge tube 114 and the discharge fitting 116. The discharge check valve 118 opens in response to this flow, permitting liquid to exit the pump chamber 102 in a single direction while preventing backflow during subsequent state changes.

[0055] In certain embodiments, the controller 126 initiates the transition to discharge only after confirming a stable high-level state, such as by requiring that the pressure sensor or switch 111 indicates a high-level condition for a minimum dwell time, or that the sensed pressure crosses a threshold with an associated rate-of-change consistent with a filled pump chamber 102. These confirmation criteria enhance repeatability of the transition and reduce susceptibility to transient conditions or oscillations that may occur as liquid enters the pump chamber 102.

[0056] The pump chamber float 124, when at or near its upper position in FIG. 3, further supports the transition logic by providing a physical state corresponding to the high-level condition. In certain embodiments, float movement provides an additional basis for the controller 126 to determine that a discharge cycle should begin, either by direct interaction with a sensor or by cooperative influence on the internal pressure characteristics detected by the pressure sensor or switch 111. In this manner, the float 124 may serve both as a mechanical indicator of liquid level progression and as a component that contributes to predictable pressure-based detection behavior.

[0057] The FIG. 3 configuration therefore represents an actively controlled transition point in which the system 100 shifts from a filling mode to a pressurized discharge mode based on detection of a predetermined high liquid level within the pump chamber 102. The transition is governed by the controller 126 in response to the pressure sensor or switch 111 and, in certain embodiments, in further response to float-related detection. This coordinated interaction enables the system 100 to initiate discharge promptly upon reaching the desired fill state, thereby improving cycle efficiency and maintaining consistent operation across varying installation depths and liquid conditions.

[0058] Following initiation of compressed air introduction in FIG. 3, the liquid within the pump chamber 102 begins to be displaced by the compressed air, resulting in the pump chamber 102 containing a mixture of pressurized air and remaining liquid as discharge proceeds. This condition is illustrated in greater detail in FIG. 4, where the discharge phase continues until a predetermined low-level state is detected and compressed air introduction is terminated.

[0059] In certain embodiments, detection of the predetermined high liquid level within the pump chamber 102 may be accomplished using multiple alternative or cooperative sensing modes. For example, the pressure sensor or switch 111 may be configured to detect a predefined absolute pressure threshold, a pressure differential relative to ambient conditions, or a pressure rate-of-change indicative of reduced air displacement as the pump chamber 102 approaches a filled condition. In other embodiments, detection of the high-level state may be based on float position, such as when the pump chamber float 124 reaches an upper position corresponding to the predetermined high level and actuates a mechanical switch, magnetic reed sensor, proximity sensor, or similar detector coupled to the controller 126. In still further embodiments, the controller 126 may determine the high-level state based on a combination of pressure-based detection and float-based detection, thereby providing redundant or corroborative indications of the filling condition.

[0060] In certain implementations, the controller 126 is configured to evaluate multiple criteria before determining that the predetermined high liquid level has been reached. Such criteria may include satisfaction of a pressure threshold for a minimum dwell time, detection of a pressure slope or inflection point associated with reduced air flow through the air valve 120, confirmation of float position, or combinations thereof. By evaluating multiple parameters, the controller 126 may reduce susceptibility to transient pressure fluctuations, splashing, or other dynamic effects that may occur during filling of the pump chamber 102.

[0061] In some embodiments, the predetermined high liquid level is not fixed, but rather is a configurable parameter stored in memory associated with the controller 126. The controller 126 may include a processor coupled to memory and may be programmed to store one or more pressure thresholds, pressure-rate criteria, float-position criteria, or timing parameters corresponding to the desired high-level condition. These parameters may be selected during installation, commissioning, or maintenance of the pneumatic pump control system 100 to accommodate variations in installation depth, discharge head, liquid density, viscosity, or other operating conditions.

[0062] In certain embodiments, the controller 126 may further be configured to adjust or select among multiple predetermined high-level setpoints during operation. For example, different setpoints may be used depending on detected operating conditions, prior cycle behavior, or operator-selected modes. This capability allows the system 100 to adapt filling and discharge behavior without requiring mechanical modification of the pump chamber 102 or manual adjustment of valves.

[0063] The use of configurable, pressure-based, and / or float-based high-level detection as described herein enables the pneumatic pump control system 100 to initiate the transition from filling to discharge in a controlled and repeatable manner across a wide range of operating environments. By relying on internal system conditions sensed within the pump chamber 102 rather than on fixed timing intervals, the system 100 maintains consistent cycle performance while accommodating variations in liquid supply, hydrostatic head, and installation geometry.

[0064] The foregoing detection modes and configurable control parameters may be employed individually or in combination, and may be implemented using hardware, software, firmware, or combinations thereof. Accordingly, the FIG. 3 high-level detection and transition logic is not limited to any single sensing mechanism, but rather encompasses a flexible control architecture in which the controller 126 governs transition to the discharge phase based on one or more sensed conditions indicative of a predetermined high liquid level within the pump chamber 102.

[0065] Referring now to FIG. 4, the pneumatic pump control system 100 is illustrated during a mid-discharge phase in which pressurized air is actively displacing liquid from the pump chamber 102. In this configuration, the pump chamber 102 contains both pressurized air and a remaining volume of liquid, with an air-to-liquid interface defined within the pump chamber 102 that advances as discharge proceeds. FIG. 4 represents a transitional state between initiation of discharge, as shown in FIG. 3, and completion of discharge, as shown in FIG. 1.

[0066] In the FIG. 4 state, the air valve 120 has been actuated by the controller 126 to introduce compressed air into the upper portion of the pump chamber 102. The compressed air occupies an increasing portion of the internal volume of the pump chamber 102 and exerts pressure on the liquid below. This pressure differential forces liquid downward through the orifices 112a, 112b formed in the base 110 and into the discharge pathway defined by the discharge tube 114 and discharge fitting 116.

[0067] The inlet check valve 106 remains in a closed or seated condition during the FIG. 4 mid-discharge phase due to the elevated pressure within the pump chamber 102. This prevents liquid from flowing backward through the inlet pathway and prevents pressurized air from escaping through the inlet. The inlet check valve 106 thereby cooperates with the air valve 120 to maintain a sealed discharge environment during the pressurized phase of operation.

[0068] As liquid is displaced from the pump chamber 102, the discharge check valve 118 opens in response to liquid flow and internal pressure conditions. In one embodiment, the discharge check valve 118 comprises a ball-type check valve that is lifted from its seat by the upward and outward flow of liquid and is permitted to move in a wobbling or floating motion as liquid passes through the discharge fitting 116. This motion allows the discharge check valve 118 to accommodate variable flow rates while maintaining directional control of the discharged liquid.

[0069] The discharge check valve 118 is configured to open only when liquid pressure within the pump chamber 102 exceeds a threshold sufficient to overcome the seating force of the valve. As a result, the discharge check valve 118 prevents reverse flow and inhibits entry of air into the discharge tube 114 during periods when liquid flow is reduced or temporarily interrupted. This dynamic response of the discharge check valve 118 contributes to maintaining a liquid-only discharge and minimizing air entrainment into downstream piping.

[0070] During the FIG. 4 mid-discharge phase, the air-to-liquid interface within the pump chamber 102 progresses downward as liquid volume decreases and air volume increases. The geometry of the pump chamber 102, in combination with the controlled introduction of compressed air through the air valve 120, promotes a stable interface that advances in a controlled manner rather than producing turbulent mixing. This controlled interface movement enhances discharge efficiency and reduces the likelihood of compressed air bypassing the liquid and entering the discharge tube 114.

[0071] The pump chamber float 124 moves downward in response to the decreasing liquid level within the pump chamber 102. During the mid-discharge phase, the float 124 may remain partially buoyant and may provide a stabilizing influence on the liquid surface. In certain embodiments, the float 124 is configured to cooperate with the internal geometry of the pump chamber 102 to influence pressure conditions as the float 124 approaches its lower position, thereby contributing to predictable end-of-cycle detection.

[0072] The pressure sensor or switch 111 continues to monitor internal pressure conditions within the pump chamber 102 during the FIG. 4 state. As liquid is expelled and the air volume increases, the pressure response within the pump chamber 102 changes in a characteristic manner. The controller 126 may evaluate absolute pressure, pressure rate-of-change, or other pressure characteristics to track progress of the discharge cycle and to anticipate completion of liquid evacuation.

[0073] In certain embodiments, the controller 126 maintains introduction of compressed air through the air valve 120 at a controlled rate during the FIG. 4 phase. This rate may be selected to balance discharge efficiency against minimization of turbulence and air entrainment. The controller 126 may also modulate the air valve 120 in response to sensed pressure conditions to maintain a desired discharge profile.

[0074] The FIG. 4 mid-discharge configuration thus represents a controlled pneumatic displacement of liquid in which pressurized air, mechanical valve elements, and internal geometry cooperate to expel liquid from the pump chamber 102 in a predictable and directional manner. The coordinated operation of the air valve 120, inlet check valve 106, discharge check valve 118, pump chamber float 124, pressure sensor or switch 111, and controller 126 ensures that liquid is discharged efficiently while preventing over-pressurization and air intrusion into the discharge tube 114.

[0075] As discharge continues and the liquid level within the pump chamber 102 approaches the predetermined low level, the system 100 transitions toward the configuration shown in FIG. 1. At that point, the controller 126 detects pressure conditions indicative of discharge completion and terminates introduction of compressed air, thereby resetting the system 100 for a subsequent filling cycle.

[0076] Taken together, FIGS. 1-4 illustrate a complete operating cycle of the pneumatic pump control system 100 in which liquid is transferred through the system using coordinated pressure responsive control rather than fixed timing or continuous mechanical pumping. The cycle begins in a controlled low-level state (FIG. 1) in which the pump chamber 102 is pressure-balanced and isolated from the discharge tube 114, transitions to a controlled filling phase (FIG. 2) in which liquid enters the pump chamber 102 under hydrostatic pressure as air is vented, advances to a predetermined high-level detection and transition state (FIG. 3) in which the controller 126 initiates pressurized discharge based on sensed internal conditions, and proceeds through a mid-discharge phase (FIG. 4) in which pressurized air displaces liquid in a directional manner while maintaining a controlled air-to-liquid interface.

[0077] Throughout the cycle, the air valve 120, inlet check valve 106, discharge check valve 118, pump chamber float 124, pressure sensor or switch 111, and controller 126 operate cooperatively as a closed-loop control system that governs filling, discharge, and cycle termination based on internal pressure and fluid dynamics. This integrated operation enables efficient, repeatable pumping while preventing air entrainment into the discharge pathway, avoiding over-discharge, and accommodating variations in liquid head, installation depth, and operating conditions without manual adjustment.

[0078] In a particular aspect, a method of operating the pneumatic pump control system includes venting air from the pump chamber through the air valve to reduce pressure within the pump chamber and allow liquid to enter the pump chamber through the inlet check valve. The method further includes permitting a liquid level within the pump chamber to rise until a predetermined high level is reached, and in response, introducing pressurized air into the pump chamber through the air valve to displace liquid from the pump chamber through the discharge tube. During introduction of pressurized air, the inlet check valve is maintained in a closed condition to prevent liquid or air from flowing through the inlet. The method further includes detecting a predetermined low liquid level within the pump chamber based on internal pressure conditions and terminating introduction of pressurized air when the predetermined low liquid level is detected.

[0079] In certain embodiments, detection of the predetermined high liquid level and the predetermined low liquid level is based on one or more pressure characteristics within the pump chamber, including absolute pressure, pressure rate-of-change, or combinations thereof, and may further be corroborated by movement of a float within the pump chamber. The method may be performed repeatedly in a cyclic manner without reliance on fixed timing intervals.

[0080] Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.

Claims

1. A pneumatic pump control system comprising:a pump chamber having a top end and a bottom end;an inlet check valve in fluid communication with the bottom end of the pump chamber;an air valve coupled to the top end of the pump chamber and configured to be coupled to a pressurized air source;a pump chamber valve coupled to the bottom end of the pump chamber and configured to open to fill the pump chamber with liquid and to close when discharging liquid from the pump chamber;a discharge tube having a bottom end in fluid communication with the bottom end of the pump chamber and a top end in fluid communication with a discharge fitting;a pump chamber float positioned around the discharge tube and configured to rise and sink with a liquid level within the pump chamber to permit liquid to be discharged from the pump chamber through the discharge tube; anda discharge check valve coupled to the top end of the discharge tube.

2. The pneumatic pump control system of claim 1, wherein the air valve is selectively operable to vent air from the pump chamber during a filling phase and to introduce pressurized air into the pump chamber during a discharge phase.

3. The pneumatic pump control system of claim 1, wherein the inlet check valve is configured to open when pressure within the pump chamber is relieved and to close in response to pressurization of the pump chamber.

4. The pneumatic pump control system of claim 1, wherein the discharge check valve is configured to permit liquid flow in a discharge direction while preventing backflow of liquid or air into the pump chamber.

5. The pneumatic pump control system of claim 1, further comprising a pressure sensor coupled to the pump chamber and configured to detect a pressure condition indicative of a predetermined liquid level within the pump chamber.

6. The pneumatic pump control system of claim 5, further comprising a controller coupled to the pressure sensor and the air valve, the controller configured to terminate introduction of pressurized air into the pump chamber when the pressure condition indicates that the pump chamber has been substantially emptied of liquid.

7. The pneumatic pump control system of claim 1, wherein the pump chamber float is configured to cooperate with internal geometry of the pump chamber to influence internal pressure conditions when the pump chamber approaches an empty state.

8. A method of operating a pneumatic pump control system, the method comprising:venting air from a pump chamber through an air valve to allow liquid to enter the pump chamber through an inlet check valve;permitting a liquid level within the pump chamber to rise until a predetermined high level is reached;introducing pressurized air into the pump chamber through the air valve to displace liquid from the pump chamber through a discharge tube;preventing liquid or air from flowing through the inlet check valve during pressurization of the pump chamber; andterminating introduction of pressurized air when a predetermined low liquid level within the pump chamber is detected.

9. The method of claim 8, wherein terminating introduction of pressurized air is based on detecting a pressure increase within the pump chamber indicative of discharge completion.

10. The method of claim 8, wherein detecting the predetermined high level comprises detecting a pressure characteristic within the pump chamber associated with reduced air displacement.

11. The method of claim 8, wherein detecting the predetermined high level further comprises detecting a position of a float within the pump chamber.

12. The method of claim 8, wherein the discharge tube remains isolated from the pump chamber by a discharge check valve until liquid pressure exceeds a threshold sufficient to open the discharge check valve.

13. The method of claim 8, further comprising repeating the venting, filling, pressurizing, and terminating steps in a cyclic manner without reliance on fixed timing intervals.

14. A pneumatic pump control system comprising:a pump chamber configured to alternately receive liquid and pressurized air;a ventable air valve coupled to the pump chamber; an inlet check valve configured to permit liquid entry into the pump chamber when the pump chamber is depressurized;a discharge pathway including a discharge check valve configured to permit unidirectional liquid discharge;a pressure sensor configured to detect internal pressure conditions within the pump chamber; anda controller coupled to the pressure sensor and the air valve, the controller configured to determine pump operating states based on internal pressure conditions and to control venting and pressurization of the pump chamber in response thereto.

15. The pneumatic pump control system of claim 14, wherein the controller is configured to detect a discharge completion state based on a pressure rate-of-change within the pump chamber.

16. The pneumatic pump control system of claim 14, wherein the controller stores one or more configurable pressure thresholds corresponding to predetermined liquid levels within the pump chamber.

17. The pneumatic pump control system of claim 14, wherein the controller is configured to confirm a detected pump operating state by evaluating multiple pressure-based criteria.

18. The pneumatic pump control system of claim 14, further comprising a float disposed within the pump chamber, wherein the float cooperates with pressure-based detection to indicate a liquid level state.

19. The pneumatic pump control system of claim 14, wherein the controller controls operation of the air valve without reliance on fixed timing intervals.

20. The pneumatic pump control system of claim 14, wherein the controller is configured to prevent introduction of pressurized air into the discharge pathway after liquid discharge from the pump chamber is complete.

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