Variable speed lineup (VSL) pump system and method for regulating flow and pressure in a water system

Abstract

A variable speed lineup (VSL) pump system for a water system and method of controlling same, the VSL pump system including a diaphragm pump assembly, a brushed, permanent magnet DC motor coupled to the diaphragm pump assembly, and a pressure transducer mechanically coupled to a pump head of the diaphragm pump assembly. The VSL pump system may also include a controller, wherein the controller is configured to receive feedback from the pressure transducer and adjust motor speed using Pulse Width Modulation (PWM) signals and a power switching element (MOSFET) to maintain a constant pressure in the water system.

Description

VARIABLE SPEED LINEUP (VSL) PUMP SYSTEM AND METHOD FOR REGULATING FLOW AND PRESSURE IN A WATER SYSTEMCROSS REFERENCE TO RELATED APPLICATIONS

[0000] The application claims benefit to provisional application no. 63 / 460,381 , filed 30 April 2024, which is hereby incorporated by reference.BACKGROUND OF THE INVENTIONField of the Invention

[0001] The present invention relates generally to pumps for pumping liquid, and in particular to a variable speed lineup (VSL) constant-pressure diaphragm pump and pump controller system for maintaining a substantially uniform and constant discharge pressure of liquid output from the pump generally irrespective of the number of open downstream outlets drawing such liquid delivered by the pump.Technical Considerations

[0002] Various liquid dispensing systems rely on one or more pumps to accomplish liquid delivery at a plurality of sites, with many such systems delivering water or water-based liquid for a myriad of uses. Examples of such applications include, e.g., recreational vehicle (RV) water systems and / or leisure marine onboard water systems. Other such applications may include, e.g., spray systems such as car- wash wands, carpet-cleaning applicators, spray-mist cooling units, auto-service coolant-change reservoirs, and / or various pumps such as transmission oil filter pumps, water pressure booster pumps, carbonator pump, foam application pumps, road compactor spray pumps, street sweeper post-suppressions pumps, and the like. In addition to the delivery of water-containing products, other liquids such aschemicals, fuels, beverages, etc. may be supplied to an end-use site by utilization of a pump.

[0003] While certain liquid delivery requirements involve transfer to only one outlet location and thus involve only a single downstream valve / opening for liquid flow, many systems include a plurality of downstream outlets available for simultaneous flow supply at a number of outlet sites. One example of such a system may be found in well-equipped motor homes that may include, e.g., kitchen and bathroom sink faucets, a shower and toilet, and possibly an outside faucet. Most of the pumps currently used in such applications are single-speed, variable pressure (standard) pumps, which have limitations on the quality of service they provide in single and multi-outlet applications. For standard pumps to operate properly, the system restriction / pressure must be less than the preset pressure of the pressure switch. If a single-outlet user partially opens a valve for low flow demand, then the pump often starts “nuisance tripping” since a partially opened valve causes pressure in the system to build up and reach the setpoint pressure level of the pressure switch commonly used on such pumps as a safety mechanism, causing the pump to turn on and off continuously. The rapid pressure spike in the pump could cause premature failure of a pump and excessive / unwanted noise to RV / boat occupants. This inability to turn down water flow is undesirable in applications such as RVs, which have limited water supplies. Additionally, if an application such as an RV water system has a multi-outlet system like a faucet (or multiple faucets), a toilet, and a shower on the same water line, there can be poor performance when multiple outlets are used simultaneously, with water interruptions and inconsistent flows.

[0004] To mitigate the above issues, in some instances an accumulator tank may be installed in-line with the standard pump’s discharge to absorb some of the pressure spike. However, such an accumulator tank requires more complex plumbingand additional space. It also has more leak points, costly additional components, complex installation, and requires more maintenance.

[0005] In view of such deficiencies, pump controller systems have been developed to maintain pressure throughout a liquid delivery network by continually sensing the pressure of liquid moving therefrom and correspondingly adjusting the speed of the pump motor to reflect pressure variations as they occur. One such pump controller system is set forth in U.S. Patent No. 6,607,360 B2, which is assigned to the assignee of the instant application and incorporated herein by reference in its entirety. U.S. Patent No. 6,607,360 B2 discloses a constant-pressure pump controller system for maintaining a uniform discharge pressure from a pump in a liquid dispensing system having downstream outlets for liquid delivery. The pump includes a housing having a liquid inlet and outlet and a pressure transducer arranged in relation to the liquid inlet and outlet, and also includes a controller and a pump motor. The pressure transducer includes a Hall Effect sensor arranged in relation to the liquid inlet and outlet that senses entering-liquid pressure and provides electrical input signals to the controller for implementing liquid pressure maintenance. The pressure transducer has an adjustable spring-loaded piston having its tension set and adjusted by rotating a screw. In operation, if the entering-liquid pressure sensed is sufficient, then the controller does not increase the motor speed; and if the entering-liquid pressure sensed is insufficient (e.g., when a number of the downstream outlets are calling for liquid delivery), then the electrical input signals activate the controller, which activates the motor to increase the exiting-liquid pressure by adjusting the speed of the motor to reflect the pressure variations as they occur. However, further improvements to the pump and pump controller system(s) as disclosed in U.S. Patent No. 6,607,360 B2 are possible and are the subject of the present invention.SUMMARY OF THE INVENTION

[0006] In one aspect of the present invention, a variable speed lineup (VSL) pump system for a pumping system having valves with valve positions is disclosed, the VSL pump system including a diaphragm pump assembly having a pump head, a motor (e.g. , including a brushed, permanent magnet DC motor) coupled to the diaphragm pump assembly, and a pressure transducer mechanically coupled to the pump head of the diaphragm pump assembly and configured to sense a pressure fluctuation in system pressure in a pumping system resulting from a change in one or more valve positions of one or more valves in the pumping system, and provide pressure transducer signaling containing feedback information about the pressure fluctuation sensed. The VSL pump system also includes a controller configured to receive the pressure transducer signaling containing feedback information from the pressure transducer, and provide controller signaling containing information to adjust motor speed using Pulse Width Modulation (PWM) signals to deliver a variable DC voltage to a pump motor and maintain a substantially constant system pressure in the pumping system.

[0007] In some embodiments, the controller continuously monitors pressure fluctuations in the pumping system and adjusts motor speed based on the pressure transducer signaling containing the feedback information received from the pressure transducer, e.g., by increasing or decreasing the motor speed using the PWM signals and a power switching element (MOSFET) to maintain the substantially constant system pressure in the pumping system.

[0008] In some embodiments, the controller includes a microcontroller having a memory module configured to store a predetermined target system pressure of the pumping system. The microcontroller is configured to calculate an error / correction needed based upon the predetermined target system pressure stored and the pressurefluctuation sensed, including by continuously comparing the predetermined target system pressure stored with the pressure fluctuation sensed.

[0009] In some embodiments, the microcontroller is programmed with procedures for implementing safety mechanisms to protect the VSL pump from at least one of overvoltage, undervoltage, and overcurrent conditions, including by comparing stored predetermined voltage and current levels to sensed voltage and current levels. The predetermined voltage and current levels are stored in the memory module as a software parameter.

[0010] In some embodiments, the microcontroller is programmed to implement procedures to stop delivery of power to the motor when voltage levels deviate from a predetermined acceptable voltage level range stored in the memory module as a software parameter.

[0011] In some embodiments, the microcontroller is programmed to implement procedures to automatically resume providing power to the motor when sensed voltage levels are again within the predetermined acceptable voltage level range stored.

[0012] In some embodiments, when water flow stops due to all valves in the pumping system being in a closed position, the microcontroller is programmed to im plement procedures to reduce the duty cycle of the PWM signal such that no power is delivered to the motor.

[0013] In some embodiments, the controller is configured to continuously execute a control cycle to compensate for changes in pressure fluctuations of the pumping system.

[0014] In some embodiments, the controller includes an accessible programming port configured to reprogram and / or update software of the controller.

[0015] In accordance with another aspect of the present invention, a method forregulating water flow and pressure in a water system using a variable speed lineup (VSL) pump is disclosed, the method including monitoring system pressure using a pressure transducer mechanically coupled to a pump head of the VSL pump and configured to provide pressure transducer signaling containing feedback information a pressure fluctuation in the water system resulting from a change in one or more valve positions of one or more outlet valves in a water system; and adjusting with a controller motor speed of a motor of the VSL pump based on the pressure transducer signaling containing feedback information received from the pressure transducer using at least Pulse Width Modulation (PWM) signals to maintain a substantially constant system pressure in the water system regardless of valve positions and / or quantity of outlet valves in the water system.

[0016] In some embodiments, the method further includes executing with the controller a control cycle to compensate for changes in system pressure fluctuations resulting from changes in the valve positions of the water system.

[0017] In some embodiments, the method further includes storing a predetermined period of time in a memory module as a software parameter, determining with the controller that the pressure transducer signaling contains no pressure fluctuations for the predetermined period of time stored indicating that water flow has stopped due to all valves in the water system being closed, and reducing with the controller a duty cycle of the PWM signal to stop power delivery to the motor when water flow stops due to all valves in the water system being closed.

[0018] In some embodiments, the method further includes adjusting the motor speed using the PWM signals and a power switching element (MOSFET) to maintain the substantially constant system pressure in the water system.

[0019] In some embodiments, the method further includes protecting with the controller the VSL pump from overvoltage, undervoltage, and overcurrent conditions bystopping delivery of power to the motor whenever voltage levels deviate from a predetermined acceptable voltage level range stored in the memory module as a software parameter.BRIEF DESCRIPTION OF THE DRAWING

[0020] The invention will be described with reference to the following drawing having figures wherein like reference numbers identify like parts throughout.

[0021] FIG. 1 is a perspective view of a variable speed lineup (VSL) pump according to one aspect of the present disclosure;

[0022] FIG. 2 is an exploded view of pumping components of the VSL pump shown in FIG. 1 in accordance with an aspect of the present disclosure;

[0023] FIG. 3 is an exploded view of a VSL pump controller of the VSP pump shown in FIG 1 in accordance with an aspect of the present disclosure;

[0024] FIG. 4 is a bottom view of the VSL pump controller of FIG. 3;

[0025] FIG. 5A is a graph showing a flow / pressure / amp curve for a standard pump known in the art; and FIG. 5B is a graph showing a flow / pressure / amp curve for a VSL pump system in accordance with the present disclosure; and

[0026] FIG. 6 is a block diagram of apparatus, e.g., including a marine vessel or recreational vehicle having a pumping system, in accordance with the present disclosure.DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] For purposes of the description hereinafter, the terms “end,” “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments or aspects of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments or aspects disclosed herein are not to be considered as limiting.

[0028] The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term “plurality” refers to two or more items or components. The terms “comprising,” “including,” “carrying,” “having,” “containing,” and “involving,” whether in the written description or the claims and the like, are open-ended terms, i.e. , to mean “including but not limited to.” Thus, the use of such terms is meant to encompass the items listed thereafter, and equivalents thereof, as well as additional items. Only the transitional phrases “consisting of” and “consisting essentially of,” are closed or semi-closed transitional phrases, respectively, with respect to the claims. Use of ordinal terms such as “first,” “second,” “third,” and the like in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.

[0029] Referring to FIGS. 1-4, a variable speed lineup (VSL) Pump 10 inaccordance with an aspect of the present disclosure is shown, e.g., which may be used in apparatus 100 (FIG. 6), such as a marine vessel MV or a recreational vehicle RV having a pumping system PS. The VSL pump 10 may be used in other applications to pump other liquids, e.g., consistent with that set forth herein. As shown in FIGS. 2 and 3, the VSL pump 10 includes various pump components 10a, 10b, 10c, ..., 10x, 10y, 10z. For example, as shown in FIG. 3, the VSL pump 10 includes a Print Circuit Board Assembly (PCBA) and heat sink sub-assembly 10r that uses a controller 102 (FIG. 6) to smoothly provide various water flow demand at a substantially constant system pressure, regardless of outlet valve positions and / or quantity of outlets fluidly coupled to the VSL pump 10, which enables reliable operation from full flow to minimal flow in the pumping system PS. In some embodiments, the controller on the VSL pump 10 achieves variable flow at the substantially constant system pressure by varying motor speed from full speed down to required speed to maintain the desirable flow / pressure. In some embodiments, the controller may include a microcontroller, e.g., including a microcontroller that takes the form of a compact integrated circuit designed to control a specific operation in an embedded system and includes a processor, memory and input / output peripherals on a single chip. Alternatively, and consistent with that shown in FIG. 6, the controller may include, or take the form of, a microprocessor, signal processor or processing module 104 having other signal processor circuits, circuitry or components 106,

[0030] In some embodiments, the VSL pump 10 includes a pump motor 10p (FIG. 3), e.g., that may be a brushed, permanent magnet DC motor, the speed of which is directly proportional to the DC voltage applied thereto. By way of example, the controller may use Pulse Width Modulation (PWM) signals and a power switching element (MOSFET) to deliver a variable DC voltage to the pump motor 10p. The power switching element (MOSFET) forms part of the PCBA and heat sink sub-assembly 10r (FIG. 3).

[0031] In some embodiments, the controller uses a pressure transducer PT (FIGS 2, 3 and 6) that is mechanically coupled to a pump head of the VSL pump 10 as a feedback element. Based on the sensed signals received from the pressure transducer PT, the controller or microcontroller is configured to calculate the error / correction needed according to a predetermined target system pressure specified within software parameters stored / em bedded within and / or accessible by the microcontroller. The controller or microcontroller may then correct the PWM’s duty cycle, which acts to adjust the water pressure in the pumping system PS (FIG. 6). The predetermined target system pressure specified within software parameters may be factory set, and / or may be set or updated by the user.

[0032] While the VSL pump 10 is operating, the controller 102 is configured to continuously execute the control cycle to compensate for changes in the pumping system’s pressure fluctuations resulting from, e.g., changes in outlet valve positions of multi-outlet valve MOVs (FIG. 6) that simultaneously open and close, e.g., including one or more faucets, a toilet or a shower in a MV or RV. For example, when water flow stops due to all valves in the pumping system being in a closed position, the controller or microcontroller reduces the duty cycle of the PWM signal to the point where no power is delivered to the motor 10p (FIG 3). The controller or microcontroller may make these reductions very quickly to prevent pressure spikes in the case of sudden pumping system changes caused by rapid valve movement.

[0033] Additionally, the controller or microcontroller may be configured to constantly monitor the system pressure in the pumping system. Whenever the system pressure drops below or increases above a pressure level specified in the software parameters, the pressure regulating cycle starts again. The pressure level specified within the software parameters may be factory set, and / or may be set or updated bythe user.

[0034] The embedded software within the controller or microcontroller may further include procedures for safety mechanisms that protect the VSL pump 10 from overvoltage / undervoltage. For example, the controller or microcontroller may stop delivery of power to the motor 10p (FIG. 3) whenever voltage levels deviate from an predetermined acceptable voltage level range, and automatically resumes providing power when the voltage levels are again within the predetermined acceptable voltage level range. In some embodiments, there are also protections for overcurrent. For example, the VSL pump 10 may stop working in the case of a current spike higher than a threshold cu rrent level defined in the embedded software and does not return to normal until it detects that power to the controller has been reset (e.g., disconnected and reconnected again). The predetermined acceptable voltage level range and threshold current level specified within the software parameters may be factory set, and / or may be set or updated by the user. As shown in FIG. 4, the controller may include a readily-accessible programming port having a connector C so as to enable reprogramming of the embedded software of the controller or microcontroller for updates, additional features (e.g., different pressure ranges, etc.), protection features, etc.

[0035] Referring to FIGS. 5A and 5B, another benefit of the VSL Pump 10 in accordance with the present disclosure is energy savings as compared to standard pumps. As described above, standard pumps typically operate at full speed, regardless of flow requirements . FIG. 5A shows a flow / pressure / amp curve for a standard pump, illustrating that energy savings is not achieved due to consistent full speed operation of the pump. On the other hand, the VSL pump’s energy consumption is varied based on the flow requirements, as is clearly illustrated in FIG. 5B.

[0036] As detailed above, the VSL pump 10 of the present disclosure may be avariable-speed, constant pressure diaphragm pump designed for various applications such as, e.g., leisure marine MV and RV applications. In some embodiments, the brushed, permanent magnet DC motor 10p and the controller 102 (Fig. 6) utilize the PWM signals and pressure feedback to adjust motor speed, e.g., including increasing or decreasing the motor speed. In some embodiments, the controller is configured to continuously monitor system pressure, ensuring smooth operation and preventing pressure spikes. The controller may include procedures to implement safety mechanisms that may protect the VSL pump 10 from voltage and current fluctuations, enhancing the pump’s reliability and longevity. The VSL Pump 10 offers energy savings compared to traditional pumps by adjusting energy consumption based on flow requirements.

[0037] By way of further example, the VSL Pump 10 may include a pump assembly having a diaphragm pump driven by the brushed, permanent magnet DC motor. The controller is configured to regulate motor speed using the PWM signals and pressure feedback from the pressure transducer PT, continuously adjusting motor speed to maintain substantially constant system pressure in the pumping system PS, regardless of flow demand. The pressure transducer PT provides feedback to the controller 102, allowing it to accurately regulate the system pressure in the pumping system PS.

[0038] The embedded software of the microcontroller or the controller includes procedures to implement safety features to protect the VSL pump 10 from overvoltage, undervoltage, and overcurrent conditions. During operation, the controller monitors the system pressure and adjusts motor speed accordingly to maintain a substantially constant system pressure. The PWM signals control the motor's speed, ensuring precise regulation of water flow in the pumping system. Safety mechanisms and features implemented by the controller prevent damage to the VSL pump 10 in the eventof voltage or current fluctuations.

[0039] The VSL pump 10 of the present disclosure is capable of providing consistent water flow and pressure, even with varying demand and valve positions in the pumping system PS. Additionally, by adjusting motor speed based on flow requirements, the VSL pump 10 optimizes energy consumption, resulting in cost savings. Built-in safety mechanisms protect the VSL pump from voltage and current fluctuations, enhancing its reliability and longevity. Furthermore, the VSL pump system of the present disclosure eliminates the need for complex plumbing solutions such as, e.g., accumulator tanks, reducing installation complexity and maintenance requirements.

[0040] The VSL pump system as disclosed herein offers a reliable and energyefficient solution for onboard water systems in, e.g., leisure marine and recreational vehicles. By combining variable-speed control with sophisticated safety mechanisms, the VSL pump system ensures consistent performance while minimizing energy consumption and maintenance requirements.

[0041] Fig. 6 shows the invention in the form of apparatus 100, e.g., such as a marine vessel MV or a recreational vehicle RV having a pumping system PS, e.g., that may include one or more inside and outside faucets, toilets and showers.

[0042] Multi-outlet valves MOVs form part of the pumping system PS, have valve positions, and may be simultaneously opened and closed by a user to provide water to the one or more inside and outside faucets, toilets and showers.

[0043] The VSL pump 10 has a pump head PH and is configured to connect to the pumping system PS, receive controller signaling and provide water to the multioutlet valves MOVs.

[0044] The pressure transducer PT is coupled to and arranged inside the pump head PH of the VSL pump 10 and is configured to sense a pressure fluctuation in thesystem pressure of the pumping system PS resulting from a change in one or more valve positions of one or more of the multi-outlet valves MOVs in the pumping system PS, and provide pressure transducer PT signaling containing information about the pressure fluctuation sensed.

[0045] The controller 102 includes a microprocessor, signal processor or processing module 104 and a memory module 106 and is configured to: receive signaling containing information about the pressure fluctuation sensed, and also containing information about a predetermined target system pressure stored in the memory module 106; and provide controller signaling containing information to increase or decrease motor speed of a pump motor using Pulse Width Modulation (PWM) signals to deliver a variable DC voltage to a pump motor of a pump and maintain a substantially constant system pressure in the pumping system, based upon the signaling received,

[0046] For example, the controller 102 is configured to increase the motor speed using the PWM signals, when the pressure fluctuation sensed and the predetermined target system pressure stored indicate a sudden drop in the system pressure of the pumping system PS resulting from one or more of the multi-outlet valves MOVs in the pumping system PS being opened, e.g., when someone opens a valve to take a shower. Alternatively, the controller 102 is configured to increase the motor speed using the PWM signals, when the pressure fluctuation sensed and the predetermined target system pressure stored indicate a sudden increase in the system pressure of the pumping system PS resulting from one or more of the multi-outlet valves MOVs in the pumping system PS being closed, , e.g., when someone closes the valve when the shower ends.

[0047] By way of further example, the controller 102 may be configured toprovide the controller signaling containing information to decrease the motor speed using the PWM signals, stop providing power to the pump motor, turn off the pump, and shut off a pressure regulating cycle if the pressure fluctuation sensed for a predetermined period of time stored in the memory module does not change indicating that all valves in the pumping system are closed, e.g., when people are sleeping in a MV or RV during the night.

[0048] By way of still further example, the controller 102 may also be configured to provide the controller signaling containing information to decrease the motor speed using the PWM signals, stop providing power to the pump motor, turn off the pump, and shut off a pressure regulating cycle, if the variable DC voltage deviates from a predetermined acceptable voltage level range stored in the memory module. In this case, the controller 102 may also be configured to restart the pressure regulating cycle if the variable DC voltage is within the predetermined acceptable voltage level range stored and increase the motor speed of the pump motor using the PWM signals.

[0049] The controller 102 may include other signal processor circuits, circuitry, or components 106 that do not form part of the underlying invention, e.g., including input / output modules / modems, one or more memory modules (e.g., RAM, ROM, etc.), data, address and control busing architecture, etc.The Microprocessor, Signal Processor or Processing Module 104

[0050] By way of example, and consistent with that described herein, the functionality of the microprocessor, signal processor or processing module 104 may be implemented to receive the signaling, process the signaling therein and / or provide the controller signaling, using hardware, software, firmware, or a combination thereof, although the scope of the invention is not intended to be limited to any particular embodiment or implementation thereof. In a typical software implementation, themicroprocessor, signal processor or processing module 104 may include, or take the form of, one or more microprocessor-based architectures having a microprocessor, a random access memory (RAM), a read only memory (ROM), input / output devices and control, data and address busing architecture connecting the same. A person skilled in the art would be able to program such a microprocessor-based implementation to perform the functionality set forth herein, as well as other functionality described herein without undue experimentation. The scope of the invention is not intended to be limited to any particular implementation using technology either now known or later developed in the future. Moreover, the scope of the invention is intended to include a signal processor as either part of the aforementioned apparatus, as a stand alone module, or in the combination with other circuitry for implementing another module.

[0051] Techniques for receiving signaling in such a microprocessor, signal processor or processing module 104 are known in the art, and the scope of the invention is not intended to be limited to any particular type or kind thereof either now known or later developed in the future. Based on this understanding, a person skilled in the art would appreciate, understand and be able to implement and / or adapt the microprocessor, signal processor or processing module 104 without undue experimentation so as to receive and process the signaling containing information about the pressure fluctuation sensed and the predetermined target system pressure stored, consistent with that disclosed and set forth herein.

[0052] Techniques for providing controller signaling from any such signaling received are also known in the art, and the scope of the invention is not intended to be limited to any particular type or kind thereof either now known or later developed in the future. Based on this understanding, a person skilled in the art would appreciate, understand and be able to implement and / or adapt the such a microprocessor, signal processor or processing module 104 without undue experimentation so as to processthe signaling received and provide controller signaling increase or decrease the motor speed of the pump motor PM using the PWM signals to deliver the variable DC voltage to the pump motor PM and maintain a substantially constant system pressure in the pumping system PS, based upon the signaling received, consistent with that disclosed and set forth herein.

[0053] Figure 2 includes at least the following parts / components:10a Motor and controller assembly,10b Drive,10c Valve housing,10d 0-ring,10e Upper housing,10f QC adapter for TE pressure sensor,10g Diaphragm for TE pressure sensor VSL,10h Screw for QC adapter 10f,10i Quick connect clip ,10j Pressure sensor cover,10k Retainer clip,10I Screws for upper housing,10m Screws for pressure sensor cover,PT Pressure transducer.

[0054] Figure 3 includes at least the following parts / components:10n Baseplate,10o Baseplate Adapter,10p Motor , 10q Gasket, 10r Printed circuit board assembly (PCBA) andheat sink sub-assembly,10s Screws for PCBA and heat sink sub-assembly,10t Flat washers for screws 10s,10u Void warranty label for affixing to 10r,10v Cable grommet,10w Cable ties,10x Rubber seal grommet, 10y Screws for baseplate 10n, 10z Wire grommet.

[0055] Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.

Claims

WHAT IS CLAIMED IS:1 . A variable speed lineup (VSL) pump system for a pumping system having valves with valve positions, comprising: a diaphragm pump assembly having a pump head; a pump motor, including a brushed, permanent magnet DC motor, coupled to the diaphragm pump assembly; a pressure transducer mechanically coupled to the pump head of the diaphragm pump assembly, configured to sense a pressure fluctuation in a system pressure resulting from a change in one or more valve positions of one or more valves in a pumping system, and provide pressure transducer signaling containing feedback information about the pressure fluctuation sensed; and a controller configured to receive the pressure transducer signaling containing feedback information from the pressure transducer and provide controller signaling containing information to adjust motor speed using Pulse Width Modulation (PWM) signals to deliver a variable DC voltage to the pump motor and maintain a substantially constant system pressure in the pumping system.

2. The VSL pump system of claim 1 , wherein the controller is configured to continuously monitor pressure fluctuations and adjusts motor speed, based on the pressure transducer signaling containing the feedback information received from the pressure transducer, including by increasing or decreasing motor speed using the PWM signals and a power switching element (MOSFET) to maintain the substantially constant system pressure in the pumping system.

3. The VSL pump system of claim 1 , wherein the controller comprises a microcontroller having a memory module configured to store a predetermined target system pressure of the pumping system; and the microcontroller is configured to calculate an error / correction needed based upon the predetermined target system pressure stored and the pressure fluctuation sensed, including by comparing the predetermined target system pressure stored with the pressure fluctuation sensed.

4. The VSL pump system of claim 3, wherein the microcontroller is programmed with procedures for implementing safety mechanisms to protect the pump from at least one of overvoltage, undervoltage, and overcurrent conditions, including by comparing predetermined voltage and current levels to sensed voltage and current levels.

5. The VSL pump system of claim 3, wherein the microcontroller is programmed to implement procedures to stop delivery of power to the motor when sensed voltage levels deviate from a stored predetermined acceptable voltage level range.

6. The VSL pump system of claim 5, wherein the microcontroller is programmed to implement procedures to automatically resume providing power to the motor when sensed voltage levels are again within the stored predetermined acceptable voltage level range.

7. The VSL pump system of claim 3, wherein when water flow stops due to all valves in the pumping system being in a closed position, the microcontroller is programmed with procedures to reduce the duty cycle of the PWM signal such that no power is delivered to the motor.

8. The VSL pump system of claim 1 , wherein the controller is configured to continuously execute a control cycle to compensate for changes in pressure fluctuations of the pumping system.

9. The VSL pump system of claim 1 , wherein the controller comprises an accessible programming port.

10. The VSL pump system of claim 1 , wherein the controller comprises a power switching element (MOSFET) configured to provide the PWM signals to the pump motor.11 . A method for controlling water flow and pressure in a water system using a variable speed lineup (VSL) pump, comprising: monitoring system pressure using a pressure transducer mechanically coupled to a pump head of the VSL pump and configured to provide pressure transducer signaling containing feedback information a pressure fluctuation resulting from a change in one or more valve positions of one or more outlet valves in a water system; and adjusting motor speed of a motor of the VSL pump based on the pressure transducer signaling containing feedback information received from the pressure transducer using at least Pulse Width Modulation (PWM) signals to maintain a substantially constant system pressure in the water system regardless of the valve positions and / or quantity of the outlet valves in the water system.

12. The method of claim 11 , further comprising executing a control cycle to compensate for changes in system pressure fluctuations resulting from the changes in the valve positions of the water system.

13. The method of claim 11 , further comprising: storing a predetermined period of time in a memory module as a software parameter; determining with a controller that the pressure transducer signaling contains no pressure fluctuations for the predetermined period of time stored indicating that water flow has stopped due to all valves in the water system being closed, and reducing with the controller a duty cycle of the PWM signals to stop power delivery to the motor when water flow stops due to all outlet valves in the water system being closed.

14. The method of claim 11 , further comprising adjusting motor speed using the PWM signals and a power switching element (MOSFET) to maintain the substantially constant system pressure in the water system.

15. The method of claim 11 , further comprising protecting the VSL pump from overvoltage, undervoltage, and overcurrent conditions by stopping delivery of power to the motor whenever voltage levels deviate from a predetermined acceptable voltage level range.

16. Apparatus, comprising: a controller having a signal processor configured to receive signaling containing information about a pressure fluctuation sensed in system pressure of a pumping system resulting from a change in one or more valve positions of one or more valves in the pumping system, and also containing information about a predetermined target system pressure stored in a memory module; and provide controller signaling containing information to increase or decrease motor speed of a pump motor using Pulse Width Modulation (PWM) signals to deliver a variable DC voltage to a pump motor of a pump and maintain a substantially constant system pressure in the pumping system, based upon the signaling received.

17. Apparatus according to claim 16, wherein the signaling received includes pressure transducer signaling containing feedback information about the pressure fluctuation sensed, and other signaling containing stored information about the predetermined target system pressure stored.

18. Apparatus according to claim 17, wherein the apparatus comprises the pressure transducer that is mechanically coupled to a pump head of the pump in the pump assembly.

19. Apparatus according to claim 18, wherein the pump is a variable speed lineup(VSL) pump.

20. Apparatus according to claim 16, wherein the controller is configured to provide the controller signaling containing information to decrease the motor speed using the PWM signals, stop providing power to the pump motor, turn off the pump, and shut off a pressure regulating cycle if the pressure fluctuation sensed for a predetermined period of time stored in a memory module does not change indicating that all valves in the pumping system are closed, or if the variable DC voltage deviates from a predetermined acceptable voltage level range stored in the memory module.

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