A controller for a pump with integrated sensing, computing, and control functionalities

Abstract

The present disclosure relates to the field of pump control and monitoring systems, and presents an integrated controller for a pump, and a method for operating the 5 controller. The controller integrates sensor circuitry, first control circuitry, and second control circuitry. The sensor circuitry obtains one or more sensor signals, each indicating a parameter related to the pump and / or a variable frequency drive (VFD) associated with the pump. The first control circuitry performs an analytics and / or data processing operation on at least one parameter related to the pump 0 and / or VFD. The second control circuitry controls at least one operational parameter of the pump and / or VFD based on a result of the analytics and / or data processing operation. The controller has a printed circuit board (PCB) comprising the sensor circuitry and the second control circuitry, and being attached to the first control circuitry.

Description

[0001] A CONTROLLER FOR A PUMP WITH INTEGRATED SENSING, COMPUTING, AND CONTROL FUNCTIONALITIES

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to the field of pump control and monitoring systems, specifically, relates to controlling a smart pump. The disclosure presents, to this end, an integrated controller for a pump, and a method for operating the pump controller. Further, the disclosure provides a pump and a variable frequency drive (VFD), which respectively include the integrated controller. The integrated controller provides sensing, high-end computing, and control functionalities in a unified manner.

[0004] BACKGROUND

[0005] Pump control and monitoring systems are essential components in various industries, including water and wastewater management, oil and gas, and manufacturing. These systems are responsible for managing the operation of pumps, ensuring optimal pump performance, energy efficiency, and maintaining the health of the pump equipment. Conventional pump control and monitoring systems typically operate independently, i.e., with separate components responsible for controlling the operation of a pump on the one hand, and monitoring its condition on the other hand. This functional separation can lead to suboptimal synchronization and delayed responsiveness, which potentially affects the overall efficiency and performance of the pump.

[0006] Furthermore, many existing pump control and monitoring systems rely on cloudbased data processing, which introduces latency in communication between the pump and, for instance, a data processing center. This delay can hinder real-time decision-making, which may affect the ability to adjust pump operations promptly in response to changing conditions. As a result, the performance and energy efficiency of the pump maybe compromised. In addition to these challenges associated with data processing and decisionmaking, since the conventional pump control and monitoring systems typically use separate components for the control and monitoring functions, larger and more complex assemblies are the result. This leads to an inefficient use of space, and an increase in material usage. In environments where compactness and efficient use of materials are priorities, such as in industrial settings or confined spaces, these conventional systems may thus not be the most suitable solution.

[0007] There is accordingly a need for improved pump control and monitoring systems, which address the challenges associated with the conventional systems.

[0008] SUMMARY

[0009] An objective of this disclosure is therefore to provide a solution that combines pump operation control and condition monitoring, and improves synchronization and responsiveness. A further objective is an immediate data handling and decision-making at the pump location, so as to enhance the pump performance.

[0010] A particular objective is to unify, at the pump location, the trinity of high- performance computing, pump application control, and pump-level sensing. In particular, to combine the functionalities of pump operation control and condition monitoring, real-time data processing, and data analysis at the pump location.

[0011] Further objectives are a better synchronization and responsiveness, an enhanced performance and energy efficiency, and a solution that occupies less space and uses fewer materials than required for conventional pump control and monitoring systems.

[0012] These and other objectives are achieved by the features of the solution of the present disclosure, as described in the claims.

[0013] A first aspect of this disclosure is an integrated controller for a pump, the controller comprising: a sensor circuitry configured to obtain one or more sensor signals, each sensor signal indicating a parameter related to the pump and / or a VFD of the pump or connected to the pump; a first control circuitry configured to perform an analytics operation and / or a data processing operation on at least one parameter related to the pump and / or the VFD; a second control circuitry configured to control at least one operational parameter of the pump and / or the VFD based on a result of the analytics operation and / or the data processing operation; and a printed circuit board (PCB) comprising the sensor circuitry and the second control circuitry, and being attached to the first control circuitry.

[0014] The integrated controller of the first aspect realizes a pump control and monitoring system for the pump, which combines pump operation control and condition monitoring, and can improve synchronization and responsiveness, as detailed in the following.

[0015] The first control circuitry of the integrated controller may be a high-performance computing unit or module, which maybe configured for real-time data processing and analysis at the pump location. This enables reduced latency compared to, for example, cloud-based systems, and allows immediate operational adjustments to be made. As a result, a more efficient and responsive pump control and monitoring system can be achieved.

[0016] The second control circuitry of the integrated controller maybe a pump application control module or unit, which may manage one or more operational parameters of the pump and / or the VFD, and may manage settings and functions that are specific to a pump application. As a result, a more precise control and management of the pump operations can be achieved.

[0017] The sensing circuitry of the integrated controller may comprise integrated pumplevel sensors or interfaces to such sensors, which can detect and measure operational metrics and parameters of the pump and / or the VFD. This may provide real-time data for the first processing circuitry to process and analyze. As a result, immediate operational adjustments are possible.

[0018] The integrated controller may also include a VFD interface, which may be used to control the VFD to regulate the speed and torque of a pump motor. This allows for a precise control of the pump speed, thus enhancing efficiency and performance. As a result, the pump operations can be optimized, which leads to energy savings and an improved pump lifespan.

[0019] The integrated controller may further include a voice command interface, which may interpret voice commands for controlling pump operations and / or may provide speech synthesized user experience (UX) feedback. This allows for handsfree management and adjustments. As a result, user convenience is enhanced, and quick and easy adjustments to the pump operations are possible.

[0020] The form factor of the integrated controller may be compact and have an efficient design. This allows integrating high-end processing functionality within standard physical form factors, wherein all standard pump functionalities may be included. This design advantage also allows for an easy installation and integration with existing pump systems. As a result, the need for extensive modifications or additional space requirements can be reduced.

[0021] In an implementation of the integrated controller, the first control circuitry is removably attached to the PCB.

[0022] Being removably attached may mean that the first control circuitry can be selectively plugged into and unplugged from the PCB. This removability should be simple, for instance, achievable by just pulling and pushing the first control circuitry with respect to the PCB. The first control circuitry may, to this end, be provided on a card or the like, which may be insertable into a slot or card holder provided on the PCB. The easy removability of the first control circuitry allows exchanging it and / or updating the pump with new, more advanced first control circuitry in the future.

[0023] In an implementation of the integrated controller, the first control circuitry comprises a communication circuit configured to establish a wireless connection with a management device and to wirelessly exchange data with the management device.

[0024] The integrated controller may comprise one or more networking and communication components for realizing this. These components may enable the first control circuitry to send or receive data and / or control commands to and from the management device, respectively. This may be beneficial for both standalone and multi-pump system configurations, and (wireless) connection with cloud and backend platforms. The management device may accordingly be a cloud-based device.

[0025] In an implementation of the integrated controller, the first control circuitry is configured to detect an event based on the at least one parameter related to the pump and / or the VFD; and the first control circuitry is configured to wirelessly transmit data related to the detected event to the management device using the wireless connection, and to suspend the wireless connection after transmitting the data related to the detected event to the management device.

[0026] In this way, the integrated controller may embody and provide an event-based communication solution, which may significantly reduce the volume of data transferred from the pump location to the management device. This can be achieved by sending data only if an event is detected - for example, detected based on monitoring one or more parameters related to the pump and / or the VFD - and only sending data that is necessary, for example, for the purposes of obtaining information about and handling the event.

[0027] The data related to the detected event may be saved by the integrated controller, for instance, for the purpose of sending the data (again) if requested. It may also be possible to save all event-related data for a limited amount of time (e.g., 5 minutes or 1 hour), so that all the data can be sent if requested. A request could, for instance, be made by the management device.

[0028] In an implementation, the wireless connection may be resumed each time a next event is detected (the wireless connection having been suspended after sending the data related to the previous event). In an implementation, the integrated controller is configured to exclusively transmit data related to the event after the wireless connection is resumed, and before the wireless connection is suspended. Thus, the event-based communication solution significantly reduces the volume of the data transferred to the management device, as no unnecessary data is transmitted and the integrated controller may be able to resolve many issues on its own. This also lowers the data costs and minimizes risks associated with connectivity of the pump.

[0029] In an implementation of the integrated controller, the first control circuitry is configured to detect the event if a value of at least one of the parameters related to the pump and / or the VFD changes by more than a threshold value and / or fulfills a predefined condition.

[0030] In an implementation of the integrated controller, the first control circuitry is configured to detect the event, if a value of the at least one parameter related to the pump and / or the VFD respectively changes by more than a threshold value and / or fulfills a predefined condition.

[0031] This allows the integrated controller to accurately detect events with low processing effort.

[0032] In an implementation of the integrated controller, the sensor circuitry comprises one or more sensors, each sensor being configured to generate a respective sensor signals; and / or one or more optical and / or electrical interfaces, each optical or electrical interface being configured to receive a respective sensor signal from a sensor of the pump or the VFD.

[0033] Thus, the sensor circuitry may obtain signals from pump-level sensors, which are either provided on the integrated controller, or are external to the controller but integrated with the pump and / or the VFD.

[0034] In an implementation of the integrated controller, the sensor circuitry further comprises one or more mechanical interfaces, each mechanical interface being connected to a sensor of the sensor circuitry and being configured to enable or support a sensing of that sensor.

[0035] The one or more mechanical interfaces may facilitate and / or improve the sensing of at least one sensor. For example, the mechanical interfaces may ensure the right sensing capabilities with the needed accuracy of the at least one sensor. In an implementation of the integrated controller, the one or more sensors of the sensor circuitry comprise at least one of: an accelerometer or gravitation sensor; a vibration sensor; an acoustic sensor; a microphone; a pressure sensor; a flow sensor; a temperature sensor; a current sensor.

[0036] These sensors may respectively provide real-time data, which the first control circuitry can process and analyze, so as to enable immediate operational adjustments of the pump operational parameter(s) by the second control circuitry. The vibration sensor maybe configured for gravity angle sensing and issuing alerts, if the pump is knocked out of its intended alignment. This can prevent damage and inefficiencies caused by misalignment. The microphone may be arranged and configured to detect audible anomalies in the vicinity of the pump. This may enable early detection and intervention of potential issues. The current sensor may be used for calculating, e.g., the power consumption of the pump and / or the VFD.

[0037] In an implementation of the integrated controller, the at least one parameter related to the pump and / or the VFD comprises at least one of: a flow rate of the pump; a pressure of the pump; a temperature of the pump and / or the VFD; a vibration of the pump and / or the VFD; a spatial orientation of the pump and / or the VFD; an acoustic profile of the pump and / or the VFD; a power consumption of the pump and / or the VFD; a driving speed of the VFD.

[0038] Different combinations of sensors and accordingly parameters of the pump indicated by sensors signals are possible. For instance, different combinations of sensors and accordingly sensor signals indicating different parameters related to the pump and / or VFD maybe beneficial for different applications.

[0039] In an example, for deriving a flow, a power consumption of the pump, a pressure of the pump, and a driving speed of the VFD maybe obtained. Accordingly, the one or more sensors may comprise a current sensor, a pressure sensor, and a speed sensor for detecting the speed of the VFD (could be measured and output by the VFD itself). Optionally, an ultrasonic sensor (acoustic sensor) could be used in addition to the before-mentioned sensors to derive the flow rate. Of course, a flow sensor could be involved as well. In another example, for pump health indication or condition monitoring, a power consumption of the VFD, a speed of the VFD, and a head of the pump (which denotes a height at which the pump can raise a fluid, and is a measure for the energy imparted to the fluid by the pump) may be obtained. Accordingly, the one or more sensors may comprise a current sensor, a speed sensor, and a flow sensor.

[0040] In another example, for cavitation detection which involves monitoring the net positive suction head (NPSH), an inlet pressure, a temperature of the pump, a head of the pump, and a flow of the pump maybe obtained. Accordingly, the one or more sensors may comprise one or more pressure sensors, a temperature sensor, a flow sensor, and a speed sensor.

[0041] In another example, for cavitation detection which involves vibration monitoring, a temperature of the pump, and inlet / outlet pressure of the pump, a speed of the VFD, a head of the pump, and a flow of the pump may be obtained. Accordingly, the one or more sensors may comprise a temperature sensor, one or more pressure sensors, a speed sensor, a vibration sensor, and a flow sensor.

[0042] In an implementation of the integrated controller, controlling the at least one operational parameter of the pump and / or the VFD by the second control circuitry comprises at least one of: controlling a driving speed of the VFD; managing a flow rate of the pump; executing a real-time control loop for maintaining a pressure and / or temperature of the pump, or a temperature of the VFD; controlling a setting of the pump and / or the VFD; optimizing an energy usage of the pump and / or the VFD.

[0043] In an implementation of the integrated controller, performing the analytics operation and / or the data processing operation by the first control circuitry comprises at least one of: performing a pressure and / or flow analysis; performing a vibration analysis; performing an energy efficiency analysis; aggregating one or more sensor signals or parameters indicated by the sensor signals; filtering one or more sensor signals or parameters indicated by the sensor signals; converting one or more sensor signals or parameters indicated by the sensor signals. According to the above implementations, the integrated controller realizes an accurate, efficient, and fast pump control and monitoring system. The integrated controller may thus be used to create an improved smart pump (system).

[0044] In an implementation of the integrated controller, the first control circuitry comprises a processor and a memory that includes a software, wherein the processor is configured to execute the software, and wherein the execution of the software causes the processor to perform the analytics operation and / or the data processing operation.

[0045] The integrated controller may further comprise software and firmware, which is also suitable for multi-pump coordination. This may enable the integrated controller to act as a digital master, which coordinates the operations of a multipump system, e.g., coordinates controllers of multiple pumps of the system. As a result, the computing performance in subordinate pumps may be scaled down for cost savings.

[0046] In an implementation, the integrated controller comprises one or more hardware accelerators configured to perform computations using one or more trained models, wherein the at least one parameter related to the pump and / or the VFD is provided as an input to the one or more trained models.

[0047] The system may include artificial intelligence (Al) hardware accelerators, which enhance the processing capabilities for executing more advanced data analytics and / or machine learning. This may result in a more efficient and accurate data processing. The trained models may be neural networks, for instance, convolutional neural networks (CNNs), or the like. The trained models maybe pretrained and / or may be further trained by the integrated controller based on the results of the analytics operation and / or the data processing operation performed by the first control circuitry, and / or based on the control operation of the at least one operational parameter by the second control circuitry. This information may be given as input, for instance as associated inputs, to the trained model.

[0048] Optionally, the Al hardware accelerator comprises at least one of a graphics processing unit (GPU), a field programmable gate array (FPGA), or a specialized Al chip, such as a tensor processing unit (TPU). These components may enhance the processing capabilities of the integrated controller, thereby enabling efficient execution of advanced data analytics and machine learning algorithms.

[0049] In an implementation of the integrated controller, the computations using the trained models are designed to implement or support the analytics operation and / or the data processing operation, or to detect an event based on the at least one parameter related to the pump and / or the VFD.

[0050] In an implementation of the integrated controller, the controller is integrated into the pump or the VFD.

[0051] The VFD may further be integrated into the pump or maybe external to the pump but operatively connected to the pump.

[0052] In an implementation of the integrated controller, the integrated controller is integrated with a processor or microcontroller of the pump; or the integrated controller is architecturally separated in the pump from the processor or microcontroller of the pump.

[0053] In an implementation of the integrated controller, the integrated controller is insertable into the pump or the VFD.

[0054] For instance, the integrated controller maybe plugged into, or slid into, or snapped onto a dedicated part (e.g., a slot, or holder) of the pump or the VFD. Simple removal of the integrated controller may likewise be possible.

[0055] In an implementation of the integrated controller, the controller is provided as or is arranged on a card, which is removably insertable into the pump.

[0056] In an implementation, the integrated controller comprises two architecturally separated but connected sub-PCBs, wherein a first sub-PCB comprises the first control circuitry and a second sub-PCB comprises the second control circuitry. The two sub-PCBs may be connectable, preferably, in an easy and / or removable manner, in order to form the PCB including the various functional circuitries of the integrated controller.

[0057] A second aspect of this disclosure is a pump comprising an integrated controller according to the first aspect or any implementation thereof.

[0058] The pump may be a smart pump, e.g., a pump integrated with processing capabilities, sensors, software, and connectivity features that is able to perform automated monitoring and control, and particularly benefits from the abovedescribed advantages provided by the integrated controller. The pump may be a centrifugal pump. The pump may be a fluid pump, or a liquid pump, or a water pump.

[0059] A third aspect of this disclosure is a VFD comprising an integrated controller according to the first aspect or any implementation thereof.

[0060] A fourth aspect of this disclosure is a method for a pump controller, the method comprising: obtaining one or more sensor signals, each sensor signal indicating a parameter related to the pump and / or a VFD of the pump or connected to the pump; performing an analytics operation and / or a data processing operation on at least one parameter related to the pump and / or the VFD; and controlling at least one operational parameter of the pump and / or the VFD based on a result of the analytics operation and / or the data processing operation.

[0061] The method of the fourth aspect achieves the same advantages as the integrated controller of the first aspect, and may be extended by respective implementations as described above for the integrated controller of the first aspect.

[0062] A fifth aspect of this disclosure is a computer program comprising instructions which, when the computer program is executed by a pump controller, e.g., the integrated controller of the first aspect, instruct the pump controller to perform the method according to the fourth aspect. In summary, the solution of the present disclosure addresses the initially mentioned challenges associated with the conventional pump control and monitoring systems, namely by providing the integrated controller that is able to combine high-performance computing (using the first control circuitry), pump application control (using the second control circuitry), and condition monitoring (using the sensing circuitry). This enables real-time data processing, e.g. of the at least one parameter related to the pump, and decision-making at the pump location. The integration of these functionalities into the controller can ensure optimal pump performance, energy efficiency, and improved operational responsiveness. Thus, it particularly overcomes the shortcomings of the decentralized and separated system components of the conventional pump control and monitoring systems.

[0063] For example, by combining the functionalities of pump control and condition monitoring within the controller, a more holistic and coordinated approach to managing the pump operations and the pump’s health is provided.

[0064] As another example, real-time processing and decision-making is facilitated, since with the high-performance computing ability, the integrated controller can perform data processing and analysis at the pump location directly, which reduces latency compared to cloud-based systems.

[0065] Additionally, the integrated controller may further provide compactness and efficiency in its component design. The integration of the various functional components (circuitries) onto a single PCB offers a more compact and efficient use of space. This contrasts with conventional pump control and monitoring systems, which require larger and more complicated assemblies.

[0066] Moreover, the integrated controller is able to streamline the architecture of smart pump systems. This can lead to easier installation and lower maintenance requirements for the smart pump system, in particular, because there are significantly fewer individual components to install and manage that for conventional pump control and monitoring systems.

[0067] BRIEF DESCRIPTION OF THE DRAWINGS The above described aspects and implementations are explained in the following description of embodiments with respect to the enclosed drawings:

[0068] FIG. 1 shows an exemplary integrated controller according to this disclosure, which is operatively connected to a pump and a VFD.

[0069] FIG. 2 shows an exemplary integrated controller according to this disclosure, which is included in a pump.

[0070] FIG. 3 shows an exemplary integrated controller according to this disclosure, which is included in a VFD.

[0071] FIG. 4 shows an exemplary integrated controller according to this disclosure with more, optional details of the functional circuitries.

[0072] FIG. 5 shows a method for operating a pump controller, according to this disclosure.

[0073] DETAILED DESCRIPTION OF EMBODIMENTS

[0074] FIG. 1 shows an exemplary integrated controller io according to this disclosure. The integrated controller io - like all variants of the integrated controller io shown in this disclosure - can be used to control a pump n and / or to control a VFD 14 associated with the pump 11. The VFD 14 may be connected to the pump 11 like in FIG. 1, or the pump 11 may comprise the VFD 14. The controller 10 is operatively connected to the pump 11 (enabled for the exchange of data, e.g., wired) and to the VFD 14 in FIG. 1. As described later, the integrated controller 10 may also be included in the pump 11 or may be included in the VFD 14. The pump 11 may be a centrifugal pump. The pump 11 maybe considered a smart pump. The pump 11 and the integrated controller 10 may be part(s) of a multi-pump system, wherein the integrated controller 10 may be able to control more than one pump and / or more than one VFD. The integrated controller 10 comprises a PCB 17, which integrates and / or has attached to it various functional circuitries of the integrated controller 10. In particular, the PCB 17 may comprise sensor circuitry 12, and may comprise a first control circuitry 15. These circuitries 12 and 15 maybe formed in the PCB 17, that is, they may be integrated into the PCB 17. Further a second control circuitry 16 maybe attached to the PCB 17, and maybe electrically connected via the PCB 17 to the first control circuitry 15 and / or the sensor circuitry 12. The first control circuitry 15 could, however, be integrated into the PCB 17 as well.

[0075] The sensor circuitry 12 is configured to obtain one or more sensor signals 13. Each sensor signal 13 indicates a parameter related to the pump 11 and / or a parameter related to the VDF 14, wherein the VFD 14 is of the pump 11 or connected to the pump 11. Each sensor signal 13 stems from a respective sensor, particularly, a pump-level sensor. The sensor circuitry 12 may comprises one or more sensors, which are respectively configured to generate a sensor signal 13. The sensor circuitry 12 may alternatively or additionally comprise one or more optical and / or electrical interfaces, which are respectively configured to receive a sensor signal 13 from a sensor of the pump 11 or of the VFD 14 (i.e., on-board sensor(s)). The sensors maybe arranged in at least one sensor array. The one or more sensors may include, for example, at least one of: an accelerometer or gravitation sensor, a vibration sensor, an acoustic sensor, a microphone, a pressure sensor, a flow sensor, a temperature sensor, and a current sensor. Each of these sensors could be conventionally implemented as known in the art.

[0076] The first control circuitry 15 is also referred to as a high-performance (or high-end) computing module or unit in this disclosure. The first control circuitry 15 is configured to perform an analytics operation and / or a data processing operation on at least one parameter related to the pump and / or at least one parameter related to the VFD. The at least one parameter may be provided by the sensing circuitry 12, for example, by providing at least one sensing signal 13 to the first control circuitry 15, or by extracting the at least one parameter from the one or more sensor signals 13 and providing it to the first control circuitry 15. The at least one parameter may comprise at least one of: a flow rate of the pump 11, a pressure of the pump 11, a temperature of the pump 11 and / or a temperature of the VFD 14, a vibration of the pump 11 and / or a vibration of the VFD 14, a spatial orientation of the pump 11 and / or a spatial orientation of the VFD 14, an acoustic profile of the pump 11 and / or an acoustic profile of the VFD 14, a power consumption of the pump 11 and / or a power consumption of the VFD 14, a driving speed of the VFD 14. The first control circuitry 15 maybe implemented by a system on module (SoM) approach, and may be removably attached to the PCB 17. For example, the first control circuitry 15 maybe a module or unit, which can be snapped onto or plugged into the PCB 17.

[0077] The second control circuitry 16 is also referred to as a pump application control module or unit in this disclosure. The second control circuitry 16 is configured to control at least one operational parameter of the pump 11 and / or at least one operational parameter of the VFD 14, wherein it controls based on a result of the analytics operation and / or the data processing operation performed by the first control circuitry 15. That is, the result obtained by the first control circuitry 15 may indicate or may be associated with the control operation of the second control circuitry. For example, the first control circuitry 15 can determine an appropriate control operation given the result, and can inform the second control circuitry 16 accordingly. The first control circuitry 15 may use a trained model for this purpose, or may use a deterministic approach, e.g., using a look-up table, to determine the control operation.

[0078] The second control circuitry 16 maybe or comprise a conventional microcontroller, for instance, a microcontroller of the pump 11 or of the VFD 14. According to, for example, the instructions and / or results provided by the first control circuitry 15, the second control circuitry 16 may, for example, control a driving speed of the VFD 14, or manage a flow rate of the pump 11, or execute a real-time control loop for maintaining a pressure and / or temperature of the pump 11, or a temperature of the VFD 14, or control a setting of the pump 11 and / or the VFD 16, or optimize an energy usage of the pump 11 and / or the VFD 14, or any combination thereof.

[0079] The integrated controller 10, the pump 11, and the VFD 14 - which may form a smart pump system - can be implemented in several variants, as described in the following. For example, in an implementation the VFD 14 may be integrated into the pump 11 together with the integrated controller 10, and may internally perform a direct pump speed control.

[0080] In another implementation, the integrated controller 10 may be integrated alone into the pump 11, and may control the pump speed via commanding an external VFD 14, which in turn drives the motor in said pump 11. This is shown in FIG. 2, which illustrates an exemplary integrated controller 10 that is included in (i.e., is part of) the pump 11.

[0081] In another implementation, the integrated controller 10 may be implemented as non-integrated electronics for the pump 11 - wherein non-integrated electronics should be understood as not being a subset of internal pump electronics, but being placed in an add-on box either residing on the pump 11 or in a location separated from the pump 11 - and is configured to monitor and command the pump 11 with an integrated VFD 14 driving the pump’s motor.

[0082] In another implementation, the integrated controller 10 may be integrated in the VFD 14, which is itself not integrated into the pump 11. The pump 11 is monitored and driven from the VFD 14 in this case, with the integrated controller 10 having unified processing capabilities. This is shown in FIG. 3, which illustrates an exemplary integrated controller 11 that is included in (i.e., is part of) the VFD 14.

[0083] In another implementation, the controller 10 according to any of the abovedescribed implementations may act as a master for a plurality of sub-ordinate controllers (i.e. slaves) - e.g., respectively implemented according to the same list of variants - in a multi-pump system. In the multi-pump system, the computing performance of the subordinate controllers may be scaled down for cost savings. In the multi-pump system, each pump may comprise a respective controller, and one controller is the digital master, the others are slaves.

[0084] FIG. 4 shows an exemplary integrated controller 10 according to this disclosure, wherein more optional details of the functional circuitries are illustrated. As shown, the sensor circuitry 12 may comprise one or more sensors 41. Each of these one or more sensors 41 maybe configured to generate a sensor signal 13 (not shown, but it could be provided to the first control circuitry 15 along the indicated arrow), which is indicative of at least one parameter related to the pump 11 and / or related to the VFD 14. Further, the sensor circuitry 12 may comprise one or more optical and / or electrical interfaces 42. Each of these optical or electrical interfaces 42 is configured to receive a respective sensor signal 13 from a sensor of the pump 11 or from a sensor of the VFD 14. These sensor signals 13 may be processed by the sensor circuitry 13 - e.g., to derive the at least one parameter related to the pump 11 and / or the VFD 14 - or may be simply forwarded to the first control circuitry 15 (along the indicated arrow).

[0085] The first control circuitry 15 may comprise a processor 43 and may comprise memory 44. The memory 44 may include software. The processor 43 may be configured to execute the software, and the execution of the software may cause the processor 43 to perform the analytics operation and / or the data processing operation based on the at least one parameter related to the pump 11 and / or the VFD 14.

[0086] Generally, the processor 43 of the first control circuitry 15 may comprise hardware and may be controlled by software. The hardware may comprise analog circuitry or digital circuitry, or both analog and digital circuitry. The circuitry may comprise components such as application-specific integrated circuits (ASICs), field- programmable gate arrays (FPGAs), field programmable analog arrays (FPAAs), analog / digital signal processors (DSPs), or multi-purpose processors. The memory 44 of the first control circuitry 15 may comprise memory circuitry, which stores one or more instruction(s) that can be executed by the processor 43, in particular, under control of the software. For instance, the memory circuitry may comprise a non-transitory storage medium storing executable software code which, when executed by the processor 43, causes the various operations of the first control circuitry 15 to be performed.

[0087] The first control circuitry 15 may further comprise a communication circuit 46, which is configured to establish a wireless connection with a management device, and to wirelessly exchange data with the management device. The management device may be cloud-based, that is, it may be situated in a cloud or may provide a cloud. For instance, the management device may be implemented on a server, or may be a server. The management device may also be a computer or the like, and may comprise a processor or controller. The management device may be configured to manage one or more pumps - specifically the pump n by interacting with the integrated controller 10.

[0088] The first control circuitry 15 may be configured to detect an event based on the at least one parameter related to the pump 11 and / or the VFD 14, and may be configured, by means of the communication circuit 46, to wirelessly transmit data related to the detected event to the management device. The first control circuitry 15 may further suspend the wireless connection after transmitting the data related to the detected event to the management device. Suspending the wireless connection may include actively pausing a link between the integrated controller 10 and the management device, such as setting the link to a power saving mode. Suspending the wireless connection could also include terminating the wireless connection or disabling the wireless functionality on the integrated controller 10, but then the wireless connection would have to be re-established when the next event is detected, which maybe less preferred. Preferably, suspending the wireless connection involves maintaining the ability to quickly resume the wireless connection, in particular, when a next event is detected. In any case, suspending the wireless connection results at least in the temporary cessation of data exchange between the integrated controller 10 and management device. An event may be detected, if a value of at least one of the parameters related to the pump 11 changes by more than a threshold value and / or fulfills a certain condition.

[0089] The integrated controller 10, e.g. its first control circuitry 15, may further comprise one or more hardware accelerators 45, which are configured to perform computations using one or more trained models. The trained models may also be maintained and executed on the first control circuitry 15. The trained models may be one or more neural networks, for instance, convolutional neural networks (CNNs), and maybe used for detecting events based on the one or more parameters related to the pump 11 and / or VFD 14 being input into the model. They may also be used for performing the analytics operation and / or a data processing operation on the at least one parameter related to the pump n and / or the VFD 14 at the first control circuitry 15.

[0090] The first control circuitry 15 may provide the results of performing the analytics operation and / or a data processing operation to the second control circuitry (along the indicated arrow). The first control circuitry 15 may also provide additional information, like regarding detected events and / or instructions for control operations, to the second control circuitry 16.

[0091] The second control circuitry 16 may comprise a microcontroller 47. The microcontroller 47 may be a standard microcontroller, as it may be used for controlling a conventional pump. The microcontroller 47 maybe part of the pump 11, and the integrated controller 10 maybe included in the pump 11.

[0092] Generally, the second control circuitry 16, e.g. the microcontroller 47, may comprise a processor, which may comprise hardware and / or maybe controlled by software. The hardware may comprise analog circuitry or digital circuitry, or both analog and digital circuitry. The circuitry may comprise components such as ASICs, FPGAs, FPAAs, DSPs, or multi-purpose processors. The second control circuitry 16 may respectively further comprise memory circuitry, which stores one or more instruction(s) that can be executed by the processor, in particular under control of the software. For instance, the memory circuitry may comprise a non- transitory storage medium storing executable software code which, when executed by the processor, causes the various operations of the second control circuitry 16.

[0093] FIG. 5 shows a flow-diagram of a method 50 for operating a pump controller for a pump 11, particularly the integrated controller 10 according to any one of the previous figures.

[0094] The method 50 comprises a step 51 of obtaining one or more sensor signals 13. Each sensor signal 13 indicates a parameter related to the pump 11 and / or a VFD 14 of the pump 11 or connected to the pump 11. The first step 51 maybe performed by the sensor circuitry 12 of the integrated controller 10. The method 50 further comprises a second step 52 of performing an analytics operation and / or a data processing operation on at least one parameter related to the pump 11 and / or the VFD 14. The second step 52 may be performed by the first control circuitry 15 of the integrated controller 10. The method 50 then comprises a third step 53 of controlling at least one operational parameter of the pump 11 and / or the VFD 14 based on a result of the analytics operation and / or the data processing operation. The third step 53 may be performed by the second control circuitry 16 of the integrated controller 10.

[0095] In the following, further details of the integrated controller 10 and specifically of its integrated circuitries 12, 145, 16 (also referred to as modules or units) are described. These details may relate to any implementation of the integrated controller 10 shown in the previous figures.

[0096] The integrated controller 10 may integrate high-performance computing, pump application control, and pump-level sensing. The integrated controller 10 may split these responsibilities between the second control circuitry 16 (a pump application control module, e.g., a standard microcontroller), the first control circuitry 15 (a high-performance edge computing unit), and the sensing circuitry 12. The second control circuitry 16 may be responsible for the direct management of one or more operational parameters of the pump 11 and / or VFD 14, and settings, and functions specific to the pump's applications, such as controlling the VFD 14, managing flow rates, and executing real-time control loops for maintaining pressure or temperature. The first control circuitry 15 may be responsible for high-end computing functionality, such as advanced data processing and analysis, machine learning for predictive maintenance, complex algorithm execution for optimization of energy usage, aggregation of sensor data (from multiple pumps), and secure communication with other devices in the network or with cloud services for broader system integration and analytics.

[0097] The second control circuitry 16 may include the software and dedicated hardware that directly manages the one or more operational parameters, settings, and functions specific to the pump application.

[0098] The first control circuitry 15 may contain the necessary processors, memory and software to perform high-speed data processing and analysis at the pump location(s) of the network, and maybe integrated in the pump 11. The first control circuitry 15 may comprise all networking and communication components that enable the controller 10 to send or receive data and control commands, necessary for both standalone and multi-pump system configurations, and connection with cloud and backend platforms. The first control circuitry 15 could be implemented using a SoM approach - e.g., as a compact, self-contained unit that can be integrated into the larger pump system's electronics. The first control circuitry 15 maybe Linux based, e.g. Linux performance (high speed CPU, large memory, large flash disk etc.).

[0099] The sensing circuitry 12 may comprise or be connected to one or more pump-level sensors. For example, the sensing circuitry 12 may comprise or be connected to a sensor array with sensor interfaces to external sensors and / or PCB-mounted sensors, integrated with the first and second control circuitry 15, 16 on the carrier board. It may be used to detect and measure various operational metrics of the pump 11 and / or the VFD 14, such as temperature, vibration, pressure, and flow.

[0100] The PCB 17 may further comprise one or more PCB-mounted sensors (e.g., accelerometer(s), vibration sensor(s), acoustic sensor(s), and / or pressure sensor(s)). These one or more sensors can be integrated directly on the PCB 17 of the integrated controller 10, and may have mechanical interfaces that ensure the right sensing capabilities with the needed accuracy.

[0101] Additional details, which are applicable to all previously discussed implementations and variants of the integrated controller 10, are described in the following.

[0102] The first control circuitry 15 can be regarded as supervisory control and data acquisition (SCAD A) or mini building management system (BMS) specifically for pump operations. The high-performance computing unit (first control circuitry 15) may serve a similar role to the central processing unit in a BMS, which analyzes data and makes decisions for system control, and the pump application control module is equivalent to the specific control logic implemented in a BMS for various subsystems. At least one, or even many, hardware accelerators can be integrated within the first control circuitry 15, in order to further enhance its processing capabilities. These accelerators maybe specialized hardware, which is designed to speed up Al-related computations, such as neural network inference and machine learning algorithms. The accelerators may also be directly integrated into a main micro-processor based on SoM. The accelerators could be components like Graphics Processing Units (GPUs), FPGAs, or specialized Al chips, such as Tensor Processing Units (TPUs). When integrated into the first control circuitry 15, these accelerators may enable the second control circuitry 16 and the sensor circuitry 12 to leverage advanced data analytics and machine learning models more efficiently and with lower latency. For instance, using Al hardware accelerators could allow the first control circuitry 15 to process real-time data from the condition monitoring sensors with advanced algorithms, which not only report the current status but also predict potential failures or required maintenance through predictive analytics. This results in optimized performance, energy savings, and lower downtime of the pump system. The scalability of the SoM enables learning at the pump location (not only inference for backend), which creates the means for self-adapting systems.

[0103] The first control circuitry 15 may include software and firmware for multi-pump coordination, i.e., programs and protocols enabling one embodiment of the integrated controller 10 to act as a digital master, coordinating the operations of a multi-pump system and possibly facilitating the scaling down of computing performance in subordinate pumps for cost savings.

[0104] The first control circuitry 15 can be designed as a removable card (e.g. “clickable”) on the PCB 17. This enables components of the first control circuitry 15 to be updated or replaced without the need to discard the entire hardware unit, i.e., the integrated controller 10. This enhances the sustainability and adaptability of solution. Also the integrated controller 10 as a whole may be provided as, or arranged on, a card, which is removably insertable into the pump 11. The card may be pluggable, and may be a hardware component designed to be easily inserted into or removed from a slot in a system, such as the pump’s electronics in this case, so as to add functionality and enhance the performance of the pump 11. If the VFD 14 is integrated in the pump 11 together with the integrated controller

[0105] 10, the second control circuitry 16 may provide the necessary electronic components and software interfaces, which may allow the integrated controller 10 to regulate the speed and torque of the pump motor via the VFD 14, thus controlling the pump speed directly.

[0106] If one or more external VFDs 14 are utilized, the second control circuitry 16 and the first control circuitry 15 may facilitate communication and control commands to an external VFD 14 for pump speed regulation.

[0107] Regarding the PCB-mounted pump-level sensors, built-in vibration sensors (primary function condition monitoring) may also allow for gravity angle sensing and issuing of alerts, if the pump 11 is knocked out of its intended alignment, for example, due to failing mechanical fixation in a sump or well.

[0108] Smart mechanical interfaces of the integrated controller 10 may further facilitate the integration of off-the-shelf sensors and multi-sensor packages for condition monitoring. The modular design of such an integrated controller 10 may allow mechanical and electrical interfaces that can accommodate standardized sensor packages, which typically include a variety of sensors to monitor crucial pump parameters such as temperature, vibration, pressure, and flow. The integrated controller 10 may be sensor-agnostic, accepting inputs from various types of sensors and allowing for easy plug-and-play capabilities. This approach not only streamlines the integration process but also provides flexibility in terms of upgrading the sensor technology or replacing sensors for maintenance without the need for complex system overhaul. Moreover, the second control circuitry 16 can be configured to interpret the data coming from such multi-sensor packages to optimize pump performance and predict maintenance needs. Real-time data from the sensors would be processed by the integrated controller 10, providing immediate analysis and feedback for operational adjustments.

[0109] Optionally, the integrated controller 10 may include one or more microphones as complementary sensor(s), also enabling voice-based interactions with the pump

[0110] 11. A speaker may also be integrated into the controller 10. The integrated controller 10 may have a standard physical form factor, and maybe able to perform all standard pump functionalities. Overall, the architecture of the integrated controller 10 may emphasize a modular approach, where the high-end computing functionality can be integrated with an existing pump structure, enabling enhancements such as smarter control systems, improved energy efficiency, predictive maintenance, and remote monitoring, all within the space constraints of the traditional pump form factor.

[0111] In summary of the above aspects and implementations, the solution of this disclosure as implemented by the integrated controller 10, the pump n, the VFD 14 and the method 40, provides several advantages.

[0112] For example, the solution integrates high-performance computing, pump application control, and condition monitoring into a unified platform - the integrated controller 10 - meaning, it consolidates multiple functions, reducing component count and potentially lowering costs related to procurement, inventory, and system complexity.

[0113] Further, the solution enables ultra-fast sampling and shifting of the sampling frequency. In particular, the integration of computing and condition monitoring sensors into the same platform allows for ultra-fast sampling of operational data. This real-time data acquisition is beneficial for large analytics, as it can capture transient events and subtle performance nuances that might be missed by slower, more disjointed systems. The high-resolution data enables more sophisticated analytics and near-instantaneous insight generation, which is critical for process optimization and predictive maintenance. The setup also for dynamically adjusting the sampling frequency, e.g., by analyzing the demands of the application in realtime, and make decisions on the optimal sampling rate for the given operational context.

[0114] Further, localized data processing with high quality is enabled. In particular, the high-performance computing capabilities allow the integrated controller 10 to process data directly at the source, minimizing latency, and enabling faster response times for critical pump operations (such as changing pump speeds through the VFD 14), which leads to a more reliable process. Fourthly, localized data processing with low cost is enabled. In particular, by processing data locally on the integrated controller 10, the solution saves resources that would otherwise be spent on sending large volumes of raw data for remote processing. This leads to reduced bandwidth requirements and the associated costs. With local computation capabilities, it also becomes possible to perform sophisticated data analytics on demand without relying on external processing resources, which would incur additional costs. As only pertinent data (like alerts and long-term trends, or data related to detected events) may need to be sent to the cloud or central servers (e.g., management device), businesses can opt for less costly data communication services. Additionally, with the capability of the module to calculate control actions locally, businesses avoid the ongoing expenditures tied to cloud-based data processing and analysis services.

[0115] Further, localized data processing with improved data privacy is enabled. In particular, the data privacy is inherently enhanced when the data processing occurs locally within the integrated controller 10. This arrangement allows for sensitive data to be analyzed and leveraged without ever leaving the protected local environment, aligning with data protection regulations and reducing the risk of data breaches or unauthorized access. By keeping sensitive operational data within the confines of the module, the risk of exposure during transmission or to external servers is mitigated. Furthermore, when data does need to be shared— for instance, for long-term analytics or remote monitoring— the computing capabilities allow for the aggregation and anonymization of such data before transmission.

[0116] Further, if implemented as a removable functional card on a carrier board, the sustainability and adaptability of the integrated controller 10 can be significantly enhanced. This design of the integrated controller 10 enables electronics and software components to be updated or replaced without the need to discard the entire hardware unit. This modularity means that advances in processing power, memory capacity, or new features can be incorporated by simply swapping out the card for a newer version. This also contributes to a reduction in electronic waste. Instead of disposing of the entire system when it becomes obsolete or requires a hardware upgrade, only the functional card maybe replaced. This approach aligns well with sustainability goals and the principles of a circular economy. Further, a centralized multi-pump management is enabled with the integrated controller 10, wherein the controller 10 may act as a master controller in a multipump setup including one or more slave controllers as well. This central coordination can optimize the efficiency of the entire system, and can reduce the computational load on individual pumps of the multi-pump system.

[0117] In the claims as well as in the description of this disclosure, the word ‘comprising’ does not exclude other elements or steps and the indefinite article ‘a’ or ‘an’ does not exclude a plurality. A single element may fulfill the functions of several entities or items recited in the claims. The mere fact that certain measures are recited in the mutual different dependent claims does not indicate that a combination of these measures cannot be used in an advantageous implementation.

Claims

Claims1. An integrated controller (10) for a pump (11), the controller (10) comprising: a sensor circuitry (12) configured to obtain one or more sensor signals (13), each sensor signal (13) indicating a parameter related to the pump (11) and / or a variable frequency drive, VFD, (14) of the pump (11) or connected to the pump (11); a first control circuitry (15) configured to perform an analytics operation and / or a data processing operation on at least one parameter related to the pump (11) and / or the VFD (14); a second control circuitry (16) configured to control at least one operational parameter of the pump (11) and / or the VFD (14) based on a result of the analytics operation and / or the data processing operation; and a printed circuit board, PCB, (17) comprising the sensor circuitry (12) and the second control circuitry (16), and being attached to the first control circuitry (15)-2. The integrated controller (10) according to claim 1, wherein the first control circuitry (15) is removably attached to the PCB (17).

3. The integrated controller (10) according to claim 1 or 2, wherein the first control circuitry (15) comprises a communication circuit (46) configured to establish a wireless connection with a management device and to wirelessly exchange data with the management device.

4. The integrated controller (10) according to claim 3, wherein the first control circuitry (15) is configured to detect an event based on the at least one parameter related to the pump (11) and / or the VFD (14); and the first control circuitry (15) is configured to wirelessly transmit data related to the detected event to the management device using the wireless connection, and to suspend the wireless connection after transmitting the data related to the detected event to the management device.

5. The integrated controller (10) according to claim 4, wherein the first control circuitry (15) is configured to detect the event, if a value of the at least oneparameter related to the pump (n) and / or the VFD (14) respectively changes by more than a threshold value and / or fulfills a predefined condition.

6. The integrated controller (10) according to one of the claims 1 to 5, wherein the sensor circuitry (12) comprises one or more sensors (41), each sensor (41) being configured to generate a respective sensor signals (13); and / or one or more optical and / or electrical interfaces (42), each optical or electrical interface (42) being configured to receive a respective sensor signal (13) from a sensor of the pump (11) or the VFD (14).

7. The integrated controller (10) according to claim 6, wherein the sensor circuity (12) further comprises one or more mechanical interfaces, each mechanical interface being connected to a sensor (41) of the sensor circuitry (12) and being configured to enable or support a sensing of that sensor (41).

8. The integrated controller (10) according to claim 6 or 7, wherein the one or more sensors (41) of the sensor circuitry (12) comprise at least one of: an accelerometer or gravitation sensor; a vibration sensor; an acoustic sensor; a microphone; a pressure sensor; a flow sensor; a temperature sensor; a current sensor.

9. The integrated controller (10) according to one of the claims 1 to 8, wherein the at least one parameter related to the pump (11) and / or the VFD (14) comprises at least one of: a flow rate of the pump (11); a pressure of the pump (11); a temperature of the pump (11) and / or the VFD (14); a vibration of the pump (11) and / or the VFD (14);a spatial orientation of the pump (n) and / or the VFD (14); an acoustic profile of the pump (11) and / or the VFD (14); a power consumption of the pump (11) and / or the VFD (14); a driving speed of the VFD (14).

10. The integrated controller (10) according to one of the claims 1 to 9, wherein controlling the at least one operational parameter of the pump (11) and / or the VFD (14) by the second control circuitry (16) comprises at least one of: controlling a driving speed of the VFD (14); managing a flow rate of the pump (11); executing a real-time control loop for maintaining a pressure and / or temperature of the pump (11), or a temperature of the VFD (14); controlling a setting of the pump (11) and / or the VFD (14); optimizing an energy usage of the pump (11) and / or the VFD (14).

11. The integrated controller (10) according to one of the claims 1 to 10, wherein performing the analytics operation and / or the data processing operation by the first control circuitry (15) comprises at least one of: performing a pressure and / or flow analysis; performing a vibration analysis; performing an energy efficiency analysis; aggregating one or more sensor signals (13) or parameters indicated by the sensor signals (13); filtering one or more sensor signals (13) or parameters indicated by the sensor signals (13); converting one or more sensor signals (13) or parameters indicated by the sensor signals (13).

12. The integrated controller (10) according to one of the claims 1 to 11, wherein the first control circuitry (15) comprises a processor (43) and a memory (44) that includes a software, wherein the processor (43) is configured to execute the software, and wherein the execution of the software causes the processor (43) to perform the analytics operation and / or the data processing operation.13- The integrated controller (10) according to one of the claims 1 to 12, further comprising one or more hardware accelerators (45) configured to perform computations using one or more trained models, wherein the at least one parameter related to the pump (11) and / or the VFD (14) is provided as an input to the one or more trained models.

14. The integrated controller (10) according to claim 13, wherein the computations using the trained models are designed to implement or support the analytics operation and / or the data processing operation, or to detect an event based on the at least one parameter related to the pump (11) and / or the VFD (14).

15. The integrated controller according to one of the claims 1 to 14, wherein the controller (10) is integrated into the pump (11) or the VFD (14).

16. The integrated controller (10) according to one of the claims 1 to 15, wherein the controller (10) is integrated with a processor or microcontroller of the pump (11); or the controller (10) is architecturally separated in the pump (11) from the processor or microcontroller of the pump (11).

17. The integrated controller (10) according to one of the claims 1 to 16, wherein the controller (10) is insertable into the pump (11) or the VFD (14).

18. The integrated controller (10) according to one of the claims 1 to 17, wherein the controller (10) is provided as or is arranged on a card, which is removably insertable into the pump (11).

19. The integrated controller (10) according to one of the claims 1 to 18, comprising two architecturally separated but connected sub-PCBs, wherein a first sub-PCB comprises the first control circuitry (15) and a second sub-PCB comprises the second control circuitry (16).

20. A pump (11) comprising an integrated controller (10) according to one of the claims 1 to 19.

21. A variable frequency drive, VFD, (14) comprising an integrated controller (10) according to one of the claims 1 to 19.

22. A method (50) for a pump controller (10), the method (50) comprising: obtaining (51) one or more sensor signals (13), each sensor signal (13) indicating a parameter related to the pump (11) and / or a variable frequency drive, VFD, (14) of the pump (11) or connected to the pump (11); performing (52) an analytics operation and / or a data processing operation on at least one parameter related to the pump (11) and / or the VFD (14); and controlling (53) at least one operational parameter of the pump (11) and / or the VFD (14) based on a result of the analytics operation and / or the data processing operation.

23. A computer program comprising instructions which, when the computer program is executed by a pump controller (10), instruct the pump controller (10) to perform the method (50) according to claim 22.

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