3D Sensorless Pump Conversion for Accurate Low-Speed Flow Estimation
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Solution Overview
Problem
Existing hydronic pump control systems face challenges in accurately determining system pressure and flow rate from motor signals, particularly at low speeds, due to limitations in 1D and 2D discrete space models, which result in significant accuracy deterioration and higher error margins.
Innovation Solution
A 3D sensorless model and converter are developed to directly resolve system flow and pressure from motor signals such as speed, current, torque, and power, using calibrated motor data, enabling more accurate control of hydronic pumping systems by processing power conversion relationships and reconstructing 3D distribution functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If 1D or 2D discrete space models are used for sensorless pump conversion, then the device complexity is reduced, but the measurement precision of system pressure and flow rate deteriorates significantly, especially at low speeds
Solution Approach 1:
The patent transitions from 1D and 2D discrete space models to a 3D sensorless model that incorporates motor speed, motor power, and equivalent system characteristics as three interconnected dimensions. This dimensional expansion enables more accurate resolution of system pressure and flow rate by capturing the complex relationships between multiple parameters simultaneously, particularly improving accuracy at low speeds where lower-dimensional models fail.
2Measurement precision
If 3D sensorless model is used, then the measurement precision of system pressure and flow rate is improved, but the device complexity and computational requirements increase
Solution Approach 1:
The 3D sensorless model is implemented by segmenting the complex conversion process into distinct functional components: motor speed measurement, motor power calculation, equivalent system characteristics determination, and the final pressure-flow rate resolution. This segmentation allows the complex 3D model to be built from manageable parts while maintaining high measurement precision.
Solution Approach 2:
The patent introduces equivalent system characteristics as an intermediary parameter that mediates between motor signals and system hydraulic parameters. This intermediary enables the 3D model to accurately resolve pressure and flow rate by serving as a bridge that captures the relationship between electrical motor parameters and hydraulic system state, reducing the direct computational complexity.
3Ease of manufacture
If sensorless conversion is used to reduce system cost, then the loss of information about system state increases, but the patent recovers this information through 3D modeling
Solution Approach 1:
The patent replaces physical sensors (mechanical/hydraulic measurement devices) with a sensorless conversion system based on 3D modeling of motor parameters. By substituting direct measurement hardware with computational modeling, the system reduces cost while recovering system state information through mathematical relationships between motor speed, power, and equivalent system characteristics.
Data Source
AI summary
The present invention provides apparatus featuring a signal processor or processing module that may be configured at least to: receive signaling containing information about calibrated motor speed and power data for a hydronic pumping system; and determine system pumping flow rate and pressure associated with an equivalent hydronic system characteristic variable, based at least partly on the signaling received. The signal processor or processing module may be configured to provide corresponding signaling containing information about the system pumping flow rate and pressure determined. The corresponding signaling may contain information used to control the hydronic pumping system.