3D Sensorless Pump Flow and Pressure Conversion for Low-Speed Accuracy
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Solution Overview
Problem
Existing hydronic pumping systems face challenges in accurately determining system pressure and flow rate using sensorless models, which are often formulated in 1D or 2D discrete spaces, leading to inaccuracies, especially at low speeds and in applications without calibration sensors.
Innovation Solution
A 3D sensorless method and converter are developed to directly obtain system flow and pressure from motor signals such as speed, current, torque, and power, using calibrated pump and motor data to implement a signal processor that processes these signals through specific equations to yield accurate flow and pressure readings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If 1D or 2D discrete sensorless models are used for pump control, then device complexity is reduced and ease of manufacture is improved, but measurement precision of system pressure and flow rate deteriorates, especially at low speeds
Solution Approach 1:
The patent transitions from traditional 1D or 2D discrete sensorless models to a 3D sensorless model formulation. This dimensional expansion incorporates additional variables and relationships, enabling more accurate determination of system pressure and flow rate from motor signals while maintaining manageable device complexity through systematic mathematical modeling.
2Measurement precision
If discrete sensorless models are used, then ease of manufacture and implementation is improved, but measurement precision is maintained within only 5-10% error margin, and deteriorates rapidly at low speeds
Solution Approach 1:
The patent changes the fundamental parameters of the sensorless model by expanding from 1D/2D to 3D formulation, incorporating calibrated pump and motor data to create a more comprehensive mathematical model. This parameter expansion improves flow and pressure conversion accuracy across the entire operating range, particularly at low speeds, while maintaining implementation feasibility through structured calibration procedures.
3Measurement precision
If theoretical approaches based on pump and system characteristics equations are used, then ease of operation is improved for simple applications, but measurement precision deteriorates with greater than 10-15% error margin and deteriorates rapidly at low speeds
Solution Approach 1:
The patent implements preliminary calibration procedures during system installation or commissioning, where calibrated pump and motor data are collected and stored. This preliminary action creates a customized 3D sensorless model specific to each system configuration, improving measurement precision while maintaining ease of operation during normal control applications through pre-established mathematical relationships.
Data Source
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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.