Condensate pump assembly & control methods
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Solution Overview
Problem
Existing condensate pump assemblies face issues with noise, vibration, and aesthetic intrusiveness due to their size and design, leading to potential water damage and mechanical fixation damage, especially in domestic environments where space is limited and noise is a concern.
Innovation Solution
A condensate pump assembly with a rotary diaphragm pump, a controller that measures current consumption to determine condensate presence, and a design that minimizes noise and vibration through resilient attachment members and a direct connection between the pump and liquid outlet, eliminating intermediate reservoirs for reduced size and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a liquid receptacle and clam-shell cover are added to secure the liquid receptacle and improve aesthetic appearance, then the aesthetic appearance is improved and the liquid receptacle is secured, but the size of the condensate pump assembly increases and additional noise is generated by rattling against the housing
Solution Approach 1:
The patent removes the liquid receptacle and clam-shell cover from the condensate pump assembly, integrating the pump directly into the housing. This extraction eliminates the additional components that caused increased size and rattling noise, while the pump remains functionally integrated into the system.
Solution Approach 2:
The patent merges the pump directly with the housing, eliminating the need for separate liquid receptacle and cover components. This integration reduces the overall assembly size and eliminates rattling noise from loose components while maintaining the pump's functional integration.
2Reliability
If the pump operates continuously to ensure sufficient condensate removal, then condensate removal reliability is improved, but air may be entrained into the pump and downstream conduits affecting pump lifespan and increasing noise
Solution Approach 1:
The patent employs a controller that monitors pump operation and liquid level conditions to control pump startup and shutdown. This feedback mechanism ensures the pump operates only when condensate is present and stops when the liquid receptacle is empty, preventing continuous operation that would entrain air and damage the pump, while maintaining reliable condensate removal when needed.
3Productivity
If the pump operates at high power to ensure efficient condensate pumping, then productivity is improved, but noise and vibration are significantly increased which may damage mechanical fixations
Solution Approach 1:
The patent incorporates vibration isolation elements and resilient attachment members between the pump and housing before the pump operates. These cushioning elements are pre-installed to absorb and dampen vibrations and noise generated during pump operation, protecting the housing and mechanical fixations from damage while allowing the pump to operate efficiently.
4Quantity of substance
If intermediate reservoirs and conduits are included in the condensate pump assembly, then condensate can be collected and pumped, but the assembly size increases and noise from rattling components is generated
Solution Approach 1:
The patent extracts and removes the intermediate liquid receptacle and associated clam-shell cover from the condensate pump assembly. The pump is integrated directly into the housing with condensate entering the pump inlet directly, eliminating the need for intermediate storage reservoirs and reducing the overall assembly size while maintaining condensate collection and pumping capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces noise and vibration, prevents water damage, and enhances the aesthetic appeal by minimizing the pump's size and visibility, making it more suitable for domestic installations while maintaining efficient condensate removal.
Implementation Method 1
a pump arranged to pump liquid from a liquid inlet to a liquid outlet
Implementation Method 2
designed to minimise noise and vibration
Data Source
AI summary
The present disclosure comprises a method of controlling a condensate pump assembly which comprises a pump and a controller connected to the pump, the method comprising measuring a current value drawn by the pump, comparing the measured current value to a predetermined threshold current value and controlling operation of the condensate pump assembly based on the current value comparison. Also provided is a condensate pump assembly for use in an air conditioning system, comprising a housing comprising an upper housing portion and a pump arranged to pump liquid from a liquid inlet to a liquid outlet.