Fluid Transfer Static Head Approximation via Shaft Torque Analysis
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Solution Overview
Problem
Existing fluid transfer systems face challenges in determining the static head and minimum applicable rotational speed efficiently, as current methods require additional measurements or high computational efforts, affecting energy efficiency and operational feasibility.
Innovation Solution
A method and apparatus that determine the static head of a fluid transfer system by analyzing shaft torque or power consumption at different rotational speeds, identifying the rotational speed at which flow begins, and using characteristics curves to approximate the static head without additional sensors, utilizing frequency converters for data logging and calculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional measurements are used to determine static head, then measurement precision is improved, but device complexity and cost increase due to additional sensors
Solution Approach 1:
The fluid transfer device uses its own existing sensors (shaft torque sensor and speed sensor) to determine static head, without requiring additional measurement devices. The control unit processes data from these self-existing sensors to calculate static head, making the system self-sufficient and avoiding additional hardware complexity
Solution Approach 2:
The patent introduces a computational intermediary approach where shaft torque and speed data are used as intermediate parameters to indirectly determine static head. Instead of directly measuring static head with additional sensors, the system uses the relationship between shaft torque, speed, and power consumption to calculate static head through mathematical models
2Measurement precision
If least squares method is used to determine system curve parameters, then measurement precision is improved, but use of energy increases due to high computational needs
Solution Approach 1:
The patent extracts only the essential parameters needed for static head determination (shaft torque and speed) from the complex system curve analysis. Instead of performing full least squares regression on system curve parameters, the method focuses on extracting critical information from torque-speed relationships, reducing computational burden while maintaining accuracy
Solution Approach 2:
The patent applies partial action by using a simplified computational approach that processes only the necessary data points for static head determination. Rather than performing complete system curve fitting with least squares method, the system uses selective data processing and simplified mathematical models that require less computational energy while achieving the same practical accuracy for control purposes
3Use of energy by moving object
If fluid transfer device operates at low rotational speed, then use of energy is reduced, but reliability decreases due to fluid recirculation and device stalling
Solution Approach 1:
The control unit continuously monitors shaft torque and speed, and uses this feedback to determine static head in real-time. Based on the calculated static head and system requirements, the control unit adjusts the rotational speed to maintain optimal operation above the minimum threshold, preventing recirculation and stalling while minimizing energy consumption
Solution Approach 2:
The patent implements dynamic speed control where the minimum rotational speed is not fixed but adapts based on real-time static head determination. The system dynamically adjusts operational parameters according to actual system conditions, allowing the fluid transfer device to operate at the lowest possible speed that still ensures reliable operation without recirculation or stalling
Data Source
AI summary
The present disclosure is directed to a method and apparatus for approximating a static head of a fluid transfer system including a fluid transfer device. The method can include determining a rotational speed and a power consumption of the fluid transfer device, determining a first set of data points, calculating a second set of data points on the basis of the first set of data points, determining a minimum rotational speed producing flow through the fluid transfer device on the basis of the second set of data points, and determining the static head on the basis of the minimum rotational speed.