Variable-Speed Hydronic Pump Control Curves for Sensorless Setup
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Solution Overview
Problem
Existing pump control systems for hydronic applications lack the ability to efficiently adjust and optimize pump performance in real-time to meet varying flow and pressure requirements without sensors, leading to suboptimal energy consumption and complex setup procedures.
Innovation Solution
A pump control design toolbox that allows for interactive, real-time adjustment of pump control curves based on system characteristics, featuring a signal processor and touchscreen interface for operators to set and redesign pump and system curves, enabling automatic setup and minimizing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional pump control systems are used without sensors, then device complexity is reduced, but measurement precision of flow and pressure parameters deteriorates
Solution Approach 1:
The patent replaces traditional mechanical sensors with a sensorless control system that uses motor current and voltage measurements combined with pump characteristic curves to infer flow and pressure parameters. This substitution eliminates physical sensors while maintaining measurement capability through computational methods.
Solution Approach 2:
The patent introduces pump characteristic curves as an intermediary between the motor control system and the hydraulic parameters. These curves serve as a transfer function that translates electrical measurements into flow and pressure information without requiring direct hydraulic sensors.
2Device complexity
If fixed pump control curves are used, then device complexity is reduced, but adaptability to varying system requirements deteriorates
Solution Approach 1:
The patent implements dynamic control curves that can be adjusted in real-time based on actual system performance and requirements. The system allows operators to modify control parameters and curves during operation, transforming a static control system into a dynamic one that adapts to changing conditions.
Solution Approach 2:
The patent enables parameter changes in the control curves through an interactive interface where operators can adjust flow rates, pressures, and curve shapes. This allows the system to adapt to different operating conditions and system configurations without requiring hardware changes.
3Manufacturing precision
If complex pump control setup procedures are used, then manufacturing precision of control curves is improved, but ease of operation deteriorates
Solution Approach 1:
The patent implements a self-service setup procedure where the system automatically generates and configures control curves based on pump specifications and system parameters entered by the operator. The interactive interface guides users through the setup process, eliminating the need for complex manual calculations or specialized programming while maintaining high precision.
Data Source
AI summary
Apparatus for providing variable speed pump control in a hydronic pump system having a system flow and pressure requirement, featuring a signal processor or processing module configured to: receive signaling containing information about a system characteristic curve, a system flow and pressure requirement for the hydronic pump system, and real time changes by a pump operator to at least one control parameter to adjust the performance of the hydronic pump system; and determine corresponding signaling containing information about a design/redesign of at least one pump, system or control curve to adjust the performance of the hydronic pump system to correspond with the system flow and pressure requirement of the hydronic system, based upon the signaling received.