Multi-Voltage Pump with Signal Processor for Run Dry Protection
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Solution Overview
Problem
Existing pump designs are often voltage-specific and lack effective protection against run dry and overcurrent conditions, leading to damage and the need for multiple pump models and frequent maintenance.
Innovation Solution
A pump equipped with an internal electronic printed circuit board assembly (PCBA) that accepts multiple voltage inputs, including 12/24/32 VDC, and features a signal processor for run dry and overcurrent protection, which can shut off the pump based on current draw levels adjusted according to the supplied voltage, providing universal compatibility and safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pump models are used for different voltages, then voltage compatibility is improved, but device complexity and inventory requirements increase
Solution Approach 1:
The patent implements a universal pump design with a single motor controller that can operate across multiple voltage levels (12V, 24V, 32V, and higher). The controller automatically detects the input voltage and adjusts its parameters accordingly, eliminating the need for multiple voltage-specific pump models while maintaining full compatibility with different voltage requirements.
Solution Approach 2:
The motor controller dynamically changes its operating parameters based on the detected voltage level. By monitoring the input voltage and adjusting current limits, PWM duty cycles, and protection thresholds accordingly, the single pump model can adapt to different voltage inputs without requiring hardware modifications or multiple models.
2Reliability
If run dry protection is not implemented, then device complexity is reduced, but reliability and pump lifespan deteriorate
Solution Approach 1:
The motor controller incorporates feedback mechanisms that continuously monitor motor current draw and operating conditions. When the pump runs dry, the current characteristics change, and the controller detects this through its sensing circuits. The system provides feedback to the user via LED indicators and can automatically shut down the pump to prevent damage, maintaining reliability without excessive complexity.
Solution Approach 2:
The pump system performs self-diagnosis and self-protection through the motor controller's built-in monitoring capabilities. The controller automatically detects run-dry conditions, overcurrent situations, and other fault states, then takes corrective action without external intervention. This self-service approach enhances reliability while minimizing the need for complex external protection circuits.
3Reliability
If overcurrent protection is not implemented, then device complexity is reduced, but reliability and damage resistance deteriorate
Solution Approach 1:
The motor controller is configured with pre-set current limits and protection thresholds that are established before operation begins. When the pump starts, the controller has already programmed the maximum safe current levels for the detected voltage. If overcurrent conditions occur, the controller immediately takes protective action, preventing damage before it can occur. This preliminary configuration approach ensures reliability without requiring complex real-time calculation circuits.
4Adaptability or versatility
If a single pump model is used for multiple voltages, then adaptability is improved, but manufacturing precision and voltage-specific optimization may worsen
Solution Approach 1:
The motor controller dynamically adjusts its operating parameters based on the detected voltage level, allowing the single pump model to achieve voltage-optimized performance. The controller modifies PWM frequencies, current limits, and timing parameters in real-time according to whether it is operating at 12V, 24V, 32V, or other voltages. This dynamic adaptation ensures that the pump maintains optimal efficiency and performance characteristics for each specific voltage input, matching the precision of voltage-specific models.
Data Source
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AI summary
A pump has a signal processor, including one forming part of a printed circuit board assembly, that receives signaling containing information about a voltage supplied to a motor to run a particular pump model, and also containing information about whether a current draw of the pump is lower than a predetermined low current level or is higher than a predetermined high current level; and determines whether to shut off the pump after a predetermined time, based on the signaling received. The signal processor provides control signalling to shut off the pump after the predetermined time if the current draw of the pump is lower than the predetermined low current level or is higher than the predetermined high current level, where the predetermined low current level and the predetermined high current level depend on the voltage being supplied to the motor to run the particular pump model.