Sensorless Multi-Pump Coordination Using Power-Speed Flow Estimation
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Solution Overview
Problem
Existing flow control systems face challenges in efficiently managing flow demand changes without exceeding pressure ratings or causing vibration, particularly in systems with multiple pumps, where traditional methods require multiple sensors and complex sequencing to maintain optimal operation.
Innovation Solution
A coordinated sensorless flow control system that uses self-detecting pumps with internal detectors to correlate power and speed with output properties like pressure and flow, allowing for coordinated control of multiple pumps to achieve a setpoint without external sensors, thereby optimizing energy use and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional flow control systems use multiple pumps with remote pressure sensors and complex sequencing to maintain pressure, then pressure control accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent removes remote pressure sensors from the system entirely. Instead of using external sensors to measure pressure, the system extracts pressure information from the electrical variables already being measured by the electronic variable speed drives, eliminating the need for complex sensor networks and reducing system complexity.
Solution Approach 2:
The electronic variable speed drives perform multiple functions: they control motor speed and simultaneously provide the electrical variables needed for pressure and flow estimation. This multi-functionality eliminates the need for separate pressure sensing systems, reducing device complexity while maintaining control accuracy.
2Device complexity
If sensorless pump control uses electrical variables to estimate pressure and flow, then device cost is reduced, but measurement precision deteriorates
Solution Approach 1:
The system continuously monitors electrical variables (current, voltage, power) from the electronic variable speed drives and uses this feedback to calculate instantaneous pressure and flow values. This real-time feedback mechanism maintains measurement precision without requiring external sensors.
Solution Approach 2:
The patent changes the measurement parameters from mechanical/physical (pressure sensors, flow meters) to electrical parameters (current, voltage, power). By measuring electrical variables that are already present in the system and correlating them with hydraulic parameters, the system achieves accurate estimation without additional sensing hardware.
3Productivity
If multiple pumps operate in parallel with coordinated control to satisfy system load, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent merges the control functions of multiple pumps into a unified coordination system. The controller integrates information from all pumps' electrical variables and coordinates their operation to satisfy the system load, improving productivity while managing complexity through consolidation rather than separate control systems.
Data Source
AI summary
A method and system for co-ordinating control of a plurality of sensorless devices. Each device includes a communication subsystem and configured to self-detect one or more device properties, the device properties resulting in output having one or more output properties. The method includes: detecting inputs including the one or more device properties of each device, correlating, for each device, the detected one or more device properties to the one or more output properties, and co-ordinating control of each of the devices to operate at least one of their respective device properties to co-ordinate one or more output properties for the combined output to achieve a setpoint. In some example embodiments, the setpoint can be fixed, calculated or externally determined.