Parallel Pump Controller Load Sharing Without Centralized PLCs
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Solution Overview
Problem
Conventional pumping systems require expensive programmable logic controllers (PLCs) and software for managing multiple pumps in parallel, leading to high costs and complexity.
Innovation Solution
A primary/master control panel communicates directly with secondary/slave control panels to manage multiple pumps, eliminating the need for a centralized PLC, and uses sensor data for load sharing and intelligent pump operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a centralized PLC and software system is used to manage multiple pumps in parallel, then intelligent pump control and flow management is achieved, but system cost and complexity increase significantly
Solution Approach 1:
The system divides the centralized PLC control into separate distributed control units, each managing individual pumps independently. This segmentation eliminates the need for a complex centralized control system while maintaining intelligent control capabilities at each local level, directly resolving the contradiction between automation extent and system complexity.
Solution Approach 2:
Each control unit autonomously manages its associated pump based on local sensor feedback and control logic, eliminating dependency on a centralized PLC. The system achieves self-service control where each component regulates itself, reducing overall system complexity while maintaining intelligent operation.
2Extent of automation
If a centralized PLC and software system is used to manage multiple pumps in parallel, then pump management capability is improved, but cost increases
Solution Approach 1:
By segmenting the control system into multiple independent control units, the patent eliminates the need for expensive centralized PLC hardware and software licensing. Each control unit uses simpler, more cost-effective components, directly reducing system cost while maintaining pump management capability.
Solution Approach 2:
The system replaces expensive, complex PLC equipment with simpler, more affordable control units that can be easily replaced or upgraded individually. This approach reduces overall system cost while maintaining the necessary pump management functions.
3Ease of operation
If conventional PLC control is used for parallel pumping, then centralized control is achieved, but maintenance difficulty and system reliability are reduced
Solution Approach 1:
The control system is segmented into independent units, each with its own control logic and sensors. This segmentation isolates potential failure points, so that issues in one control unit do not propagate to the entire system, thereby improving overall reliability while maintaining ease of operation through distributed intelligence.
Solution Approach 2:
Each control unit incorporates local feedback from sensors to continuously monitor pump performance and adjust operation accordingly. This distributed feedback mechanism improves system reliability by enabling rapid local responses to conditions without requiring centralized intervention, while maintaining operational simplicity.
Data Source
AI summary
Disclosed are parallel pumping controllers (e.g., control panels, etc.) with load sharing and systems including such parallel pumping controllers. An exemplary system includes first and second controllers. The first controller is configured for communication with a first engine for controlling operation of a first pump via the first engine. The second controller is configured for communication with the second engine for controlling operation of the second pump via the second engine. The first controller is further configured for communication with the second controller, whereby the first controller is operable for controlling operation of the first pump via the first engine and for controlling operation of the second pump via communications with the second controller, which responsively controls operation of the second engine according to the communications from the first controller.