Pump Control Apparatus Using Current Sensing and Float Monitoring
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Solution Overview
Problem
Current pump monitoring and control systems lack comprehensive protection for pumps and motors, primarily relying on mechanical floats for liquid level monitoring and providing limited alarm indications for adverse operating conditions, which can lead to premature pump failure and maintenance issues.
Innovation Solution
A pump control apparatus and method that includes a power circuit with a relay and current sensing circuit to monitor and regulate power to the pump, a controller to calculate baseline operating current and detect adverse conditions, and an alarm circuit for visual and audible alerts, along with a level sensing circuit to combine current and liquid level data for accurate monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical floats are used for liquid level monitoring, then liquid level detection is achieved, but pump and motor protection is insufficient
Solution Approach 1:
The patent combines mechanical float-based liquid level detection with electronic pump monitoring systems. The controller integrates both liquid level sensor data and pump operating parameter data (current, voltage, power) into a unified monitoring system that provides comprehensive protection for both liquid level control and pump motor safety.
Solution Approach 2:
The controller serves multiple functions: it monitors liquid level via mechanical floats, tracks pump operating parameters (current, voltage, power consumption), detects adverse conditions, and provides alarm indications. This multi-functional approach replaces specialized separate systems with a single integrated controller that handles both liquid level detection and pump protection.
2Loss of information
If electronic floats are used for liquid level monitoring, then alarm indication is provided, but pump operation protection is limited
Solution Approach 1:
The system continuously monitors pump operating parameters (current, voltage, power) and compares them against baseline values and threshold limits. When adverse conditions are detected, the controller provides immediate alarm indications and can control pump operation. This closed-loop feedback mechanism provides both information about system state and active protection for pump operation.
3Measurement precision
If pump monitoring systems focus on liquid level detection, then level control is achieved, but comprehensive pump failure detection is insufficient
Solution Approach 1:
The monitoring system is segmented into distinct functional modules: liquid level sensing, electrical parameter monitoring (current, voltage, power), baseline establishment, adverse condition detection, and alarm indication. Each module handles specific aspects of monitoring, allowing comprehensive pump failure detection while maintaining precise liquid level control through specialized sub-systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively determines pump and motor failures, provides timely alarm indications, and extends the lifespan of pump systems by accurately monitoring operating conditions and liquid levels, reducing maintenance needs and preventing premature failures.
Implementation Method 1
The current transformer is configured so that the current flowing through the current transformer is proportional to current flowing at the pump
Implementation Method 2
The rectifier receives the current signal sensed at the current transformer and provides a rectified current waveform as an input to the controller
Data Source
AI summary
An apparatus, system and method for more accurately monitoring and determining pump failure. The apparatus and system include at least a power circuit, a current sensing circuit, alarm circuit and a controller. The controller is connectable to and receives an input from the current sensing circuit. The controller is configured to calculate a baseline operating current, current thresholds and operating conditions affecting the operation of the pump. The alarm circuit is connectable to and receives outputs from the controller, and provides alarm indications corresponding to operating conditions determined by the controller.