Pump Assembly Control via Dynamic Limit Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current pump units require extensive metrological recording and evaluation of characteristic curves to determine the boundary line for switching between base-load and peak-load operations, making them more expensive and resource-intensive.
Innovation Solution
A method that operates a pump unit with a first base-load pump and a second peak-load pump by dynamically adjusting upper and lower limit values based on synchronous speed or power consumption, allowing for efficient switching without prior measurement of characteristic curves, enabling energy-optimized operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If extensive metrological recording and evaluation of characteristic curves is performed to determine the boundary line for switching between base-load and peak-load operations, then the precision of determining the optimal switching point is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The control system automatically determines the boundary line for switching between base-load and peak-load operations by evaluating operating points against stored characteristic curve data, eliminating the need for manual measurement and evaluation processes. The system serves itself by autonomously identifying optimal switching points based on pre-stored pump characteristic data.
Solution Approach 2:
The characteristic curves and boundary lines are pre-calculated and stored in the control system before actual pump operation. This preliminary preparation of data allows the control system to quickly determine optimal switching points during operation without requiring real-time measurement and evaluation, reducing operational complexity.
2Measurement precision
If the family of characteristic curves is measured operating point by operating point with considerable human and time resources, then the accuracy of efficiency-optimized range determination is improved, but the loss of time and manufacturing resources increase
Solution Approach 1:
Instead of performing actual physical measurements during operation, the system uses pre-stored characteristic curve data that represents the pump's performance characteristics. This copying of measurement data into the control system allows accurate determination of efficiency ranges without repeating time-consuming physical measurements.
Solution Approach 2:
All characteristic curve measurements are performed in advance during manufacturing or setup, and the results are stored for use during operation. This preliminary measurement action separates the time-consuming measurement process from operational use, allowing fast, accurate control decisions without real-time measurement delays.
3Use of energy by moving object
If synchronous operation of base-load and peak-load pumps is used to cover the efficiency-optimized range, then the energy efficiency is improved, but the device complexity for controlling multiple pumps increases
Solution Approach 1:
The control system continuously monitors the current operating point and compares it against the stored characteristic curves and boundary lines. Based on this feedback, the system automatically determines whether to operate in base-load mode or synchronous mode, and adjusts pump speeds accordingly to maintain energy-efficient operation across varying demand conditions.
Solution Approach 2:
The control system dynamically adjusts the operating mode between base-load and synchronous operation based on real-time demand conditions. The boundary line for switching modes is determined dynamically by evaluating the current operating point against pre-stored characteristic data, allowing the system to adapt to changing conditions while maintaining energy efficiency.
4Reliability
If prior measurement and evaluation of characteristic curves is performed in the factory, then the reliability of energy-optimized operation is improved, but the manufacturing cost and time increase
Solution Approach 1:
The system copies pre-measured characteristic curve data into the control system during manufacturing or setup. This copying process transfers the reliability of factory measurements to the operational system without requiring complex manufacturing processes, as the data can be imported or loaded into the control unit.
Solution Approach 2:
The control system uses the pre-stored characteristic data to autonomously determine optimal operating modes and switching points during operation. This self-service capability ensures reliable energy-optimized operation without requiring continuous manufacturer intervention or complex manufacturing processes.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The method involves operating a pump assembly (1) either with two pumps (2a, 2b) or with one pump based on upper and lower limit values of an operating parameter. A value of the operating parameter is stored as a reference value, and volume flow conveyed by one of the pumps is reduced. Assigning of operating points to load areas is carried out based on reaction of another pump, where the upper or lower limit value is replaced by the reference value. Power received by the pump assembly in a synchronous operation is determined and stored as reference power. Independent claims are also included for the following: (1) a computer program with instructions for executing a method for operating a pump assembly (2) a pump assembly comprising two pumps.