Pump Control System for Residential Booster Pressure and Flow Management
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Solution Overview
Problem
Residential booster pump systems require large diaphragm pressure tanks to prevent short cycling, and existing control methods are inefficient in managing pressure and flow rates, leading to energy wastage and potential leaks.
Innovation Solution
A pump control system with a controller that offers selectable modes based on pressure start and flow start conditions, utilizing sensors to manage pump operation, including a delay timer feature to prevent false starts and cycling, allowing for efficient operation with smaller tank sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an on/off pressure type switch is used to control the booster pump, then the pump can maintain system pressure, but the system requires a relatively large diaphragm pressure tank to prevent short cycling
Solution Approach 1:
The control system monitors multiple parameters simultaneously (pressure and flow rate) rather than relying on pressure alone, enabling more precise control decisions that reduce the need for large tank capacity
Solution Approach 2:
The system uses real-time feedback from both pressure sensors and flow rate sensors to dynamically adjust pump operation, preventing short cycling through intelligent control logic that considers system state beyond simple pressure thresholds
2Reliability
If a large diaphragm pressure tank is installed to prevent short cycling, then pump operation stability improves, but system complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical solution of using a large pressure tank with an electronic control system that uses sensors and a microcontroller to manage pump operation, reducing mechanical complexity while maintaining reliability
3Reliability
If the pump starts at a preselected pressure greater than city pressure, then system pressure is maintained, but energy consumption increases due to unnecessary pump operation
Solution Approach 1:
The control system dynamically adjusts the pump start decision based on real-time flow rate detection and pressure conditions, allowing the pump to remain off when city pressure is sufficient and flow demand is low, thereby reducing energy consumption while maintaining pressure when needed
4Volume of stationary object
If flow rate-based control is used to stop the pump, then a smaller diaphragm tank can be used, but the system becomes more complex due to additional sensing requirements
Solution Approach 1:
The flow rate sensor serves multiple functions: it determines pump start/stop decisions, enables energy-saving operation modes, and provides data for the microcontroller's control logic, making the additional component worthwhile despite increased complexity
Data Source
AI summary
A pump control (20) and method are provided for controlling a pump (16) for a pressurized liquid supply system (10). The pump control (20) includes a controller (38) configured to provide at least two selectable modes of pump operation as follows:a flow start mode wherein the controller (38) starts the pump (16) in response to a desired start flow rate of the liquid in the system (10) and stops the pump (16) in response to a desired stopping low flow rate of the liquid in the system; anda pressure start mode wherein the controller (38) starts the pump (16) in response to a desired start pressure of the liquid in the system (10) and stops the pump (16) in response to the desired stopping low flow rate.