Pump Output Calibration for Stable Flow and Fast Response

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Solution Overview

Problem

Existing pump flow control systems face challenges in maintaining consistent flow rates when the type of pump is unknown and the system configuration is variable, particularly in agricultural applications, leading to slowed response times due to the need for robust control algorithms.

Innovation Solution

A method and system for calibrating pumps by determining the relationship between pump duty cycle and total flow, involving stepped duty cycle adjustments, pressure measurement, and flow control device positioning to achieve maximum and minimum flow rates while ensuring sufficient pressure and optimal valve operation, allowing for fine-tuned flow control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a robust control algorithm is used to maintain consistent flow to each application unit, then flow consistency is improved, but response speed deteriorates

Engineering Contradiction:

Improveflow consistencyVSAvoidresponse speed

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

The system performs preliminary calibration by determining the relationship between pump duty cycle and total flow rate before operation. This pre-established relationship allows the controller to directly calculate required duty cycle without complex iterative control algorithms, achieving both flow consistency and fast response

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex control algorithms with a mathematical model based on the calibrated linear relationship between duty cycle and flow rate. This substitution of computational mechanics for control logic enables rapid calculation and response while maintaining consistent flow distribution

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If the system is designed to accommodate unknown pump types and variable configurations, then adaptability is improved, but system complexity increases

Engineering Contradiction:

Improvesystem adaptabilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system determines the relationship between pump duty cycle and total flow rate through calibration, establishing a parameter model that adapts to different pump types and configurations. This parameter-based approach allows the same control system to work with variable pump configurations without increasing system complexity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system performs self-calibration by automatically determining the duty cycle to flow rate relationship during installation or setup. This self-service calibration process eliminates the need for complex preconfiguration or manual setup, allowing the system to adapt to unknown pump types while maintaining simplicity

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP3582602B1Method of calibrating a pump output

Publication Date: 2022.04.20 PRECISION PLANTING LLC

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AI summary

Embodiments of the present disclosure includes a method of calibrating a pump in a system to determine a minimum pump duty cycle needed. The system comprises a pump, a plurality of application lines downstream of the pump, and a flow control device in each application line. The method determines the minimum pump duty cycle to achieve total flow in the system, achieves a minimum pressure in the system, and ensures that the flow control device is not at or beyond a maximum open position.