Circulating Pump Power Derating Using Critical Component Temperature
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Solution Overview
Problem
Existing methods for controlling the power limit of circulating pumps are overly conservative, leading to reduced performance and the need for larger pumps due to fixed power limits set for worst-case temperature scenarios, which are not frequently encountered, resulting in inefficient operation and potential damage from excessive temperatures.
Innovation Solution
A method that uses a temperature sensor to monitor the critical components on a printed circuit board, allowing for dynamic power limit adjustment based on a performance derating curve, enabling the pump to operate at a lower power level when temperatures exceed a critical threshold, thus preventing damage and optimizing pump size for typical operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed power limit is used based on worst-case temperature scenarios, then the reliability of the pump is improved, but the performance and productivity of the pump deteriorates
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed power limit to a dynamic power limit that adjusts in real-time based on actual operating conditions. The controller continuously monitors temperatures from multiple sensors (media temperature, ambient temperature, and critical component temperature) and dynamically modifies the power limit according to a performance derating curve, allowing the pump to operate at optimal performance when conditions permit while maintaining reliability when temperatures rise.
Solution Approach 2:
The patent implements parameter changes by modifying the power limit parameter based on temperature parameters. Instead of using a single fixed power limit, the system changes the power limit parameter dynamically according to the measured temperatures of the media, ambient environment, and critical components, using a performance derating curve to determine the appropriate power level at any given moment.
2Reliability
If a fixed power limit is used to prevent overheating, then the safety against malfunctioning is improved, but the pump size must be increased leading to higher cost and complexity
Solution Approach 1:
The system uses dynamic power limit adjustment to prevent overheating without requiring an oversized pump. By continuously monitoring temperatures and adjusting the power limit in real-time, the pump can safely operate at its full designed capacity when conditions allow, eliminating the need to select a larger pump based on rare worst-case scenarios.
Solution Approach 2:
The patent implements feedback control by using temperature sensors to continuously monitor the media temperature, ambient temperature, and critical component temperature, then feeding this information back to the controller which adjusts the power limit accordingly. This closed-loop feedback system ensures safety against malfunctioning while maintaining optimal pump size.
3Measurement precision
If multiple temperature sensors are used to monitor different temperatures, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The patent applies universality by designing a controller that handles multiple temperature measurements and performs multiple functions: monitoring media temperature, ambient temperature, and critical component temperature, then integrating all these measurements into a unified power limit determination process using a single performance derating curve. This multi-functional approach achieves comprehensive temperature monitoring without proportionally increasing complexity.
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
This approach allows for efficient and safe operation by dynamically adjusting power limits based on real-time temperature measurements, preventing overheating and enabling the use of a pump size suitable for most operating conditions, thereby enhancing performance and reliability while reducing the risk of malfunction.
Implementation Method 1
a first temperature sensor arranged and configured to measure the temperature of the critical component
Data Source
AI summary
The invention relates to a method of controlling a power limit (P) of a circulating pump (1) comprising a critical component (4) and a first temperature sensor (5) arranged and configured to measure the temperature of the critical component. The first temperature sensor may be arranged on top of, below, integrated with, or in the vicinity of the critical component. The method comprises monitoring the temperature (T) of the critical component by use of the first temperature sensor and using an output signal (6) from the first temperature sensor as a first temperature input signal (7) to a controller (8). By use of the controller and based on the first temperature input signal, the power limit of the circulating pump is controlled in accordance with a performance derating curve for the circulating pump. The invention further relates to a system (3) for controlling a power limit of a circulating pump by use of such a method.