Reciprocating Pump Torque Control for Pressure Pulse Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Reciprocating linear-motion double-acting pumps experience significant pressure drops and spikes during direction reversal due to inertia in electric-motor-drive systems, leading to inefficient liquid or pasty product delivery.
Innovation Solution
Implementing a control method that uses speed-regulating control during piston ascent and descent phases, followed by torque-regulating control after direction reversal, with a pressure sensor to monitor and adjust motor torque, ensuring a constant flow rate and reducing pressure pulses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If speed-regulating control is used during piston ascent and descent phases, then the pump operates efficiently during steady motion, but pressure drops and spikes occur during direction reversal due to motor inertia
Solution Approach 1:
The control method dynamically switches between speed-regulating control during piston ascent/descent phases and torque-regulating control during direction reversal phases. This dynamic adaptation of control parameters compensates for motor inertia effects, maintaining efficient pump delivery while reducing pressure drops and spikes during reversal.
Solution Approach 2:
The invention changes the control parameter from speed regulation to torque regulation during direction reversal phases. By adjusting the motor torque immediately after reversal, the system compensates for inertia-induced pressure variations while maintaining constant flow rate, thus resolving the contradiction between productivity and pressure stability.
2Stress or pressure
If torque-regulating control is used immediately after direction reversal, then pressure pulses are reduced and flow rate is maintained constant, but control system complexity increases
Solution Approach 1:
The control cycle is segmented into distinct phases: speed-regulating control during piston ascent/descent and torque-regulating control during direction reversal. This segmentation allows each control mode to be optimized for its specific phase, reducing pressure pulses during reversal without requiring complex continuous control.
Solution Approach 2:
The control system uses feedback from pressure sensors and motor position sensors to determine when to switch between speed-regulating and torque-regulating modes. This feedback mechanism enables automatic adaptation to the pump's operational phase, achieving pressure pulse reduction through a relatively simple control architecture.
3Stress or pressure
If the motor inertia is reduced to minimize pressure drops during reversal, then pressure stability improves, but motor power and speed control capability are compromised
Solution Approach 1:
The control system applies preliminary torque adjustment immediately after direction reversal is detected. By proactively regulating torque during the critical reversal phase, the system compensates for motor inertia effects without requiring physical modification of the motor's inertial properties, thus maintaining both pressure stability and motor power capability.
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 maintains a substantially constant flow rate of liquid or pasty products by compensating for pressure variations, adapting to changes in substance viscosity, temperature, and delivery rates, and simplifies control devices with real-time pressure feedback.
Implementation Method 1
a pressure sensor sensing the pressure of the liquid or pasty product delivered by the reciprocating linear-motion double-acting pump
Data Source
AI summary
A method for controlling a drive unit mechanically connected to a reciprocating linear-motion double-acting pump includes the use of speed-regulating control during the phase in which the piston is moving in just one direction, ascent (109) or descent (102), and the use of torque-regulating control immediately after the reversal (107, 114) of the direction of travel. The method is applicable to a control device and to a drive unit mechanically connected to a reciprocating linear-motion double-acting pump.