Sensorless Converter for Pump Pressure Monitoring
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Solution Overview
Problem
Existing hydronic pumping systems face challenges in accurately controlling and monitoring pump differential pressure and flow rate without instrumentation calibration, especially at low speeds, due to the lack of pressure sensors and flow meters, leading to reduced conversion accuracy.
Innovation Solution
A mixed theoretical and discrete sensorless converter is developed using pump and system characteristics equations, along with a discrete system power inversion equation, to accurately determine pump differential pressure and system flow rate from motor power and speed signals, eliminating the need for instrumentation calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a theoretical sensorless converter is used for pump differential pressure and flow monitoring, then device complexity is reduced and ease of operation is improved, but measurement precision deteriorates especially at low speeds
Solution Approach 1:
The patent changes the operating parameters by introducing a mixed theoretical and discrete model that adapts to different speed ranges. The system switches between theoretical calculations for high speeds and discrete calibrated values for low speeds, thereby maintaining measurement precision across the entire operating range while avoiding the need for complex instrumentation calibration
Solution Approach 2:
The patent creates a composite monitoring system that combines two different approaches: a theoretical sensorless converter for high-speed operation and a discrete calibrated model for low-speed operation. This composite approach leverages the strengths of both methods, achieving high conversion accuracy across all speeds without requiring full instrumentation calibration
2Ease of manufacture
If a discrete sensorless model is used without instrumentation calibration, then ease of manufacture and ease of operation are improved, but measurement precision is reduced especially at low speeds
Solution Approach 1:
The patent segments the operating range into two distinct zones: a high-speed region where theoretical calculations are accurate, and a low-speed region where discrete calibrated values are used. This segmentation allows each method to operate in its optimal performance range, maintaining high conversion accuracy while avoiding the need for complex instrumentation calibration across the entire system
Data Source
AI summary
The present invention provides apparatus featuring a signal processor or processing module that may be configured at least to: process signaling containing information about an equilibrium point of pump differential pressure and system pressure formulated in a hydronic domain by utilizing pump and system characteristic curve equations so as to yield system pressure and flow rate at any particular load and time in a pump hydronic system, including using a multi-dimensional sensorless conversion technique; and determine equivalent hydronic system characteristics associated with the pump differential pressure and flow rate to their corresponding motor power and speed reconstructed and remapped by using a discrete numerical approach, based at least partly on the signaling received. The signal processor or processing module may provide corresponding signaling containing information about the system pumping flow rate and pressure determined.