Sensorless Multi-Pump Control for Flow and Pressure Setpoints
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Solution Overview
Problem
Existing flow control systems in pumping systems face challenges in adapting to changing flow demands without exceeding pressure ratings or causing vibration, and they often require external sensors for accurate control, which can be costly and complex to implement, especially when dealing with multiple pumps.
Innovation Solution
A coordinated sensorless flow control system that uses self-detecting circulating devices with internal detectors to correlate power and speed with output properties like pressure and flow, allowing for coordinated control of multiple pumps to achieve a setpoint without external sensors, thereby optimizing energy use and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external sensors are used for accurate flow and pressure control in multiple pump systems, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The pump system performs its own measurement function by using the motor's existing sensors (current, voltage, speed) to infer flow and pressure conditions. The control system processes electrical variables and motor performance data to determine operational status without requiring external flow meters or pressure sensors, making the system self-measuring and eliminating the need for separate measurement devices
Solution Approach 2:
The motor's electrical sensors and control system serve multiple functions: they control motor operation and simultaneously provide flow and pressure measurement capabilities. The same hardware infrastructure (sensors, controllers, electrical connections) that exists for motor control is leveraged to perform measurement functions, eliminating the need for dedicated measurement equipment
2Adaptability or versatility
If multiple pumps operate independently to satisfy flow demand, then adaptability is improved, but coordination difficulty and control complexity increase
Solution Approach 1:
Multiple pump control systems are merged into a coordinated network where each pump's controller communicates with others and shares measurement data. The controllers work together as an integrated system, using combined information from all pumps to make coordinated control decisions that optimize overall system performance rather than operating independently
Solution Approach 2:
The system implements coordinated feedback control where each pump's controller receives feedback not only from its own performance sensors but also from other pumps in the system. This shared feedback mechanism allows controllers to adjust their operation based on the aggregate system state, enabling adaptive coordination without requiring complex centralized control architecture
3Productivity
If pump speed is increased to meet higher flow demand, then productivity is improved, but risk of exceeding pressure rating and causing vibration increases
Solution Approach 1:
The system dynamically adjusts pump speed based on real-time inferred flow and pressure conditions rather than operating at fixed speeds. The control system continuously monitors electrical variables and motor performance to determine optimal operating points, allowing the pumps to adapt their speed to match actual system demands while staying within safe operational limits
Solution Approach 2:
The control system takes preliminary action to prevent harmful conditions by monitoring operational parameters and adjusting pump speed before excessive pressure or vibration can occur. By using inferred measurements from electrical variables, the system can detect approaching dangerous conditions and reduce speed proactively, preventing rather than reacting to harmful effects
Data Source
AI summary
A method and system for co-ordinating control of a plurality of sensorless devices. Each device includes a communication subsystem and configured to self-detect one or more device properties, the device properties resulting in output having one or more output properties. The method includes: detecting inputs including the one or more device properties of each device, correlating, for each device, the detected one or more device properties to the one or more output properties, and co-ordinating control of each of the devices to operate at least one of their respective device properties to co-ordinate one or more output properties for the combined output to achieve a setpoint. In some example embodiments, the setpoint can be fixed, calculated or externally determined.