3D Sensorless Pump Conversion for Accurate Low-Speed Flow Control
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Solution Overview
Problem
Existing pump control systems face accuracy issues at low motor speeds due to the curvature of surfaces changing, leading to reduced accuracy in bilinear inversion algorithms.
Innovation Solution
A direct numerical 3D pump sensorless conversion procedure using higher order numerical interpolation and more direct numerical conversion methods to improve accuracy in low speed regions, by deriving discrete arrays from 3D discrete distribution surfaces of motor power, pump differential pressure, and flow rate, and then obtaining pump pressure and flow rate through numerical interpolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If bilinear inversion algorithm is used for 3D sensorless converter, then conversion procedure is simple, but conversion accuracy deteriorates at low motor speeds
Solution Approach 1:
The patent changes the mathematical parameters of the interpolation algorithm from bilinear to higher-order numerical interpolation. This parameter change in the conversion method enables accurate tracking of surface curvature variations at low speeds while maintaining computational feasibility, thus resolving the contradiction between algorithm simplicity and conversion accuracy.
2Measurement precision
If higher order numerical interpolation is used, then conversion accuracy is improved, but computational complexity increases
Solution Approach 1:
The patent segments the 3D conversion problem into multiple discrete speed points with pre-calculated higher-order interpolation coefficients. By dividing the continuous conversion process into discrete segments with pre-computed parameters, the system achieves high accuracy through higher-order interpolation while reducing real-time computational complexity through offline pre-calculation.
3Measurement precision
If discrete arrays are derived from 3D distribution surfaces, then direct numerical conversion is achieved, but data processing complexity increases
Solution Approach 1:
The patent performs preliminary action by pre-deriving discrete arrays from 3D distribution surfaces offline before actual pump operation. The discrete arrays containing interpolation coefficients and conversion parameters are calculated in advance and stored, enabling direct numerical conversion during operation without real-time complex data processing, thus resolving the contradiction between accuracy and processing complexity.
Data Source
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AI summary
A pump controller features a signal processor configured to respond to signaling containing information about three corresponding discrete arrays with respect to a discrete motor speed for each system position at a motor speed derived from 3D discrete distribution surfaces of motor power, pump differential pressure and flow rate by respective numerical interpolations; and determine corresponding signaling containing information to control a pump, or pumps in a system of pumps, or a system of pumps based upon a corresponding pump differential pressure and flow rate at the motor speed for a corresponding power reading value determined using a numerical interpolation of the three corresponding discrete arrays, the signaling received. The signal processor is configured to provide the corresponding signaling as control signaling to control the pump, or the pumps in the system of pumps, or the system of pumps.