Coordinated Sensorless Pumps Using Self-Detected Pressure Estimation
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Solution Overview
Problem
Existing flow control systems for pumping systems face challenges in efficiently adapting to changing flow demands without exceeding pressure ratings or causing vibrations, particularly in systems with multiple pumps, where coordinating sensorless pumps to maintain pressure setpoints is costly and requires extensive sensor installations.
Innovation Solution
A control system that coordinates multiple sensorless pumps by using internal detectors to self-detect power and speed, correlating these parameters to output properties like pressure and flow, and adjusting pump speeds to maintain setpoints without external sensors, allowing for efficient operation and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If remote pressure sensors are installed to directly measure pressure for controlling multiple pumps, then pressure control accuracy is improved, but system cost and installation complexity increase
Solution Approach 1:
The patent extracts the pressure measurement function from external remote sensors and relocates it to the pump controller itself. The controller estimates pressure by processing motor electrical variables (current, voltage, frequency) and pump operational parameters, eliminating the need for separate pressure sensing devices in the piping system.
Solution Approach 2:
The pump controller performs multiple functions: it controls motor speed via VSD, monitors pump operational parameters, estimates system pressure, and coordinates with other pump controllers. This multi-functionality consolidates what would traditionally require separate dedicated pressure sensors into the existing control device.
2Device complexity
If sensorless pump control is implemented to reduce sensor costs, then system cost is reduced, but coordination between multiple pumps becomes difficult
Solution Approach 1:
Each pump controller continuously monitors its own motor electrical variables and pump performance parameters, using this feedback to estimate pressure conditions. This self-generated feedback enables sensorless controllers to perceive system state and adjust their operation accordingly, facilitating coordination without external sensors.
Solution Approach 2:
The patent merges the pressure estimation function into each individual pump controller, creating a distributed control architecture where each controller independently estimates pressure based on its own operational data. This consolidation enables coordination between multiple sensorless pumps through their shared ability to estimate common pressure conditions.
3Productivity
If pump speed is increased to meet higher flow demand, then flow delivery is improved, but pressure rating limits and vibration risks increase
Solution Approach 1:
The system dynamically adjusts pump speed based on real-time pressure estimates and flow demands. By continuously monitoring estimated pressure and comparing it against rated limits, the controller can modulate speed to meet demand while preventing pressure rating exceedance and associated vibration problems.
Solution Approach 2:
Each pump controller independently monitors its own operational parameters and estimated pressure conditions, automatically adjusting its speed to maintain safe operation. This self-regulation capability allows pumps to respond to changing demands while inherently protecting against pressure rating violations and vibration.
Data Source
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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.