Sensorless Multi-Pump Control for Pressure and Flow 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, optimizing energy use, and efficiently managing multiple pumps, often requiring external sensors and complex sequencing methods.
Innovation Solution
A coordinated sensorless flow control system that uses self-detecting pumps and controllers to correlate power and speed with output properties like pressure and flow, allowing multiple pumps to operate in parallel to achieve a setpoint without external sensors, optimizing pump operation and energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional systems use remote pressure sensors to control pump speed, then pressure control accuracy is improved, but system cost and complexity increase due to sensor installation and wiring
Solution Approach 1:
The patent extracts the pressure sensing function from external remote sensors and relocates it to the pump controller itself. The controller estimates remote pressure by calculating pressure drop in pipes based on local measurements and pump operating conditions, eliminating the need for expensive remote sensor installation and wiring while maintaining adequate pressure control accuracy
Solution Approach 2:
The patent introduces an intermediary calculation model that uses locally measured pressure and flow data, combined with pipe characteristics and pump operating parameters, to estimate remote pressure. This intermediary approach avoids direct remote sensing while providing sufficient accuracy for control purposes
2Productivity
If multiple pumps are coordinated using conventional sequencing methods, then flow demand satisfaction is improved, but operational complexity increases due to pump sequencing logic
Solution Approach 1:
The patent enables each pump controller to independently determine its own operating status and coordination with other pumps. Controllers exchange information and autonomously make decisions about pump start/stop and speed adjustment based on aggregate flow demand, eliminating complex centralized sequencing logic and reducing operational complexity
Solution Approach 2:
The patent implements dynamic pump coordination where each pump's speed and operational status continuously adjusts based on real-time feedback from itself and other pumps. This dynamic self-regulation replaces static sequencing schedules and complex control logic while maintaining flow demand satisfaction
3Productivity
If pump speed is increased to meet higher flow demand, then flow delivery is improved, but energy consumption increases
Solution Approach 1:
The patent implements feedback control where pump speed is continuously adjusted based on actual flow demand measurements and pressure conditions. The controller modulates pump speed to match the minimum required to satisfy demand, preventing unnecessary energy consumption while maintaining adequate flow delivery
Solution Approach 2:
The patent changes the operating parameters of pumps from fixed speed to variable speed control. By dynamically adjusting speed as a controllable parameter based on demand conditions, the system optimizes the relationship between flow delivery and energy consumption, delivering required flow at minimum energy cost
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.