Stacked Submersible Pumps With Autonomous Level-Based Speed Control
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Solution Overview
Problem
Existing submersible pumping systems lack efficient autonomous control and adaptability to varying fluid levels and flow rates, particularly in stacked configurations, which can lead to inefficiencies and potential clogging issues.
Innovation Solution
A system comprising multiple submersible pumps with independent controllers, fluid level sensors, and optional fluid pressure sensors, arranged in a vertical stack, allowing for autonomous activation and speed control based on sensed fluid levels and pressure, enabling efficient fluid management and automatic backflushing to clear obstructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple submersible pumps are stacked vertically to handle varying fluid levels and flow rates, then the system's adaptability and pumping capacity are improved, but the device complexity and control coordination become more difficult
Solution Approach 1:
The system divides the pumping function into multiple independent pump units stacked vertically, each with its own controller and fluid level sensor. This segmentation allows each pump to operate autonomously based on local fluid level conditions, providing adaptability to varying fluid levels while maintaining manageable complexity through modular design.
Solution Approach 2:
Each pump's controller dynamically adjusts the pumping mechanism speed based on real-time fluid level sensor data, enabling the system to adapt to changing fluid levels and flow rates. The dynamic control allows pumps to transition between different operating states (off, variable speed, full speed) based on current conditions.
2Productivity
If each submersible pump operates autonomously with independent control, then the system's responsiveness to fluid level changes is improved, but the control system complexity increases
Solution Approach 1:
Each pump unit is equipped with its own controller and fluid level sensor, enabling it to autonomously monitor local conditions and adjust its operation without requiring external control signals. This self-service capability improves responsiveness to fluid level changes while the modular nature of independent controllers keeps individual control logic simple and manageable.
Solution Approach 2:
The controllers are pre-programmed with control logic that automatically responds to fluid level sensor readings, eliminating the need for complex real-time decision-making or external coordination. This preliminary programming of control strategies simplifies the operational complexity while maintaining high responsiveness.
3Use of energy by moving object
If pump speed is dynamically adjusted based on fluid level sensing, then energy efficiency and flow rate optimization are improved, but the control precision requirements increase
Solution Approach 1:
The system uses fluid level sensors to continuously monitor the fluid level and provides feedback to the controller, which then adjusts the pumping mechanism speed accordingly. This feedback loop enables energy-efficient operation by matching pump output to actual demand, while the feedback mechanism itself helps compensate for measurement variations through continuous adjustment.
Solution Approach 2:
The controller changes the operational parameters (pump speed) based on fluid level measurements, optimizing energy efficiency by running the pump at higher speeds when fluid levels are high and lower speeds when fluid levels are low. This parameter adjustment approach allows the system to achieve energy efficiency without requiring extreme measurement precision.
4Reliability
If the system includes pressure sensors and backflushing capability, then reliability and clogging prevention are improved, but the device complexity increases
Solution Approach 1:
The system proactively prevents clogging by using pressure sensors to detect potential blockages before they become severe problems. When obstruction is detected, the controller automatically initiates backflushing operation, reversing the flow to clear the obstruction before it causes system failure. This preliminary anti-action maintains reliability without requiring overly complex monitoring systems.
Solution Approach 2:
The backflushing feature converts the potentially harmful effect of clogging into a beneficial self-cleaning operation. By detecting pressure changes that indicate obstruction and then reversing flow direction, the system uses the same pumping mechanism to eliminate the problem, adding reliability without requiring entirely separate cleaning systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables efficient and adaptive fluid pumping with autonomous operation, ensuring optimal flow rates and preventing clogging by dynamically adjusting pump speeds and activating additional pumps as needed, while maintaining system flexibility and reducing operational complexity.
Implementation Method 1
the fluid level sensor may sense the weight of the fluid above the fluid level sensor
Implementation Method 2
the submersible pumps may further comprise a fluid pressure sensor for measuring the degree of obstruction of the inlet
Implementation Method 3
a pumping mechanism that pumps fluid from the inlet to the outlet
Implementation Method 4
turn off the pumping mechanism when the fluid pressure detected by the fluid pressure sensor reaches a predetermined level of obstruction such that the fluid in the vertical fluid line is allowed to backflow through the inlet and flush the obstruction from the inlet
Data Source
AI summary
A system for pumping fluid is provided, having two or more submersible pumps, each submersible pump having an inlet, an outlet, a pumping mechanism that pumps fluid from the inlet to the outlet, a fluid level sensor for measuring a fluid level above the inlet, and a controller. The controller is programmed to activate the pumping mechanism when the fluid level sensor senses a minimum fluid level above the inlet and control the speed of the pumping mechanism based on the fluid level sensed by the fluid level sensor above the minimum fluid level between a minimum operating pump speed and a maximum operating pump speed. The submersible pumps are arranged in a vertical stack with the inlets of the submersible pumps spaced vertically. Each controller of each submersible pump operates autonomously relative to controllers of other submersible pumps in the vertical stack.