Submersible Pump Control Circuit Without Microprocessors

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Solution Overview

Problem

Submersible pumps in enclosed spaces face challenges in efficiently managing fluid levels due to rain, irrigation, and leaks, requiring a system that can effectively control pump activation sequences and prevent overflow or low fluid levels without relying on microprocessors or microcontrollers, which can be costly and prone to software issues.

Innovation Solution

An electronically controlled pump system with multiple pumps, sensors, and a control circuit that selectively activates pumps based on fluid levels, operating in standard and jockey modes, and includes a switching power supply to convert AC to DC voltage, allowing for flexible power usage and reducing pump wear through pump rotation and auxiliary pump exercise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If microprocessors or microcontrollers are used to control pump activation sequences, then the control system becomes more programmable and adaptable, but the cost increases and software reliability issues arise

Engineering Contradiction:

ImproveprogrammabilityVSAvoidsoftware reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent replaces microprocessor-based electronic control with a purely electronic control circuit implementation using discrete logic components, flip-flops, and timing circuits. This substitution eliminates software entirely, achieving microprocessor-free operation while maintaining adaptability through hardware-based mode selection and pump sequencing logic.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses inexpensive, simple electronic components such as relays, timing circuits, and logic gates instead of expensive microprocessors. These discrete components are individually cheap and can be replaced easily if needed, providing a cost-effective control solution that avoids the high cost and potential software failures of programmable controllers.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Productivity

If multiple pumps are operated simultaneously to handle high fluid levels, then the pumping capacity increases, but the energy consumption and system complexity increase

Engineering Contradiction:

Improvepumping capacityVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by stationary object

Solution Approach 1:

The patent divides the pumping system into multiple individual pump units that can be independently controlled. Each pump is activated based on specific fluid level thresholds, allowing the system to segment the total pumping capacity into discrete, manageable units that are activated only when needed, rather than running all pumps continuously or simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements periodic pump activation based on fluid level cycling. Pumps are turned on and off in sequence as fluid levels rise and fall, with timing circuits controlling the activation sequences. This periodic action allows pumps to operate only when fluid levels require intervention, reducing overall energy consumption compared to continuous operation.

Inventive Principle:

Principle #19Periodic action

3Reliability

If pumps operate continuously to maintain low fluid levels, then the fluid level control is reliable, but the pump wear increases

Engineering Contradiction:

Improvefluid level controlVSAvoidpump wear

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent uses timing circuits and delay elements to introduce preliminary actions before pump activation. When fluid levels trigger pump activation, timing circuits provide deliberate delays and sequencing to ensure pumps are activated at optimal moments rather than immediately, reducing unnecessary wear while maintaining effective fluid level control through proactive monitoring and staged response.

Inventive Principle:

Principle #10Preliminary action

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

The system effectively manages fluid levels by sequentially activating pumps, preventing overflow and low fluid issues, and reducing wear through pump rotation, while being cost-effective and reliable without microprocessors, suitable for various applications including sewage and transformer vaults.

Implementation Method 1

a switching power supply circuit configured to convert an AC input voltage to a regulated DC voltage that powers the logic circuitry

Methodology Applied

Scientific EffectElectrical energy conversion:

Data Source

PatentUS10634133B2Electronic systems for controlling submersible pumps

Publication Date: 2020.04.28 SEEWATER

AI summary

Electronic systems for controlling submersible pumps are provided herein. In certain configurations, a pump system includes three or more submersible pumps used for pumping fluid from a reservoir, sensors used for generating sense signals indicating a fluid level of the reservoir, and a control circuit for selectively activating the pumps based on the sense signals so as to control pumping of fluids from the reservoir. In certain implementations, the control circuit is operable in a plurality of user-selectable operating modes associated with different pump activation sequences in response to the fluid level of the reservoir rising.