Synchronous Torque Control for Multi-Pump Flow Balance
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Solution Overview
Problem
Existing multiple pump systems face flow imbalances and reduced efficiency due to fixed speed and synchronous speed control methods, which lead to uneven wear and decreased reliability, especially when pumps have different hydraulic head curves or experience mechanical wear.
Innovation Solution
Implementing a system controller that operates multiple pumps in a substantially synchronous torque mode, using variable speed drives to balance flow by calculating and adjusting torque and speed of each pump to maintain a desired setpoint, even when pumps have different hydraulic head curves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed speed pumps with variable speed trim pump control is used, then flow control flexibility is improved, but pump efficiency deteriorates due to flow imbalance and trim pump operating below recommended minimum flow
Solution Approach 1:
The patent changes the control parameter from speed-based control to torque-based control. By controlling pumps to operate at synchronous torque rather than synchronous speed, the system allows each pump to operate at its optimal efficiency point while maintaining balanced flow distribution, eliminating the efficiency losses associated with trim pumps operating below minimum flow
2Quantity of substance
If multiple pump synchronous speed control is used, then flow balance is improved when pumps are identical, but reliability deteriorates when pumps have different hydraulic head curves or experience mechanical wear
Solution Approach 1:
The patent applies local quality by allowing each pump to have individual torque characteristics based on its specific hydraulic head curve and wear condition. Instead of forcing all pumps to operate at the same speed, each pump's torque is independently controlled to match the lead pump's torque, accommodating local differences in pump performance while maintaining overall system balance
Solution Approach 2:
The system dynamically adjusts each pump's operating speed based on real-time torque requirements. The control system continuously monitors and adjusts pump speeds to maintain synchronous torque operation, allowing the system to adapt to changing pump conditions such as mechanical wear or hydraulic variations, thereby maintaining both flow balance and reliability
3Ease of operation
If synchronous speed control is used to balance flow, then ease of operation is improved, but manufacturing precision deteriorates as pump head curves drift due to wear and hydraulic differences
Solution Approach 1:
The patent implements feedback control by continuously monitoring the torque of each pump and adjusting their speeds to maintain synchronous torque operation. The control system uses torque feedback from each pump to dynamically adjust operating parameters, compensating for drift in pump head curves due to wear or manufacturing variations, thereby maintaining flow balance without requiring precise manual calibration
Data Source
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AI summary
The present invention provides a new and unique method and apparatus for operating and running multiple pumps in a system together at a substantially synchronous torque to achieve a desired setpoint. Each of the multiple pumps may be operated with a variable speed drive. The present invention may also take the form of the system having the multiple pumps with a system controller for operating and running the multiple pumps, a pump for operating and running in such a system, a system control module for such a system controller, as well as a pump control module for running and operating such a pump.