Universal Pump Controller with Run Dry Protection
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Solution Overview
Problem
Existing pump systems are often voltage-specific, requiring multiple pump models for different voltages and are prone to damage when running dry, lacking efficient protection mechanisms against overcurrent conditions.
Innovation Solution
A pump system featuring a signal processor integrated into a printed circuit board assembly (PCBA) that can accept multiple voltage settings (e.g., 12/24/32 VDC) and an external power supply to convert 115/230 VAC, providing run dry and overcurrent protection by monitoring current draw and shutting off the pump accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pump models are used for different voltages, then voltage compatibility is improved, but device complexity increases
Solution Approach 1:
The pump is designed with a universal motor and control system that can operate across multiple voltage levels (12V, 24V, 32V, and higher). The motor controller automatically detects and adapts to the input voltage, allowing a single pump model to replace multiple voltage-specific models while maintaining full functionality at each voltage level.
Solution Approach 2:
The system dynamically adjusts operational parameters including PWM duty cycle, switching frequency, and current limits based on the detected voltage level. This parameter adaptation enables the same hardware to optimize performance across different voltage inputs without requiring physical reconfiguration or multiple models.
2Duration of action of moving object
If the pump runs without protection, then operational continuity is improved, but reliability deteriorates due to run dry and overcurrent damage
Solution Approach 1:
The motor controller continuously monitors operational parameters including current draw, temperature, and runtime. When abnormal conditions are detected (such as excessive current indicating run-dry operation or overheating), the system automatically adjusts PWM duty cycle, shuts down the motor, or triggers protection modes to prevent damage while maintaining operational continuity under normal conditions.
Solution Approach 2:
The system implements preemptive protection measures by setting current thresholds and thermal limits before damage occurs. The controller proactively reduces power output or shuts down the motor when approaching dangerous operating conditions, preventing run-dry and overcurrent damage before they can occur.
3Device complexity
If a single pump model is used for multiple voltages, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces mechanical voltage selection (physical switches, relays, or mechanical transformers) with electronic control through PWM and digital voltage detection. The motor controller uses electronic sensing and processing to adapt to different voltages, requiring precise electronic component matching and calibration but eliminating complex mechanical switching mechanisms.
Data Source
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AI summary
A pump system features a power adapter and a pump having a signal processor. The power adapter includes voltage settings that respond to a voltage setting by a user and provide a selected voltage. The signal processor receives signaling containing information about the selected voltage supplied to a motor to run the pump, and also containing information about whether a current draw of the pump is lower than a predetermined low current level or is higher than a predetermined high current level; and determines whether to shut off the pump after a predetermined time, based on the signaling received.