Self-Learning Variable-Speed Control for Sensorless Flow Setpoint Holding
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Solution Overview
Problem
Existing control systems for flow and temperature control in circulating devices, such as pumps and fans, are limited in their ability to adapt to changing environments and optimize energy use, as they often rely on constant speed operations and external sensors, which can lead to inefficiencies and increased costs.
Innovation Solution
A self-learning control system that uses intelligent variable speed devices with internal sensors to detect power and speed, allowing for the inference of pressure and flow without external sensors, and adjusts operation to maintain setpoints through a control curve, optimizing energy consumption and system performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If constant speed operation is used in circulating devices, then system simplicity is maintained, but energy consumption increases and adaptability to changing environments decreases
Solution Approach 1:
The patent applies dynamics by transitioning from constant speed operation to variable speed operation. The circulating device's speed is dynamically adjusted based on real-time detection of flow, pressure, and power consumption, allowing the system to adapt to changing environmental conditions while optimizing energy usage at different load levels.
Solution Approach 2:
The patent changes the operational parameters of the circulating device by adjusting speed rather than maintaining constant speed. By varying speed as a parameter based on detected system conditions, the system achieves adaptability to different environments and load requirements while reducing energy consumption during partial load operation.
2Measurement precision
If external sensors are used to detect flow and pressure, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the measurement function from separate external sensors and integrates it into the existing motor control system. By utilizing the motor's built-in current sensors and power detection capabilities, the system derives flow and pressure information without requiring additional external flow meters or pressure sensors, thereby reducing complexity.
Solution Approach 2:
The motor control system performs self-service by using its own power detection and current measurement capabilities to infer flow and pressure conditions. The system serves its own measurement needs through intelligent calculation based on electrical parameters, eliminating the need for separate measurement devices.
3Use of energy by moving object
If variable speed control is implemented, then energy consumption at partial loads is reduced, but control system complexity increases
Solution Approach 1:
The control system achieves multi-functionality by using a single integrated controller that performs both motor speed control and system optimization functions. The same control unit that regulates motor speed also monitors power consumption, detects flow and pressure conditions, and adjusts operational parameters, eliminating the need for separate control devices and reducing overall system complexity.
Solution Approach 2:
The patent implements feedback control by continuously monitoring power consumption, flow, and pressure parameters and using this information to adjust motor speed. The control system receives feedback from the system's operational state and dynamically adjusts speed to optimize energy consumption while maintaining required performance levels.
Data Source
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AI summary
A control system for an operable system such as a flow control system or temperature control system. The system operates in a control loop to regularly update a model with respect at least one optimizable input variable based on the detected variables. The model provides prediction of use of the input variables in all possible operation points or paths of the system variables which achieve an output setpoint. In some example embodiments, the control loop is performed during initial setup and subsequent operation of the one or more operable elements in the operable system. The control system is self-learning in that at least some of the initial and subsequent parameters of the system are determined automatically during runtime.