Variable Speed Vacuum Pump Control for Milking Systems
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Solution Overview
Problem
Vacuum regulation systems in milking systems face challenges in maintaining a constant vacuum level without fluctuations, which can harm animals and increase energy consumption, especially when controlling multiple vacuum pumps simultaneously, and there is a need for an efficient method to manage the number of pumps and maintain them without disrupting operations.
Innovation Solution
A method using at least two identical variable speed vacuum pumps, where the first pump creates the required vacuum level and a second pump is started when the first reaches a certain speed threshold, both running in parallel under the same control signal, and pumps are turned off when not needed to minimize energy consumption and facilitate maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If two or more vacuum pumps are controlled simultaneously to meet high vacuum requirements, then the required vacuum level can be achieved, but it becomes difficult to keep the vacuum level at a constant level without fluctuations
Solution Approach 1:
The patent applies dynamics by making the vacuum pump system adjustable and flexible. Instead of controlling multiple pumps simultaneously at fixed speeds, the system dynamically selects the optimal number of pumps to operate and adjusts their speeds continuously based on real-time vacuum requirements. This dynamic adaptation eliminates vacuum fluctuations while maintaining the required vacuum level.
Solution Approach 2:
The patent changes the operating parameters of the vacuum pumps by allowing continuous speed adjustment within a wide range (e.g., 10-100% of maximum speed). This parameter flexibility enables the system to maintain stable vacuum levels by precisely matching pump capacity to actual demand, avoiding the instability caused by discrete speed steps or simultaneous multi-pump operation.
2Use of energy by moving object
If vacuum pumps are run at low speed to meet low air removal requirements, then energy consumption is reduced, but the risk of overheating the vacuum pumps increases
Solution Approach 1:
The system dynamically adjusts pump operation based on actual demand. When low air removal is needed, the system can either run a single pump at low speed (reducing energy consumption) or switch to a different pump configuration that maintains adequate cooling. This dynamic decision-making balances energy efficiency with thermal management.
Solution Approach 2:
The patent implements periodic monitoring and adjustment of pump operation. The control system continuously monitors vacuum requirements and pump operating conditions, periodically adjusting which pumps are active and at what speeds. This periodic action ensures that pumps are not continuously run at suboptimal speeds that could cause overheating, while still minimizing energy consumption during low-demand periods.
3Device complexity
If a single vacuum pump is used to meet maximum vacuum requirements, then device complexity is reduced, but the pump must be over-dimensioned leading to higher energy consumption during normal operation
Solution Approach 1:
The patent applies segmentation by dividing the vacuum pump capacity into multiple smaller units. Instead of using one large over-dimensioned pump, the system uses multiple smaller pumps that can be operated individually or in combination. This segmentation allows the system to match pump capacity precisely to actual vacuum requirements, eliminating the energy waste associated with running an oversized pump at low load.
Solution Approach 2:
The system dynamically determines the optimal number of pumps to operate based on real-time vacuum requirements. When high vacuum is needed, multiple pumps operate simultaneously; when lower vacuum is sufficient, fewer pumps are activated. This dynamic pump selection and speed adjustment optimizes energy consumption while maintaining adequate vacuum levels without requiring an over-dimensioned single pump.
4Adaptability or versatility
If multiple vacuum pumps are installed to meet varying vacuum demands, then adaptability to different vacuum requirements is improved, but maintenance and servicing become more difficult as pumps must be taken out of operation
Solution Approach 1:
The patent segments the vacuum pump system into multiple independent, identical units. This segmentation provides inherent redundancy, allowing one or more pumps to be taken offline for maintenance while the remaining pumps continue to operate and maintain the required vacuum level. The modular design makes maintenance easier compared to a single large pump.
Solution Approach 2:
The system applies local quality by having different pumps potentially perform different functions or be in different operational states. One pump can be in service while another is under maintenance, and the control system locally adjusts the operation of active pumps to compensate. This localized management of pump resources improves both adaptability and maintenance ease.
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 approach ensures a stable vacuum level, reduces energy consumption by optimizing pump usage, and allows for easy maintenance without interrupting milking operations, as only the necessary number of pumps are used, and they are run at optimal speeds to prolong their service life.
Implementation Method 1
a vacuum pump, which is chosen so as to be able to remove air from within the milking system to meet a required maximum vacuum level
Data Source
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AI summary
The invention relates to a method in a milking system for creating a required vacuum level, the milking system comprising at least two variable speed vacuum pumps P1, P2. The method comprises the steps of: utilizing a first variable speed vacuum pump P1 for creating the required vacuum level within the milking system; monitoring the vacuum level requirement within the milking system, and when the vacuum level requirement of the milking system is such that the speed of the first variable speed vacuum pump P1 reaches a first speed threshold then: starting a second variable speed vacuum pump P2, and running the first and second variable speed vacuum pumps P1, P2 in parallel for creating the required vacuum level. The invention also relates to computer program products.