TECHNICAL FIELD
[0001] The present disclosure relates to a pump. More specifically, the present disclosure
relates to the pump that includes a controller for controlling an operation of the
pump.
BACKGROUND
[0002] A pressure tank unit may include a pump, a pressure tank, and a pressure switch.
A pressure tank may often be utilized to provide water under pressure to an irrigation
system, plumbing system, and the like. The pressure tank may supplement the pump and
may also allow the pump to operate intermittently. The pump may be operated intermittently
because a continuously operating pump may have a shorter operational lifetime.
[0003] Further, the pressure switch may enable the pump to operate intermittently while
also ensuring that the system (say irrigation system) maintains pressure. The pressure
switch is a device that opens and closes an electrical contact based on a liquid pressure
acting against an input of the pressure switch. The pressure switch is configured
to close the electrical contact, and therefore activate the pump, when the pressure
acting against the input falls to a predetermined cut-in pressure. Similarly, the
pressure switch is configured to open the electrical contact (i.e. turn off the pump)
when the pressure acting against the input rises to a predetermined cut-out pressure.
[0004] An example of a pressure tank unit is provided in
PCT application 2020/023836 (hereinafter referred to as
'836 reference). The
'836 reference provides a well management system. The well management system provides
an Internet-enabled monitoring, configuration, and control of a well system that includes
a pump and a pressure tank. A controller is operatively coupled to the pump. The controller
controls the pump based on pressure readings from a pressure sensor to maintain a
configured pressure range within the system. The controller may communicate with a
management system via a communications network. The management system is further in
communication with one or more client devices. Via the management system, the client
devices may receive information from the controller and send commands to the controller.
However, there is still a need for a pressure tank unit which may provide constant
liquid pressure throughout an operation of any known domestic or industrial applications
such as spraying, sprinkling, and the like.
SUMMARY
[0005] In view of the above, it is an objective of the present invention to solve or at
least reduce the drawbacks discussed above. The objective is at least partially achieved
by a pump. The pump includes a storage tank adapted to store a pressurized liquid
and a pumping unit configured to supply the pressurized liquid to the storage tank.
The pumping unit includes a drive motor. The pump further includes at least one operational
parameter sensor configured to measure one or more operational parameters of the pump.
Furthermore, the pump includes a controller communicably coupled with the pumping
unit, and the at least one operational parameter sensor. The controller is configured
to receive the one or more operational parameters of the pump from the at least one
operational parameter sensor. The controller is further configured to determine an
operational condition of the pump based on the received one or more operational parameters
and activate at least one of a first operational mode and a second operational mode
of the pump based on the determined operational condition. The first operational mode
corresponds to controlling an operation of the pumping unit based on the one or more
operational parameters. The pump is characterized in that the second operational mode
corresponds to controlling the operation of the pumping unit irrespective of the one
or more operational parameters.
[0006] Thus, the present disclosure provides a pump that is advantageously operable in two
different operational modes. The two different operational modes provide a benefit
of operating the pumping unit as per the requirements of an operational condition.
The two different operational modes further allow a pump to selectively account for
one or more operational parameters of the pump calculated by at least one operational
parameter sensor.
[0007] According to an embodiment of the present disclosure, the controller is further configured
to receive a user input indicative of selection of the at least one of the first operational
mode and the second operational mode. The controller then activates the at least one
of the first operational mode and the second operational mode based on the received
user input. In some embodiments, the decision to operate the pump in the first operational
mode or the second operational mode may be made and communicated to the controller
by the user. The user may make the decision to select a particular operational mode
of the pump based on the operational conditions, storage tank size, pump specifications
among other factors.
[0008] According to an embodiment of the present disclosure, the user input is received
through a user interface configured with the controller. The user interface may obtain
the user input by virtue of one or more input devices and may further communicate
the user input with the controller. The user interface may also include a set-up such
as a display screen or a blinking light that may acknowledge the user input.
[0009] According to an embodiment of the present disclosure, the user interface is one or
more of a toggle switch, a push button, a rotary button. The user interface may be
commonly known and understood in the art. Further, the user interface may be cost-effective
and easy to operate.
[0010] According to an embodiment of the present disclosure, the user interface is configured
with a mobile device. The user interface may be wirelessly coupled with a mobile device
(say a smartphone). Thus, the pump may be easily and effectively operable from a remote
location.
[0011] According to an embodiment of the present disclosure, at least one of the first operational
mode and the second operational mode is activated automatically. The controller implements
a process or an algorithm to automatically activate the first operational mode or
the second operational mode without any human intervention.
[0012] According to an embodiment of the present disclosure, the automatic activation is
governed by the operational parameter of the pump. The algorithm implemented by the
controller makes use of detected operational parameters such as the pressure in the
storage tank, liquid flow rate in the pump to make decision about the automatic activation
of the first operational mode or the second operational mode.
[0013] According to an embodiment of the present disclosure, the operational condition is
an irrigation event. Different operational conditions may demand different one or
more operational parameters such as, but not limited to, liquid pressure, liquid flow
rate etc., in the pump. The pump may then be selectively operated in the first operational
mode or the second operational mode to meet the demand for the one or more operational
parameters.
[0014] According to an embodiment of the present disclosure, the at least one operational
sensor includes a pressure sensor. Pressure is one of the most important operational
parameters for the operation of the pump. The pressure sensor communicates the pressure
reading of the pump with the controller. The controller then controls the operation
of the pump based on the pressure reading for smooth and efficient operation of the
pump under different operational conditions.
[0015] According to an embodiment of the present disclosure, the operational parameter is
a pressure of the storage tank. The storage tank may function to supplement the pump
and may improve the durability of the pump. Further, the pump may be required to operate,
or cease operating based on the pressure of the storage tank.
[0016] Other features and aspects of this invention will be apparent from the following
description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention will be described in more detail with reference to the enclosed drawings,
wherein:
FIG. 1 shows a schematic block diagram of a pump, in accordance with an aspect of the present
disclosure;
FIG. 2 shows a schematic block diagram of a pump operating in a first operational mode,
in accordance with an aspect of the present disclosure; and
FIG. 3 shows a schematic block diagram of a pump operating in a second operational mode,
in accordance with an aspect of the present disclosure;
FIG. 4 shows a schematic block diagram of a controller for a pump, in accordance with an
aspect of the present disclosure; and
FIG. 5 is a flowchart illustrating a process for an automatic operation of a pump, in accordance
with an aspect of the present disclosure
DESCRIPTION OF EMBODIMENTS
[0018] The present invention will be described more fully hereinafter with reference to
the accompanying drawings, in which example embodiments of the invention incorporating
one or more aspects of the present invention are shown. This invention may, however,
be embodied in many different forms and should not be construed as limited to the
embodiments set forth herein; rather, these embodiments are provided so that this
disclosure will be thorough and complete, and will fully convey the scope of the invention
to those skilled in the art. For example, one or more aspects of the present invention
may be utilized in other embodiments and even other types of structures and/or methods.
In the drawings, like numbers refer to like elements.
[0019] Certain terminology is used herein for convenience only and is not to be taken as
a limitation on the invention. For example, "upper", "lower", "front", "rear", "side",
"longitudinal", "lateral", "transverse", "upwards", "downwards", "forward", "backward",
"sideward", "left," "right," "horizontal," "vertical," "upward", "inner", "outer",
"inward", "outward", "top", "bottom", "higher", "above", "below", "central", "middle",
"intermediate", "between", "end", "adjacent", "proximate", "near", "distal", "remote",
"radial", "circumferential", or the like, merely describe the configuration shown
in the Figures. Indeed, the components may be oriented in any direction and the terminology,
therefore, should be understood as encompassing such variations unless specified otherwise.
[0020] FIG. 1 illustrates a schematic block diagram of a pump
100. The pump
100 includes a storage tank
110 adapted to store a pressurized liquid. The pump
100 further includes a pumping unit
120 configured to supply the pressurized liquid to the storage tank
110 and/or a distribution system
130 (e.g., a plumbing system of a structure). The pump includes a drive motor (not shown).
The storage tank
110 may be a pressure vessel having an internal diaphragm that separates an interior
volume into an air chamber from a liquid chamber. The air chamber may be provided
with a pre-charge of air pressure so as to provide liquid under pressure to the distribution
system
130 even when the pumping unit
120 is not operating.
[0021] The pump
100 further includes at least one operational parameter sensor
140 configured to measure one or more operational parameters of the pump
100. The one or more operational parameters of the pump
100 may be a liquid pressure, liquid flow rate, liquid level, and the like. The at least
one operational parameter sensor
140 may measure one or more operational parameters of the pump
100 for an efficient operation of the pump
100. Further, the at least one operational parameter sensor
140 may measure one or more operational parameters of the pump
100 for improving the durability of various elements or parts associated with the pump
100.
[0022] Further, the pump
100 includes a controller
150 communicably coupled with the pumping unit
120, the at least one operational parameter sensor
140, a remote server
160 and a user interface
170. The controller
150 is configured to receive the one or more operational parameters of the pump
100 from the at least one operational parameter sensor
140. In some embodiments, the controller
150 may receive the liquid level within the storage tank
110 from a liquid level sensor (not shown) or the liquid temperature from a temperature
sensor (not shown). In some embodiments, as shown in
FIGS. 2 and
3, the controller
150 receives the pressure of the storage tank
110 from a pressure sensor
142.
[0023] Furthermore, the controller
150 is configured to determine an operational condition of the pump
100 based on the received one or more operational parameters and activate at least one
of a first operational mode "
P1" and a second operational mode
"P2" of the pump
100 based on the determined operational condition as shown in
FIGS. 2 and
3. The first operational mode "
P1" corresponds to controlling an operation of the pumping unit
120 based on the one or more operational parameters (as shown in
FIG. 2). The second operational mode
"P2" corresponds to controlling the operation of the pumping unit
120 irrespective of the one or more operational parameters (as shown in
FIG. 3).
[0024] In some embodiments, as shown in
FIG. 2, the operational condition may be an operational condition requiring very small amount
of water such as a toilet washing or a hand washing event that may generally require
a less quantity of the liquid (say water). In such events, the controller
150 may activate the first operational mode "
P1"
. By way of example, an operational configuration may include pressure setpoints and
the operational parameter includes pressure reading from the pressure sensor
142. The pressure sensor
142 is coupled to liquid flow lines between the pumping unit
120 and the storage tank
110 or the distribution system
130. The pressure sensor
142 provides the pressure reading in the liquid flow lines and communicates the pressure
reading with the controller
150. In accordance with the first operational mode "P
1", the controller
150 activates the pumping unit
120 when the pressure reading falls below a cut-in pressure and deactivates the pumping
unit
120 when the pressure reading is at or above a cut-out pressure.
[0025] In some embodiments as shown in
FIG. 3, the operational condition is an irrigation event such as a sprinkling event or a
spraying event that may generally require large quantity of the liquid (say water).
In such events, the pressure may be required to be continuously maintained within
the pump
100. Hence, it may not be preferable to switch the pumping unit
120 ON/OFF based on the pressure reading from the pressure sensor
142. Thus, in such events, the controller
150 may activate the second operational mode "P
2". In accordance with the second operational mode "P
2", the controller
150 completely disregards or disobeys the pressure reading from the pressure sensor
142. The pumping unit
120 then operates continuously throughout the period of the irrigation event or the operational
condition.
[0026] Although the pressure sensor
142 is depicted in
FIGS. 2 and
3, as being separate from the controller
150, in some embodiments, as shown in
FIG. 4, the pressure sensor
142 may be integrated with the controller
150. For instance, the pressure sensor
142 may be at least partially integrated with a circuit board of the controller
150 and/or enclosed within a common housing. Moreover, the common housing that includes
the controller
150 and/or the pressure sensor
142 may be installed on or attached to the storage tank
110.
[0027] Further,
FIG. 4 illustrates a schematic block diagram of an exemplary, nonlimiting embodiment for
the controller
150. As shown in
FIG. 4, the controller
150 includes one or more processor(s)
200 configured to executed computer-executable instructions
204 such as instructions composing a control and communication process for the pump
100. Such computer-executable instructions
204 are stored on one or more computer-readable media including non-transitory, computer-readable
storage media such as memory
202. For instance, memory
202 may include non-volatile storage to persistently store the instructions
204, settings
206 (e.g. operational configuration settings, operational parameter settings, pressure
setpoints, etc.), and/or data
208 (e.g., operational data, history data, water usage data, system health data, pressure
data, current data, voltage data, resistance data, user-stored data, etc.). Memory
202 may also include volatile storage that stores the instructions
204, other data (working data or variables), or portions thereof during execution by the
processor
200.
[0028] The controller
150 further includes a communication interface
210 to couple the controller
150, via the Internet or other communications network, to the remote server
160. The communication interface
210 may be a wired or wireless interface such as, but not limited to, a Wi-Fi interface,
an Ethernet interface, a Bluetooth interface, a fiber optic interface, a cellular
radio interface, a satellite interface, etc. The communications settings, thus established,
may be stored in memory
202.
[0029] Further, a component interface
212 is also provided to couple the controller
150 to various components of the pump
100. For instance, the component interface
212 may connect the controller
150 to the at least one operational parameter sensor
140 such as the pressure sensor
142, the pumping unit
120. Via the component interface
212, the controller
150 may activate the pumping unit
120 (i.e. close an electrical switch), deactivate the pumping unit
120 (i.e. open the electrical switch), acquire electrical properties (i.e., current,
voltage, resistance, etc.) of the pumping unit
120, acquire readings from the at least one operational parameter sensor
140, or the like. Accordingly, the component interface
212 may include a plurality of electrical connections on the circuit board or internal
bus of the controller
150 that may be further coupled to the processor
200, memory
202, etc. Further, the component interface
212 may implement various wired or wireless interfaces such as, but not limited to, a
USB interface, a serial interface, the Wi-Fi interface, a short-range RF interface
(Bluetooth), an infrared interface, a near-field communication (NFC) interface, etc.
[0030] In the operation of the pump
100, the controller
150 determines the operational condition such as the irrigation event, the hand washing
event, or any other event based on the received one or more operational parameters
received from the at least one operational parameter sensor
140. The one or more operational parameters may then be compared with the information
or data stored in the memory
208 and/or the remote server
160. The memory
208 and/or the remote server
160 may already include a database for the relationship between the operational conditions
and the operational parameters. For example, on receiving the one or more operational
parameters such as the flow rate of the liquid or the pressure of the liquid, the
controller may check with the memory
208 and/or the remote server
160 to understand whether the received one or more operational parameters correspond
to the irrigation event or some other event to accordingly activate the at least one
of the first operational mode "P
1" and the second operational mode "P
2" of the pump
100. Thus, the controller
150 automatically decides whether to operate the pump
100 in the first operational mode "P
1" or the second operational mode "P
2" without any intervention by a user.
[0031] FIG. 5 is a flowchart illustrating a process
300 for automatic operation of the pump
100 by the controller
150, according to another embodiment of the present disclosure. The process
300 is embodied as an algorithm implemented by the controller
150 (as shown in
FIG. 4) including the processor
200. Further, the process
300 or the algorithm may be stored in the memory
202.
[0032] At step
302, the process
300 begins. The process
300 then moves to step
304 to turn ON the drive motor of the pumping unit
120 in order to start the operation the pumping unit
120 of the pump
100. Once the drive motor is turned ON in step
304, the process
300 moves to step
306 and the liquid flow rate is detected in the pump
100. If the liquid flow rate is not detected at step
306, the process
300 moves to step
310 to detect if the pressure in the storage tank
110 is greater than or equal to a predetermined cut-out pressure. In an embodiment, the
cut-out pressure is the maximum pressure value after which the drive motor is turned
OFF.
[0033] If the pressure in the storage tank
110 turns out to be greater than or equal to the predetermined cut-out pressure in step
310, then the process
300 moves to step
312 and the drive motor is turned OFF. The process
300 then moves to step
314 to detect if the pressure in the storage tank
110 is less than or equal to a predetermined cut-in pressure after turning OFF the drive
motor at step
312., The cut-in pressure is the minimum pressure value below which the drive motor is
turned ON.
[0034] If the pressure in the storage tank
110 does not turn out to be less than or equal to the predetermined cut-in pressure,
then the process
300 moves to step
332 to detect if the liquid flow rate in the pump
100 is greater than a pre-determined threshold value. If the liquid flow rate turns out
to be greater than the predetermined threshold value, then the process
300 moves to step
304 to start the drive motor else the process
300 moves back to step
314. Further, if the pressure in the storage tank
110 as detected in the step
314 turns out to be less than or equal to the predetermined cut-in pressure, then the
process
300 moves to step
304 and the drive motor starts.
[0035] If the pressure in the storage tank
110 turns out to be less than the predetermined cut-out pressure at step
310, then the process
300 moves to step
316. At step
316, the pressure in the storage tank
110 is again detected or measured after a pre-determined time period. In an embodiment,
the pre-determined time period is
1 minute. In other embodiments, the pre-determined time period may be any other suitable
time period as per application requirements.
[0036] If the detected pressure is still less than the predetermined cut-out pressure than
the process
300 moves to step
318 to verify if there is an error and then further moves to step
320 to confirm the error. However, if the detected pressure reaches the predetermined
cut-out pressure after the pre-determined time period, then the process
300 moves to step
322 to verify if the value of the detected pressure is less than or equal to a pre-determined
pressure value. In an embodiment, the predetermined pressure value is
0.5 bar. In other embodiments, the pre-determined pressure value may be any other suitable
pressure value as per application requirements.
[0037] If the detected pressure in step
322 is less than or equal to the predetermined pressure value then the process
300 moves to step
324 to verify if there is an error and then further moves to step
320 to confirm the error. If the detected pressure in step
322 is greater than the pre-determined pressure value, then the process
300 moves to step
306.
[0038] At step
306, the liquid flow rate is again detected. If at step
306, the liquid flow rate is detected, then the process
300 moves to step
308. At step
308, the pump system checks if the second operational mode (that is the so called PowerBoost
mode) is selected, then the process
300 moves to step
326 else the process
300 moves to step
310. At step
326, two conditions are tested. First condition is if the pressure in the storage tank
110 is greater than or equal to the cut-off pressure of the second operational mode and
second condition is if the pressure in the storage tank
110 was detected before the pre-determined time period.
[0039] If both the conditions at step
326 are not met simultaneously, then the process
300 moves to step
306 else the process
300 moves to step
328. At step
328, the drive motor is turned OFF. Thus any flow in the pump results from the water in
the pressure tank. The process
300 then moves to step
330 to detect if the liquid flow rate in the pump
100 is greater than the pre-determined threshold value. If the liquid flow rate in the
pump
100 turns out to be greater than the predetermined threshold value, then the process
300 moves to step
304 else the process
300 moves to step
314.
[0040] The process
300 is repeated at regular intervals to detect the operational state of the pump
100 and thereby automatically and selectively operates the pump
100 in the at least one of the first operational mode "P
1" and the second operational mode "P
2".
[0041] Thus, the controller
150 determines the characteristic curve range in which the pumping unit
120 works in coordination with the pressure of the storage tank
110. In the event that the pressure of the storage tank
110 is below the cut-out pressure, a power off of the pumping unit
120 is prevented and the pumping unit
120 remains in continuous operation. If cut-out pressure is reached, the pumping unit
120 switches off. The liquid flow rate is then calculated by the pressure change in the
storage tank
110 over the time. This flow rate is used for further decision making. If this flow rate
falls below the pre-determined threshold value, the pumping unit
120 operates in the first operational mode "P
1" and remains in the power off state until the cut-in pressure of the pumping unit
120 is reached. However, if the algorithm running in the controller
150 detects the liquid flow rate above the pre-determined threshold value, the pumping
unit
120 remains in continuous operation and operates in the second operational mode "P
2".
[0042] In some embodiments, the user may opt to disregard or disobey the judgement or the
decision of the controller
150 to activate the at least one of the first operational mode "P
1" and the second operational mode "P
2" of the pump
100. The user may do so by switching OFF a switch (not shown) provided with the controller
150 or with the help of a voice command to the controller
150, or any other means to provide user input without limiting the present disclosure
in any manner.
[0043] In this embodiment, the controller
150 may be configured to receive a user input indicative of selection of the at least
one of the first operational mode "P
1" and the second operational mode "P
2". The controller
150 may then activate the at least one of the first operational mode "P
1" and the second operational mode "P
2" based on the received user input. In this embodiment, the decision to operate the
pump
100 in the first operational mode "P
1" or the second operational mode "P
2" may be made and communicated to the controller
150 by the user. The user may make the decision to select the at least one of the first
operational mode "P
1" and the second operational mode "P
2" of the pump
100 based on the operational conditions, storage tank size, pump specifications among
other factors. In some embodiments, the user may bias the decision of selection of
the operational mode between the at least one of the first operational mode "P
1" and the second operational mode "P
2" of the pump
100 based on the operational parameters such as liquid pressure in the storage tank
120 being displayed on a display screen (not shown) provided with the controller
150.
[0044] In some embodiments, the user input is received through the user interface
170 configured with the controller
150. The user interface
170 may obtain the user input by virtue of one or more input devices and may further
communicate the user input with the controller
150. The user interface
170 may also include a set-up such as the display screen (which is different from the
display screen provided with the controller
150) or a blinking light that may acknowledge the user input.
[0045] In some embodiments, the user interface
170 may be one or more of a toggle switch, a push button, a rotary button. The user interface
170 such as the toggle switch, the push button and the rotary button may be commonly
known and understood in the art. Further, they may be cost-effective and easy to operate.
In some embodiments, the user interface
170 may be configured with a mobile device (say a smartphone). The user interface
170 may be wirelessly coupled with a mobile device using any known technology such as
the Bluetooth, Wi-Fi, among others. Thus, the pumping unit
120 may be easily and effectively operable from a remote location.
[0046] Thus, the present disclosure provides the pump
100 that is advantageously operable in two different operational modes "P
1, P
2". The two different operational modes "P
1, P
2" provide a benefit of operating the pump
100 as per the requirements of the operational condition such as the irrigation event,
hand washing event among others. The two different operational modes "P
1, P
2" further allow the pumping unit
120 to selectively obey one or more operational parameters of the pump
100 calculated by at least one operational parameter sensor
140.
[0047] In the drawings and specification, there have been disclosed preferred embodiments
and examples of the invention and, although specific terms are employed, they are
used in a generic and descriptive sense only and not for the purpose of limitation
of the scope of the invention being set forth in the following claims.
LIST OF ELEMENTS
[0048]
- 100
- Pump
- 110
- Storage Tank
- 120
- Pumping unit
- 130
- Distribution System
- 140
- Operational Parameter Sensor
- 142
- Pressure Sensor
- 150
- Controller
- 160
- Remote Server
- 170
- User Interface
- 200
- Processors
- 202
- Memory
- 204
- Instructions
- 206
- Settings
- 208
- Data
- 210
- Communication Interface
- 212
- Component Interface
- P1
- First Operational Mode
- P2
- Second Operational Mode
- 300
- Process
- 302
- Step
- 304
- Step
- 306
- Step
- 308
- Step
- 310
- Step
- 312
- Step
- 314
- Step
- 316
- Step
- 318
- Step
- 320
- Step
- 322
- Step
- 324
- Step
- 326
- Step
- 328
- Step
- 330
- Step
- 332
- Step