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  Integral sensor and control for dry run and flow fault protection of a pumpUSPTO Application #: 20070177985Title: Integral sensor and control for dry run and flow fault protection of a pump Abstract: A pump providing fault protection based on a controller receiving sensed pressure values from a pressure sensor included in a cavity of the pump, so as to be integral with the pump. (end of abstract) Agent: Ware Fressola Van Der Sluys & Adolphson, LLP - Monroe, CT, US USPTO Applicaton #: 20070177985 - Class: 417044200 (USPTO) Related Patent Categories: Pumps, Condition Responsive Control Of Pump Drive Motor, By Control Of Electric Or Magnetic Drive Motor, Responsive To Pump Fluid Pressure The Patent Description & Claims data below is from USPTO Patent Application 20070177985. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCE TO RELATED APPLICATION [0001] Reference is made to and priority claimed from U.S. provisional application Ser. No. 60/701,607 filed Jul. 21, 2005. FIELD OF THE INVENTION [0002] The present invention relates to a pump, and more particularly to a controller or device built into a pump for providing protection for the pump against dry run and flow fault conditions. BACKGROUND OF THE INVENTION [0003] Existing pump control devices for providing protection for a smaller-sized water pump against dry run and flow fault conditions typically include a pressure-activated electrical switch that turns off power to the pump when the monitored pressure is too low (or is a vacuum). The pressure-activated switch is installed externally to the pump, in such a way as to monitor the inlet and/or outlet pressure. The control is reflexive, in that a drop in pressure below the threshold of the pressure-activated switch will cause the switch to operate. The pressure-activated switch is typically mechanical or electro-mechanical in construction. [0004] The pressure sensing components for such pump control devices are typically inserted into the plumbing lines leading into and/or out of the pump. A common method consists in inserting a vacuum-sensing switch into the plumbing line on the supply side of the pump. This creates a risk of leaks in the plumbing, increases the work required for installation, and adds to the physical component count. [0005] In addition, such pump control devices typically lack input and decision-making flexibility in that they are designed to respond to a single-variable input stimulus (pressure), and they typically lack variable output functionality since they can only switch the pump to an ON or OFF state. This can be problematic if conditions on the sensed side of the pump are within acceptable operating limits, but conditions on the other side are not. For example, if a pump control device is configured only to respond to vacuum conditions appearing on the supply side of a pump, then no protection is afforded against uncontrolled flows resulting from catastrophic failure of, or damage to, the plumbing system charged by the pump. SUMMARY [0006] The invention provides a pump having integral dry run and flow fault protection via a controller using a pressure sensor embedded in either the inlet or outlet cavity of the pump, and the method of operation of the controller. The controller operation is based on the sensed pressure as well as possibly other control parameters that are monitored for protecting the pump from one or more fault conditions. The controller is programmable so that the value, interpretation and response associated with the values of the one or more control parameters--or with trends in the values of the one or more control parameters--may be set and/or changed based on a desired operational performance for the pump. [0007] The one or more control parameters may include the outlet pressure of the pump, as well as any number of conceivable additional system parameters or control inputs in order to suit the particulars of a given application system or context, such as the inlet pressure, internal or external temperatures, external operational mode signals, supply voltage, electrical current, override commands, emergency shutdown commands, motor RPM, and so on. [0008] A method of operation of the controller may include one or more steps run as a computer program on a computer processor or other suitable processing device or module that forms part of the controller. Thus, all or part of the operation of a controller according to the invention may be encoded as instructions for execution by a processor, and the instructions may be stored on a storage medium where the processor can execute the instructions such as read-only memory (ROM) or re-writeable program memory such as FLASH. Therefore, the invention also provides a computer program product, i.e. the computer program instructions and the storage medium holding the instructions. [0009] Alternatively, the logic according to which the controller operates can be encoded and provided as one or more application specific integrated circuits (ASICs). As a further alternative, the full logic by which the controller operates can be provided by a combination of stored computer programs and one or more ASICs. [0010] In operation, the invention uses a microcontroller (MCU), and one or more computer programs, a pressure sensor integral to the pump, and electrical or electronic power switching components. As such, the invention does not require components external to the pump, nor does it require intrusions into the inlet or outlet plumbing lines, thus avoiding the risk of damage to the plumbing caused by inserting the pressure sensor into the plumbing line, and thus also avoiding the associated burdens of parts and installation. [0011] However the logic of operation is provided, either via computer programs used by a microcontroller or via ASICs or both, the pump controller operation is interpretive and dynamic and can provide optimized behavior unique to a given application, i.e. the complex logic allows transcending first-order reflexive response behavior. The computer program parameters can be set such that any desired threshold of low pressure, alone or in combination with other monitored parameters, can trigger a corresponding desired response. For example, the pump controller can combine electrical current data with pressure data over time, and then calculate a threat index which in turn is used as a basis for response to the sensed current and pressure data. In particular for example, the pump controller logic can be tailored to incorporate fixed or variable time delays, to operate the pump at single or multiple reduced or increased power levels, to attempt resumption of operation based on any number of decision criteria, to observe configurable discretion and response criteria set at the time of manufacture or in the field, and so on. [0012] As is known, unusually large fluid flows in a plumbing system may result from failure or damage to the plumbing system. Such "flow faults" (analogous to excessively large electrical current flow in an "electrical fault") can cause the pressure of the fluid in the system served by the pump to fall to a low value. The pump controller can be configured (via the computer programs or ASICs) to disregard flow fault pressures, or to act on them in a protective response in conjunction with any of various decision approaches. Thus, the invention not only can protect against dry run conditions (where there is no fluid remaining to be supplied to the fluid system), but also against undesired, unusually large flow conditions, i.e. flow faults. [0013] An illustrative application of the invention is for a Bag-in-Box beverage syrup dispensing system, where beverage syrups are stored in non-pressurized bags. The syrup is pumped from the bags upon demand, such as to fill a drink container. When the bag is emptied, the described invention senses the drop in system pressure via the integral pressure sensor in the pump, stopping the pump after a pre-determined service time, thus avoiding further operation of the pump sans syrup. Alternatively, an integral pressure sensor can be configured such that it senses vacuum at the pump inlet and/or differential pressure between the inlet and outlet, depending on the particular characteristics of a target system that need be served. The invention may also sense and factor changes in electrical current delivered to the pump motor as electrical current drawn by the pump motor often drops considerably upon depletion of the fluid supply. Finally, the invention can be realized in such a way that the low pressures resulting from flow faults can result in a protective response, such as pump shutdown. BRIEF DESCRIPTION OF THE DRAWINGS [0014] The above and other objects, features and advantages of the invention will become apparent from a consideration of the subsequent detailed description presented in connection with accompanying drawings, in which: [0015] FIG. 1 is a block diagram/ schematic of an integral pump control typical system diagram according to the present invention. [0016] FIG. 2 shows an operational flowchart of the steps of operation of a pump controller according to the invention. DETAILED DESCRIPTION FIG. 1 [0017] FIG. 1 shows a pump system 10 according to the invention, for pumping a fluid. It includes a pump control module (PCM) 15 serving as a controller for a pump electric motor 16, built into or attached to the pump. An electrical power source 13 (AC or DC), is connected to the PCM 15 by an electrical connection 14. Continue reading... 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