Pump control unit located in the power cord and compatible with multiple pump units

• US 10,240,605 B2
• Filed: 05/03/2013
• Issued: 03/26/2019
• Est. Priority Date: 05/04/2012
• Status: Active Grant

• Current Assignee: Sulzer Management AG (Sulzer AG)
• Original Assignee: Sulzer Management AG (Sulzer AG)
• Inventors: Magnusson, Niklas, Hokby, Nils
• Primary Examiner(s): Lettman, Bryan
• Assistant Examiner(s): Solak, Timothy P
• Application Number:
  US13/887,251
• Publication Number:
  US 20130294931A1
• Time in Patent Office: 2,153 Days
• Field of Search: 4174233
• CPC Class Codes: F04D 13/0686 Mechanical details of the pump control unit pump control F04D15/00
• CPC Class Codes: F04D 13/0693 Details or arrangements of the wiring
• CPC Class Codes: F04D 13/086 the pump and drive motor are both submerged
• CPC Class Codes: F04D 15/00 Control, e.g. regulation, of pumps, pumping installations or systems
• CPC Class Codes: F04D 15/0027 Varying behaviour or the very pump F04D15/0055 and F04D29/46 take precedence
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine
• CPC Class Codes: F04D 15/0088 Testing machines
• CPC Class Codes: F04D 15/0218 the condition being a liquid level or a lack of liquid supply
• CPC Class Codes: F04D 15/0245 responsive to a condition of the pump
• CPC Class Codes: H01R 13/523 for use under water
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 31/065 with built-in electric apparatus
• CPC Class Codes: H04B 2203/5445 Local network
• CPC Class Codes: H04B 2203/5475 adapted for drill or well combined with data transmission
• CPC Class Codes: H04B 3/54 Systems for transmission via power distribution lines
• CPC Class Codes: H04B 3/60 Systems for communication between relatively movable stations, e.g. for communication with lift H04B3/54 takes precedence

Abstract

Disclosed is a system for controlling a pump, such as a submersible pump intended for pumping water, including a pump and a separate electronic control unit connected to the pump by an electrical cable. The control unit is adapted to be detachably connected to the pump. The control unit is adapted to allow the pump'"'"'s power supply to pass through the control unit. An electronic controller is arranged in the pump for controlling at least one of the pump'"'"'s functions and/or monitoring at least one of the pump'"'"'s operating conditions. The pump and the control unit are adapted to communicate with each other and transmitting signals, including necessary control and/or monitoring information/data, between each other.

Claims

1. A system for controlling a pump, comprising a pump and a control unit connected to the pump by a three phase electrical power supply cable, wherein:

the control unit is, irrespective of a power rating of the pump, detachably connectable to the pump via the electrical power supply cable,

the control unit is compatible with pumps having different power ratings,

an electronic controller is arranged in the pump, the electronic controller including a soft starter unit for starting the pump and a microcontroller unit for monitoring at least one of the pump'"'"'s operating conditions,

the pump and the control unit are adapted to communicate with each other and transmit data/signals over the electrical power supply cable, comprising control and/or monitoring information/data for managing the system,

the pump and the control unit pair automatically such that the control unit receives signals or transmits signals adapted to a specific power rating of the pump paired to the control unit,

the control unit is connected to the electronic controller of the pump and located along the electrical power supply cable between a power supply and the pump, and

the pump is maintained operational by the electronic controller arranged in the pump when the control unit is bypassed.

2. The system according to claim 1, wherein internal cables are arranged within the control unit in order to allow power supply of the pump to pass through the control unit.

3. The system according to claim 1, wherein the control unit is adapted to automatically detect at least one characteristic of the connected pump, and to adjust the data/signals so that a different connected pump with a different characteristic can be automatically controlled by the same control unit.

4. The system according to claim 1, wherein the system is arranged to provide communication between the pump and the control unit via galvanic connection to the electrical power supply cable.

5. The system according to claim 1, wherein the data between the pump and the control unit are transmitted via signals that are superimposed on one or more conductors in the electrical power supply cable.

6. The system according to claim 1, wherein:

the pump includes a plurality of sensors; and

the control unit is adapted to generate and transmit the data/signals to the pump based on sensor signals from the plurality of sensors.

7. The system according to claim 1, wherein the control unit is adapted to generate and transmit the data/signals to the pump by a user operating actuating means of the control unit.

8. A pump having an electrical motor and a mechanical pump wheel, comprising an inlet for incoming fluid and a discharge outlet for outgoing fluid, wherein

an electronic controller is arranged in the pump for controlling at least one of the pump'"'"'s functions and/or monitoring at least one of the pump'"'"'s operating conditions, and that a direct or soft starter unit necessary for starting the electrical motor to drive the mechanical pump wheel is arranged in the pump,

communication between the pump and an external control unit is made via a three phase power supply cable,

the external control unit is connected to the electronic controller of the pump and located along the power supply cable between a power supply and the pump,

the external control unit is compatible with multiple pumps with different power ratings,

the pump and the external control unit pair automatically such that the external control unit receives signals or transmits signals adapted to a specific power rating of the pump paired to the control unit, and

the pump is maintained operational by the electronic controller arranged in the pump when the control unit is bypassed.

9. The pump according to claim 8, wherein:

the pump includes a plurality of sensors; and

a microcontroller unit (MCU) is adapted in the pump to generate and transmit data signals to the external control unit based on sensor signals from the plurality of sensors.

10. An electronic control unit for controlling and monitoring of a pump, wherein:

the electronic control unit is adapted to be detachably connectable to the pump and to a power supply for providing current to the pump, the electronic control unit is compatible with multiple pumps with different power ratings,

communication between the pump and the electronic control unit is made via a three phase power supply cable,

the electronic control unit is detachably connectable to an internal electronic controller of the pump and located along the power supply cable between the power supply and the pump,

the internal electronic controller of the pump includes a soft starter unit for starting the pump and a microcontroller unit for monitoring at least one of the pump'"'"'s operating conditions,

the electronic control unit is provided with at least one operating switch for controlling the pump as well as with indicators for indicating at least one operating condition of the pump,

a communications unit is arranged in the electronic control unit to receive data from the pump and for transmitting control commands to the pump over the power supply cable,

the pump and the electronic control unit pair automatically such that the electronic control unit receives signals or transmits signals adapted to a specific power rating of the pump paired to the control unit, and

the pump is maintained operational by the electronic controller arranged in the pump when the control unit is bypassed.

11. The electronic control unit according to claim 10, wherein the communications unit is arranged to receive data from the pump and to transmit control commands to the pump via signals transmitted by one or more wires within the power supply cable.

12. The electronic control unit according to claim 10, wherein a circuit board is arranged to superimpose the signals over a normal frequency of drive current in the power supply cable.

13. The electronic control unit according to claim 10, wherein the communications unit is galvanically connected to one or more wires in the power supply cable located between the electronic control unit and the pump.

14. The electronic control unit according to claim 10, wherein electrical plug connectors are arranged at opposite end areas of the electronic control unit.