Soft-start pump control system

• US 5,545,012 A
• Filed: 01/27/1994
• Issued: 08/13/1996
• Est. Priority Date: 10/04/1993
• Status: Expired due to Fees

• Current Assignee: Rule Industries Incorporated (ITT, Inc.)
• Original Assignee: Rule Industries Incorporated (ITT, Inc.)
• Inventors: Boyd, Stephen B., Anastos, William N.
• Primary Examiner(s): Berisch, Richard A.
• Assistant Examiner(s): THAI, XUAN MARIAN
• Application Number:
  US08/204,193
• Time in Patent Office: 929 Days
• Field of Search: 417/12, 417/44.1, 417/44.11, 417/45, 417/423.3, 307/118, 307/135, 307/141, 361/28, 361/29, 361/31, 318/431, 318/482, 318/484, 388/811
• US Class Current: 417/44.11
• CPC Class Codes: F04B 2203/0201 Current
• CPC Class Codes: F04B 2205/09 Flow through the pump
• CPC Class Codes: F04B 49/02 Stopping, starting, unloading or idling control
• CPC Class Codes: F04B 49/06 Control using electricity regulating by means of floats actuating electric switches F04B49/04
• CPC Class Codes: F04D 15/0236 Lack of liquid level being detected by analysing the parameters of the electric drive, e.g. current or power consumption
• CPC Class Codes: H02H 7/08 for dynamo-electric motors
• CPC Class Codes: H02H 9/001 limiting speed of change of electric quantities, e.g. soft switching on or off progressive control of electronic switches for eliminating interferences H03K17/16

Abstract

A soft-start pump controller system for controlling a pump motor includes a switching device for supplying power to the pump motor; a periodic duty cycle generator for periodically actuating the switching device at a fraction of the full duty cycle to operate the pump at a reduced, quieter level; a sensor for sensing the current drawn by the pump motor; a reference circuit; and a liquid detector for detecting the presence of the liquid to be pumped, responsive to the sensor and the reference circuit, for overriding the periodic duty cycle generator and actuating the switching device to operate the pump motor continuously at full power when the motor current exceeds a predetermined level indicating liquid is present.

Claims

1. A soft-start pump control system for controlling a pump motor comprising:

switching means for supplying power to a pump motor;

a periodic duty cycle generator for periodically actuating said switching means at a fraction of the full duty cycle, to operate the pump motor at reduced power for quieter operation;

sensor means for sensing the current drawn by the pump motor;

a reference circuit; and

liquid detector means for detecting the presence of liquid to be pumped, responsive to said sensor means, and said reference circuit, for overriding said periodic duty cycle generator and actuating said switching means to operate said pump motor continuously at full power when the motor current exceeds a predetermined level indicating liquid is present.

2. The soft-start pump controller system of claim 1 in which said periodic duty cycle generator includes a duty cycle generator for providing a fractional duty cycle to said switching means and a cycle timer for periodically operating said duty cycle generator.

3. The soft-start pump controller system of claim 2 in which said duty cycle generator provides a 30% duty cycle.

4. The soft-start pump controller system of claim 1 in which said liquid detector includes a comparator responsive to said reference circuit and said sensor means.

5. The soft-start pump controller system of claim 1 further including an overload detector responsive to said sensor means and said reference circuit for overriding said periodic duty cycle generator and said liquid detector to actuate said switching means to deenergize the pump motor.

6. The soft-start pump controller system of claim 1 in which said reference circuit includes a reference adjustment means, responsive to said liquid detector, for adjusting the reference level as a function of the current drawn by the pump motor under full power and at a fraction of the duty cycle.

7. A soft-start pump controller system for controlling a pump motor, comprising:

a switching device for supplying power to the pump motor;

a periodic duty cycle generator for periodically actuating said switching device at a fraction of the full duty cycle;

a current sensor for sensing the current drawn by the pump motor;

a reference circuit; and

a liquid detector for detecting the presence of liquid to be pumped by the pump motor, responsive to said current sensor, and said reference circuit.

8. A soft-start pump control system for controlling a pump motor comprising:

switching means for supplying power to a pump motor;

a periodic duty cycle generator for periodically actuating said switching means at a fraction of the full duty cycle, to operate the pump motor at reduced power for quieter operation;

sensor means for sensing the current drawn by the pump motor;

a reference circuit;

liquid detector means for detecting the presence of liquid to be pumped, responsive to said sensor means, and said reference circuit, for overriding said periodic duty cycle generator and actuating said switching means to operate said pump motor continuously at full power when the motor current exceeds a predetermined level indicating liquid is present; and

a reference adjustment means, responsive to said liquid detector, for adjusting the reference level of the reference circuit as a function of the current drawn by the pump motor under full power and at a fraction of the duty cycle.