Method and system for adjusting operating parameters of computer controlled pumps

• US 6,638,023 B2
• Filed: 01/07/2002
• Issued: 10/28/2003
• Est. Priority Date: 01/05/2001
• Status: Expired due to Term

• Current Assignee: Little Giant Pump Company
• Original Assignee: Little Giant Pump Company
• Inventors: Scott, Thomas R.
• Primary Examiner(s): Tyler, Cheryl J.
• Application Number:
  US10/041,288
• Publication Number:
  US 20020090303A1
• Time in Patent Office: 659 Days
• Field of Search: 417/12, 417/36, 417/40, 417/44.11, 417/53
• US Class Current: 417/36
• CPC Class Codes: F04D 15/0209 responsive to a condition of the working fluid F04D15/029 takes precedence
• 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

Abstract

A system and methods for automatically adjusting pump operating parameters for at least one pump to accommodate solids encountered during a pumping operation. The output signal of a level sensor may be monitored so as to detect and account for variations therein. The power draw of the pump may also be monitored so as to detect and account for the presence of solids.

Claims

1. A method for adjusting pump operating parameters for at least one pump to accommodate solids encountered during a pumping operation, the method comprising the steps of:

a) providing a level sensor adapted to provide an output signal corresponding to a fluid level;

b) assigning a value of the output signal to correspond to a predetermined maximum fluid level;

c) assigning a value of the output signal to correspond to a predetermined minimum fluid level;

d) programming the pump to turn on when the output signal is at a certain predetermined value and off when the output signal is at another predetermined value, the predetermined values being less than the value that corresponds to the maximum fluid level and greater than the value that corresponds to the minimum fluid level; and

e) monitoring the values of the output signal that correspond to the maximum and minimum fluid levels so as to periodically update the values at which the pump will turn on and off in accordance with variations that may occur in the values of the signal that correspond to the maximum and minimum fluid levels.

2. The method of claim 1 wherein the step of monitoring the values of the output signal that correspond to the maximum and minimum fluid levels comprises;

a) taking a first reading of the value of the output signal generated by the level sensor in response to an alarm signal indicating that the level of fluid is above the maximum fluid level and that the pump has not begun pumping;

b) adjusting the value of the output signal that corresponds to the maximum fluid level so that the value of the output signal taken as the first reading corresponds to the maximum fluid level;

c) reducing the level of fluid to below the minimum fluid level;

d) taking a second reading of the value of the output signal generated by the level sensor while the fluid level is below the minimum fluid level;

e) adjusting the value of the output signal that corresponds to the minimum fluid level so that the value of the output signal taken as the second reading corresponds to the minimum fluid level; and

f) using the values of the output signal taken as the first and second reading to calculate new output signal values at which the pump will turn on and off.

3. The method of claim 2 comprising the additional steps of:

a) continuing to monitor the values of the output signal taken as the first and second reading so as to detect any further variations in the values of the output signal that correspond to the maximum and minimum fluid levels; and

b) adjusting the values of the output signal at which the pump will turn on and off in accordance with any variations detected in the values of the output signal that correspond to the maximum and minimum fluid levels.

4. The method of claim 3 wherein the step of continuing to monitor the values of the output signal taken as the first and second reading further comprises:

a) allowing the fluid level to periodically rise above the maximum fluid level at predetermined intervals.

5. The method of claim 4 further comprising the step of determining whether the pump is grinding debris so that when the pump is grinding debris, the pump may continue grinding the debris regardless of whether the value of the output signal is below the value at which the pump would otherwise turn off.

6. The method of claim 5 wherein the step of determining whether the pump is grinding debris further comprises:

a) monitoring the power draw of the pump.

7. The method of claim 1 wherein the variations in the values of the output signal that correspond to the maximum and minimum fluid levels occur as a result of solids becoming attached to the level sensor.

8. The method of claim 1 wherein the value of the output signal that corresponds to the maximum fluid level is a range of values.

9. The method of claim 1 wherein the value of the output signal that corresponds to the minimum fluid level is a range of values.

10. A method for adjusting pump operating parameters for at least one pump to accommodate solids encountered during a pumping operation, the method comprising the steps of:

a) providing a level sensor adapted to provide an output signal corresponding to a fluid level;

b) assigning a value of the output signal to correspond to a predetermined maximum fluid level;

c) assigning a value of the output signal to correspond to a predetermined minimum fluid level;

d) programming the pump to turn on when the output signal is at a certain predetermined value and off when the output signal is at another predetermined value, the predetermined values being less than the value that corresponds to the maximum fluid level and greater than the value that corresponds to the minimum fluid level;

e) monitoring the values of the output signal that correspond to the maximum and minimum fluid levels so as to periodically update the values at which the pump will turn on and off in accordance with variations that may occur in the values of the signal that correspond to the maximum and minimum fluid levels; and

f) determining whether the pump is grinding debris so that when the pump is grinding debris, the pump may continue grinding the debris regardless of whether the value of the signal is below the value at which the pump would otherwise turn off.

11. A method for adjusting pump operating parameters for at least one pump to accommodate solids encountered during a pumping operation, the method comprising the steps of:

a) providing a level sensor adapted to provide an output signal corresponding to a fluid level;

b) assigning a value of the output signal to correspond to a predetermined maximum fluid level;

c) assigning a value of the output signal to correspond to a predetermined minimum fluid level;

d) programming the pump to turn on when the output signal is at a certain predetermined value and off when the output signal is at another predetermined value, the predetermined values being less than the value that corresponds to the maximum fluid level and greater than the value that corresponds to the minimum fluid level;

e) taking a first reading of the value of the output signal generated by the level sensor in response to an alarm signal indicating that the level of fluid is above the maximum fluid level and that the pump has not begun pumping;

f) adjusting the value of the output signal that corresponds to the maximum fluid level so that the value of the output signal taken as the first reading now corresponds to the maximum fluid level;

g) reducing the level of fluid to below the minimum fluid level;

h) taking a second reading of the value of the output signal generated by the level sensor while the fluid level is below the minimum fluid level;

i) adjusting the value of the output signal that corresponds to the minimum fluid level so that the value of the output signal taken as the second reading now corresponds to the minimum fluid level; and

j) using the values of the output signal taken as the first and second reading to calculate new output signal values at which the pump will turn on and off.

12. The method of claim 11 further comprising the steps of:

a) continuing to monitor the values of the output signal taken as the first and second reading so as to detect any further variations in the values of the output signal that correspond to the maximum and minimum fluid levels; and

b) adjusting the values of the output signal at which the pump will turn on and off in accordance with any variations detected in the values of the output signal that correspond to the maximum and minimum fluid levels.

13. The method of claim 12 wherein the step of continuing to monitor the value of the output signal taken as the first reading further comprises:

a) allowing the fluid level to periodically rise above the maximum fluid level at predetermined intervals.

14. The method of claim 13 further comprising the steps of:

a) determining whether the pump is grinding debris so that when the pump is grinding debris, the pump may continue grinding the debris regardless of whether the value of the output signal is below the value at which the pump would otherwise turn off.

15. The method of claim 14 wherein the step of determining whether the pump is grinding debris further comprises:

a) monitoring the power draw of the pump.

16. A method for adjusting pump operating parameters for at least one pump to accommodate solids encountered during a pumping operation, the method comprising the steps of:

a) providing a level sensor adapted to provide an output signal corresponding to a fluid level;

b) assigning a value of the output signal to correspond to a predetermined maximum fluid level;

c) assigning a value of the output signal to correspond to a predetermined minimum fluid level;

d) programming the pump to turn on when the output signal is at a certain predetermined value and off when the output signal is at another predetermined value, the predetermined values being less than the value that corresponds to the maximum fluid level and greater than the value that corresponds to the minimum fluid level;

e) taking a first reading of the value of the output signal generated by the level sensor in response to an alarm signal indicating that the level of fluid is above the maximum fluid level and that the pump has not begun pumping;

f) adjusting the value of the output signal that corresponds to the maximum fluid level so that the value of the output signal taken as the first reading corresponds to the maximum fluid level;

g) reducing the level of fluid to below the minimum fluid level;

h) taking a second reading of the value of the output signal generated by the level sensor while the fluid level is below the minimum fluid level;

i) adjusting the value of the output signal that corresponds to the minimum fluid level so that the value of the output signal taken as the second reading corresponds to the minimum fluid level;

j) using the values of the output signal taken as the first and second reading to calculate new output signal values at which the pump will turn on and off;

k) continuing to monitor the values of the output signal taken as the first and second reading so as to detect any further variations in the values of the output signal that correspond to the maximum and minimum fluid levels;

l) adjusting the values of the output signal at which the pump will turn on and off in accordance with any variations detected in the values of the output signal that correspond to the maximum and minimum fluid levels; and

m) determining whether the pump is grinding debris so that when the pump is grinding debris, the pump may continue grinding the debris regardless of whether the value of the output signal is below the value at which the pump would otherwise turn off.

17. A pump control system wherein pump operating parameters of at least one pump may be adjusted to accommodate solids encountered during a pumping operation, the system comprising:

a) at least one pump;

b) a level sensor adapted to provide an output signal corresponding to a fluid level wherein a value of the output signal is predetermined to correspond to a predetermined maximum fluid level and a value of the output signal is predetermined to correspond to a predetermined minimum fluid level;

c) the system being adapted to cause the pump to turn on when the output signal is at a certain level and off when the output signal is at another predetermined value wherein the predetermined values are within the range of values that correspond to the minimum and maximum fluid levels;

d) at least one microprocessor adapted to monitor the output signal of the level sensor and periodically recalculate the values of the output signal at which the pump will turn on and off in accordance with variations that may occur in the values of the output signal that correspond to the maximum and minimum fluid levels; and

e) at least one microprocessor adapted to determine whether the pump is grinding debris so that when the pump is grinding debris, the pump may continue grinding the debris regardless of whether the value of the output signal is below the value at which the pump would otherwise turn off.

18. A method of adjusting pump operating parameters for at least one pump to accommodate solids encountered during a pumping operation, the method comprising the steps of:

a) providing a level sensor adapted to provide an output signal corresponding to a fluid level;

b) programming the pump to begin pumping when the level of fluid rises above a predetermined maximum fluid level and stop pumping when the level of fluid falls below a predetermined minimum fluid level by assigning a value of the output signal to correspond to the maximum fluid level and a value of the output signal to correspond to the minimum fluid level; and

c) monitoring the values of the output signal that correspond to the maximum and minimum fluid levels so as to periodically update the values of the output signal that correspond to the maximum and minimum fluid levels in accordance with variations that may occur in the values of the output signal that correspond to the maximum and minimum fluid levels.

19. The method of claim 18 further comprising the step of determining whether the pump is grinding debris so that when the pump is grinding debris, the pump may continue grinding the debris regardless of whether the value of the output signal is below the value at which the pump would otherwise stop pumping.