Abstract:
In accordance with some embodiments, a pumping station controller ( 14 ) is provided for monitoring pumping station hardware such as a well level sensor ( 8 ) and pumps ( 10   a   , . . . , 10   n ). A user interface ( 12 ) enables a user to input data to the controller ( 14 ) for controlling the operation of the pumps ( 10 ) based on the sensed liquid level. Pumping hardware configurations vary from site to site so that wiring the hardware to the controller may be confusing for the user. To address this problem the controller may comprise a software product ( 20 ). The software product may comprise instructions for processor ( 19 ) to determine a suitable wiring configuration between the controller ( 14 ) and the pumping station hardware, based upon user entered parameters identifying the pumping station hardware to be used.

Description:
TECHNICAL FIELD 
       [0001]    The present invention generally relates to the configuration of pumping stations. The present invention has particular, although not exclusive application to pumping stations for emptying sewage wells or for filling water wells. 
       BACKGROUND 
       [0002]    The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge. 
         [0003]    Pumping stations  2  for emptying sewage wells ( FIG. 1   a ) and filling water wells ( FIG. 1   b ) are known. These pumping stations  2  typically include a well  4  in which liquid  6  is located, a level sensor  8  for sensing the liquid level in the well  4 , a pair of pumps  10  for pumping liquid into or out of the well  4  as required, and a controller (not shown) in communication with sensor  8  for controlling the operation of the pumps  10  based on the sensed liquid level in the well  4 .  FIG. 1  shows various level trigger-points along the level sensor  8  in the form of electrodes. The controller independently activates or de-activates each pump  10  in response to it sensing the liquid level via the electrodes. 
         [0004]    The controller may take the form of a programmable logic controller (PLC) coupled to pumping station hardware (e.g. level sensors  8  and pumps  10 ). Since the hardware is prone to variation from station to station, it is often wired to the PLC in a different manner at each pumping station. The PLC can then be programmed to suit the particular hardware and wiring configuration. The variation of hardware configurations between respective pumping stations can complicate the reconfiguration of the pumping station hardware at a later stage, particularly in the event of documentation relating to the existing pumping station configuration being incomplete or misplaced. 
         [0005]    Embodiments of the present invention may provide a systematic method for facilitating coupling of a controller to associated pumping station hardware. 
       SUMMARY 
       [0006]    According to one embodiment of the present invention, there is provided a method for determining a coupling configuration between a pumping station controller and pumping station hardware, the method comprising:
       receiving in a processor at least one parameter relating to the pumping station hardware; and   determining, with the processor, a coupling configuration between the pumping station controller and the pumping station hardware using the at least one parameter.       
 
         [0009]    The method may further comprise coupling the pumping station controller to the pumping station hardware in accordance with the determined coupling configuration. The coupling may involve wiring input/output (I/O) ports of the controller to the hardware. 
         [0010]    The processor may define a database comprising a plurality of wiring diagram records, each wiring diagram record comprising:
       at least one unique record parameter relating to possible pumping station hardware; and   a wiring diagram identifier for identifying a wiring diagram comprising the coupling configuration between the pumping station controller and the possible pumping station hardware.       
 
         [0013]    The determining may comprise corresponding the at least one received parameter with the at least one record parameter and then displaying the wiring diagram identifier of the corresponding record. 
         [0014]    Prior to the receiving, the method may further involve inputting or selecting the at least one parameter using a user interface which is coupled to the processor. 
         [0015]    In one embodiment, the processor comprises the controller. 
         [0016]    The method may further comprise configuring one or more input/output (I/O) ports of the controller in accordance with the at least one parameter. The configuring the ports may comprise configuring a software interface linking control routines for controlling the hardware with the I/O ports. 
         [0017]    The hardware may comprise any one or more of the following devices: a pump, a variable speed drive pump, a digital liquid level sensor, an analogue liquid level sensor, a leakage sensor of the pump, a thermal sensor of the pump, a remote terminal unit (RTU), communications devices comprising a modem or a radio transceiver, and digital or analogue sensors comprising, for example, pulsed rain gauges and liquid flow rate sensors. 
         [0018]    The at least one parameter may comprise any one or more of the following group: the number of pumps of the pumping station, the type of liquid level sensor to be used in sensing the liquid level of the pumping station, and the type of leakage sensor of each pump. 
         [0019]    According to one embodiment of the present invention, there is provided a method for determining a coupling configuration between a pumping station controller and pumping station hardware, the method comprising:
       determining, with a processor, a coupling configuration between the pumping station controller and the pumping station hardware using at least one parameter relating to the pumping station hardware.       
 
         [0021]    According to a further embodiment of the present invention, there is provided a system for performing any one or more of the preceding methods. 
         [0022]    According to a further embodiment of the present invention, there is provided a computer usable medium, such as a magnetic or optical disk or solid state memory, containing computer readable instructions for execution by the processor to thereby perform any one or more of the preceding methods. 
         [0023]    According to a further embodiment of the present invention, there is provided the computational device arranged to perform any one or more of the preceding methods. 
         [0024]    According to a further embodiment of the invention there is provided a pump controller for monitoring pumping hardware of a well, comprising:
       a user interface having a display screen and user input keys;   a processor in communication with the user interface and in communication with ports for connection to the pumping hardware; and   a memory in communication with the processor;
 
wherein the memory contains a software product comprising:
   a control software block comprising control routines for monitoring and controlling the pumping hardware;   a configuration software block arranged to variably interface the control routines to the communication ports in response to user input parameters specifying the pumping hardware.       
 
         [0030]    The pump controller may comprise connection points corresponding to the communication ports for wiring to the pumping hardware, wherein the software product further comprises instructions to display information to assist a user to connect the hardware to connection points in response to the user input parameters. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0031]    Features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: 
           [0032]      FIG. 1   a  is a schematic diagram of a pumping station for emptying a sewage well; 
           [0033]      FIG. 1   b  is a schematic diagram of a pumping station for filling a water well; 
           [0034]      FIG. 2   a  is a block diagram of a pumping station in accordance with an embodiment of the present invention; 
           [0035]      FIG. 2   b  is a functional block diagram of a software product executed by a microprocessor of the pumping station of  FIG. 2   a;    
           [0036]      FIG. 3  is a schematic diagram of a database of the software product of  FIG. 2   b;    
           [0037]      FIG. 4  is a front view of a user interface of the pumping station of  FIG. 2   a;    
           [0038]      FIG. 5  is a flowchart of a method for determining a coupling configuration between a pumping station controller and pumping station hardware in accordance with the embodiment; 
           [0039]      FIG. 6   a  is a first possible wiring diagram for the pumping station of  FIG. 2   a ; and 
           [0040]      FIG. 6   b  is a second possible wiring diagram for the pumping station of  FIG. 2   a.    
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0041]    An embodiment of the present invention will now be described with reference to pumping station  2  as shown in  FIG. 2   a . The pumping station  2  includes a level sensor  8  for sensing the liquid level in a well, a pair of pumps  10   a ,  10   b  (e.g. variable speed drive (VFD) pumps) for pumping liquid into or out of the well as required, and a logic controller  14  for controlling the operation of the pumps  10  based on the sensed liquid level in the well. A user interface  12  is provided to enable a user to input data to the controller  14  and review controller data relating to the operation of the pumping station  2  on a display. The user interface  12  is fixedly wired to fixed input/output (I/O) ports  16  of the controller  14  which, in turn, are interfaced using suitable circuitry to a microprocessor  19  that executes a software product  20 . 
         [0042]    The level sensor  8  and pumps  10  are wired to variable I/O ports  18  of the controller  14  which, in turn, are interfaced using suitable circuitry to the microprocessor  19 . The wiring configuration between the variable I/O ports  18  and the hardware is prone to variation depending upon the type of hardware (e.g. level sensor  8 , pumps  10 , etc.) used in the pumping station  2 . The software product  20  includes instructions for processor  19  to perform a method for determining a suitable wiring configuration between the controller  14  and the pumping station hardware, based upon the pumping station hardware to be used. Software product  20  is typically provided as firmware in an integrated circuit memory device or as a magnetic or optical disc  21  which microprocessor  19  can access by means of disc drive  23 . 
         [0043]      FIG. 2   b  schematically depicts the functional software modules of the software product  20  including a control software block  22  for controlling the operation of the pumps  10 , and a configuration software block  28  for facilitating configuration of the coupling of the pump station hardware to the controller  14 , when setting up or reconfiguring the pumping station  2 . 
         [0044]    The control software block  22  includes a fixed set of control routines  24  which control the operation of the pumps  10  based upon feedback provided from the level sensor  8  or any other sensing devices. As the hardware and the wiring configuration of the hardware to the controller  14  is subject to variation from pumping station to pumping station, the control software block  22  includes a software interface block  26  which can be configured so that the control routines  24  are linked to the required I/O ports  18 . That is, the control routines  24  and variable I/O ports  18  remain static whereas the interface block  26  can be configured to suit the particular hardware wiring arrangement using the configuration software block  28 . 
         [0045]    The configuration software block  28  includes configuration routines  30  for configuring the interface block  26  as previously described. The configuration routines  30  further perform the method of determining a suitable wiring diagram to be used when coupling the controller  14  to the pumping station hardware, based upon one or more hardware parameters received from the user via the user interface  12 . The controller  14  accesses a database  32  which is utilized by the configuration routines  30  when determining a suitable wiring diagram. 
         [0046]    Turning to  FIG. 3 , the database  32  includes a plurality of wiring diagram records  28  (as depicted as a row of data). Each wiring diagram record  28  includes a unique combination of hardware parameters  38  each relating to possible pumping station hardware. The hardware parameters  38  may include the number of pumps of the pumping station  38   a , the type of liquid level sensor to be used in sensing the liquid level of the pumping station  38   b , and the type of leakage sensor of each pump (not shown). Each wiring diagram further includes a wiring diagram identifier  36  (e.g. WD A) which is indicative of a wiring diagram  40  ( FIG. 6 ) that shows a wiring configuration between the controller  14  and the possible pumping station hardware (e.g. level sensor  8 , pump  10 , etc.). 
         [0047]    Referring to  FIG. 4 , the user interface  12  includes a display  42  for displaying pump station data from the controller  14 , and a keypad  44  for a user to input data to be sent to the controller  14 . The user interface further includes a plurality of peripheral selection buttons  46  surrounding the display  42  by which the user can select displayed data to be sent to the controller  14 . The data displayed on the display  42  can change over time, and displayed data is selected by pressing the button  46  which is located in register with the data at the time. The user can initiate control functions including stopping and starting pumps, or resetting faults using the selection buttons  46 . 
         [0048]    The user can execute the configuration software  28  on the controller  14  when setting up a pump station  2 . The configuration software  28  includes instructions for the microprocessor  19 , and hence the controller  14 , to perform the pump station wiring configuration method  50  as described in detail below with reference to  FIG. 5 . An authorization procedure may be conducted using a username and password, before the user can initiate the method  50 . 
         [0049]    At element  52 , the user interface  14  receives user inputs or user selected criteria parameters. The criteria parameters relate to the hardware to be used when setting up the pumping station  2  and may include, for example, the number of pumps  10  of the pumping station (e.g. 2) and the type of liquid level sensor to be used in sensing the liquid level of the pumping station (e.g. digital). The user interface  14  sends the criteria parameters to the controller  14 . 
         [0050]    At element  54 , the controller  14  receives the criteria parameters relating to the pumping station hardware. 
         [0051]    At element  56 , the controller  14  determines a suitable wiring configuration between the controller  14  and the pumping station hardware using the received criteria parameters. The criteria parameters (e.g. number of pumps=2, liquid level sensor type=digital) which were input by the user are corresponded to record parameters  38   a ,  38   b  of the record  28   a  stored within the database  32  (and no other record). The wiring diagram  40   a  (see  FIG. 6   a ) which corresponds to the wiring diagram identifier  36  (i.e. WD A) of the record  28   a  is thereby decided upon as providing a suitable wiring configuration for coupling the controller  14  to the pumping station hardware to be used. 
         [0052]    At element  58 , the user interface  12  displays the wiring diagram identifier  36  of the record  28   a  on the display  42 . 
         [0053]    At element  60 , the configuration software  28  may configure one or more of the variable I/O ports  18  of the controller  14  in accordance with the criteria parameters (and the wiring diagram  40   a  decided upon in element  56 ). In this manner, the configuration software  28  can initialize variables (or constants) in the software interface block  26  so that like referenced variables in the control routines  24  are linked with the required variable I/O ports  18 . For example, if a digital level sensor  8   a  is to be used, the control routines  24  using input level sensor data would be linked with a digital I/O port  18   a  ( FIG. 6   a ). Alternatively, if an analog level sensor  8   a  is to be used, the control routines  24  using input level sensor data would instead be linked with an analog I/O port  18   b  ( FIG. 6   b ). 
         [0054]    At element  62 , the user refers to a manual of wiring diagrams and selects the wiring diagram  40   a  shown in  FIG. 6   a  which corresponds to the determined wiring diagram indicator  36  (e.g. WD A). The wiring diagram  40   a  shows the wiring connections required between the variable I/O ports  18  of the controller  14  and the hardware (i.e. pumps  10   a ,  10   b  and digital level sensor  18   a ) which meets the criteria parameters (e.g. number of pumps=2, liquid level sensor type=digital). 
         [0055]    At element  64 , the user wires the controller  14  to the pumping station hardware (e.g. pumps  10   a ,  10   b , level sensor  8   a , etc.) in accordance with the selected wiring diagram  40   a  shown in  FIG. 6   a . The hardware is thereby wired to the variable I/O ports  18  of the controller  14  as required. At element  66 , the display  42  of the user interface  12  displays a user interface screen. The user interface screen includes control options for controlling the mode of operation of each pump  10  (e.g. manual, off, auto), the number of pumps  38   a  of the record  28   a , the type of level sensor  38   b  of the record  28   a , and fault settings relating to pump seal faults and thermal faults for example. The user may select and toggle various control options using the selection buttons  46 . 
         [0056]    The foregoing method  50  of deciding upon a suitable wiring diagram using the criteria parameters provides a systematic and repeatable technique for facilitating coupling of the controller  14  to the pumping station hardware. Accordingly, any pumping stations  2  having the same hardware and associated criteria parameters will also have the same determined wiring diagram  40 , and will be wired in the same manner. This will enable users to readily reconfigure pumping stations  2  as they are familiar with the wiring configuration, and the wiring documentation is readily available in the form of a wiring diagram  40 . 
         [0057]    In addition, any upgrades or repairs to a pumping station involving the addition or replacement of hardware can be readily performed, by performing the method  50  and inputting the new hardware criteria parameters. Advantageously, the user need not have sophisticated programming skills to perform the method  50 , such as those skills required by users that set up PLC based systems. 
         [0058]    As previously mentioned, the software  20  would typically be provided on a media  21 , such as a magnetic or optical disk or solid state memory, which contains computer readable instructions for execution by the controller  14  to thereby perform the preceding method  50 . 
         [0059]    A person skilled in the art will appreciate that many embodiments and variations can be made without departing from the ambit of the present invention. 
         [0060]    In the configuration method  50  described in one embodiment, both the hardware wiring configuration and software interface configuration was performed at elements  64  and  60  respectively. In alternative embodiments, the software interface block  26  need not be configured as the software  20  can accommodate a number of different wiring configurations. 
         [0061]    In one embodiment, the configuration software  28  for deciding upon a suitable wiring diagram  40  was loaded on and executed using the controller  14 . In an alternative embodiment, the configuration software  28  can be loaded on and executed using a personal computer or other like processor which is separate from the controller  14 . 
         [0062]    In one embodiment, a plurality of criteria parameters relating to pumping station hardware was input by the user. In alternative embodiments a sole parameter may be inputted. In other embodiments, the hardware may include a leakage sensor of the pumps, a thermal sensor of the pumps or a remote terminal unit (RTU), and corresponding criteria parameters may also be inputted. Other criteria parameters which may be entered can include the number of wells in which pumps are located and the mode of discharge of the pumps (i.e. empty or fill the well). 
         [0063]    In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises illustrative forms of putting the invention into effect.