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, by that the control unit is adapted to allow the pumps power supply to pass through the control unit, by that an electronic controller is arranged in the pump for controlling at least one of the pump&#39;s functions and/or monitoring at least one of the pump&#39;s operating conditions, and by that 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.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a pump system, such as a submersible pump for example intended for pumping water. The present invention also relates to a pump and a separate control unit for use in the system. 
       BACKGROUND ART 
       [0002]    Pumps are normally controlled by a conventional control cabinet or panel located between the power supply and the pump. Such conventional control panels are designed to be manually set to supply power with a specific current, phase direction etc suitable for a specific pump. This is a problem as the operator has to careful do and monitor these settings every time a new pump is installed. If the settings are incorrect the pump will not work properly or may be damage. It is advantageous if the pump also could be automatic monitored with respect to different operations parameters such as temperature, overheating, low voltage etc. 
         [0003]    If for instance one phase is gone the pump may continue to pump, but will require more power/current and will get overheated by time. In order to monitor problems in the pump, for example overheating, the cables between the pump and the conventional control panel must be replaced with cables comprising additional electrical wires for the signal transmitting or separate signal cables have to be used for this purpose and connected between the pump and the control panel. Conventional control panels may also comprise a level sensing device for the water to be pumped and connected by a separate cable to the control panel. 
         [0004]    Different control panels have to be used depending on the power rating of the pump and it is not possible to use the same identical control panel for all pumps. The specific control panel is therefore often attached or stored adjacent to its respective pump. This makes the equipments complicated to handle for the user and there is a need for improvements in the systems with pumps and control panels. 
       SUMMARY OF THE INVENTION 
       [0005]    The object of the present invention is to provide a system for easy and flexible connection and controlling of a pump and where the above mentioned problems are solved or avoided. 
         [0006]    This object is achieved by the present invention in that the system comprises a pump including an electronic controller and where the system also comprises a separate electronic control unit, connected and located along the power cable to the pump, i.e. between the power supply and the pump. The control unit is moreover adapted to be detachably connected to the pump, and adapted to allow the drive current to the pump to pass through the control unit or allow galvanic connection to the pumps power supply at power connection point. The electronic controller arranged within the pump is adapted to control at least one of the pumps operating functions and/or monitoring at least one of the pumps operating conditions. The pump and the control unit are also arranged to communicate with each other and to transmit signals, carrying information, data and/or control commands necessary for the operation of the pump. 
         [0007]    The control unit is provided with at least one operating switch for controlling at least one function of the pump as well as provided with a display for indicating of at least one operating condition of the pump and arranged to send or receive data from the pump and for transmitting control commands to the pump. 
         [0008]    In addition, the object of the present invention is also achieved by a pump having an electrical motor and a mechanical pump wheel, comprising an inlet for incoming fluid and a discharge outlet for the outgoing fluid. An electronic controller is arranged in the pump for controlling at least one of the pumps functions and/or monitoring at least one of the pumps operating conditions. A Direct or Soft Starter Unit is arranged in the pump for starting the electrical motor to drive the pump wheel. 
         [0009]    According to the present invention and said above the system, the pump and the separate electronic control unit do not need to be switched in order to adapt to the power rating of the specific pump. The technical effect of this is that it is possible to use one and the same electronic control unit for all or most pumps, regardless of the power rating of the pump. The advantage of this is that it makes the pump and the electronic control unit considerable easier to handle. 
         [0010]    When using the electronic control unit according to the invention, a conventional control panel is not needed. 
         [0011]    Conventional control panels comprise all the software needed and the level sensing apparatus is connected separately to the control panel. According to the present invention some of the electronic logic and control functions are transferred from the control panel to the pump. The advantage of this is that the user does not need to make any software or level setting adjustments in a control panel. The pump and the control unit will pair automatically and the control unit will receive/transmit signals only to the paired pump. 
         [0012]    Other objectives, embodiments and advantages of the present invention are described in closer detail in the description below and in the subsequent drawings and patent claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The present invention will now be described in detail according to embodiments of the present invention with reference to the figures, wherein: 
           [0014]      FIG. 1  shows a conventional control panel connected to a pump according to prior art; 
           [0015]      FIG. 2  shows a system according to the present invention, including an electronic control unit connected along the power cable to a pump 
           [0016]      FIG. 3  shows an electronic control unit according to the present invention in more detail and where the design of the display and actuating means are illustrated enlarged; 
           [0017]      FIG. 4  shows the electronic control unit according to the present invention in an exploded view; 
           [0018]      FIG. 5  shows an alternative way to connect the system according to the invention directly to a power outlet; 
           [0019]      FIG. 6  shows a block diagram illustrating the electrical and electronic circuitry according to the invention; 
           [0020]      FIG. 7  shows a pump according to the invention, including an electronic controller; and 
           [0021]      FIG. 8  shows the electronic controller in the pump comprising all electronics necessary for operating the electrical motor to drive the pump wheel, such as for example starting equipment and/or electronics for monitoring at least one of the pumps operating conditions, 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    The present invention relates to a system for using and controlling a pump, such as a submersible pump, for example intended for pumping water. The present invention also relates to a pump and an electronic control unit for use in the system according to the invention. 
         [0023]      FIG. 1  shows prior art, a conventional pump system  1  including a pump  2  and its control equipment. The control equipment comprises a conventional control panel  3  connected to the pump  2  via an electrical power cable  4  and the control panel  3  includes all necessary electronics and electrical equipment for controlling the pump  2  such as starting equipment/electronics and electronics for monitoring the operating conditions of the pump  2 . The control panel  3  is in turn connected to a power supply (not shown). This type of control equipment must be manually and individually adjusted to the specifications for each new connected pump and be adapted to the size of the pump, i.e. to the pumps current consumption. Therefore the user/operator of the pump system has to make individual settings in the control panel/equipment each time a pump is connected. This is associated with several drawbacks such as it takes time to make appropriate settings, the operator/user needs to have knowledge of the settings as if the settings are done incorrectly the pump may be damaged or will operate ineffective. A water level sensor  5  can also be connected to the control panel  3  witch is shown in  FIG. 1 . 
         [0024]      FIG. 2  shows a pump system  6  according to the invention. An electronic control unit  7  is connected between a power supply outlet  8  and the pump  9 . The electronic control unit  7  has an elongated design with an electrical plug  10 ,  11  connector located in each end. The electronic control unit  7  is also equipped with an operating panel  12  including operating switches for manual operation and controlling of the pump as well as with a display with indicators for showing the current operating conditions of the pump  9 . The electronic control unit  7  is connected to the pump  9  by a three phase power cable  13  and connected to the power supply outlet  8  via a further three phase power cable  14 . It is possible to use the same electrical plugs and cables for many different pumps, regardless of the power consumption of the pump. 
         [0025]      FIG. 3  shows the electronic control unit  7  in more detail. The housing  15  of the electronic control unit  7  is a longitudinal extending body made of a plastic material such as PA6-6 (Polyamide also known as Nylon) and it also comprises the operating panel  12  with its indicating and actuating means. 
         [0026]    A first electric power connector (female)  10  is arranged in one end of the housing  15  and intended for electrical connection of a pump  9 , via a first three phase power cable  13 . A second electric power connector (male)  11  is attached to the housing  15  at its other end which is adapted for electrical connection to a power supply  8 . 
         [0027]    In the same figure, and to the lower left, the operating panel  12  with its indicating and actuating means is further enlarged to illustrate the individual indicating means and actuating means in more detail. The operating panel comprises light emitting diodes  16   a - c  that indicates alarms and warnings regarding the condition of the pump  9 . A first indicating means, a light emitting diode,  16   a  for example indicate if the pump needs service due to water in oil. Oil is present between the two mechanical seals that seals the motor shaft and could be leaking. The insulation of the pump  9  could also be a problem due to leaks of water into the electrical motor. The second indicating means or diode  16   b  indicates if the pump is cut out due to power failure, e.g, if a phase is missing or if the phases are largely unbalanced. The third indicating means or diode  16   c  indicates if the pump is cut out due to high temperature in the motor or in the strarter unit. An alarm or a warning is indicated by that the diode is flashing or lighting constantly. 
         [0028]    The user may also manually control the pump  9  by using the actuating means  17   a - c . The first actuating means  17   a  is used to stop the pump and the button lights up when the pump is stopped. The second actuating means  17   b  is used to put the pump in continues running mode, which is the standard start mode. The button lights up when the pump is running. The third actuating means  17   c  is pressed for Energy save mode and lights up when the Energy save mode is on. 
         [0029]    A ring of indicating means  16   d  shows the status of the pump, such as green light when the pump is running, red light when pump is stopped manually, flashing red light when the pump is stopped due to an alarm and blue light lights when the pump is working in the Energy save mode. 
         [0030]      FIG. 4  shows the electronic control unit  7  according to the present invention, in an exploded view. The electronic control unit  7  comprises a housing  15  having at one end area a first electric power connector (female)  10  arranged for electrical connection of a pump  9 , via a first three phase power cable  13 . A second electric power connector (male)  11  is attached to the housing  15  at its other end which is adapted for electrical connection to a power supply outlet  8  via a second three phase power cable  14 . The housing  15  comprises two shells  18   a,b,  that are demountable from each other. The housing  15  further comprises a recess  22  for an operating panel  12 , located on one side of the house  15 , including indicating and actuating means. Within the housing  15  three phase conductors  19   a - c  are arranged as well as a ground conductor  19   d  and a neutral conductor  19   e  running from the first connector  11  through the housing  15  to the second connector  10 , essentially in the longitudinal direction of the housing  15 . Two or more electrical conductors  20   a - c  are galvanically connected to the three phase conductors  19   a - c  at one end and at the other end connected to a circuit board  21  arranged within the housing  15 . The operating panel  12  is inserted and installed in the recess  22  in the housing  15 , such that the front of the operating panel  12  is facing the outer surrounding of the the housing  15 . The operating panel  12  and its indicating and actuating means are connected to the internal circuit board  21  so command signals could be generated in the circuit board  21  and transferred via the three phase power cable  13  to the pump  9 . The operation of the pump  9  could in this way be controlled and data/information from the pump  9  could be transferred back to the electronic control unit  7  and the operating conditions of the pump  9  may in this way be monitored and indicated to the operator via the indicating means, and controlled by activating the operating means. The circuit board  21  is supported within the housing  15  by supporting structures and sealed from the surroundings in order to be waterproof. 
         [0031]      FIG. 5  shows an alternative way to connect the pump  9  and the system  6  according to the invention to a power outlet  8 . In this case the control unit  7  is connected directly to the power outlet  8 , without a separate power cable between. 
         [0032]      FIG. 6  shows a block diagram illustrating the system  6  according to the invention. An electronic control unit  7  is connected between a power supply  8  and a pump  9  with its internal electronic equipment, such as an electronic controller  26 . The electronic control unit  7  includes the operating panel  12 , a MCU  23 , a PLC  24  and a filter  25  and is used for communication of signals to the power line cable. The electronic control unit  7  also comprises a number of indicating means  16   a - d , such as light emitting diods, that indicates flashing alarm warnings, high current or high motor temperature, phase failure or phase unbalance and warnings. Operating switches  17   a - c  are arranged for starting and stopping the pump  9  and for initiating an energy save mode etc. 
         [0033]    The MCU  23  in the control unit  7  controls all signals and information in the unit and the indicators and operating switches and sends/receives signals to and from the PLC  24 . The PLC  24  is connected to the power lines via a first filter  25 . All signals are transmitted via the power cable  13  to and from the pump  9  and the pump  9  includes in turn several functions and electronic internal units. 
         [0034]    The power cable  13  comprises in this case four cores  13   a - d , three phase wires  13   a - c  and one ground wire  13   d,  which are standard when using submersible pumps  9 . The length of the power cable  13  could typically be about 20 meter, but could of course be both shorter and longer. Power line communication will work with a cable length of up to at least 100 meter. The cable could be extended with standard extension cables (not shown). 
         [0035]    The signals transferred via the power cable  13  are received and detected in the pump  9  via the electronic controller  26  including an MCU  38  and a PLC  27  connected to a second filter  28 . In the pump  9  also several sensors  29   a - f  are arranged that detects the motors  30  temperature and moisture as well as the temperature in the different windings of the motor  30  etc. A sensor  29   f  is also arranged for detecting water in oil. Optional is a level sensor  31  connected to the MCU  38  for the external water level. The MCU  38  constantly or regularly measures the current in each phase of the motor  30  as well as the voltage in each phase. The MCU  38  controls a direct or soft starter unit  32  arranged to start the pump motor  30  in a correct manner when receiving a start signal from the MCU  38 . The motor  30  is connected to a pump wheel  33 . 
         [0036]      FIG. 7  shows a pump  9  according to the invention where the interior is partly exposed. Inside the top cap  34  of the pump  9  the electronic controller  26  is arranged comprising the electronics necessary for operating the electrical motor  30  to drive the pump  9 , such as for example a starting equipment and/or electronics for monitoring at least one of the pumps operating conditions. The power cable  13  is connected to this electronic controller  26  and all transferred signals are received and transmitted via this power cable  13 . 
         [0037]      FIG. 8  shows the electronic controller  26  in more detail as well as the incoming power cable  13  as well as the cable  35  for transferring current to the motor  30 . 
         [0038]    Reference signs mentioned in the claims should not be seen as limiting the extent of the matter protected by the claims, and their sole function is to make claims easier to understand. And as will be realised, the invention is capable of modification in various obvious respects, all without departing from the scope of the appended claims. Accordingly, the drawings and the description thereto are to be regarded as illustrative in nature, and not restrictive.