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WO2018160175A1 - Système de moteur et de pompe - Google Patents

Système de moteur et de pompe Download PDF

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Publication number
WO2018160175A1
WO2018160175A1 PCT/US2017/020203 US2017020203W WO2018160175A1 WO 2018160175 A1 WO2018160175 A1 WO 2018160175A1 US 2017020203 W US2017020203 W US 2017020203W WO 2018160175 A1 WO2018160175 A1 WO 2018160175A1
Authority
WO
WIPO (PCT)
Prior art keywords
fluid
motor
controller
back electromotive
electromotive force
Prior art date
Application number
PCT/US2017/020203
Other languages
English (en)
Inventor
Fernando A. Ubidia
Original Assignee
Ubidia Fernando A
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ubidia Fernando A filed Critical Ubidia Fernando A
Priority to PCT/US2017/020203 priority Critical patent/WO2018160175A1/fr
Publication of WO2018160175A1 publication Critical patent/WO2018160175A1/fr

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06—Control using electricity
    • F04B49/065—Control using electricity and making use of computers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B17/00—Pumps characterised by combination with, or adaptation to, specific driving engines or motors
    • F04B17/03—Pumps characterised by combination with, or adaptation to, specific driving engines or motors driven by electric motors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2201/00—Pump parameters
    • F04B2201/12—Parameters of driving or driven means
    • F04B2201/1201—Rotational speed of the axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2203/00—Motor parameters
    • F04B2203/02—Motor parameters of rotating electric motors
    • F04B2203/0202—Voltage

Definitions

  • the technology described herein generally relates to a motors and pump system, as well as the control of systems employing them, such as fluid dispensing systems.
  • One type of fluid dispensing system includes, but is not limited to, a beverage dispensing system.
  • Such systems use a number of electrical and mechanical components to dispense fluids.
  • the system pumps both a base liquid (such as carbonated water) and one or more products (such as flavored soda syrups) and combines them to create the desired soda.
  • the process requires that the carbonated water and syrup each be pumped at precise flowrates in order to properly mix the ingredients and create the desired flavor profile for the soda.
  • One standard beverage dispensing unit uses a fluid pump (a "bag-in- box” or “BIB” pump) during operation.
  • a fluid pump a "bag-in- box” or “BIB” pump
  • the BIB pumps used on standard beverage dispensers are either gas driven, such as by CO2, or electrically powered, but they lack accurate flow control.
  • BIB pumps operate such that they are either under full power or are off. They do not modulate their flowrates.
  • the dispensing systems use the BIB pump to flow fluid, such as a product, from a storage container, such as a bag-in-box or other package, through a tube and dispensing valve and out through a dispensing nozzle.
  • Current beverage dispensing units rely on mechanical flow control devices external to the pumps to control or regulate flow.
  • the dispensing valve may include flow control devices for each product and a solenoid valve.
  • Flow control devices are complex and expensive. They require a number of components, such as, pistons, sleeves, springs, and adjustment screws to operate.
  • Gas driven or electrically powered BIB pumps operate under constant pressure and require pressure switches to operate. Changes of pressure within the system activate the pumps, but the flowrate is not metered by the pumps.
  • Standard beverage dispensing systems use dispensing apparatuses typically comprised of an electromechanical solenoid valve and a mechanical flow control device comprised of a piston, cylinder, spring and adjustment screw. Each product dispensed from the apparatus has one of these mechanical flow controls.
  • the combination of these components and the apparatus is commonly referred to as the dispensing valve.
  • the standard dispensing valve may provide acceptably precise product flow after a technician performs an initial setup calibration.
  • the mechanical flow control cannot compensate for changes in the dispensing system which may affect flow.
  • the flow precision of the standard dispensing valve will decrease, or the nominal flow rate will drift.
  • the technician typically returns to recalibrate the dispensing valve once or twice a year, but during the intervening period the flow precision and beverage quality will decrease.
  • gas driven BIB pumps have a gas coupling regulated with a mechanical pressure regulator set to a specific gas pressure, typically 50-60 psig, and they include a pressure switch.
  • Electrically powered BIB pumps are driven at their rated voltage, typically 12VDC or 120V AC, and they also include a pressure switch. Both are demand based pumps that operate based on pressure differential. That is, once a sufficient pressure differential develops downstream due to the standard dispensing valve's solenoid valve opening, the pump will begin flowing product. The pump will continue flowing product while the pressure differential is sustained.
  • BIB racks typically have different BIB set at different vertical heights, for example the top BIB can be 5 to 6 feet above the lowest BIB in the rack.
  • the difference in head height of the product with respect to the dispense point affects the pressure of the product in the line and the amount of vacuum required to flow the product at a specific flow rate.
  • line length, line diameter, and product density are also affect pressure drop and flowrate.
  • Standard BIB pumps have no feedback for flow control. They run open loop and have no means to automatically adjust flow their flow rate as any of the aforementioned variables affecting flow change. Standard BIB pumps are specifically designed to operate within a limited flow range, but they are not designed for precision flow. The flow control device within the standard dispensing valve is relied upon to provide flow control of the product, while the standard BIB pump is designed to provide bulk flow. The standard BIB pump and the standard dispensing valve flow control do not perform well when running outside of the limited, design flow range. [013] Standard BIB pump systems do not include a device to specifically detect a sold out condition.
  • the only evidence that a sold out condition has occurred is when a person operating the dispensing unit views a disruption in the flow of product from the dispensing unit, or through the lower quality taste of the beverage dispensed.
  • changeover valves operate using a vacuum switch, typically detecting between 10-20 in. Hg. However, these devices are not sensitive to small pressure changes. By the time the changeover valve switches the BIB connection, a substantial amount of product has been evacuated from the line, being replaced with air. The evacuation of
  • the actual amount of product dispensed deviates from the target volume.
  • 10 or more product dispenses may deviate from the specified volume by an order of 20-25% of the target volume before the changeover valve switches the BIB. This level of deviation will affect the quality of
  • the dispensed beverage (the acceptable level of deviation is 5% of the target volume).
  • Standard BIB pumps do not provide precise flowrates, and additional flow control devices are required to control preset flowrates. Standard flow devices are expensive, complex and difficult to adjust. Because they lack accurate flow
  • the present system provides precise closed-loop flow control.
  • the present system provides several benefits
  • control system replaces the standard dispensing valve equipment for products and provide a system having fewer mechanical components and at a lower component cost. While the present system may be utilized in a beverage dispensing system, such as a BIB system, it should be understood that the
  • present system is not limited to such applications. Rather, one of ordinary skill in the art will understand that the present system may be adapted to various applications where control of fluid flow is required.
  • the present system provides closed loop flow control to provide self
  • a fluid component i.e. a product
  • BEMF Back Electro-Motive Force
  • the BEMF provides an indication of the operation of the motor.
  • the BEMF can be interpreted as providing an indication of the flowrate of fluid through the pump that is operated by the motor. Monitoring the BEMF and controlling the actual operation of the motor can therefore be used to indirectly monitor and control the fluid flow through the pump.
  • the control system is used to measure BEMF and modulate the pulse width of the voltage applied to the motor (hereinafter referred to as the "PWM voltage” or simply “PWM”) to maintain consistent pump flow.
  • PWM voltage pulse width of the voltage applied to the motor
  • the need for flow control devices and solenoid control valves is eliminated.
  • Additional parameters can also be accounted for. For example, as the product in the BIB is depleted, the pump must work harder to pump the same amount of product. The relationship between the depletion and the operation of the pump is known. The BEMF of the pump will change due to the depletion of the fluid, but that change may be corrected and accounted for in order to maintain constant and accurate
  • FIG. 1 is a generic depiction of a motor rotationally coupled to pump by a shaft.
  • FIG. 2 is a depiction of graph illustrating BEMF relationship to RPM
  • FIG. 3 is a depiction of an exemplary measurement (e.g. oscilloscope graph) of PWM signal and BEMF signal.
  • FIG. 4 is a depiction of block diagram of a control system.
  • FIG. 5 is a depiction of block diagram of a network connection of
  • FIG. 6 is a depiction of block diagram of a simplified control system operation in conjunction with a beverage dispensing unit and associated pump.
  • FIG. 7 is an exemplary graph depicting the difference in BEMF at differing temperatures that correspond to the same flow rate.
  • FIG. 8 is a flowchart depiction of an example measurement
  • FIG. 9A is a depiction of a BIB product container showing a full bag.
  • FIG. 9B is a depiction of a BIB product container showing depleted bag. 180 [032]
  • FIG. 10 is a graphic depiction of the relationship between of flow rate,
  • FIG. 11 is a graphic depiction of the operation of the fluid dispensing system showing the relationship between the fluid dispensed (dose) the applied 185 voltage (volt) and the BEMF of the system (BEMF) over a number of dosing cycles.
  • FIG. 12A is a depiction of an embodiment of a beverage dispensing unit.
  • FIG. 12B is a depiction of an internal view of a beverage dispensing unit.
  • FIG. 12C is a depiction of a keypad of a beverage dispensing system.
  • FIG. 13 is a depiction of an alternate embodiment of a beverage dispensing system including a beverage dispensing unit and rack of associated BIB containers.
  • FIG. 14A is a depiction of an alternate embodiment of a beverage
  • dispensing system including a beverage dispensing unit and rack of associated BIB containers.
  • FIG. 14B is a depiction of a control system and pump array for operating an embodiment of a beverage dispensing system.
  • Figure 1 is a generic depiction of a motor and pump assembly 100. It includes a motor 101 connected to a pump 102 by a shaft 103. The motor includes
  • a PWM voltage 106 is applied to the motor across connections 104 and 105 causing the motor 101 to rotate shaft 103.
  • the application of PWM 106 also causes the motor to generate BEMF 107.
  • Pump 102 includes a fluid inlet 108 and a fluid outlet 109. Activation of pump 102 causes the inflow of fluid 110 into the
  • the fluid pump 102 is a positive displacement type pump, and its RPM is proportional to the fluid flowrate of the pump.
  • the motor 101 and the pump 102 are coupled together such that the rotation of the motor's shaft rotates the shaft of the pump thereby creating negative
  • the pump such that the shafts of the motor and the pump rotate at different RPMs, though still remain proportional to one another.
  • the flowrate of fluid through the pump is determined by measuring motor BEMF voltage.
  • the motor and pump in addition to inducing fluid flow through the system, effectively function as a flow meter.
  • Specific examples of pumps that could be used are the pumps
  • Figure 2 is a graph 200 showing the relationship of the BEMF, the
  • the BEMF scale 201 is
  • BEMF is the voltage generated by the motor as the motor windings rotate relative to a magnetic field.
  • the control system applies PWM to the motor to power the motor.
  • Figure 3 is a graph 300 depicting the PWM and BEMF signals as measured by an oscilloscope monitoring the electrical operation of the motor. The graph depicts three PWM periods. The voltage signal of the system actually shows
  • the PWM voltage 301 the negative voltage spike 302 caused by the motor's inductance
  • the BEMF 303 generated by the motor.
  • the ON segment 304 during which the voltage signal 301 is applied (i.e. the power supply voltage)
  • the OFF segment 305 during which the voltage signal is off (i.e. ground).
  • BEMF is generated by the motor anytime there is relative
  • the ON segment of the PWM signal and negative voltage spike mask the BEMF signal. It is after these two events pass that the BEMF signal 303 is visible. It is during the OFF time 305 of the PWM period that BEMF signal 303 is optimally measured by the control system. Preferably, the measurement of the BEMF signal (shown as 306 for exemplary
  • the ratio of the ON time 304 to the OFF time 305 is referred to as the
  • PWM duty cycle and may be expressed as a percentage (PWM duty cycle
  • the PWM average voltage is the power source voltage multiplied by the PWM duty cycle percentage. By varying the PWM duty cycle, the PWM average voltage may be adjusted to change the voltage powering the motor without actually changing the base power source voltage.
  • BEMF voltage may be correlated to specific speeds of the motor.
  • Those BEMF voltage values may be stored in the memory of a computer control system. It should be understood by those of ordinary skill that storing the BEMF voltage values, or other values, in the memory may simply be storing a representation of the BEMF values, or
  • the control system measures the BEMF voltage, compares it to a stored target value BEMF voltage, and the control system either increases or decreases the PWM average voltage (preferably by adjusting the PWM duty cycle) as needed in order to match the BEMF voltage
  • the control system increases the PWM voltage to raise the motor BEMF voltage back to the target value BEMF voltage. That increases the flowrate back to the desired value. Conversely, as the motor RPM and pump flowrate
  • control system decreases the PWM voltage to lower the motor BEMF voltage back to the target value BEMF voltage. That will decrease the flowrate back to the target value BEMF voltage.
  • Figure 4 is an example of one embodiment of a system that may be a beverage dispensing system 400 that utilizes the described BEMF control for
  • the system includes a controller 401.
  • the controller 401 is a printed circuit board that includes motor connections 402, 403, 404, 405 that connect to motors 406, 407, 408, 409 respectively. It should be appreciated that the components of the controller could be discrete and separate or integrated.
  • the motors are discrete and separate or integrated.
  • wire 410 is connected by electrical conductors, such as wires.
  • electrical conductors such as wires.
  • wire 410 electrical conductors
  • the controller 401 also includes a microprocessor 412, memory 295 413, an analog to digital converter 414 and PWM driver 415 along with an I/O
  • connection array 416
  • the microprocessor uses information regarding the PWM voltage and the BEMF for each motor to control each motor.
  • the BEMF voltage is fed to the analog to digital converter 414 that acts as a sensor and
  • microprocessor 412 in the control of the motor. Additional sensors could also be used to sense the PWM voltage being applied to each respective motor and to sense and measure the BEMF of each respective motor and then transmit that information to the microprocessor.
  • a power supply 417 provides power to the system and can be used
  • memory 413 is a programmable memory that stores target BEMF values 406a, 407a, 408a, 409a (which correspond to target values for motors 406, 407, 408, 409 respectively) and other variables such as sold-out threshold values (not shown).
  • the PWM driver 415 may produce the PWM voltage signals to power the motors.
  • the I/O connections may include of a combination of digital and analog outputs, digital and analog inputs, and communication interfaces such as RS-232 or RS-485 connections.
  • External systems may be connected to the controller through the I/O connection array, systems such as an input device 418 (which may have one or more 315 inputs, such as buttons 418a, 418b, 418c, 418d), beverage dispensing unit 419,
  • LEDs 421, and additional systems 422 all of which may be separate from one another as depicted in Figure 4, included together within a single housing, integrated together, or a combination thereof.
  • the controller may control one or more motor connections such that a
  • the controller may power several motors individually, or several motors simultaneously so that, as particular needs arise, the control system may cause individual pumps to flow products one at a time or may cause several pumps to flow several products at the same time.
  • the controller may include several network address variables 325 assignable in its memory, and its I/O connections may be compatible with network communication protocols such as RS-485 and Ethernet so that several controllers may be networked together and execute commands independently or in tandem from a single input source such a keypad or beverage dispensing unit.
  • network communication protocols such as RS-485 and Ethernet
  • control system memory may have an assignable master/slave variable defining its network hierarchy so that several slave control systems may be operated by a single master control system.
  • An example network application of the control system is a beverage dispensing unit with a master assigned control system issuing dispense commands to several slave control systems at
  • Figure 5 is a depiction of an embodiment where multiple control systems may be networked together. That embodiment includes four control systems, each of which include a controller like that of controller 401 depicted in Figure 4.
  • a 340 master controller 501 is connected to beverage dispensing unit 419 as well as a
  • Slave control systems 503a, 503b, and 503c are each connected to a plurality of motors 504a, 504b, and 504c, respectively.
  • the slave control systems are connected to each other and to the master control system to form a network.
  • Figure 6 is a simplified schematic depiction of the pumping
  • the system includes the motor and pump assembly 100 which is made up of the motor 101 and pump 102.
  • the pump 102 includes an inlet 108 on the suction side which is coupled through a line 601 (such as a tube or hose) to a fluid source 602 (which may contain,
  • the pump 102 also includes an outlet 109 on the discharge side which is coupled through a line 610 to a dispensing point 611 such as a nozzle on a beverage dispensing unit.
  • a backflow prevention device 612 such as a check valve, is placed on the discharge side of the pump.
  • vacuum is generated within the suction line 601.
  • Backfiow prevention device 612 resists the vacuum in the suction line 601 and does not allow product to flow in reverse. The backfiow
  • 360 prevention device creates a restriction in the system due to the dynamic flow losses through the backflow prevention device or because of the pressure required to open the backfiow prevention device to allow fluid to flow through the device - known as cracking pressure - or both.
  • the restriction may also smooth out the small flow oscillations created by the reciprocal action of the pump 102, resulting in increased
  • the control system is programmed so that each particular product dispensed by the beverage dispensing unit has a target BEMF voltage value.
  • the target BEMF voltage value is programmed and stored in the control system's memory.
  • the target BEMF voltage is based on the correlated flowrate for the particular BEMF value for each particular product, and a different target BEMF may be programmed for each product.
  • the differences in flowrates and target BEMF are generally due to the nature of the product and required output of the dispensing system in order to provide a properly mixed beverage. For example, cola beverage syrup may have a
  • FIG 8 is a simplification of Figure 4 showing only select components for explanatory purposes including a flowchart depicting the operation of an embodiment of the control system.
  • the control system when the control system receives an instruction to dispense a product, the control system provides power to the respective motor, takes 385 BEMF measurements, compares the BEMF measurements to the programmed target BEMF for the product, and adjusts the PWM voltage as needed to match the BEMF generated by the motor to the target BEMF.
  • the overall process can be considered a combination of the BEMF measurement process 801 and the Adjust Voltage process 802. 390 [056]
  • An example of the process is as follows:
  • a selection of input 418b is made resulting in a selection signal 423 being sent to the controller 401 through the I/O connection array 416 which relays the selection signal to the microprocessor 412;
  • the microprocessor 412 instructs the PWM driver 415 to supply an 395 initial PWM voltage to the motor 407 (for example a 5 volt pulse is provided at a PWM period of 10 milliseconds (100 Hz PWM frequency), an example of which is shown in Figure 3.
  • the ADC 414 samples the BEMF 107 at 400 step 810.
  • An example sampling scheme is the control system taking 5 samples at 2 microseconds apart (8 microsecond sampling period). Preferably, the sampling starts at the center of the PWM OFF segment (See, Fig. 3, sample 306). More or less samples could be taken.
  • the instantaneous BEMF samples are averaged at 811 to create a 405 representative BEMF for the period [bemf_period]. Averaging the sample values result in a more accurate measurement of the BEMF voltage.
  • the BEMF average is processed by low pass filtering (LPF) at step 812 to separate and discard electrical noise from the BEMF average signal and to produce [bernf running] .
  • LPF low pass filtering
  • the control system updates the running parameters of the system with the new [bernf running] at step 813.
  • the PWM voltage supplied to the motor is updated, for example, every 1.5 seconds after it has started running.
  • the system modifies the PWM voltage by continuing the process.
  • a theoretical voltage is calculated [V_theoretical] by dividing the programmed target BEMF 407a [bemf target] by [bernf running] and multiplying it by the present motor voltage [V run] at step 820. It should be understood that the "present" voltage is the voltage that is applied to the motor when the BEMF measurement is made.
  • a new motor voltage is calculated [V newrun] by adding an adjustment percentage of [V adjust] to [V run] at step 822.
  • the adjustment percentage is tuned to provide enough of a response in flowrate without
  • the PWM driver is updated to use the new voltage [V_newrun] at step 823 thereby causing an adjustment to the motor voltage.
  • the updating process occurs by converting the [V_newrun] into a value corresponding to
  • V_newrun As discussed previously, adjusting the duty cycle adjusts the average voltage while allowing the base input voltage to remain constant. In the preferred embodiment, to update the PWM voltage all that is required is an adjustment to the duty cycle.
  • an optimal range for a source voltage is one that provides a PWM duty cycle that is in 450 the 20% - 40% duty cycle range.
  • the particular source voltage value is specific to each application and its respective motors' electrical characteristics.
  • the system can be utilized to pump a different product with each motor and pump assembly.
  • different beverage products may have different viscosities, and the amount of product required per ounce of carbonated
  • the correlated values of flowrate and target BEMF for different products are determined empirically by using the control system to dispense each product and measuring its BEMF and flowrate relation. Due to the precise flowrate control of the control system, the nominal target BEMF values of the products are determined using the
  • the BEMF measurements are provided from the control system measurements, and true volumetric measurements of the products are validated using a volumetric or weight measurement such as a graduated cylinder or scale respectively. This measurement is repeated several times until an appropriate degree of statistical significance to the flowrate and BEMF relation is established.
  • Variations in temperature and viscosity in fluid can alter the operating characteristics of the system. Those variables can be tested and empirical data for how different fluids operate in the system can be ascertained though the tests. One or more additional control parameters accounting for the variations of individual fluids can then be determined from that data and those control parameters may further be
  • the new control parameters may be used to alter the percentage of the duty cycle used to adjust the PWM and so that the control system can more accurately and quickly bring the actual BEMF in line with the target BEMF in order to maintain a constant desired flowrate.
  • FIG. 9A shows a BIB box 900 having a BIB bag 901 filled with a beverage product 902.
  • the BIB bag also contains air pockets 903.
  • a tube 904 connects the BIB bag 901 to a dispensing system (not shown) and allows 480 product to flow out of the BIB bag.
  • the BIB bag collapses and eventually the product will become depleted to the point where insufficient fluid flows. Additionally, a fluid line may become blocked or another anomaly may occur resulting in insufficient fluid flow.
  • Figure 9B shows the BIB box 900 with the collapsed BIB bag 901 and depleted product 902.
  • the tube 904 contains some
  • the present system can reliably provide adequate fluid flow to that point and during the evacuation process detect anomalies and indicate that the product is sold out or flow has stopped.
  • a BEMF of 800 mV -/+ 5% may be expected for normal
  • standard BIB product containers include a small amount of air 903 within the bag 901. When product is depleted, this air will enter the product line, and there will be a sudden drop in vacuum required for the pump to flow product through the line. The drop in required vacuum will cause the pump and motor to speed up, and an abrupt
  • This change for example a 20% increase in BEMF, is stored in the controller as a sold out threshold value and used by the control system to generate an output to indicate a sold out condition (such as an instruction to light an LED or display a message on a display).
  • the sold out threshold can be set to different values for different products, as well as different
  • FIG. 10 depicts three representative graphs, flowrate graph 1001, BEMF graph 1002, and PWM Voltage graph 1003.
  • the graphs show the 510 relationship between the flowrate, motor BEMF, and PWM voltage applied to the motor over time as fluid is pumped.
  • the flowrate 1004 and motor BEMF 1005 remain relatively constant.
  • the PWM voltage 1006 steadily increases. The increase is due to the operation described with relation to Figure 8. The increase in PWM is necessary because the pump must work harder to
  • the control system responds by first decreasing the PWM voltage (1006a) in an attempt to compensate for the rise in BEMF.
  • the detection may be based on a target value BEMF for indicating a sold out condition that may be a preset BEMF value, a total change in BEMF value, a percentage change in BEMF value or other BEMF value indicator.
  • lowering the PWM does not produce the expected decrease in BEMF, leading the control system detects a sold out condition and reacts by suspending power to the pump.
  • the system may be calibrated such that it may detect a rise in BEMF, decrease the PWM applied in the next voltage pulse, detect a further rise in BEMF in the next consecutive sample, and decrease the
  • the system samples the BEMF again and if the BEMF has risen further the system identifies that as an unexpected rise in BEMF over time and then immediately stops applying power to the motor.
  • the system includes a threshold change in BEMF
  • 535 value for example, a 20% change in BEMF.
  • the system shuts off the power to the motor.
  • Figure 11 is a depiction of empirical measurements of the system during operation. It includes a flowrate graph 1101 showing flowrate 1104, a motor 540 BEMF graph 1102 showing BEMF signal 1105, and a PWM graph 1103 showing PWM signal 1106.
  • the system ran for 159 cycles (starting at cycle 1, 1107, and ending at cycle 159, 1108). Each data point has dispense duration ("Pour") of 2.50 seconds, and the each dispense was performed 30.0 seconds apart (“Cycle").
  • the BEMF signal 1105 received from the motor fluctuated between 971 545 mV (1109) to 990 mV (1110) during the 159 cycles.
  • the target BEMF for the cycles was set at 980 mV, and the system was able to maintain an average BEMF of 982.4 mV (1112), only slightly off from the target value.
  • the flowrate 1104 was held within a range of 8.917 grams (1113) and 9.135 grams (1114) thereby providing an average dose of 9.042 grams of product (1115) over the 159 cycles.
  • the PMW voltage 1106 escalated from approximately 4.02 volts (1116) to 4.14 volts (1117). Through controlling the PWM voltage as described above, the PWM voltage 1106 is slowly increased while the motor BEMF 1105 and flowrate 1104 are maintained relatively constant.
  • control system may also utilize BEMF measurements to execute
  • 555 pump priming functions Whenever the product supply is depleted on a beverage dispensing unit, some amount of air will enter the lines.
  • the pump will need to be primed whenever a new product supply is connected to it in order to fill the lines and pump with product and bleed any air out from the lines.
  • the prime function will power the pump, and the control system will monitor the BEMF during the prime 560 function. Similar to the sold out condition, the air in the line will increase the pump RPM and in turn the BEMF measured by the control system until the line and pump fill with product. Once the line and pump have been filled, the pump RPM will return to normal operating range, the control system will measure BEMF within the target range, and the control system will end the prime function.
  • the motor BEMF is used for detecting other abnormal conditions.
  • a condition can be programmed in the control system that the target BEMF should be reached within a set amount of time when initially priming the pump. For example, the target BEMF should be reached in 6 seconds. If the target BEMF is not reached within this time, it is indicative that the product container
  • 580 blockage is as follows: a BEMF threshold value is programmed into the control
  • control system memory for example 300 mV; if the control system measures a BEMF 300 mV or less, the control system determines that a blocked condition is present.
  • a PWM voltage threshold is programmed into the control system memory, for example 4 V; if the
  • control system has increased the PWM voltage to 4 V without an increase in BEMF, the control system determines that a blocked line condition is present.
  • control system uses BEMF measurements to detect if the motor has failed or is disconnected from the control system. If the control system measures no BEMF or a BEMF value lower than the expected magnitude of electrical 590 noise, the control system determines that a failed motor condition is preset.
  • control system is programmed through a user interface connected to the control system I/O such as a keypad or touchscreen interface, or through an external device connected to the I/O such as a PC 595 or laptop.
  • the target BEMF for the products is one variable.
  • one product may require a flowrate of 3.0 mL per second and have a corresponding target BEMF value of 750 mV.
  • Another example is a different product requiring a flowrate of 3.3 mL per 600 second and having a corresponding target BEMF of 850 mV.
  • the BEMF values programmed into the control system are then called upon during the adjustment voltage calculations in order to maintain consistent pump flowrate.
  • the control system may be incorporated into a beverage dispenser 1200.
  • the beverage dispenser 1200 includes a housing 1201 that may be mounted to a surface 1202.
  • the dispenser includes a keypad 1203.
  • the keypad may be a physical
  • the keypad 1203 may include a plurality beverage selection keys 1204a, 1204b, 1204c, 1204d, 1204e, and 1204f, each corresponding to a different beverage, as well as beverage volume keys 1205a, 1205b, and 1205c.
  • the keys may also be
  • the dispenser also includes at least one dispensing point, such as nozzle 1207 for dispensing beverages.
  • the housing may house a plurality of motor and pumps 100. Each pump may be connected to a product BIB (not shown) by a supply line 1208 and connected to the nozzle 1207 by output line 1209. It should be appreciated that all the components of a product BIB (not shown) by a supply line 1208 and connected to the nozzle 1207 by output line 1209. It should be appreciated that all the components of a product BIB (not shown) by a supply line 1208 and connected to the nozzle 1207 by output line 1209. It should be appreciated that all the
  • 620 pumps may include such lines, but that not all lines are shown in Fig. 12B for
  • the housing may also house the controller 401 and a power supply 417 may be provided internally or externally.
  • the motor and pumps 100 are electrically connected to the controller, for example, by wires 1210, and the controller is electrically connected to the power supply, for example, by wires 1211.
  • keypad 1203 is electrically connected to the controller as well, for example, by ribbon cable 1212.
  • the control system can be configured for either momentary dispensing or portion control dispensing modes.
  • the control system powers the motor to dispense product for as long as a dispense 630 command is received by the control system; once the dispense command is stopped, the control system removes power from the motor. For example, a user may depress key 1204a for a period of time thereby causing the controller to dispense the corresponding beverage for that time.
  • One method of portion control dispensing is accomplished using a time
  • the dispense size specified is a time value.
  • a user may press volume key 1205a for a small beverage and then select the particular type of beverage by pressing key 1204b (or vice versa). Pressing the second selection initiates a dispense command, and the control system powers the motor and continues to supply 640 power to the motor for the duration of a preset time value associated with the selected volume.
  • Another method of portion control dispensing is achieved by dispensing a total volume (or mass) of product.
  • the keys are configured to allow the operator to specify an arbitrary total amount of product.
  • keypad includes an increase amount key, such as an up arrow icon, and a decrease amount key, such as a down arrow icon, and the present amount to be dispensed is shown on a display.
  • Another configuration of the keypad includes numerical keys so that the desired amount may be entered as a numerical value directly by the operator, and the entered amount is shown on a display. The value for the flowrate and BEMF
  • control system calculates the time required to dispense the operator entered amount of product.
  • One method of programming the control system variables is through the use of a keypad connected to the control system I/O. For example, a single key on the keypad is pressed and held for a duration longer than normal operation would call for, such as pressing a product flavor selection key for 3 seconds, or two keys pressed simultaneously, such as two different flavor keys for 3 seconds, which would put the
  • an LED connected to the I/O illuminates indicating that the control system is in programming mode.
  • Momentarily pressing a product flavor key activates the respective product in the control system and flags it for programming. Holding the portion size dispense key on the keypad for a desired duration sets the
  • a display is also included on the housing to allow the programmer to view the changes made to the 670 control system.
  • the control system can save sold out and abnormal operation detection events, as well as operational data such as total product dispensed, the number of BIB changes and prime commands issued, and similar dispensing related data, in its internal memory. This information may then be communicated through its I/O
  • control system alerting the operator when a product supply BIB is sold out by illuminating an LED connected to the control system I/O or beverage dispensing unit's structure.
  • Another example is posting a text string notification, such as that a BIB is decoupled or that there is a leak in the suction line, to a display, such
  • control system 680 as an LCD, connected to the control system I/O.
  • the information stored in the control system internal memory can also be polled through the I/O by a restaurant manager, for example, to determine consumption rate of a particular product for planning how much of the product needs to be reordered.
  • the information can further be routed to a server and accessed over an intranet or the internet. The data may be accessed or
  • one of the keys may be programmed to dispense a half-
  • a dispensing button is programmed to dispense
  • the lemonade is programed to dispense at 40% of the power requirement that would be used by the system if a lemonade only drink had been selected, and the iced tea is programmed to dispense at 55% of the power requirement that would have been used by the system if an iced tea only drink had been selected. Additionally, appropriate target BEMF values for the fluids are programed for reference by the
  • Selecting the half-and-half button causes the system to pump the appropriate fluids simultaneously, using the lower power requirements and alternate BEMF target values to maintain proper control over the flow of each fluid throughout the course of the dispensing. This allows the system to dispense preselected ratios of different fluids (some of which may have different viscosities) and dispense each
  • Figures 13 and 14A are examples of alternate embodiments. The
  • the motor and pump systems are connected to a rack 1304 of BIB packages 900
  • tube 1305 is shown for exemplary
  • the power supply 417 is located within the beverage dispenser 1300.
  • FIG 14A is an embodiment where the control system I/O is compatible with and can be connected to wireless data transceivers, such as a wireless 730 Ethernet adapter. It will be understood by those of skill in the art that other wireless transmission protocols, such Bluetooth, RF, infrared, or other system could be utilized.
  • wireless connection allows the control system to communicate and operate with devices and equipment that are not physically wired to it.
  • One such application of the wireless functionality is the control system 1400 located remotely
  • the controller 401 and a plurality of motors and pumps 100 are placed at the product supply rack 1304, or BIB rack, which is typically located a substantial distance away from the beverage dispensing unit 1401, for example at a distance of 100 feet away.
  • the pump fluid inlet be located as close as
  • the beverage dispensing unit 1401 also has a transmitting and receiving device 1402 wirelessly coupled to the control system 1400. Dispense and programming commands may be communicated wirelessly from the beverage dispensing unit to the control system. Data, sold out notification and abnormal operation alerts may be wirelessly sent from the control system to the
  • a touchscreen display 1403 is used for an operator interface.
  • the display 1403 can display a number of icons (not shown) that can be selected in the same manner as traditional keys.
  • the controller and motor and pump systems shown in greater detail in Figure
  • controller 750 14B are located remotely and operated wirelessly.
  • the controller 401 includes a display 1405 and keypad 1406.
  • a transceiver 1407 and antenna 1408 can be connected to the controller or integrated with the controller.
  • the motor and pump assemblies are each connected to the controller, for
  • the controller is powered through an electrical connection
  • Sensor data can be input into the controller through additional connections, such as wire 1411, and the controller can be electrically connected to additional components, such as one or more valves 1412, through for example, wire 1413.
  • Each pump includes an inlet tube 1414 for receiving product and
  • the beverage dispenser 1401 has a housing 1416 that includes an antenna 1417 and transceiver 1418 for sending and receiving signals.
  • a rack 1304 holds BIB containers 900 that are connected to the assemblies of motors and pumps 100.
  • multiple BIB containers may be connected to a single pump 765 thorough a solenoid valve 1412.
  • the control system reacts by activating the solenoid valve to switch to another BIB container coupled to the solenoid valve.
  • a sensor 1419 such as a temperature sensor, may be placed inline with the supply line 1420 and connected electrically, such as by wire 1411, to the
  • the control system I/O may be configured to accept one or more temperature sensor inputs, such as a thermocouple or thermistor.
  • the control system memory is programmable to store temperature offset values for the target BEMF voltage values for several products. Several product target BEMF
  • the control system maintains consistent flow rate as product temperature varies.
  • the temperature sensors are in physical contact with the product within the line and are located at the pump inlet, or at the product storage container, or at both the pump inlet and storage container, and the temperature
  • sensors may be located at several additional positions along the line between the pump inlet and product container.
  • a diaphragm pump uses bellows-like chambers constructed from a flexible material that expand and compress fluid as the fluid is pumped. There is also a small amount of internal flow bypass within the pump
  • bypass flow circulates internally within the pump.
  • a significant increase in the viscosity of the fluid causes less fluid to be drawn into the chambers for a particular pump RPM due to the flexible property of the chamber material, and it cause a larger amount of the fluid to contribute to the bypass flow.
  • the control system adds a temperature compensated offset values to the target BEMF.
  • a target BEMF value is programmed to accept temperature compensated adjustments
  • the control system measures the temperature of the product and calculates an adjusted target BEMF using the measured BEMF, the 800 product temperature measured through one or more temperature sensor inputs, and one of several temperature offset values programmed into memory.
  • tempAdjust_BEMF_target tempOffset x (20 - tempMeasured)
  • tempAdjust_BEMF_target BEMF target + tempAdjust
  • 20 represents 20 degrees Celsius as the nominal operating temperature
  • an example temperature offset value may be 5 mV per degree Celsius, in which the target BEMF is adjusted 5mV for every degree Celsius change in measured product temperature.
  • Figure 7 is a graph 700 depicting
  • the system may include programed BEMFs for temperature 1 (Tl), temperature 2, (T2) and temperature 3 (T3), where Tl > T2 > T3. These are shown as BEMF (Tl), BEMF (T2), and BEMF (T3).
  • Tl temperature 1
  • T2 temperature 2
  • T3 temperature 3
  • BEMF BEMF
  • T2 BEMF
  • T3 BEMF
  • the motor must work harder to pump colder product, resulting in higher BEMF.
  • the flowrate may be held constant by the control system
  • one or more temperature sensors are placed on
  • the control system memory is programmable to store temperature compensated offset values for the target BEMF based on the motor temperature. It should be understood by those of skill in the art that BEMF generated by a motor is dependent on the magnetic flux density produced by the motor's magnet, and that a rise in the
  • the 835 system monitors the motor temperature, and as the motor temperature increases, the temperature offset values are subtracted from the target BEMF by the control system. That is, the control system adjusts the PWM voltage until it measures the target BEMF minus the additional offset value as a function of motor temperature. As the temperature of the motor decreases, the control system reduces the offset value
  • the temperature offset values are based on the magnetic materials and construction of the motor, information which is commonly available from the motor manufacturer or may be calculated using empirical data. The offset values may then be preprogramed into the system for the corresponding motors.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Control Of Positive-Displacement Pumps (AREA)

Abstract

De manière générale, le présent système concerne un système d'écoulement de fluide dans lequel un dispositif de commande et des ensembles pompes à moteur sont utilisés pour optimiser la commande de l'écoulement de fluide à travers le système. Le dispositif de commande échantillonne la force contre-électromotrice des ensembles moteur et pompe et peut utiliser la force contre-électromotrice échantillonnée conjointement avec des valeurs de force contre-électromotrice cibles prédéfinies, de préférence déterminées de manière empirique et ajustées à un moteur individuel et à un fluide choisi, pour ajuster la tension appliquée au système, commander la force contre-électromotrice du système et, par extension, commander l'écoulement de fluide.
PCT/US2017/020203 2017-03-01 2017-03-01 Système de moteur et de pompe WO2018160175A1 (fr)

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EP3799292A1 (fr) * 2019-09-30 2021-03-31 Rockwell Automation Technologies, Inc. Systèmes et procédés pour la mise en uvre de multiples démarreurs de moteurs à l'aide d'une carte de circuit imprimé

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US20070206436A1 (en) * 2006-03-01 2007-09-06 Niermeyer J K System and method for controlled mixing of fluids
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US20140093866A1 (en) * 2009-11-24 2014-04-03 Opko Diagnostics, Llc Fluid mixing and delivery in microfluidic systems
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US20160084245A1 (en) * 2011-10-03 2016-03-24 Fernando A. Ubidia Dosing pump system
US20160184496A1 (en) * 2013-08-13 2016-06-30 Smith & Nephew, Inc. Systems and methods for applying reduced pressure therapy

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US5360320A (en) * 1992-02-27 1994-11-01 Isco, Inc. Multiple solvent delivery system
US20050035152A1 (en) * 2002-05-17 2005-02-17 Bethuy Timothy W. Beverage forming and dispensing system
US20040055363A1 (en) * 2002-05-31 2004-03-25 Bristol L. Rodney Speed and fluid flow controller
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US20140309617A1 (en) * 2013-02-05 2014-10-16 Jesse E. Ambrosina Fluid flow measurement and control
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3799292A1 (fr) * 2019-09-30 2021-03-31 Rockwell Automation Technologies, Inc. Systèmes et procédés pour la mise en uvre de multiples démarreurs de moteurs à l'aide d'une carte de circuit imprimé
US11215666B2 (en) 2019-09-30 2022-01-04 Rockwell Automation Technologies, Inc. Systems and methods for implementing multiple motor starters with a printed circuit board

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