Controller for pump system

Abstract

A pump control system includes a pump operable via actuation of an actuator that moves an actuating element to cause the pump to generate an intake stroke and a discharge stroke to pump media along a pipe or conduit. A sensor is disposed at the actuator and is operable to sense the position of the actuating element during operation of the actuator and pump. A controller is operable to control the actuator. The controller, responsive to an output of the sensor, determines the current position of the actuating element and automatically controls the actuator to provide a selected performance of the pump.

1 . A pump control system comprising:
 a pump operable via actuation of an actuator that moves an actuating element to cause the pump to generate an intake stroke and a discharge stroke to pump media along a pipe or conduit;   a sensor disposed at the actuator and operable to sense the position of the actuating element during operation of the actuator and pump; and   a controller operable to control the actuator, wherein the controller, responsive to an output of the sensor, determines the current position of the actuating element and automatically controls the actuator to provide a selected performance of the pump.   
     
     
         2 . The pump control system of  claim 1 , wherein the selected performance comprises a selected stroke rate of the pump. 
     
     
         3 . The pump control system of  claim 1 , wherein the selected performance comprises a selected pump discharge pressure. 
     
     
         4 . The pump control system of  claim 1 , wherein the actuator comprises a pneumatic or hydraulic cylinder and the actuating element comprises a piston that moves within the cylinder responsive to pressurization of the cylinder. 
     
     
         5 . The pump control system of  claim 4 , wherein the sensor comprises an ultrasonic sensor disposed at an end region of the cylinder to sense the location of the piston relative to the cylinder. 
     
     
         6 . The pump control system of  claim 4 , wherein the pump comprises a diaphragm pump and wherein the piston moves relative to the cylinder to move a diaphragm element of the diaphragm pump. 
     
     
         7 . The pump control system of  claim 1 , wherein the actuator comprises a suction device that applies suction at the pump to draw a diaphragm of the pump upward during an intake stroke of the pump. 
     
     
         8 . The pump control system of  claim 1 , wherein the controller is operable to control the actuator to provide the selected performance of the pump irrespective of changes in viscosity of the media pumped by the pump. 
     
     
         9 . The pump control system of  claim 1 , wherein the controller is operable to control the actuator to provide the selected performance of the pump irrespective of changes in pressure in the pipe or conduit. 
     
     
         10 . The pump control system of  claim 1 , wherein the controller is operable to control a stroke rate of the pump irrespective of changes in pressure in the pipe or conduit. 
     
     
         11 . The pump control system of  claim 1 , wherein the controller is operable to control a stroke rate of the pump irrespective of changes in viscosity of the media pumped by the pump. 
     
     
         12 . The pump control system of  claim 1 , wherein the controller adjusts operation of the pump responsive to changes in pressure in the pipe or conduit. 
     
     
         13 . The pump control system of  claim 1 , wherein the controller adjusts operation of the pump responsive to changes in viscosity of the media pumped by the pump. 
     
     
         14 . The pump control system of  claim 1 , wherein the controller is operable to control the actuator to enhance efficiency of the pump. 
     
     
         15 . The pump control system of  claim 1 , wherein the controller continuously determines the position of the actuating element during operation of the actuator and pump. 
     
     
         16 . The pump control system of  claim 15 , wherein the controller determines and applies optimum operating suction and discharge pressures of the pump. 
     
     
         17 . The pump control system of  claim 15 , wherein the controller controls the actuator to make the pump take a complete stroke during operation of the pump. 
     
     
         18 . The pump control system of  claim 1 , wherein, responsive to a determination of a partial blockage condition of the pipe or conduit, the controller switches the pump to a short stroke mode. 
     
     
         19 . The pump control system of  claim 1 , wherein the system comprises a plurality of pumps and a sensor disposed at an actuator of each of the pumps, and wherein the controller, responsive to the outputs of the sensors, automatically controls the actuators to provide selected performance of the pumps. 
     
     
         20 . The pump control system of  claim 19 , wherein the controller is operable to control the pumps such that each pump will stroke at least partially out of phase with the other pumps.