Automated cross-phase pump and controller

Abstract

In one example, a pump controller includes a power connection, one or more control signal connections, a feedback signal connection, one or more programmable elements, and one or more processors connected with the programmable elements and the feedback signal connection. When the programmable elements are programmed for automatic control of a fluid pump, the pump controller is operable to automatically control operation of the fluid pump through a closed loop system, and wherein the pump controller is further operable to control a pulse value associated with operation of the fluid pump.

What is claimed is: 
     
         1 . A pump controller, comprising:
 a power connection;   a plurality of control signal connections;   a feedback signal connection;   one or more programmable elements; and   one or more processors connected with the programmable elements and the feedback signal connection,   wherein when the programmable elements are programmed for automatic control of a fluid pump, the pump controller is operable to automatically control operation of the fluid pump through a closed loop system, and wherein the pump controller is further operable to control a pulse value associated with operation of the fluid pump.   
     
     
         2 . The pump controller as recited in  claim 1 , wherein the pump controller is configured to be connected with one or more elements of a control air system. 
     
     
         3 . The pump controller as recited in  claim 1 , wherein the fluid pump is an air-operated diaphragm pump. 
     
     
         4 . The pump controller as recited in  claim 1 , wherein the pump controller is configured to be directly mounted to the fluid pump. 
     
     
         5 . The pump controller as recited in  claim 1 , wherein when the programmable elements are programmed for automatic control of a fluid pump, the pump controller is operable to automatically control a regulator, flow control valve, and solenoid valve. 
     
     
         6 . The pump controller as recited in  claim 1 , wherein the pump controller is responsive to a signal received from a differential pressure measurement device. 
     
     
         7 . The pump controller as recited in  claim 1 , wherein the fluid pump is a bellows pump. 
     
     
         8 . A pump controller, comprising:
 a plurality of connections, comprising:
 an electrical power input connection; 
 a fluid feedback connection; 
 an electronically controlled regulator control connection; 
 a first solenoid valve control connection; 
 a second solenoid valve control connection; 
 a first flow control valve control connection; and 
 a second flow control valve control connection; 
   one or more programmable elements; and   one or more processors connected with the programmable elements and the fluid feedback connection,   wherein when the programmable elements are programmed for automatic control of a fluid pump, the pump controller is operable to automatically control, by transmitting and/or receiving signals by way of the connections, a phase overlap associated with suction and discharge operations of the fluid pump.   
     
     
         9 . The pump controller as recited in  claim 8 , wherein automatic control of the phase overlap comprises automatic control of an amount of time that one or more chambers of the fluid pump are in a positive pressure state and in a vacuum state. 
     
     
         10 . The pump controller as recited in  claim 8 , wherein automatic control of the phase overlap comprises automatic control of a flow of control fluid to one or more chambers of the fluid pump. 
     
     
         11 . The pump controller as recited in  claim 8 , wherein automatic control of the phase overlap comprises automatic control of a pulse value associated with operation of the fluid pump. 
     
     
         12 . The pump controller as recited in  claim 8 , wherein automatic control of phase overlap comprises control of a flow of control fluid to each of first and second chambers of the fluid pump independently of each other. 
     
     
         13 . The pump controller as recited in  claim 8 , wherein automatic control of phase overlap comprises control of movement of first and second diaphragms of the fluid pump independently of each other. 
     
     
         14 . The pump controller as recited in  claim 8 , wherein the pump controller is configured to be mounted to, or integrated with, the fluid pump. 
     
     
         15 . The pump controller as recited in  claim 8 , wherein the pump controller is operable to receive, and act upon, feedback received from a differential pressure measurement device by way of the fluid feedback connection. 
     
     
         16 . The pump controller as recited in  claim 8 , wherein the programmable elements are programmable to include values for the following: one or more acceptable flow rates; and, one or more acceptable pulse values. 
     
     
         17 . The pump controller as recited in  claim 8 , wherein the programmable elements are programmable to include values for the following: air supply pressure; vacuum pressure; pump cycle time; phase overlap; and pump head air supply orifice size. 
     
     
         18 . The pump controller as recited in  claim 8 , wherein the pump controller is operable to facilitate control of any one or more of: control fluid supply pressure to first and second chambers of the fluid pump; vacuum pressure in the first and second chambers; fluid pump cycle time; and, fluid pump head air supply orifice size. 
     
     
         19 . The pump controller as recited in  claim 8 , wherein the pump controller is operable, in response to feedback received from a differential pressure measurement device, to generate and transmit a control signal to any one or more of: an electronically controlled regulator control; a first solenoid valve; a second solenoid valve; a first flow control valve control; and, a second flow control valve.