Fluid flow systems and methods of using the same

Abstract

A pump system and a method of using the same is designed to provide a precision flow of a fluid. The pump system comprises a motor having a motor shaft, a pump having a pump shaft, and a coupler configured to be coupled to each of the motor shaft and the pump shaft in a non-rotational and fixed fashion. A shroud is configured to be coupled with the motor on a first end and to be coupled with the pump on a second end such that the shroud encloses the coupler therein.

1 . A pump system for providing a precision flow of a fluid, the pump system comprising:
 a motor having a motor shaft extending from a motor-coupling end of the motor;   a pump having a pump shaft extending from a pump-coupling end of the pump;   a coupler having a first portion configured to be coupled to the motor shaft in a non-rotational and fixed fashion and a second portion configured to be coupled to the pump shaft in a non-rotational and fixed fashion, the first portion of the coupler being configured to be non-rotationally coupled to the second portion of the coupler; and   a shroud having a first end configured to be coupled with the motor-coupling end of the motor and a second end configured to be coupled with the pump-coupling end of the pump such that (i) the shroud, (ii) the motor-coupling end, and (iii) the pump-coupling end enclose the coupler therein.   
     
     
         2 . The pump system of  claim 1 , wherein an outer diameter of the first end of the shroud is smaller than an outer diameter of the second end of the shroud. 
     
     
         3 . The pump system of  claim 2 , wherein the outer diameter of the first end of the shroud is about the same as an outer diameter of the motor-coupling end and the outer diameter of the second end of the shroud is about the same as an outer diameter of the pump-coupling end. 
     
     
         4 . The pump system of  claim 1 , wherein responsive to the motor-coupling end of the motor being coupled to the first end of the shroud, at least a portion of the motor-coupling end is received within the first end of the shroud. 
     
     
         5 . The pump system of  claim 1 , wherein the first portion of the coupler is coupled to the motor shaft via a first key exteriorly positioned along the motor shaft, and the second portion of the coupler is coupled to the pump shaft via a second key exteriorly positioned along the pump shaft. 
     
     
         6 . The pump system of  claim 1 , wherein the coupler includes an insert adaptor, the insert adaptor being axially coupled to the first portion of the coupler and the second portion of the coupler. 
     
     
         7 . The pump system of  claim 6 , wherein:
 the first portion of the coupler includes two or more first fingers distally distributed on the first portion;   the second portion of the coupler includes two or more second fingers distally distributed on the second portion;   the insert adaptor has four or more fingers radially distributed on the insert adaptor; and   the insert adaptor is configured to receive, in a corresponding gap between two adjacent fingers of the four or more fingers, each of the two or more first fingers of the first portion and each of the two or more second fingers of the second portion.   
     
     
         8 . The pump system of  claim 1 , further comprising a first gasket positioned between the first end of the shroud and the motor-coupling end of the motor. 
     
     
         9 . The pump system of  claim 8 , further comprising a second gasket positioned between the second end of the shroud and the pump-coupling end of the pump. 
     
     
         10 . The pump system of  claim 1 , further comprising a control system having one or more processors configured to execute machine-executable instructions to cause the pump system to:
 monitor one or more parameters of the pump;   adjust one or more variables of the motor; and   based at least in part on the one or more variables of the motor, cause the motor to switch between an ON state and an OFF state to deliver the precision flow of the fluid.   
     
     
         11 . The pump system of  claim 10 , wherein the control system is configured to cause the pump system to monitor a batching process or a dosing process, and wherein:
 the batching process is configured to deliver the precision flow in a plurality of first intervals with each of the plurality of first intervals having a first flow volume;   the dosing process is configured to deliver the precision flow in a plurality of second intervals with each of the plurality of second intervals having a second flow volume; and   each of the plurality of first intervals has a greater duration than each of the plurality of second intervals, and the first flow volume is greater than the second flow volume.   
     
     
         12 . The pump system of  claim 11 , wherein the batching process has a first flowrate and the dosing process has a second flowrate, the first flowrate being greater than the second flowrate. 
     
     
         13 . The pump system of  claim 11 , further comprising:
 a calibration program for a specific fluid, the specific fluid having a process pressure and a delivery flowrate;   wherein the control system is configured to cause the system to:
 operate at the process pressure in the batching process; 
 monitor the first flow volume per each of the plurality of first intervals to be within a target range of the delivery flowrate; and 
 record the calibration program into a calibration registry for the specific fluid. 
   
     
     
         14 . The pump system of  claim 13 , wherein the target range is about 97% to about 103% of the delivery flowrate. 
     
     
         15 . The pump system of  claim 10 , wherein the one or more parameters of the pump includes a revolution rate of the pump shaft or a start position of the pump shaft, or any combination thereof. 
     
     
         16 . The pump system of  claim 10 , wherein the one or more variables of the motor includes a motor temperature, a motor current, a motor voltage, a revolution rate of the motor shaft, a start position of the motor shaft, a torque output of the motor shaft, a power output of the motor shaft, or any combination thereof. 
     
     
         17 . The pump system of  claim 1 , further comprising a mounting bracket configured to be coupled to a flat portion of the shroud to aid in attaching the pump system, via the mounting bracket, to an external surface. 
     
     
         18 . (canceled) 
     
     
         19 . The pump system of  claim 1 , wherein the shroud has a general cone shape. 
     
     
         20 . The pump system of  claim 1 , wherein the motor is a servo motor, a high precision motor, a stepper motor, a step motor, a non-magnetic motor, a synchronous motor, a direct-current motor, or any combination thereof, and wherein the pump is a four-piston pump. 
     
     
         21 . (canceled) 
     
     
         22 . A method for providing a precision flow of a fluid, the method comprising:
 providing a coupler having a first portion and a second portion;   using the coupler, connecting the first portion of the coupler to a motor shaft of a motor;   connecting the second portion of the coupler to a pump shaft of a pump;   using a shroud, enclosing therewithin the coupler, the motor shaft, and the pump shaft, in an air-tight fashion;   monitoring, via a control system, one or more parameters of the pump;   adjusting one or more variables of the motor; and   based at least in part on the one or more variables of the motor, causing the motor to switch between an ON state and an OFF state to deliver the precision flow of the fluid.   
     
     
         23 - 29 . (canceled)