CN101982659B - 用于控制泵和电机的方法 - Google Patents
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- 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
- F04B49/08—Regulating by delivery pressure
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- 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
- F04B47/00—Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps
- F04B47/06—Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps having motor-pump units situated at great depth
-
- 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
-
- 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
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D13/00—Pumping installations or systems
- F04D13/02—Units comprising pumps and their driving means
- F04D13/06—Units comprising pumps and their driving means the pump being electrically driven
- F04D13/08—Units comprising pumps and their driving means the pump being electrically driven for submerged use
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D13/00—Pumping installations or systems
- F04D13/02—Units comprising pumps and their driving means
- F04D13/06—Units comprising pumps and their driving means the pump being electrically driven
- F04D13/08—Units comprising pumps and their driving means the pump being electrically driven for submerged use
- F04D13/10—Units comprising pumps and their driving means the pump being electrically driven for submerged use adapted for use in mining bore holes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/0066—Control, e.g. regulation, of pumps, pumping installations or systems by changing the speed, e.g. of the driving engine
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/0088—Testing machines
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/02—Stopping of pumps, or operating valves, on occurrence of unwanted conditions
- F04D15/0209—Stopping of pumps, or operating valves, on occurrence of unwanted conditions responsive to a condition of the working fluid
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/02—Stopping of pumps, or operating valves, on occurrence of unwanted conditions
- F04D15/0209—Stopping of pumps, or operating valves, on occurrence of unwanted conditions responsive to a condition of the working fluid
- F04D15/0218—Stopping of pumps, or operating valves, on occurrence of unwanted conditions responsive to a condition of the working fluid the condition being a liquid level or a lack of liquid supply
- F04D15/0236—Lack of liquid level being detected by analysing the parameters of the electric drive, e.g. current or power consumption
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- 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
- F04B2203/0204—Frequency of the electric current
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- 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
- F04B2205/00—Fluid parameters
- F04B2205/04—Pressure in the outlet chamber
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- 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
- F04B2205/00—Fluid parameters
- F04B2205/05—Pressure after the pump outlet
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- 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
- F04B47/00—Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps
-
- 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
- F04B49/10—Other safety measures
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/0077—Safety measures
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/02—Stopping of pumps, or operating valves, on occurrence of unwanted conditions
- F04D15/0245—Stopping of pumps, or operating valves, on occurrence of unwanted conditions responsive to a condition of the pump
- F04D15/0254—Stopping of pumps, or operating valves, on occurrence of unwanted conditions responsive to a condition of the pump the condition being speed or load
Abstract
本发明涉及一种用于控制泵和电机的方法。本发明的实施方式提供了一种变频驱动器系统和控制通过电机驱动的泵的方法,所述泵与流体系统流体连通。该驱动器系统和方法可以提供如下中的一个或多个:睡眠模式、管道破裂检测、管路填充模式、自动启动模式、空运行保护、与接地故障断路器兼容的电磁干扰滤波器、两线和三线及三相电机兼容性、简单启动处理、自动口令保护、抽出模式、数字输入/输出终端和可移除的输入和输出功率终端块。
Description
背景技术
潜井泵连接到地面驱动器系统,所述地面驱动器系统控制该泵的操作。一些传统的泵控制器只包括启动电容器和继电器,以基于系统压力打开和关闭泵。这些泵控制器对于泵的控制、安全和用户化来说能力有限。变频驱动器(VFD)也已经用于控制潜井泵,但是在用户友好控制和用户化方面能力有限。传统的驱动器还通常设计用于特定类型的电机,通常不能用于改装已经安装在井中的电机,特别是两线单相电机。
发明内容
本发明的一些实施方式提供了一种控制通过电机驱动的泵的方法,该泵与流体系统流体连通。该方法可以包括确定该电机是否已经达到稳定状态操作频率,和一旦该电机已经达到稳定状态操作频率,使得该泵临时地升高该流体系统中的压力。该方法还可以包括在临时地升高压力之后确定流体系统中的压力是否下降,和如果在临时地升高压力后压力不下降,则使得该泵进入睡眠模式。
在一些实施方式中,控制该泵的方法可以包括确定该泵是否在预定的时间期间内已经进入该睡眠模式,和如果该泵在预定的时间期间内没有进入睡眠模式,则由于管道破裂故障而关闭该泵。
根据一些实施方式,控制该泵的方法可以包括当泵启动时确定流体系统中的压力,和如果流体系统中的压力小于最小压力设定点,为填充该流体系统,用低的频率以管路填充模式使该电机运行一个时间期间。该方法还可以包括在达到最小压力设定点之后,为将压力增加到正常压力设定点,以正常的频率操作该电机。
本发明的一些实施方式可以提供一种控制器,该控制器包括控制该泵的操作的变频驱动器电路,和连接到该变频驱动器电路的控制面板。该控制面板可以包括自动启动按钮和停止按钮。当该自动启动按钮接合(engage)时,该变频驱动器电路在该泵启动时可以自动地以管路填充模式运行,当该停止按钮接合时,该泵可以被禁用。
根据一些实施方式,方法可以包括以正常操作频率操作该电机,确定流体系统中的实际压力,将该实际压力与压力设定点作比较,和如果通过正常操作频率操作该电机不能达到该压力设定点,则产生空运行故障。
附图说明
图1是根据本发明的一个实施方式的变频驱动器的透视图。
图2是图1的变频驱动器移除盖子时的透视图。
图3是图1的变频驱动器的内部视图。
图4是图1的变频驱动器的控制面板的前视图。
图5是图1的变频驱动器安装在流体系统中的示意图。
图6是图1的变频驱动器的示意图。
图7是表示抽出操作的流程图。
图8是表示自动管路填充操作的流程图。
图9是表示手动管路填充操作的流程图。
图10是表示停止操作的流程图。
图11是表示比例/积分/微分(PID)模式控制操作的流程图。
图12是表示睡眠模式操作的流程图。
图13是表示交替睡眠模式操作的流程图。
图14是表示数字输入控制操作的流程图。
图15是表示继电器输出控制操作的流程图。
图16是表示主菜单的流程图。
图17是表示设定菜单的流程图。
图18是表示时间参数菜单的流程图。
图19是表示PID控制参数菜单的流程图。
图20是表示睡眠参数菜单的流程图。
图21是表示口令参数菜单的流程图。
图22是表示外部设定点参数菜单的流程图。
图23是表示电机参数菜单的流程图。
图24是表示传感器参数菜单的流程图。
图25是表示管道破裂参数菜单的流程图。
图26是表示空运行参数菜单的流程图。
图27是表示输入/输出参数菜单的流程图。
图28是表示重置参数菜单的流程图。
图29是表示后门参数菜单的流程图。
图30是表示过热防止操作的流程图。
图31是表示过电流防止操作的流程图。
图32是表示卡住防止操作的流程图。
图33是表示管道破裂防止操作的流程图。
图34是表示空运行检测操作的流程图。
图35是表示空运行故障操作的流程图。
图36是表示卡住故障操作的流程图。
图37是表示温度过高故障操作的流程图。
图38是表示过电流故障操作的流程图。
图39是表示过电压故障操作的流程图。
图40是表示内部故障操作的流程图。
图41是表示接地故障操作的流程图。
图42是表示开路变送器故障操作的流程图。
图43是表示短路变送器故障操作的流程图。
图44A-44B是表示多故障操作的流程图。
图45是表示欠压故障操作的流程图。
图46是表示硬件故障操作的流程图。
图47是表示外部故障操作的流程图。
图48是表示抽出按钮控制操作的流程图。
图49是表示压力预设按钮控制操作的流程图。
图50是表示主菜单按钮控制操作的流程图。
图51是表示故障记录按钮控制操作的流程图。
图52是表示回车按钮控制操作的流程图。
图53是表示后退按钮控制操作的流程图。
图54是表示上/下按钮控制操作的流程图。
图55是表示左/右按钮控制操作的流程图。
图56是表示口令按钮控制操作的流程图。
图57是表示语言按钮控制操作的流程图。
图58是表示状态按钮控制操作的流程图。
图59是表示停止按钮控制操作的流程图。
图60是表示自动启动按钮控制操作的流程图。
图61是表示故障重置按钮控制操作的流程图。
图62A-62D是表示LFD指示器控制操作的流程图。
图63A-63D是表示错误显示控制操作的流程图。
具体实施方式
在详细解释本发明的任何实施方式之前,需要理解的是,本发明不是将其应用限定在下面说明中所陈述或在下面附图中所示出的组件的详细结构和布置中。本发明能够有其他的实施方式,并能够以不同的方式实践或实现。还需要理解的是,这里使用的措词和术语是为了说明目的,而不认为是作为限制。这里所使用的“包括”、“包含”或“具有”及其变形指的是包括在其后所列的物品及其等同物以及另外的物品。除非特别说明或限定,术语“安装”、“连接”、“支撑”和“耦接”及其变形被广义地使用,并包括直接和间接的安装、连接、支撑和耦接。而且,“连接”和“耦接”不限于物理的或机械的连接或耦接。
下面的讨论呈现用于使本领域技术人员能够制造和使用本发明的实施方式。对示例的实施方式的各种变形对于本领域技术人员将是非常显而易见的,并且这里的一般原理可以应用于其他实施方式和应用而不脱离本发明的实施方式。这样,本发明的实施方式不旨在限定于所示的实施方式,而是与这里公开的原理和特征的最广范围相一致。下面详细的说明将通过参考图进行阅读,其中,不同图中类似的元件具有类似的附图说明。这些图不必是依比例的,它们描述了选定的实施方式,并不旨在限定本发明的实施方式的范围。本领域技术人员应当认识到,这里提供的例子具有许多有用的变形,它们落入本发明的实施方式的范围中。
图1示例了根据本发明一个实施方式的变频驱动器(VFD,下文中称为“驱动器”)10。在一些实施方式中,驱动器10可以用于控制AC感应电机11的操作,该AC感应电机驱动水泵12(如在图5中示出)。该驱动器10可以用于住宅、商业或工业泵系统,以维持基本恒定的压力。电机11和泵12可以是潜水型或地面型。驱动器10可以监测某些操作参数并响应于检测的条件控制电机11的操作。
如图1和2所示,驱动器10可以包括外壳13和控制面板14。该外壳13可以是NEMA 1室内外壳或NEMA3R室外外壳。在一个实施方式中,外壳13可以具有约9.25英寸的宽度、约17.5英寸的高度和约6.0英寸的深度。该外壳13可以包括键孔安装架16,以快速和容易地安装到墙壁上,例如地库墙。该外壳13可以包括槽18,用于冷却驱动器10的空气可以通过所述槽18流出外壳13。控制面板14可以定位在外壳13里面,用于通过矩形孔20访问。
如图2所示,外壳13可以包括可移除的盖子22,该盖子22具有附接的侧面板。移除该盖子22允许到达接线区域24,该接线区域24邻接外壳13的具有几个导管孔26的底部面板25处。如在图2和3中示出的,接线区域24没有任何可以阻止任何接线的电气组件或印刷电路板材料。该接线区域24可以提供到达输入功率终端块28、输入/输出(I/O)弹簧(spring)终端30和输出功率终端块32。每个导管孔26可以与输入功率终端块28、I/O弹簧终端30和输出功率终端块32中的其中一个对齐。此外,在一些实施方式中,I/O弹簧终端30可以包括数字输出终端30A、数字输入终端30B、I/O电源终端30C和模拟输入终端30D。
该接线区域24可以包括在底部面板25和输入功率终端块28、I/O弹簧终端30及输出功率终端块32之间的接线空间34。该接线空间34高度可以在约三英寸和约六英寸之间,以允许安装者有足够空间到达输入功率终端块28、I/O弹簧终端30和输出功率终端块32。
输入功率终端块28、I/O弹簧终端30和输出功率终端块32可以用于控制电机11,并提供任意数目的配置和应用的输出信息。各种类型的输入可以提供给驱动器10进行处理并用于控制电机11。模拟输入终端30D可以接收模拟输入,而数字输入终端30B可以接收数字输入。例如,任何合适类型的运行/允许(enable)开关可以提供作为到驱动器10的输入(例如经由数字输入终端30B)。该运行/允许开关可以是草坪灌溉系统、spa泵控制器、水池泵控制器、浮动开关或时钟/定时器的一部分。在一些实施方式中,数字输入终端30B可以接受多种输入电压,例如在从大约12V到大约240V的范围内的直流(DC)或交流(AC)电压。
数字输出终端30A可以连接到数字输出,例如继电器输出。任何合适类型的指示器设备、状态输出或故障警报输出可以用作数字或继电器输出(例如被连接到数字输出终端30A)。状态输出可以用于控制第二泵,例如当泵12运行时运行该第二泵。故障警报输出可以,例如在确定有故障时,采用预定电话号码呼叫、发信号给住宅警报系统和/或关闭泵12。例如,当存在管道破裂故障时(如下文中参考图33所述),该数字输出终端30A可以激活继电器输出,引起预定电话号码自动拨号。输入功率终端块28、I/O弹簧终端30和输出功率终端块32都可以耦接到驱动器电路板(未示出),以连接到驱动器10的控制器75(如图6所示)。而且,输入功率终端块28和/或输出功率终端块32可移除和可更换的,而不用更换驱动器电路板或整个驱动器10。
如图1-4所示,驱动器10的控制面板14可以包括背光液晶显示器36和几个控制按钮38。如图4所示,控制按钮38可以包括抽出按钮40、压力预设按钮42、主菜单按钮44和故障记录按钮46。控制按钮38可以包括键盘锁定按钮48和语言按钮50。该控制面板14可以包括几个方向按钮52、后退按钮54和回车按钮56。该控制面板14还可以包括状态按钮58、停止按钮60、自动启动按钮62和故障重置按钮64。最后,该控制面板14可以包括发光二极管(LED)指示器66,以指示驱动器10的状态,例如ON LED 68、警报LED 70和故障LED 72。
如图2和3所示,驱动器10可以包括电磁干扰(EMI)滤波器74。该EMI滤波器74可以减小电机11产生的电噪声,尤其是干扰AM无线电台的噪声。该驱动器10可以减小电噪声,同时与接地故障断路器(GFCI)兼容。在电流源和地表面之间非故意的电路通常称为“接地故障”。接地故障发生在电流在一些地方泄漏的时候,事实上,电逃逸到地上。
驱动器10可以与许多不同类型的电机11兼容,包括但是不限于:AC感应电机,其为两线永久分相式电容器(PSC)单相电机;三线单相电机;或三相电机。驱动器10可以连接到预先安装的电机11上以改进电机11的控制。如果电机是单相电机,安装者可以采用控制面板14选择两线或三线之一。对于三线电机11,驱动器10可以自动产生第一波形和第二波形,第二波形具有与第一波形偏置大约90度的相位角。此外,控制器75(如图6所示)能够根据选择,为电机11设定最小和最大频率容差。
在使用者用控制面板14进行简单的启动处理之后,驱动器10可以被编程操作。该启动处理对于单相电机11可以是五步处理,对于三相电机11可以是四步处理。单相电机11的启动处理可以包括:(1)输入服务因子当前值,(2)选择两线电机或三线电机之一,(3)输入当前时间,(4)输入当前日期,和(5)接合抽出按钮40或自动启动按钮62。三相电机11的启动处理可以包括:(1)输入服务因子当前值,(2)输入当前时间,(3)输入当前日期,和(4)接合抽出按钮40或自动启动按钮62。
抽出按钮40可以用于使驱动器10进入抽出模式,以从新挖的井中清除沙子和污物。一旦泵12安装在新井中并且一旦驱动器10连接到电机11上,该抽出按钮40就可以被接合。该抽出模式可以提供从井中开放排出沙子和污物,例如排出到草坪上。在一个实施方式中,驱动器10可以使泵12在抽出模式下以约45赫兹(Hz)操作。该抽出模式操作进一步描述在下面对图7的描述中,而抽出按钮控制操作进一步描述在下面对图48的描述中。
控制器75可以包括通过数字信号处理器(DSP,如图6所示)或微处理器执行的软件,并可以执行实时控制,包括软启动、速度调节和电机保护。可以控制驱动器10,使之在水系统中维持基本恒定的水压,该水系统可能采用或可能不采用储罐。为此,控制器75可以通过将压力误差作为输入而执行典型的比例/积分/微分(PID)方法。压力误差可以通过从想要的水压(也即压力设定点)减去实际水压而计算得到。然后可以通过将压力误差乘以比例增益,将压力误差的积分乘以积分增益,将压力误差的微分乘以微分增益,并将结果相加而产生更新的速度控制指令。这样,控制器75可以增加或减小电机11的速度以维持恒定的压力设定点。该PID模式将进一步参考图11在下文中描述。
控制器75可以从电子压力变送器15(例如,经由模拟输入终端30D与控制器75连通)确定实际水压值。在一些实施方式中,如图5所示,压力变送器15可以位于流体地连接到泵12的压力储罐17的附近。
如果电机11关闭(即没有被驱动),水压仍然可以被监测,但是不采取任何行动,直到压力降到某一值以下(例如低带压力值)。如果水压降到低带压力以下,控制器75可以重启电机11。在一些实施方式中,低带压力可以设定或默认为小于压力设定点1-10磅每平方英寸(PSI)。一旦电机11重启,具有PID控制的正常操作(即PID模式)就可以开始。在一个实施方式中,下列两个条件中的一个可以触发控制器75关闭电机11。第一个条件可以是如果睡眠模式(在对于图12的描述中)触发的话。第二个条件可以是如果压力超出某一安全值(即约超出压力设定点20PSI)的话。其他可以停止驱动器10的条件是各种故障(进一步在下面描述),使用者按下停止按钮60,并对可选的运行允许模式缺少数字输入。
对于正常的操作,当电机11被驱动时,控制器75可以用PID控制以连续的方式调节泵速,只要压力保持在安全压力值下,例如在压力设定点之上约20PSI。只要实际的压力超过安全压力值,驱动器10就可以停止电机11。在正常的操作过程中,只要水的使用不超出电机/泵的容量,压力就可以在大约压力设定点处保持恒定。流量需求中大的瞬时改变可能导致想要的压力带的改变。例如,如果停止流动,引起压力快速增加,电机11可以停止(也即设定到0Hz)。这可以认为是交替睡眠模式操作,进一步描述在下面对图13的描述中。
图7-15是描述根据本发明一些实施方式的泵控制的流程图。图7的流程图示例了当控制器75接收信号以抽出模式76运行泵(例如当抽出按钮40按下时)的情形。控制器75首先在步骤78中确定泵是否已经运行在抽出模式中。如果是,对于抽出模式,泵以正确固定的频率运行(步骤80)。如果否,控制器75在步骤82倾斜上升给电机11的功率输入频率到正确的频率,然后进入到步骤80。
图8表示根据一些实施方式的自动管路填充操作84。该操作可以自动在驱动器启动时运行(例如当驱动器10被供电时,在功率中断之后,当电机11重启时,或当自动启动按钮62压下时)。这样,电机可以在该操作的开始处关闭(即为0Hz)。控制器75首先能够在小于第一时间期间内将驱动电机的频率从0Hz斜坡上升到约45Hz,该第一时间期间例如为大约两秒(步骤86)。在第二时间期间中,例如大约两分钟,或者在一些实施方式中大约五分钟,控制器75可以开始将频率从例如45Hz斜坡上升到大约55Hz(步骤88)。在第二时间期间期间,控制器75经由来自压力变送器15的输入确定压力(步骤90)。如果检测到的压力已经达到最小压力,或者压力设定点(例如大约10PSI),指示管路已经填充,该填充操作完成,且控制器75进入PID模式(步骤92)。然而,如果步骤90中检测到的压力小于10PSI,控制器75确定第二时间期间(例如大约两分钟或大约五分钟)是否已经过去(步骤94)。如果第二期间还没有过去,控制器75返回到步骤88并继续斜坡改变电机频率。如果第二时间期间已经过去,控制器75将保持频率在大约55Hz约一分钟(步骤96)。然后控制器75确定检测到的压力是否是大约10PSI(步骤98)。如果检测到的压力是大约10PSI,指示管路已经填充,该填充操作完成,且控制器75进入PID模式(步骤92)。然而,如果在步骤90中检测到的压力仍然小于10PSI,控制器75确定一分钟是否已经过去(步骤100)。如果一分钟还没有过去,那么控制器75返回到步骤96。如果一分钟已经过去,则认为是空运行故障,并执行空运行故障操作(步骤102)(例如停止系统)。
在一个可选的实施方式中,步骤88可以包括对于第二时间期间设定频率为大约45Hz,如果在第二时间期间之后检测到的压力小于10PSI,则将频率设定到大约50Hz,在另一个第二时间期间中重复步骤88。如果在50Hz下经过第二时间期间之后检测到的压力仍然小于10PSI,则将频率设定为大约55Hz,重复步骤88又一个第二时间期间。如果在55Hz下的第二时间期间之后检测到的压力仍然小于10PSI,那么控制器75可以继续到步骤96。
图9示例了根据一些实施方式的手动管路填充操作104。电机11在步骤106中以手动控制的频率(例如通过使用者输入)运行。电机11在该频率下保持运行,直至检测到的压力达到大约10PSI(步骤108)。一旦检测到的压力已经达到大约10PSI,控制器75就进入PID模式(步骤110)。在一些实施方式中,如果控制器75在一时间期间(例如15分钟)内不进入PID模式,那么停止驱动器10。
手动填充管路操作可以认为总是允许的,因为其可以在自动管路填充操作过程的任何时间执行。例如,通过采用控制面板14上的向上和向下按钮52,使用者能够中断自动管路填充操作,并调节到电机11的频率输出,从而改变电机速度。一旦处于手动管路填充模式,使用者就可以根据需要在任意时间连续改变速度。电机10可以在新设定的频率下继续操作,直至检测到的压力达到大约10PSI,然后将进行到如上所述的PID模式。手动填充管路操作可能对于垂直或水平管道填充应用都是有利的。此外,自动填充管路操作和手动填充管路操作都可以防止传统系统中常见的电机问题,例如电机过载和水锤的发生。
图10示例了根据一些实施方式的停止操作112。控制器75确定泵是否正在运行(步骤114)。如果泵没有在运行(例如如果驱动器10处于睡眠模式或者没有触发运行允许命令),则驱动器10停止(步骤116)。如果泵在运行,那么电机被允许在步骤118中惯性减速至停止(即0Hz),然后进行到步骤116。
图11示例了根据一些实施方式的PID模式操作120。控制器75持续确定压力是否处于编程设定点(步骤122)。如果压力没有处于编程设定点,则利用PID反馈控制斜坡改变频率,直至压力达到设定点(步骤124)。
图12示例了控制器75,其运行在PID模式下(步骤126),检测泵是否需要进入睡眠模式。首先,在步骤128,控制器75确定电机11的频率是否稳定在+/-3Hz(例如在稳定状态频率)内。如果没有(步骤130),升压延迟定时器被重置,且控制器75返回到步骤126。如果电机11的频率是稳定的,则升压延迟定时器在步骤132中增加。如果在步骤134中升压延迟定时器在增加后没有终止(expire),则控制器75返回到步骤126。然而,如果在步骤134中升压延迟定时器已经终止,那么控制器75到步骤136,并且压力在一个短的时间期间内(例如大约15秒或大约30秒)升高(例如大于压力设定点约3PSI)。
直到短的时间期间已经过去(步骤138),控制器75确定压力是否处在压力设定点(例如大约10PSI)和升高的压力之间(步骤140)。如果在该短的时间期间中,压力落到在压力设定点和升高的压力之间的范围的外面(即在下面),则控制器75返回到步骤126。然而,如果压力落在压力设定点和升高的压力之间,那么控制器75在另一个短的时间期间上降低压力(步骤142)。直到该短的时间期间已经过去(步骤144),控制器75确定压力是否落在压力设定点(例如稳定状态的压力)和升高的压力之间(步骤146)。如果在该短的时间期间中,压力落到在压力设定点和升高的压力之间的范围的外面,指示发生了流动,控制器75返回到步骤126。然而,如果压力落在压力设定点和升高的压力之间,指示没有流动,那么控制器75确定压力是否在压力设定点之上(步骤148)。如果否,控制器75返回到步骤126。如果压力是在压力设定点之上,那么泵进入睡眠模式,使得电机频率惯性下降到0Hz(步骤150),且“睡眠模式激活”消息显示在液晶显示器36上(步骤152)。当在睡眠模式下,在步骤154,控制器75连续地确定压力是否落在叫醒压差(例如大约在压力设定点以下5PSI)之上。如果压力下降到叫醒压差以下的话,控制器75返回到步骤126。
在一些实施方式中,如果压力已经稳定至少最小的时间期间(例如一或二分钟),控制器75将只从步骤126前进到步骤128。另外,当控制器75循环从步骤128到步骤130并返回到步骤126时,控制器75可以在再次前进到步骤128之前等待一个时间期间(例如一或二分钟)。在一些实施方式中,控制器75在步骤128处可以确定电机速度是否稳定。此外,控制器75可以同时执行图11和12中的一些步骤。
通过采用睡眠模式操作,无需为驱动器10采购分开的设备(例如流量计)。而且,睡眠模式操作可以对泵性能的改变或泵送系统的改变进行自调节。例如,井泵系统通常具有井中水深的改变,这是由于水位下降和由于年份的时间或干旱条件。睡眠模式操作可以独立于这些改变而执行。此外,睡眠模式操作对采用的泵不需要专门的速度条件。
图13示例了控制器75,其操作在PID模式下,检测泵是否需要进入替代的睡眠模式156。首先,在步骤158,控制器75确定压力是否处于大于压力设定点的预设值(例如大于压力设定点20PSI)。如果否(步骤160),定时器重置且控制器75返回步骤156。如果压力大于压力设定点20PSI,定时器在步骤162中增加。如果在步骤164中定时器小于一个值,例如0.5秒,控制器75返回步骤156。然而,如果在步骤164中定时器超出0.5秒,控制器75前进到步骤166,且定时器重置。然后控制器75将电机频率设为0Hz(步骤168),并在液晶显示器36上显示“睡眠模式激活”消息170。然后控制器75再次增加定时器(步骤172),直至时间达到另一个值,例如1分钟(步骤174),然后前进到步骤176。在步骤176,控制器75保持电机频率在0Hz并在液晶显示器36上显示“睡眠模式激活”消息178,只要压力在叫醒压差之上的话(步骤180)。如果压力下降到叫醒压差以下(例如正使用水),那么控制器75返回到步骤156。
图14示例了采用数字输入的控制器操作的例子。控制器75首先识别数字输入(步骤182)。如果外部输入参数不使用(步骤184),则控制器75不采取行动,不管输入是高还是低(分别在步骤186和188)。如果外部参数设定为运行允许模式(步骤190)且输入是高的(例如指示允许驱动器10运行),控制器75确定驱动器10是否正在运行(步骤192)。如果驱动器10正在运行,则控制器75可以不采取行动(步骤196)并继续其当前的操作模式。如果驱动器10没有在运行,则控制器75能够启动自动管路填充操作(步骤194),如参考图8所述的(例如,类似于自动启动按钮62被按下时采取的行动)。如果外部输入参数设定到运行允许模式(步骤190)且输入是低的(例如指示停止驱动器10),那么控制器75能够检测驱动器10是否停止(步骤198)。如果驱动器10没有停止,那么控制器75可以执行停止操作(步骤200),如参考图10所述的。如果驱动器10是停止的,那么控制器75可以不采取行动(步骤202)。如果外部输入参数设定到外部故降模式(步骤204)且输入是高的(例如指示外部故障),则控制器75可以执行外部故障操作(步骤206),如参考图47所述的。如果外部输入参数设定到外部故障模式(步骤204)且输入是低的(例如指示不存在外部故障),那么控制器75可以清除任何外部故障指示(步骤208)。如果外部输入参数设定到外部设定点模式(步骤210)且输入是高的,控制器75设定PID设定点到例如“外部”(步骤212),从而数字输入控制PID压力控制的压力设定点。如果外部输入参数设定到外部设定点模式(步骤210)且输入是低的,那么控制器75设定PID设定点到例如“正常”(步骤214),从而数字输入对PID压力控制的压力设定点没有控制。
图15示例了继电器输出的控制器操作。当驱动器10被供电时(步骤216),控制器75确定继电器输出参数是否没有采用(步骤218)。如果是,控制器75关闭继电器(步骤220)。如果否,控制器75确定继电器输出参数是否设定到运行模式(步骤222)。如果继电器输出参数设定到运行模式(222),那么控制器75确定驱动器10是否正在运行(步骤224)。然后,如果驱动器10没有在运行,则控制器75将关闭继电器(步骤226),或者,如果驱动器10在运行,则控制器75将打开继电器(步骤228)。如果继电器输出参数没有设定为运行模式(步骤222),那么控制器75确定继电器输出参数是否设定到故障模式(步骤230)。如果是,那么控制器75在步骤232中确定驱动器10是否出错(trip)(例如发生了故障且驱动器10已经停止)。然后,如果驱动器10还没有出错则控制器75将关闭继电器(步骤234),如果驱动器10已经出错则控制器75将打开继电器(步骤236)。例如,如果警报是继电器输出,那么警报可以在驱动器10出错的情况下被激活,以向使用者指示故障状况。
图16-29是描述根据本发明的一些实施方式的菜单操作的流程图。图16示例了控制器75的主菜单238。该主菜单238可以包括如下参数:设定菜单240、电机242、传感器244、管道破裂246、空运行248、I/O(输入/输出)250和重置到默认值252。使用者可以采用控制面板14上的主菜单按钮44在液晶显示器36上观看主菜单238。然后使用者可以采用方向按钮52上下拨动主菜单238的参数。使用者可以采用回车按钮56选择一个参数。
使用者可以从主菜单238选择设定菜单240。使用者可以上下拨动设定菜单240以观看下面的参数,如在图17中示出的:时间254、PID控制256、睡眠258、口令260和外部设定点262。
图18示例了在从设定菜单240选择了时间参数254之后使用者的选项。使用者可以在设定当前小时264或日期266之间上下拨动。如果使用者选择小时参数264,使用者可以输入当前时间268,用于控制器75的时间值将根据使用者的输入而改变270。如果使用者选择日期参数266,使用者可以输入当前日期272,用于控制器75的日期值将根据使用者的输入而改变270。
图19示例了在从设定菜单240选择PID控制参数256之后的使用者的选项。可以在选择PID控制256之后选择如下参数:比例增益274、积分时间276、微分时间278、微分极限280和恢复到默认值282。使用者可以选择274-282的任何参数以改进与参数相关的一个或多个优选(preference),且用于控制器75的合适的值将改变270。
图20示例了在从设定菜单240选择睡眠参数258之后的使用者的选项。可以在选择睡眠258之后选择如下参数:升压压差284、升压延迟286、叫醒差288和恢复到默认值290。使用者可以选择284-290的任何参数以改进与参数相关的一个或多个优选,且用于控制器75的合适的值将改变270。可以设定参数以改变或调节参考图12所述的睡眠模式操作。
图21示例了在从设定菜单240选择口令参数260之后的使用者的选项。可以在选择口令260之后选择如下参数:口令超时292和口令294。使用者可以选择292-294的任何参数以改进与参数相关的一个或多个优选,且用于控制器75的合适的值将改变270。口令超时参数292可以包括超时期间值。如果控制面板14在设定的超时期间内没有被访问,控制器75可以自动锁定控制面板14(即进入口令保护模式)。为了解锁键,或者离开口令保护模式,使用者必须输入在口令参数294下设定的口令。这参考图56在下面进一步描述。
图22示例了在从设定菜单240选择外部设定点参数262之后的使用者的选项。使用者可以选择外部设定点参数296以改进与参数296相关的一个或多个优选,且用于控制器75的合适的值将改变270。
图23示例了在从主菜单238选择电机参数242之后的使用者的选项。可以在选择电机242之后选择如下参数:服务因子安培298、连接类型300、最小频率302、最大频率304和恢复到默认值306。连接类型参数300只有在驱动器10用于运行单相电机时才可以用。如果驱动器10用于运行三相电机,可以不提供连接类型参数300。使用者可以选择298-306的任何参数以改进与参数相关的一个或多个优选,且用于控制器75的合适的值将改变270。
图24示例了在从设定菜单240选择传感器参数244之后的使用者的选项。可以在选择传感器244之后选择如下参数:最小压力308、最大压力310和恢复到默认值312。使用者可以选择308-312的任何参数以改进与参数相关的一个或多个优选,且用于控制器75的合适的值将改变270。
图25示例了在从主菜单238选择管道破裂参数246之后的使用者的选项。可以在选择管道破裂246之后选择如下参数:允许管道破裂检测314和不睡眠的天数316。使用者可以选择314-316的任一参数以改进与参数相关的一个或多个优选,且用于控制器75的合适的值将改变270。在一些实施方式中,不睡眠的天数316可以包括在从大约4小时到大约十四天的范围中的值。允许管道破裂检测314可以允许使用者能够或不能够进行管道破裂检测。
图26示例了在从主菜单238选择空运行参数248之后的使用者的选项。可以在选择空运行248之后选择如下参数:自动重置延迟318、重置数320和重置窗口322。使用者可以选择318-320的任一参数以改进与参数相关的一个或多个优选,且用于控制器75的合适的值将改变270。使用者可以选择重置窗口参数322以观看指示控制器75的重置窗口的值324。重置窗口值可以基于为自动重置延迟318和重置数320选定的值。这样,重置窗口参数322可以是只读(即不能调节)参数。
图27示例了在从主菜单238选择I/O参数250之后的使用者的选项。可以在选择I/O 250之后选择如下参数:外部输入326和继电器输出328。使用者可以选择326-328的任一参数以改进与参数相关的一个或多个优选,且用于控制器75的合适的值将改变270。
图28示例了在从主菜单238选择重置到默认参数252之后的使用者的选项。使用者可以选择参数330以将所有值改变为出厂默认值270。
图29示例了根据一些实施方式的后门参数332。通过后门参数332,使用者可以选择通过其他菜单不能正常访问的参数334。使用者可以选择参数334以改进与参数相关的一个或多个优选,且用于控制器75的合适的值将改变270。使用者选择的参数334可以来自参数列表336。该参数列表336可以包括上面公开的一个或多个参数和其他参数。
图30-47是描述根据本发明的一些实施方式的驱动器警报和故障的流程图。图30示例了控制器75的过热防止操作。当驱动器10运行时(步骤338),控制器75首先在步骤340确定功率模块温度是否大于第一温度(例如115摄氏度)。如果是,则执行过热故障操作(步骤342)。如果否,那么控制器75在步骤344确定功率模块温度是否大于第二温度(例如大约113摄氏度)。如果是,控制器75在步骤346减小电机速度一个第一值(例如大约12Hz每分钟)并继续到步骤348。如果否,那么控制器75在步骤350确定功率模块温度是否大于第三温度(例如大约110摄氏度)。如果是,控制器75在步骤352减小电机速度一个第二值(例如大约6Hz每分钟)并继续到步骤348。如果否,那么控制器75在步骤354确定功率模块温度是否大于第四温度(例如大约105摄氏度)。如果是,控制器75在步骤356减小电机速度一个第三值(例如大约3Hz每分钟)并继续到步骤348。如果否,那么控制器75前进到步骤348。在步骤348,控制器75确定速度是否已经减小(即控制器75是否执行了步骤346、352或356)。如果是,控制器75在步骤358确定功率模块温度是否小于第五值(例如大约95摄氏度)。如果功率模块温度小于第五值,那么控制器75增加电机速度一个第四值(例如大约1.5Hz每分钟),直到达到电机的初始速度(步骤360),且显示警报消息“TPM:速度减小”(步骤362)。如果功率模块温度大于第五值,控制器75直接前进到步骤362。从步骤362,控制器75返回到步骤338,并重复上述过程。如果控制器75在步骤348确定速度还没有减小(即控制器75没有执行步骤346、352或356),那么“TPM:速度减小”的警报消息被清除(步骤364),控制器75返回到步骤338,且重复上述操作。在一些实施方式中,被监测的功率模块可以是驱动器10本身或驱动器10的各种组件(例如控制器75的散热器、电机11或泵12)。
图31示例了控制器75的过热防止操作。当驱动器10运行时(步骤366),控制器75在步骤368确定驱动器电流是否受限(例如因为在图23中其大于参考服务因子安培参数298)。如果是,警报消息“TPM:服务安培”被显示(步骤370)且警报LED70点亮(步骤372)。然后控制器75返回到步骤366,在那里重复操作。如果驱动器电流没有受限,“TPM:服务安培”警报消息和警报LED70被清除(步骤374)。
图32示例了控制器75的卡住防止操作。当电机被触发启动(步骤376)时,控制器75在步骤378中确定启动序列是否完成。如果是,定时器和计数器被重置(步骤380),任何警报消息被清除(步骤382),且电机操作(步骤384)。如果启动序列在步骤378中没有完成,那么控制器75前进到步骤386以检测电流限制是否激活。如果没有,定时器和计数器可以被重置(步骤388),控制器75可以返回到步骤376。如果控制器75在步骤386检测到电流限制是激活的,那么定时器增加(步骤390)。如果定时器在步骤392处尚未达到五秒,控制器75返回到步骤376。然而,如果定时器已经在步骤392处达到五秒,控制器前进到步骤396。控制器75设定卡住警报(步骤396)并使计数器增加(步骤398)。如果计数器在步骤400处大于五,控制器75执行卡住故障操作(步骤402)。如果计数器不大于五,控制器75确定是否控制两线电机(步骤404)。如果是,控制器75为电机提供大约三倍的脉冲(步骤406),然后返回到步骤376。如果电机不是两线(例如如果电机是三线电机),那么控制器75执行一连串三个前进-反向循环(步骤408),然后返回到步骤376。
图33示例了控制器75的管路或管道破裂故障操作。在PID控制(步骤410)过程中,控制器75确定管道破裂参数(例如来自图25的管道破裂检测参数314)是否允许(步骤412)。控制器75继续返回步骤410,直至该参数允许。如果控制器75确定该参数在步骤412允许,则定时器增加(步骤414),且控制器75确定泵是否处于睡眠模式(步骤416)。如果泵处于睡眠模式,定时器被重置(步骤418),控制器75返回到步骤410。如果泵没有处于睡眠模式,控制器75在步骤420确定定时器是否已经增加到某个天数之上(例如通过没有睡眠的天数参数316来设定)。如果定时器没有超出设定的天数,则控制器75返回到步骤410。如果定时器已经超出设定的天数,电机惯性减速至停止,且显示“可能管道破裂”的故障信息(步骤422),使得驱动器10停止(步骤424)。
图34示例了控制器75的空运行检测操作。在PID控制(步骤426)过程中,控制器75在步骤428确定输出到电机的频率是否大于频率预设值(例如大约30Hz)。如果是,定时器被重置(步骤430)且控制器75返回到步骤426。如果频率在频率预设值之下,那么控制器75在步骤432确定压力是否大于压力预设值(例如大约10PSI)。如果是,定时器被重置(步骤430)且控制器75返回到步骤426。如果压力小于10PSI,定时器增加(步骤434)且控制器75确定定时器是否已经达到15秒(步骤436)。如果否,控制器75返回到步骤426。然而,如果定时器已经达到15秒,那么控制器75确定空运行已经发生并执行空运行故障操作(步骤438)。可以检测步骤428中的预设值以确保电机11操作在正常的操作频率(例如大于30Hz)。
图35示例了控制器75的空运行故障操作。如果达到了图34的步骤438,控制器75可以前进到步骤440。从步骤440,控制器75可以在步骤442检测重置计数器值是否小于设定值(例如设定在小于图26的重置参数320数之下的值)。如果重置计数器不小于设定值,则控制器75可以更新故障记录(步骤444),使电机惯性减速到停止并显示“空运行”故障消息(步骤446),从而停止驱动器10(步骤448)。如果在步骤442重置计数器小于设定值,该重置计数器增加(步骤450),且更新故障记录(步骤452)。然后控制器75可以使电机惯性减速到停止并显示“空运行-即将自动重启”故障信息(步骤454),然后启动故障定时器(步骤456),并持续检测使用者是否已经按下故障重置按钮64(步骤458)或者定时器是否已经超出时间值(步骤460)。该时间值可以是使用者设定的自动重置延迟参数318(在图26中示出)。如果使用者按下故障重置按钮64,控制器75将从步骤458前进到步骤462,并清除显示的故障消息,然后停止驱动器10(步骤448)。如果定时器超出时间值,那么控制器75将从步骤460前进到步骤464并清除显示的故障消息,然后以PID模式重启驱动器10(步骤466)。
图36示例了控制器75的卡住故障操作。当检测到卡住(步骤468),故障记录被更新(步骤470)。在步骤470之后,电机惯性减速到停止并显示“外部物体卡住”故障消息(步骤472),然后停止驱动器10(步骤474)。
图37示例了控制器75的过热温度故障操作。当驱动器10得到供电(步骤476)时,控制器75确定功率模块温度是否太高(步骤478),例如采用图30中的过热防止操作。如果功率模块温度不是太高,故障被清除(步骤480)且控制器75返回到步骤476。如果功率模块温度太高,故障记录被更新(步骤482),电机惯性减速到停止并显示“驱动器温度-即将自动重启”故障消息(步骤485),且故障定时器增加(步骤486)。然后控制器75持续确定使用者是否已经按下故障重置按钮64(步骤488),直到定时器已经增加超过一个值(步骤490)。如果使用者已经按下故障重置按钮64或者如果定时器已经增加超过所述值,控制器75分别地从步骤488或步骤490前进到步骤492以检测故障状况是否仍然存在。如果故障状况仍然存在,控制器75返回到步骤486。如果故障状况不存在,控制器75将清除故障(步骤480)并返回到步骤476。
电机11和泵12的组合可以满足泵制造商指定的典型的性能要求,同时使得电流保持在电机11指定的服务因子安培之下。对于提供的每个电机HP,性能可以匹配典型的电容器启动/电容器运行控制箱。如果电机11操作在这样的指定之外,那么控制器75可能产生故障并停止电机11。例如,图38示例了控制器75的过电流故障操作。当驱动器10被供电时(步骤494),控制器75确定是否存在高的电流峰值(步骤496),例如采用图31的过电流防止操作。如果没有高的电流峰值,故障被清除(步骤498),控制器75返回到步骤494。如果存在高的电流峰值,故障记录被更新(步骤500),电机惯性减速到停止,显示“电机高电流-即将自动重启”的故障消息(步骤502),且故障定时器增加(步骤504)。然后控制器75持续确定使用者是否已经按下故障重置按钮64(步骤506),直至定时器已经增加超过一个值(步骤508)。如果使用者已经按下故障重置按钮64或者如果定时器已经增加超过所述值,控制器75从步骤506或步骤508分别地前进到步骤510以检测故障状况是否仍然存在。如果故障状况仍然存在,则控制器75返回到步骤504。如果故障状况不存在,则控制器75将清除故障(步骤498)并返回到步骤494。
图39示例了控制器75的过电压故障操作。当驱动器10被供电时(步骤512),控制器75确定是否已经超出最大总线电压(步骤514)。如果总线电压尚未超出最大值,故障被清除(步骤516),控制器75返回到步骤512。如果总线电压已经超出最大值,故障记录被更新(步骤518),电机惯性减速到停止,显示“过电压-即将自动重启”的故障消息(步骤520),且故障定时器增加(步骤522)。然后控制器75持续确定使用者是否已经按下故障重置按钮64(步骤524),直至定时器已经增加超过一个值(步骤526)。如果使用者已经按下故障重置按钮64或者如果定时器已经增加超过所述值,控制器75从步骤524或步骤526分别地前进到步骤528以检测故障状况是否仍然存在。如果故障状况仍然存在,则控制器75返回到步骤522。如果故障状况不存在,则控制器75将清除故障(步骤516)并返回到步骤512。
图40示例了控制器75的内部故障操作。当驱动器10被供电时(步骤530),控制器75确定是否任何内部电压在范围之外(步骤532)。如果内部电压不在范围之外,故障被清除(步骤534),控制器75返回到步骤530。如果内部电压在范围之外,故障记录被更新(步骤536),电机惯性减速到停止,显示“内部故障-即将自动重启”的故障消息(步骤538),且故障定时器增加(步骤540)。然后控制器75持续确定使用者是否已经按下故障重置按钮64(步骤542),直至定时器已经增加超过一个值(步骤544)。如果使用者已经按下故障重置按钮64或者如果定时器已经增加超过所述值,控制器75从步骤542或步骤544分别地前进到步骤546以检测故障状况是否仍然存在。如果故障状况仍然存在,则控制器75返回到步骤540。如果故障状况不存在,则控制器75将清除故障(步骤534)并返回到步骤530。
图41示例了控制器75的接地故障操作。当驱动器10被供电时(步骤548),控制器75持续确定在接地或地面引线和任何电机引线(步骤550)之间是否存在电流流动。如果是,故障记录被更新(步骤552),电机惯性减速到停止,显示“接地故障”的故障消息(步骤554),且停止驱动器10(步骤556)。
图42示例了控制器75的开路变送器故障操作。当在PID模式时(步骤558),控制器75确定变送器输入端测量到的电流是否小于一个值,例如2毫安(步骤560)。如果电流不小于该值,控制器75返回到步骤558。如果电流小于该值,故障记录被更新(步骤562),电机惯性减速到停止,显示“开路变送器-即将自动重启”的故障消息(步骤564),且故障定时器增加(步骤566)。然后控制器75持续确定使用者是否已经按下故障重置按钮64(步骤568),直至定时器已经增加超过一个值(步骤570)。如果使用者已经按下故障重置按钮64或者如果定时器已经增加超过所述值,控制器75从步骤568或步骤570分别地前进到步骤572以检测故障状况是否仍然存在。如果故障状况仍然存在,控制器75返回到步骤566。如果故障状况不存在,控制器75返回到步骤558。
图43示例了控制器75的短路变送器故障操作。当在PID模式时(步骤574),控制器75确定变送器输入端测量到的电流是否大于一个值,例如25毫安(步骤576)。如果电流不大于该值,则控制器75返回到步骤574。如果电流大于该值,故障记录被更新(步骤578),电机惯性减速到停止,显示“短路变送器-即将自动重启”的故障消息(步骤580),且故障定时器增加(步骤582)。然后控制器75持续确定使用者是否已经按下故障重置按钮64(步骤586),直至定时器已经增加超过一个值(步骤588)。如果使用者已经按下故障重置按钮64或者如果定时器已经增加超过所述值,控制器75从步骤586或步骤588分别地前进到步骤590以检测故障状况是否仍然存在。如果故障状况仍然存在,则控制器75返回到步骤582。如果故障状况不存在,则控制器75返回到步骤574。
图44A-44B示例了控制器75的多故障操作。参见图44A,当驱动器10被供电时(步骤592),控制器75持续地确定是否已经发生故障(步骤594)。如果故障已经发生,计数器增加(步骤596)且控制器75确定计数器是否已经达到一个值,例如十(步骤598)。如果计数器已经达到该值,电机惯性减速到停止,显示“多故障”故障消息(步骤600),且驱动器10停止(步骤602)。图44B的步骤用于提供计数器可以达到该值的时间范围。当驱动器10被供电时(步骤592),控制器75持续地确定计数器(即在图44A的步骤596中的计数器)是否已经增加(步骤604)。如果是,定时器增加(步骤606)。只要计数器大于零,控制器75就持续增加定时器,直到定时器达到一个值,例如三十分钟(步骤608)。一旦定时器已经达到该值,计数器减少且定时器重置(步骤610)。
图45示例了控制器75的欠电压故障操作。当驱动器10被供电时(步骤612),控制器75确定总线电压是否在最小值以下(步骤614)。如果总线电压没有在最小值以下,故障被清除(步骤616),控制器75返回到步骤612。如果总线电压小于最小值,故障记录被更新(步骤618),电机惯性减速到停止,显示“欠电压-即将自动重启”的故障消息(步骤620),故障记录保存在存储器中,例如该设备的电可擦除可编程只读存储器,或者EEPROM(步骤622),且故障定时器增加(步骤624)。然后控制器75持续确定使用者是否已经按下故障重置按钮64(步骤626),直至定时器已经增加超过一个值(步骤628)。如果使用者已经按下故障重置按钮64或者如果定时器已经增加超过所述值,控制器75从步骤626或步骤628分别地前进到步骤630以检测故障状况是否仍然存在。如果故障状况仍然存在,则控制器75返回到步骤624。如果故障状况不存在,则控制器75将清除故障(步骤616)并返回到步骤612。
图46示例了控制器75的硬件故障操作。当控制器75识别到硬件错误(步骤632),故障记录被更新(步骤634)。在步骤634之后,电机惯性减速到停止,显示“硬件错误”的故障消息(步骤636),且停止驱动器10(步骤638)。
图47示例了控制器75的外部故障操作。当驱动器10被供电时(步骤640),控制器75持续地确定是否存在任何外部故障参数,例如从在输入功率终端块28或者数字输入/输出(I/O)弹簧终端30的继电器输入(步骤642)。如果是,控制器75确定数字输入是否高(步骤644)。如果数字输入不高,控制器75确定外部故障是否激活(步骤646)。如果外部故障没有激活,控制器75返回到步骤640。如果外部故障是激活的,控制器75在步骤648中清除“外部故障”故障消息(如果其被显示的话),且恢复设备先前的状态和操作(步骤650)。如果在步骤644中数字输入是高的,故障记录被更新(步骤652),且设备的当前状态和操作被保存(步骤654)。步骤654之后,电机惯性减速到停止,显示“外部故障”的故障消息(步骤656),然后驱动器10停止(步骤658)。
图48-63是描述根据本发明的一些实施方式的控制面板14的控制操作的流程图。图48示例了根据一些实施方式的抽出按钮控制操作。当抽出按钮40压下时(步骤660),控制器75首先确定控制面板14是否锁定或者处于口令保护模式(步骤662)。如果是,控制器75执行键锁定错误操作(步骤664)。如果否,阀屏幕666显示(步骤668),询问使用者阀是否是打开的。一旦使用者选择阀是打开还是不打开并按下回车,阀参数值被改变(步骤670)。然后控制器75在步骤672确定阀参数值是否为是(即阀是否是打开的)。如果阀参数不为是(即如果使用者选择阀没有打开),则显示停止的屏幕(步骤674),指示泵12是停止的。如果阀参数为是,控制器75相应地设定LED指示器66开或关(步骤676),显示状态屏幕678(步骤680),并运行抽出操作以抽出模式驱动电机11(步骤682)。状态屏幕678可以包括关于泵12的信息,例如在抽出模式过程中的电机频率、压力和电机电流。
图49示例了根据一些实施方式的压力预设按钮控制操作。当按下压力预设按钮42时(步骤684),控制器75首先确定控制面板14是否锁定(步骤686)。如果是,控制器75执行键锁定错误操作(步骤688)。如果控制面板14没有锁定,控制器75相应地设定LED指示器66开或关(步骤690),显示预设压力参数(步骤692)。使用者可以采用键盘调整显示的压力参数,并点击回车改变预设压力参数的值,从而改变控制器75的压力设定点(步骤694)。
图50示例了根据一些实施方式的主菜单按钮控制操作。当按下主菜单按钮44时(步骤696),控制器75首先确定控制面板14是否被锁定(步骤698)。如果是,控制器75执行键锁定错误操作(步骤700)。如果控制面板14没有被锁定,控制器75相应地设定LED指示器66开或关(步骤702),且显示如在关于图16的描述中所述的主菜单(步骤704)。
图51示例了根据一些实施方式的故障记录按钮控制操作。当按下故障记录按钮46时(步骤706),控制器75相应地设定LED指示器66开或关(步骤708),且显示故障记录,为使用者提供详细的故障历史信息(步骤710)。
图52示例了根据一些实施方式的回车按钮控制操作。当按下回车按钮56时(步骤712),控制器75首先在步骤714中确定故障记录是否激活(例如被显示)或者停止的状态屏幕是否被显示(步骤716)。如果步骤714或步骤716的任一个为真(ture),控制器75执行无效键错误操作(步骤718)。如果故障记录或停止的状态屏幕都没有显示,控制器75确定控制面板14是否被锁定(步骤720)。如果是,控制器75执行键锁定错误操作(步骤722)。如果控制面板14没有锁定,控制器75确定当前显示是否选择了菜单选项或参数(步骤724)。如果显示的是当前选择的菜单选项,控制器75将进入选择的菜单(步骤726)。如果显示的是当前选择的参数选项,则控制器75确定参数是否突出显示(步骤728)。如果参数突出显示,控制器75保存所选择的参数的值并取消参数的突出显示(步骤730)。如果在步骤728中参数没有突出显示,则控制器75确定参数是否可以随着电机的运行和驱动器10的停止而改变(步骤732)。如果否,则执行运行错误操作(步骤734)。如果参数可以改变,那么所选择的参数突出显示(步骤736)。
图53示例了根据一些实施方式的后退按钮控制操作。当按下后退按钮54时(步骤738),控制器75确定状态屏幕是否被显示(步骤740)。如果是,则执行无效键错误操作(步骤742)。如果状态屏幕没有显示,则控制器75确定显示中的行是否突出显示(步骤744)。如果是,突出显示行上的新值被取消且突出显示也被取消(步骤746)。如果在步骤744中没有突出显示行,则显示父级或前一级菜单(步骤748)。
图54示例了根据一些实施方式的上/下按钮控制操作。当按下上或下方向按钮的任一个52时(步骤750),控制器75确定显示中的行是否突出显示(步骤752)。如果是,那么控制器75确定自动管路填充操作是否执行(步骤754)。如果是,控制器75前进到手动管路填充操作(步骤756),如参考图9所述的,然后滚动到显示中的另一个值(步骤758)。如果控制器75确定在步骤754中没有执行自动管路填充操作,控制器75前进到步骤758并滚动到显示中的另一个值。如果在步骤752中控制器75确定没有突出显示行,那么控制器75确定显示中的菜单是否可以流动(步骤760)。如果是,菜单被流动(步骤762)。如果否,执行无效键错误操作(步骤764)。
图55示例了根据一些实施方式的左/右按钮控制操作。当按下左或右方向按钮52时(步骤766),控制器75确定显示中的行是否突出显示(步骤768)。如果否,执行无效键错误操作(步骤770)。如果在步骤768中控制器75确定有行突出显示,那么控制器75确定显示中的光标是否可以移动(步骤772)。如果是,光标被移动(步骤774)。如果否,执行无效键错误操作(步骤776)。
图56示例了根据一些实施方式的口令按钮控制操作。当按下口令按钮48时(步骤778),控制器75首先确定控制面板14是否被锁定(步骤780)。如果否,显示状态屏幕(步骤782)。如果控制面板14被锁定,控制器75相应地设定LED指示器66为开或关(步骤784),且执行键锁定错误操作(步骤786)。如果使用者然后输入口令(步骤788),控制器75确定口令是否正确(步骤790)。如果口令是正确的,则解锁任何可锁定的键(792),并且显示状态屏幕(步骤794)。如果口令是不正确的,执行无效口令错误操作(步骤796),然后显示状态屏幕(步骤794)。在一些实施方式中,可锁定的键可以包括方向按钮52、语言按钮50、抽出按钮40、压力预设按钮42和/或主菜单按钮44。
图57示例了根据一些实施方式的语言按钮控制操作。当按下语言按钮50时(步骤796),控制器75首先确定控制面板14是否被锁定(步骤798)。如果是,控制器75执行键锁定错误操作(步骤800)。如果控制面板14没有被锁定,控制器75相应地设定LED指示器66开或关(步骤802),且显示语言参数(步骤804)。使用者可以采用键盘改变显示的语言,并点击回车以更新语言参数(步骤806)。
图58示例了根据一些实施方式的状态按钮控制操作。当按下状态按钮58时(步骤808),控制器75相应地设定LED指示器66开或关(步骤810),并确定当前状态屏幕是否显示(步骤812)。如果否,则显示当前状态屏幕814或816(步骤818)。如果控制器75在步骤812中确定当前状态屏幕显示,则当前状态屏幕被清除并显示功率状态屏幕820或822(步骤824)。
图59示例了根据一些实施方式的停止按钮控制操作。当按下停止按钮60时(步骤826),控制器75相应地设定LED指示器66开或关(步骤828),并显示停止的状态屏幕830(步骤832)。然后控制器75停止驱动器10(步骤834),如参考图10所述的。
图60示例了根据一些实施方式的自动启动按钮控制操作。当按下自动启动按钮62时(步骤836),控制器75相应地设定LED指示器66开或关(步骤838),并显示状态屏幕840(步骤842)。然后控制器75运行自动管路填充操作(步骤844),如参考图8所述的。
图61示例了根据一些实施方式的故障重置按钮控制操作。当按下故障重置按钮64时(步骤846),控制器75确定是否存在激活的故障(步骤848)。如果否,控制器75执行无效键错误操作(步骤850)。如果存在激活的故障,控制器75确定故障状况是否仍然存在(步骤10)。如果是,控制器75停止驱动器10(步骤854),如参考图10所述的。如果否,控制器75首先清除故障(步骤856),然后停止驱动器10(步骤854)。
图62A-62D示例了根据一些实施方式的LED指示器控制操作。如图62A所示,如果故障激活并即将重启(步骤856),故障LED72闪光(步骤858),且显示“即将重启”消息(步骤860)。如图62B所示,如果故障是激活的且驱动器10停止(步骤862),故障LED72闪光(步骤864),且显示“停止驱动器”消息(步骤866)。如图62C所示,如果TPM激活且驱动器10仍然运行(步骤868),警报LED70亮(步骤870),且显示描述警报的消息(步骤872)。如图62D所示,当驱动器10被供电时(步骤874),开LED68亮(步骤876)。
图63A-63D示例了根据一些实施方式的错误显示控制操作。如图63A所示,对于无效键错误操作(步骤878),可以显示“键错误!无效键”的错误屏幕(步骤880)。控制器75可以显示该错误屏幕持续一个时间期间,例如0.9秒(步骤882),然后该显示回到先前的屏幕(步骤884)。如图63B所示,对于键锁定错误操作(步骤886),可以显示“错误!按口令键”的错误屏幕(步骤888)。控制器75可以显示该错误屏幕持续一个时间期间,例如0.9秒(步骤890),然后该显示回到先前的屏幕(步骤892)。如图63C所示,对于无效口令错误操作(步骤894),可以显示“错误!无效口令”的错误屏幕(步骤896)。控制器75可以显示该错误屏幕持续一个时间期间,例如0.9秒(步骤898),然后该显示回到先前的屏幕(步骤900)。如图63D所示,对于运行错误操作(步骤902),可以显示“错误!编辑前停止”的错误屏幕(步骤904)。控制器75可以显示该错误屏幕持续一个时间期间,例如0.9秒(步骤906),然后该显示回到先前的屏幕(步骤908)。
本领域技术人员可以理解的是,尽管本发明已经结合特定的实施方式和例子在上文中描述,但是本发明不必如此受限,许多其他实施方式、例子、使用、变形和对上述实施方式、例子和使用的脱离都意在通过后面的权利要求而包含在内。这里引用的每个专利和公开文本的整个公开通过引用结合于此,如同每个这样的专利或公开文本单独地通过引用结合于此。本发明的各种特征和优点在下面的权利要求中陈述。
Claims (20)
1.一种控制通过电机驱动的泵的方法,该泵与流体系统流体连通,该方法包括:
确定该电机的操作频率是否已经达到稳定状态操作频率,所述稳定状态操作频率由控制器确定;
一旦该电机已经达到稳定状态操作频率,使得该泵临时地升高该流体系统中的压力,压力的临时升高是通过增大电机的操作频率为高于所述稳定状态操作频率而导致的,并且该流体系统中的临时升高的压力大于压力设定点;
确定在通过降低电机的操作频率而使得泵停止该临时升高之后流体系统中的压力是否下降为低于临时升高的压力;和
如果在通过降低电机的操作频率而使得泵停止该临时升高之后临时升高的压力不下降,则使得该泵进入睡眠模式。
2.根据权利要求1所述的方法,还包括如果在泵停止该临时升高之后临时升高的压力下降,则使得该泵继续正常操作。
3.根据权利要求2所述的方法,还包括周期性地确定该电机是否已经再次达到稳定状态操作频率。
4.根据权利要求3所述的方法,还包括大约每两分钟,确定该电机是否已经达到稳定状态操作频率。
5.根据权利要求1所述的方法,其中确定该电机是否已经达到稳定状态操作频率包括确定该电机的速度是否是稳定的。
6.根据权利要求1所述的方法,其中进入该睡眠模式是独立于井深的。
7.根据权利要求1所述的方法,还包括将压力升高大约三磅每平方英寸。
8.根据权利要求7所述的方法,还包括确定该流体系统中的临时升高的压力是否下降到或者低于压力设定点。
9.根据权利要求1所述的方法,还包括当该流体系统中的压力下降到或者低于压力设定点减去大约五磅每平方英寸时,禁止该睡眠模式。
10.根据权利要求1所述的方法,还包括通过确定该电机的频率是否已经保持恒定至少大约一分钟,来确定该电机是否已经达到稳定状态操作频率。
11.根据权利要求1所述的方法,还包括确定在泵停止该临时升高之后的大约15秒内流体系统中的临时升高的压力是否下降。
12.一种控制通过电机驱动的泵的方法,该泵与流体系统流体连通,该方法包括:
如果流体系统中的压力在临时地升高压力后不下降,则使得该泵进入睡眠模式,压力的临时升高是通过增大电机的操作频率为高于稳定状态操作频率而导致的;
确定该泵是否在预定的时间期间内已经进入睡眠模式,所述确定是由控制器执行的;和
如果所述控制器确定该泵在该预定的时间期间内没有进入睡眠模式,则关闭该泵。
13.根据权利要求12所述的方法,其中所述预定的时间期间是至少大约四小时。
14.根据权利要求12所述的方法,其中所述预定的时间期间可达大约十四天。
15.根据权利要求12所述的方法,还包括确定该电机是否已经达到稳定状态操作频率。
16.根据权利要求15所述的方法,还包括一旦该电机已经达到稳定状态操作频率,使得该泵临时地升高流体系统中的压力。
17.根据权利要求12所述的方法,还包括在显示器上指示存在管道破裂故障。
18.根据权利要求12所述的方法,还包括当存在管道破裂故障时自动地使得继电器输出激活。
19.根据权利要求12所述的方法,还包括修改该预定的时间期间。
20.根据权利要求12所述的方法,还包括如果所述控制器确定该泵在该预定的时间期间内没有进入睡眠模式,则临时关闭该泵。
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US20100310382A1 (en) | 2010-12-09 |
CN104033367B (zh) | 2017-04-12 |
US20170234117A1 (en) | 2017-08-17 |
AU2010202387B2 (en) | 2015-01-29 |
AU2010202387A1 (en) | 2010-12-23 |
EP2273127B1 (en) | 2019-11-06 |
CA2707269A1 (en) | 2010-12-09 |
US20230068188A1 (en) | 2023-03-02 |
EP2273127A3 (en) | 2017-01-04 |
CN104074731B (zh) | 2017-10-20 |
US20200088189A1 (en) | 2020-03-19 |
CN101982659A (zh) | 2011-03-02 |
MX2010006269A (es) | 2011-08-10 |
CA2707269C (en) | 2018-08-21 |
US10590926B2 (en) | 2020-03-17 |
US9556874B2 (en) | 2017-01-31 |
US11493034B2 (en) | 2022-11-08 |
CN104033367A (zh) | 2014-09-10 |
CN104074731A (zh) | 2014-10-01 |
EP2273127A2 (en) | 2011-01-12 |
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