Remote Drag Hose Pump Control System
A pump control system is described, that is suitable for controlling multiple pumps coupled in series to pump fluids great distances. The apparatus of the invention is particularly well suited for pumping liquid manure or other fluid slurries from a main tank to a pumping field using booster pumps. The apparatus includes a control system that remotely controls functions on the main pump and booster pumps.
Not Applicable
FEDERAL SPONSORSHIPNot Applicable
JOINT RESEARCH AGREEMENTNot Applicable
TECHNICAL FIELDThis invention pertains generally to control systems for fluid pumps. More particularly, the invention pertains to a control system for remotely controlling multiple fluid pumps coupled in series in liquid manure drag hose or other fluid delivery applications.
BACKGROUNDFrom time to time there has been a need to pump fluids through hose or pipe over considerable distances from a fluid source to a desired location where the fluid is dispersed. A pump may be utilized to pump these fluids from the fluid source and through the pipe. As fluid is pumped from the fluid source the fluid pressure within the pipe drops as the fluid travels away from the fluid source. Booster pumps or relay pumps have been utilized to keep the fluid pressure above a desired threshold, however these relay pumps have required hard wiring or manual operation of the master and relay pumps. Those skilled the art will appreciate that some fluids pumped over considerable distances may include solids suspended within the fluid however this combination is referred to herein simply as a fluid.
In recent years, a main or primary pump and auxiliary pumps have been utilized in a variety of situations including pumping water for irrigation, pumping waste fluids from oil, gas and coal activities, and distributing liquid manure or fluids from dairy and hog farms. When pumping fluids, the agricultural field on which the manure is applied may be several miles from the barn or holding tank of the manure. A series of hoses and relay pumps may be utilized to pump the liquid manure to a desired field and then a tractor or other farm implement may pull a length of drag hose across the field. When applying manure to a field the hose may be connected to a tool bar pulled by the tractor so that the manure exits the tool bar beneath the soil. Although the flow of manure out the end of the hose and tool bar may be controlled at the tractor, the primary pump and auxiliary pumps have required manual adjustment to create the desired fluid pressure throughout the length of hose. In recent years, the desire to control the auxiliary pumps remotely has been recognized, however the seclusion of many agricultural fields and varying pump electronics have proven difficult to affectively overcome.
SUMMARYEmbodiments according to aspects of the invention are capable of controlling, from the cab of a tractor, a fluid flow and pressure of a remote primary pump and secondary or auxiliary pumps. The pumps may be coupled in series to pump fluid from a supply tank to a tool bar or applicator pulled by the tractor. The invention may be implemented in a drag line circuit including a primary pump, secondary pumps, fluid conduits, and a master control system to remotely control the functions of the primary and secondary pumps and to adjust flow rate from the primary pump and secondary pumps.
In an embodiment of the invention the pump control apparatus includes a fluid pump control system to remotely control a primary pump and secondary pumps. The control system may also remotely adjust flow rate from the primary pump and secondary pumps. The apparatus further includes bi-directional, radio frequency modems coupled to the primary pump, secondary pumps and control system to facilitate wireless transmission of data between the primary pump, secondary pumps and control system. The modems may be of the Wireless Link Module (WLM) type having a spread spectrum serial interface. The control system may further include programmable logic controls electrically coupled to the primary pump and secondary pumps. A MODBUS communication protocol and RS 485 electrical standard may be utilized to couple the WLM's and programmable logic controls within the control system. In this way the control system may control the primary pump and secondary pumps from a remote location.
In another embodiment of the invention the pump control apparatus includes a liquid pump control system to remotely stop a master and secondary pumps and adjust flow rate from the master pump and secondary pumps. The apparatus of the invention also includes bi-directional, spread spectrum, radio frequency, serial interface modems coupled to the master pump and secondary pumps to facilitate wireless transmission of data between the master pump, secondary pumps and control system. Further, programmable logic controls may be electrically coupled to the primary and secondary pumps. The modems may incorporate a MODBUS communication protocol and RS 485 electrical standard to couple the programmable logic controls with the control system.
Another embodiment according to aspects of the invention includes a fluid tank, a transportable applicator, fluid conduits coupling the fluid tank in fluid communication with the transportable applicator, a master pump, secondary pumps, a control system including programmable logic controls to remotely control the master and secondary pumps and adjust flow rate from the master pump and secondary pumps, and bi-directional, spread spectrum, radio frequency, serial interface modems coupled to the master pump and secondary pumps to facilitate wireless transmission of data between the master pump, secondary pumps and control system, utilizing a MODBUS communication protocol and RS 485 electrical standard. The transportable applicator includes a fluid outlet and a shutoff valve controlling flow of fluid from the transportable applicator. In this aspect of the invention the master pump is coupled to the fluid conduits between the fluid tank and the transportable applicator and the secondary pumps are coupled to the fluid conduits between the master pump and the transportable applicator.
The transportable applicator may include a high speed fluid volume counter and flow meter and likewise the master and secondary pumps may also include high speed fluid volume counters and flow meters. The control system may control the master pump and secondary pumps remotely or from a location proximate the transportable applicator. The counters coupled to the applicator and pumps transmit an analog or digital signal associated fluid volume and the flow meters coupled to the applicator and pumps transmits a signal associated with fluid flow rate.
Another embodiment according to aspects of the invention includes a fluid tank, a transportable applicator having a fluid outlet and a shutoff valve controlling flow of fluid from the transportable applicator. The transportable applicator further includes a high speed fluid volume counter and flow meter. Fluid conduits couple the fluid tank in fluid communication with the transportable applicator. A master pump having pressure sensors is coupled to the fluid conduits between the fluid tank and the transportable applicator and secondary pumps having pressure sensors are coupled to the fluid conduits between the master pump and the transportable applicator. A control system coupled to the pumps includes programmable logic controls to remotely shut off the master and secondary pumps and to adjust a flow rate from the master pump and secondary pumps. Bi-directional, spread spectrum, radio frequency, serial interface modems couple the master pump and secondary pumps to facilitate wireless transmission of data between the master pump, secondary pumps and control system. The modems are of the Wireless Link Module (WLM) type and utilize a MODBUS communication protocol and RS 485 electrical standard. The master pump sensors outputs an analog signal associated with pressure and the secondary pumps sensors outputs analog signals associated with pressure.
The accompanying drawings, which are incorporated in and constitute a portion of this specification, illustrate embodiments of the invention and, together with the detailed description, serve to further explain the invention. The embodiments illustrated herein are presently preferred; however, it should be understood, that the invention is not limited to the precise arrangements and instrumentalities shown. For a fuller understanding of the nature and advantages of the invention, reference should be made to the detailed description in conjunction with the accompanying drawings.
In the various figures, which are not necessarily drawn to scale, like numerals throughout the figures identify substantially similar components.
The following description provides detail of various embodiments of the invention, one or more examples of which are set forth below. Each of these embodiments are provided by way of explanation of the invention, and not intended to be a limitation of the invention. Further, those skilled in the art will appreciate that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. By way of example, those skilled in the art will recognize that features illustrated or described as part of one embodiment, may be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present invention also cover such modifications and variations that come within the scope of the appended claims and their equivalents.
The pump control system of the present invention allows a user to remotely control multiple functions of primary and secondary pumps coupled in series to pump fluids considerable distance in remote locations where telephone, satellite and other wireless services are not available. The apparatus of the present invention is particularly well suited for pumping liquid manure or water for irrigation over great distances. In an embodiment of the invention a control system of the present invention is particularly well suited to, for example, give a tractor driver complete monitoring and control capabilities of both primary and secondary mechanical or digital diesel pumps coupled in series in a drag line setup. A touch screen having an operator interface that is mounted in the tractor cab gives the user the ability to throttle up or down all of the pumps in the drag line setup. The user may also control an idle, gate valve, and off switch of each pump. Further, the control system includes a PLC (Programmable Logic Controller) coupled to each pump and the system is suitable for use with diesel pumps having either analog or digital sensors.
Also, a WLM (Wireless Link Module) modem is coupled to each pump and transmits data associated with each pump utilizing a MODBUS communication protocol and RS 485 electrical standard. In an alternative embodiment, the modems may further couple to a wireless card and router to electrically couple the system and transmit data to a smart phone or other computer via wi-fi and the internet, for example, if service is available. The WLM modems of known suitable construction are of the bi-directional, radio frequency, serial interface type capable of transmitting data wirelessly between pumps (at least 7 miles, for example). The modems on the secondary pumps also act as repeaters between the primary pump and the controller located in the tractor cab.
The PLC incorporated into the Operator Interface touch screen monitor located in the tractor cab may act as the “master” controller of the MODBUS and sends commands and receives signals from the subservient or “slave” PLC controllers coupled to each pump. Each pump PLC controller may gather vital data such as engine rpm, temp, oil pressure, and inlet/outlet pressures, and may execute commands sent by the master PLC. The user may use the operator interface and touch screen display to evaluate the data from each pump and may make any throttle changes to the pumps to obtain the exact desired fluid flow to the field. The user also has the ability to turn off any pump motor, if desired. The control system may also display the current fluid or product flow rate (gpm), as well as the total gallons pumped. This information may be stored in an internal memory coupled with the control system and the data may be stored in separate counter registers.
In an embodiment of the invention the MODBUS master is positioned in the cab of the tractor and is hard wired with a tool bar implement pulled behind the tractor. The implement includes a flow meter, counter and shutoff valve that may also be controlled by the PLC of the MODBUS master. The MODBUS master is coupled to an Operator Interface touch screen monitor. The monitor may display all of the data from any pumps coupled in the system. The info may be displayed, for example, on a quad screen showing information corresponding to four pumps or may include a single screen mode that displays information and data corresponding to a selected pump. The MODBUS master may also be utilized to communicate and effectively control the pumps to throttle up or throttle down the pumps according to the user's needs. The MODBUS master may also control the gate valve and off switches on all of the pumps as well. The master controller also calculates the total gallons pumped using HSC's (high speed counters). The individual counters may include separate start, stop, and reset buttons and may be controlled separately. Further, information from the counters may be displayed or stored into four separate registers. The stored information may be used to monitor a particular field or workflow. The control system may incorporate an alert screen on the monitor if any predetermined thresholds for a pump are exceeded. The alert screen may, for example, indicate information to a user concerning a pump motor's temp, oil pressure, and outlet pressure.
In an embodiment of the invention MODBUS slaves are coupled to the primary and secondary pumps. For each pump the MODBUS slave may be coupled to a PLC and OI (operator interface) touch screen of suitable known construction. The user may utilize the PLC and OI monitor to control the pump manually or allow the control system to control the pumps via the master MODBUS. The pumps may include one or more sensors that transmit analog or digital signals corresponding to the pump engine or motor temp, oil pressure and rpm's.
A mechanical pump may, for example, include separate analog sensors that transmit separate analog signals associated with the temperature, pressure and rpm's of the pump's engine. A first analog 4-20 mA sensor may be plumbed into the engine's radiator coolant circuit to calculate engine temp. Another 4-20 mA sensor may be installed in the engine block to calculate the oil pressure and data signals associated with the engine rpm's may be obtained from an analog sensor coupled to the pump engine's alternator. The analog signals may be processed through a signal conditioner and the signals may be amplified or stepped to 24 v with an op amp, which results in a 24 v pulse for each engine revolution, calculated by the control system. Sensors may also be mounted on the inlet and outlet sides of the pump's fluid flow to gather the pressure of the fluid flow.
The MODBUS slave may also take commands from the MODBUS master (positioned in the tractor cab) and executes the command at the pump. For example if a user wants to throttle up a particular pump the user selects the pump on the tractor cab OI (Operator Interface display monitor) and selects the throttle up button. The MODBUS master communicates to the corresponding MODBUS slave a command to throttle up the pump. The control system may also utilize an addressing system. From each pump's OI a user may set a pump crew number and address associated with the pump. The associated crew number allows a master having a corresponding crew number to control any pumps within that crew. If a pump is disabled, a user may enable the pump as the long as the crew number of the pump matches the crew number of the master controller running the pump. The pumps address (1-4) may determine where the pump will be displayed on the master's quad screen.
In an embodiment, the control system may be utilized to run multiple crews. For example a farmer having multiple drag hose systems may utilize a single master to control the serial coupled pumps as long as it is addressed accordingly with the corresponding group of pumps. A master controller's crew number is set utilizing the OI, which may provide further flexibility between the master and slaves. From the master controller a user may also enable or disable pumps according to the number of pumps connected in the particular drag hose arrangement. The OI master screen may be programmed to display a different visual indication (changing the shade of buttons to grey, for example) for pumps within a drag line fluid circuit that are disabled.
With reference now to the Figures, details of embodiments of the invention will be further discussed. Referring first to
Those skilled in the art will appreciate that the WLM may utilize frequency hopping, a high radio frequency data rate, a sensitive RF receiver and a 32 bit error correction to ensure data throughput in high interference or reflective environments. Further, utilizing the utilizing a MODBUS communication protocol and RS 485 standard allows the user to affectively link and control either mechanical, digital or a combination of mechanical and digital motors. With reference to
In an embodiment according to aspects of the invention the default screen for the Operator Interface is split into quadrants and displays information corresponding to the lead or primary pump 90 and secondary or booster pumps 92 coupled in the system (see
The default touch screen may also provide to the user additional options to control the pump utilizing a menu button 130 that, when depressed, displays additional pump control options (see
From the menu 130 screen the user may also depress gallon counter 134 button that, when depressed, displays secondary screens (see
The crew number 196 and pump number 198 may be set by accessing the pump address 194 secondary screen. The user may also control the throttle for each pump by accessing the interactive secondary screen 200 corresponding to the throttle control. The user may use toggle buttons 202, 204 and 206 to increase or decrease the throttle or to idle the pump. The user may further access a secondary screen 210 for digital pumps that displays data associated with the pumps high speed counter frequency 212, inlet fluid pressure 214, outlet fluid pressure 216, pump engine temperature 218 and engine oil pressure 220. A secondary screen 230 is also provided for mechanical pumps that displays data associated with the pump numbers 232, pump analog output signal 234, throttle time 236 and idle time 238. Those skilled in the art will appreciate that other secondary screens may be advantageous for the user to further remotely manipulate the control of multiple fluid pumps coupled in series over a substantial distance.
These and various other aspects and features of the invention are described with the intent to be illustrative, and not restrictive. This invention has been described herein with detail in order to comply with the patent statutes and to provide those skilled in the art with information needed to apply the novel principles and to construct and use such specialized components as are required. It is to be understood, however, that the invention can be carried out by specifically different constructions, and that various modifications, both as to the construction and operating procedures, can be accomplished without departing from the scope of the invention. Further, in the appended claims, the transitional terms comprising and including are used in the open ended sense in that elements in addition to those enumerated may also be present. Other examples will be apparent to those of skill in the art upon reviewing this document.
Claims
1. A pump control apparatus, said apparatus comprising:
- a fluid pump control system to remotely control a primary pump and secondary pumps and adjust flow rate from the primary pump and secondary pumps; and
- bi-directional, radio frequency, serial interface modems coupled to said primary pump, secondary pumps and control system to facilitate radio transmission of data between the primary pump, secondary pumps and control system.
2. The apparatus as recited in claim 1, wherein said modems are of the Wireless Link Module (WLM) type having a spread spectrum serial interface.
3. The apparatus as recited in claim 2 further including programmable logic controls electrically coupled to said primary pump and said secondary pumps.
4. The apparatus as recited in claim 3, further including a MODBUS communication protocol and RS 485 electrical standard that couples said modems and programmable logic controls with said control system.
5. The apparatus as recited in claim 1, further including a transportable applicator in fluid communication with said primary pump, said applicator including a high speed fluid volume counter and flow meter.
6. The apparatus as recited in claim 1, wherein said secondary pumps include high speed fluid volume counters and flow meters.
7. The apparatus as recited in claim 5, wherein said control system controls the primary pump and secondary pumps from a location proximate said transportable applicator.
8. The apparatus as recited in claim 5, wherein said volume counter outputs an analog signal associated with fluid volume and said flow meters outputs an analog signal associated with fluid flow rate.
9. The apparatus as recited in claim 6, wherein said volume counters outputs an analog signal associated with fluid volume and said flow meters outputs an analog signal associated with fluid flow rate.
10. A pump control apparatus, said apparatus comprising:
- fluid conduits;
- a master pump coupled to the fluid conduits;
- secondary pumps coupled to the fluid conduits between said master pump and an outlet of said fluid conduits;
- a control system including programmable logic controls to remotely stop said master and secondary pumps and adjust flow rate from the master pump and secondary pumps;
- bi-directional, radio frequency modems coupled to said master pump and secondary pumps to facilitate wireless transmission of data between the master pump, secondary pumps and control system, utilizing a MODBUS communication protocol and RS 485 electrical standard.
11. The apparatus as recited in claim 10, wherein said modems are of the Wireless Link Module (WLM) type having a spread spectrum serial interface.
12. The apparatus as recited in claim 10, further including a high speed fluid volume counter and flow meter coupled near the outlet of said fluid conduits.
13. The apparatus as recited in claim 12, wherein said secondary pumps include high speed fluid volume counters and flow meters.
14. The apparatus as recited in claim 13, wherein said control system controls the master pump and secondary pumps from a location proximate said outlet of said fluid conduit.
15. The apparatus as recited in claim 14, wherein said counter outputs an analog signal associated with fluid volume and said flow meters outputs an analog signal associated with fluid flow rate.
16. The apparatus as recited in claim 13, wherein said counter outputs an analog signal associated with fluid volume and said flow meters outputs an analog signal associated with fluid flow rate.
17. A pump control apparatus, said apparatus comprising:
- a fluid tank;
- a transportable applicator having a fluid outlet and a shutoff valve controlling flow of fluid from the transportable applicator and said transportable applicator including a high speed fluid volume counter and flow meter;
- fluid conduits coupling the fluid tank in fluid communication with the transportable applicator;
- a master pump having pressure sensors and being coupled to the fluid conduits between said fluid tank and said transportable applicator;
- secondary pumps having pressure sensors and being coupled to the fluid conduits between said master pump and said transportable applicator;
- a control system including programmable logic controls to remotely start and stop said master and secondary pumps and adjust flow rate from the master pump and secondary pumps;
- bi-directional, radio frequency, serial interface modems coupled to said master pump and secondary pumps to facilitate wireless transmission of data between the master pump, secondary pumps and control system, utilizing a MODBUS communication protocol and RS 485 electrical standard.
18. The apparatus as recited in claim 17, wherein said modems are of the Wireless Link Module (WLM) type.
19. The apparatus as recited in claim 17, wherein said master pump sensors outputs an analog signal associated with pressure.
20. The apparatus as recited in claim 15, wherein said secondary pumps sensors outputs analog signals associated with pressure.
Type: Application
Filed: May 31, 2013
Publication Date: Dec 4, 2014
Inventor: Joel Hotovec (New Ulm, MN)
Application Number: 13/907,363
International Classification: F04B 49/08 (20060101);