US20260185528A1 · App 18/855,430
METHOD FOR CONTROLLING A CIRCULATION PUMP
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Applicants
GRUNDFOS HOLDING A/S
Inventors
Erik Baasch SØRENSEN, Christian BLAD
Abstract
A method controls a circulation pump installed in a system, equipped with one or more temperature-controlled valves for heating or cooling. The pump is operated at an operating point defined as an intersection point of an adaptable pump characteristic curve and a variable system characteristic curve, that varies with a common degree of openness of the valves. The pump characteristic curve is adapted by setting a pump speed, controlled such that the operating point follows an adjustable control curve, adjusted when the system characteristic curve changes in order to keep the common degree of openness in a desired range between a minimum and a maximum common degree of openness, including determining a system variable that is susceptible to system characteristic curve changes, and using the system variable as an input to provide a feed forward signal to automatically adjust the control curve in a feed forward control.
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Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001]This application is a United States National Phase Application of Inter-national Application PCT/EP2024/060246, filed Apr. 16, 2024, and claims the benefit of priority under 35 U.S.C. § 119 of Danish (DL) Application PA 2023 70348, filed Jun. 30, 2023, the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002]The present disclosure is directed to a method for controlling a circulation pump being installed in a system for heating or cooling, wherein the system is equipped with one or more temperature-controlled valves. For example, the system may be an ordinary household heating system with radiators that are equipped with temperature-controlled valves, e.g. thermostatic radiator valves (TRVs). Alternatively, or in addition, the temperature-controlled valves of the system may be “smart valves” being remotely temperature-controlled by a smart valve application.
BACKGROUND
[0003]A circulation pump is typically installed at a piping system as a standalone circulation pump assembly comprising a pump, an electric motor for driving the pump and an electronics housing with electronics for controlling the speed of the motor. The circulation pump may be operated in different selectable control modes, e.g. constant pressure control mode or proportional pressure control mode. Each control mode may include a certain number of selectable pump control curves. If the pump is operated to follow a certain pump control curve, the operating point of the pump sticks to the pump control curve if possible.
[0004]When the piping system comprises temperature-controlled valves, the valves gradually close when the demand for thermal energy decreases and they gradually open when the demand for thermal energy increases in order to achieve a target temperature. Typically, the circulation pump as a stand-alone pump assembly does not get any direct information about how much the valves are opened or closed. If the pump sticks to its set pump control curve, it may run with an unnecessary high speed when the valves close or with a too low speed when the valves open. A too high speed of the pump waists energy saving potential and leads to undesired flow noise. A too low speed of the pump has a negative impact on the user comfort, because the cooling or heating system does not achieve its target temperatures, at least not within a desired time frame.
[0005]It is known in the prior art to automatically adapt the pump control curve in a closed-loop control based on a pipe resistance value as a feedback value. For example, EP 0 726 396 B1 or EP 1 323 986 B1 describe such an automatic adaptation of the pump control curve in a closed-loop control.
[0006]It has shown that the known methods of automatic adaptation of the pump control curve successfully reduce the energy consumption and flow noise when the valves close. However, the known methods of automatic adaptation of the pump control curve have also shown to be too slow when the valves open during high thermal energy demand. The user thus experiences a lack of comfort, because the cooling or heating system does not achieve its target temperatures, at least not within a desired time frame.
[0007]It is therefore an object of the present disclosure to provide a method for controlling a circulation pump that on the one hand adapts the pump control curve quickly enough both when the proportional control valves in the system are closing and when they are opening. On the other hand, the energy consumption and the flow noise is still to be reduced as much as possible when the proportional control valves are closing.
SUMMARY
- [0009]operating the pump at an operating point, wherein the current operating point is defined as the intersection point of an adaptable pump characteristic curve and a variable system characteristic curve, wherein the system characteristic curve varies with a common degree of openness of the one or more temperature-controlled valves, wherein the pump characteristic curve is adapted by setting the speed of the pump, wherein the speed of the pump is controlled in such a way that the operating point follows an adjustable pump control curve; and
- [0010]automatically adjusting the pump control curve when the system characteristic curve changes in order to keep the common degree of openness of the one or more temperature-controlled valves in a desired range between a minimum common degree of openness and a maximum common degree of openness,
characterised in that,
automatically adjusting the pump control curve comprises determining a system variable being susceptible to system characteristic curve changes, and using the system variable as an input to provide a feed forward signal to automatically adjust the pump control curve in a feed forward control.
[0011]The term “common degree of openness” of the one or more temperature-controlled valves, i.e. in form of proportional control valves, is to be understood as an absolute or relative measure of how much open or closed all those temperature-controlled valves are through which the circulation pump pumps heating or cooling liquid, e.g. ranging from 0% to 100%. If only one valve exists in the system, the “common degree of openness” may simply be the opening degree of said valve. If there are two or more valves in the system, a weighted or unweighted average of the opening degrees of the valves may be considered as the “common degree of openness”. A stand-alone pump assembly has no information about the common degree of openness, but it “feels” a pipe resistance that scales with the common degree of openness of the valves. When all valves of the system are open to a maximum degree, the pump experiences the lowest pipe resistance. When all of the valves but one are closed, and the one open valve is nearly closed, the pump experiences the highest pipe resistance. It can be assumed that the pipe resistance is constant as long as the common degree of openness of the valves does not change.
[0012]The system characteristic curve varies with the pipe resistance, i.e. it varies with the common degree of openness of the valves. If the system characteristic curve changes, the pump characteristic curve is adapted by changing the pump speed to keep the operating point on the pump control curve. If the pump control curve, e.g. a proportional pressure control curve in form of a linear line in a head-flow-diagram, is fixed, undesirable situations occur in which the pump does not run at full speed when the valves are fully open for high thermal energy demand and in which the pump runs too quickly when the valves are nearly or fully closed for low or no thermal energy demand. In other words, it is most desirable to have the common degree of openness of the valves in a desired range between a minimum common degree of openness and a maximum common degree of openness. In that desired range, the temperature-controlled valves can react to a rise and fall of the thermal energy demand. Thus, the pump control curve is not fixed, but adjustable to keep the common degree of openness of the valves within the desired range as much as possible.
[0013]The inventive idea is now to speed up the adjustment of the pump control curve by determining a system variable that is susceptible to system characteristic curve changes and by using the system variable as an input to provide a feed forward signal to automatically adjust the pump control curve in a feed forward control.
[0014]For example, the system variable may be the flow factor, also denoted as kv-value. The kv-value is, for example, defined in “Fluidic characteristic quantities of control valves and their determination”, VDI, VDE, September 2007, 2173, retrieved 17 Apr. 2020. The kv-value expresses the amount of water flow in units of m3/h through the system at a given common degree of openness with a pressure drop of 1 bar across the valves. It should be noted that the complete definition says that the flow medium must have a specific gravity of 1000 kg/m3 and a kinematic viscosity of 10−6 m2/s, e.g. water. The kv-value is generally defined as
wherein q is the flow in units of m3/h, Dp is the pressure drop across the valves in units of bar, and SG is the specific gravity of the flow medium (SG=1 for water).
[0015]The pump is able to determine or estimate the system variable based on its current operating point and performance indicators, such as its provided head and/or flow, its current pump speed, power consumption and/or the electric current currently drawn by the pump drive motor. The determined or estimated system variable is then used as an input to provide a feed forward signal to automatically adjust the pump control curve in a feed forward control.
[0016]Optionally, the method may further comprise continuously or regularly monitoring a head value h indicative of the head currently provided by the circulation pump and a flow value q indicative of the flow currently provided by the circulation pump, wherein the head value h and the flow value q are used to determine the system variable, e.g. the kv-value. In order to avoid the need for a pressure sensor and/or a flow sensor, it is beneficial to derive the head value and the flow value from electric performance indicators of the pump moto, e.g. motor speed and power consumption.
- [0018]logging a maximum and a minimum of the system variable that has been determined over a past period of time; and
- [0019]determining a common degree of openness value indicative of the common degree of openness of the one or more temperature-controlled valves in dependence of the distance of the system variable from the logged maximum and/or logged minimum.
[0020]The maximum and minimum kv-values may be used to estimate over time the kv-values for the highest common degree of opening of the valves and the lowest common degree of opening of the valves, respectively.
[0021]Optionally, automatically adjusting the pump control curve may further comprise using a stored adaptable mapping between the system variable and the feed forward signal to be applied for the feed forward control. This is beneficial to account for deviations from the target opening degree as indicated by a PI controller. The mapping used for the feed forward may be adapted to keep the deviation from the target opening degree at a minimum.
[0022]Optionally, a deviation of the determined common degree of openness value from a pre-determined reference common degree of openness may be used as a further input in addition to the system variable to provide the feed forward signal, and wherein said deviation is used to update the stored adaptable mapping. It should be noted that this further input is, under normal operation, much smaller than the contribution of the system variable to the feed forward control. The contribution of the deviation of the opening degree from the target opening degree is rather a minor correction, e.g. in the range of +/−5%, to the feed forward control.
[0023]Optionally, the stored adaptable mapping may comprise a list of relative values defining which pump control curve is applied within a total range of applicable pump control curves at pre-determined system variable points, wherein the relative values are interpolated between the pre-determined system variable points. For example, the applicable pump control curves may range between a lowest proportional pressure curve PP1 and a highest proportional pressure curve PP3. The stored adaptable mapping may comprise a list of relative values in terms of percentage ranging from 0% for the lowest proportional pressure curve PP1 and 100% for the highest proportional pressure curve PP3.
- [0025]for the relative values at all higher pre-determined system variable points by shifting those relative values upward by an amount that is needed to avoid the updated mapping from having a negative gradient, and/or
- [0026]for the relative values at all lower pre-determined system variable points by shifting those relative values downward by an amount that is needed to avoid the updated mapping from having a negative gradient.
[0027]The mapping between the system variable and the feed forward signal to be applied for the feed forward control must not have a negative gradient, because the pump must not reduce the pump control curve when the valves open, i.e. the kv-value rises. Similarly, the pump control curve must not increased when the valves close.
[0028]Optionally, the adjustable pump control curve may be a proportional pressure curve. This is particularly beneficial if the valves are installed at heating radiators.
[0029]Optionally, the system may comprise one or more thermal energy consumers and the one or more temperature-controlled valves may be automatically and/or thermostatically actuated valves installed at said thermal energy consumers. Preferably, the thermal energy consumers are radiators of a heating system.
[0030]Optionally, the feed forward signal may be low-pass filtered with a predetermined time constant before it is used to automatically adjust the pump control curve in the feed forward control if the determined system variable is smaller than the previously determined system variable. This is particularly beneficial to avoid undesired rapid oscillations between the control curves. Such oscillations have shown to occur at households with low variations of the kv-value, where small changes of the opening degree of the valves may lead to larger changes of the pump head which the valves try to compensate. Preferably, in order to avoid such oscillations, a first order filter, for instance with a time constant of 1200 seconds, may be applied if the kv-value is dropping. A rising kv-value, however, may be used unfiltered as input into the feed forward control.
[0031]Optionally, the pump control curve may be adjustable without steps within a total range of applicable pump characteristic curves.
[0032]Optionally, the method may further comprise operating the pump in a first boost mode and/or in a second boost mode, wherein a gain factor is applied in the first boost mode for stronger adjusting the pump control curve as long as a determined common degree of openness value indicative of the common degree of openness of the one or more temperature-controlled valves is within a pre-determined low boost area adjacent to a minimum common degree of openness or within a pre-determined high boost area adjacent to a maximum common degree of openness, and wherein the pump is operated at maximum speed in the second boost mode if the system variable is within a pre-determined speed boost area adjacent to a logged maximum of the system variable, and a maximum pump control curve is currently applied, and a pre-determined period of maximum boosting time has not lapsed.
[0033]The first boost mode may be referred to as a PI controller boost. It is preferably applied as a first stage boosting when the kv-value and/or the opening degree is close to a maximum or minimum value, i.e. in a boost area. If the first boost mode is not successful to get the system out of the high boost area within a given time period, the second boost mode is activated to run the pump at maximum speed for a certain maximum boosting time.
[0034]According to another aspect of the present disclosure, a computer program is provided with instructions which, when the program is executed by a computer, cause the computer to carry out the previously described method.
[0035]According to another aspect of the present disclosure, a circulation pump is provided for being installed in a system for heating or cooling, wherein the circulation pump comprises control electronics being configured to carry out the previously described method or to execute the above-mentioned program.
[0036]Optionally, the circulation pump may be automatically programmed at a manufacturing site of the circulation pump to carry out the previously described method or to execute the previously described program. Thereby, the fully assembled circulation pump may leave the manufacturing site fully programmed for shipping to customers, such that there is no need for customers to program the circulation pump.
[0037]The method disclosed herein may be implemented in form of compiled or uncompiled software code that is stored on a computer readable medium with instructions for executing the method. Preferably, the software is installed on control electronics within the circulation pump according to the present invention. Alternatively, or in addition, the method may be executed by software in a cloud-based system and/or a building management system (BMS).
BRIEF DESCRIPTION OF THE DRAWINGS
[0038]Embodiments of the present disclosure will now be described by way of example with reference to the following figures of which:
[0039]
[0040]
[0041]
[0042]
[0043]
[0044]
[0045]
[0046]
[0047]
[0048]
[0049]
DETAILED DESCRIPTION
[0050]
[0051]The system 1 is further equipped with one more temperature-controlled valves 9, e.g. thermostatic radiator valves (TRVs), smart valves or other kinds of temperature-controlled valves. Each of the temperature-controlled valves 9 may be installed in the vicinity of one of the thermal consumers 5 to control the fluid flow through that respective thermal energy consumer 5. The thermal energy consumers 5 are installed in parallel in the system 1, such that each of the thermal energy consumers 5 has a fluid inlet connected to a feed line of the system 1 and a fluid outlet to a return line of the system 1. The associated temperature-controlled valve 9 is preferably installed at a fluid inlet of the thermal energy consumer 5.
[0052]Usually, there is no direct control connection between the circulation pump 7 and the temperature-controlled valves 9. The temperature-controlled valves 9 are each controlled by a closed-loop control using a thermostat, wherein a temperature sensor is used to determine the current temperature and a target temperature can be set for the thermostat. In case of a heating system, for example, the valves 9 open when the measured temperature is below a target temperature in order to increase the flow of the heating fluid through the respective thermal energy consumer 5. Analogously, the valve 9 closes when the measured temperature is above a target temperature in order to reduce the flow of the heating fluid through the thermal energy consumer 5.
[0053]It is in principle known that it is useful to adapt the speed of the circulation pump 7 depending on the common degree of openness of the temperature-controlled valves 9. As the circulation pump 7 is a stand-alone device without direct knowledge of the opening degree of the temperature-controlled valves 9, it would in principle run too fast when the common degree of openness of the valves 9 is low or too slow when the common degree of openness of the valves 9 is high. This would lead to the undesirable situation that the circulation pump 7 consumes unnecessary power and produces unnecessary flow noise when the valves 9 are nearly closed. Furthermore, the circulation pump 7 may not provide sufficient flow when the valves 9 are open to a maximum degree during times of high thermal energy demand. Therefore, there may be a lack of comfort during times of high thermal energy demand, because it takes too long to reach the target temperature. It has shown that known “auto adapt”—algorithms do not react quickly enough to provide the required thermal energy flow in situations of high thermal energy demand.
[0054]
[0055]Furthermore, the circulation pump 7 comprises control electronics (not visible) within the motor housing 15 in order to control the speed of the circulation pump 7. A lid 17 of the motor housing 15 comprises a front face 19 with human-machine-interface elements, such as a display, LED indicators, one or more buttons or switchers. A user may manually set the circulation pump 7 to follow a fixed control curve or to run in an “auto adapt” control mode to automatically adapt the applied control curve. For example, in case of a heating system 1 with radiators as thermal energy consumers 5, the circulation pump 7 may be set to one of three fixed proportional pressure curves PP1, PP2 and PP3. For example,
[0056]The circulation pump 7 may further comprise a wireless interface or a connector via which the control electronics within the circulation pump 7 can be programmed, reprogrammed or updated. The circulation pump 7 may thus be programmed at the time of manufacturing and assembly and/or when it is already installed in a cooling or heating system 1.
[0057]
[0058]Therefore, the control schematics shown in
[0060]
- [0064]wherein ffkv,0 is the point just below the current kv-value and ffhref,0 is the corresponding relative proportional pressure curve. ffkv,1 is the point that is just above the current kv-value kv and ffhref,1 is the corresponding relative proportional pressure curve. The relative proportional pressure curve value of the first and the last point in the mapping are used if the kv-value is outside the range of the mapping.
[0067]
[0068]
[0069]
[0070]
[0071]The adaptation of the feed forward control 29 is only performed if the variation of the kv-value is above a noise level, i.e. kv,Δ≥kv,dynband,min and there is no kv-spike currently detected. A limitation of the output 28 OutPI of the PI controller 25 based on a PI controller limiting parameter prevents a too aggressive adaptation when the PI controller 25 is operated in the first boost mode. A non-zero output 28 OutPI of the PI controller 25 shows as a deviation of the current kv-value from the interpolated mapping and triggers a correction of the closest two mapping points in proportion to the output 28 OutPI of the PI controller 25 such that the interpolation between those two corrected mapping points lies on the current kv-value. If the current kv-value is outside of the mapped range of kv-values, only the lowest or highest mapping point is adapted accordingly. The adapted mapping points are limited to relative proportional pressure curve values between 0% and 100%.
[0072]In order to avoid a negative gradient in the mapping, the mapping points at all kv-values above the adapted higher closest mapping point are shifted upward by the minimum amount that is needed to avoid the updated mapping from having a negative gradient. Similarly, in case of a downward adaptation of the lower closest mapping point, all mapping points with kv-values below said downward adapted closest lower mapping point are shifted downward by an amount that is needed to avoid the updated mapping from having a negative gradient. Finally, the updated mapping is stored for the subsequent iteration of the feed forward control 29.
[0073]
[0074]Where, in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present disclosure, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the disclosure that are described as optional, preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims.
[0075]The above embodiments are to be understood as illustrative examples of the disclosure. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. While at least one exemplary embodiment has been shown and described, it should be understood that other modifications, substitutions and alternatives are apparent to one of ordinary skill in the art and may be changed without departing from the scope of the subject matter described herein, and this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.
[0076]In addition, “comprising” does not exclude other elements or steps, and “a” or “one” does not exclude a plural number. Furthermore, characteristics or steps which have been described with reference to one of the above exemplary embodiments may also be used in combination with other characteristics or steps of other exemplary embodiments described above. Method steps may be applied in any order or in parallel or may constitute a part or a more detailed version of another method step. It should be understood that there should be embodied within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of the contribution to the art. Such modifications, substitutions and alternatives can be made without departing from the spirit and scope of the disclosure, which should be determined from the appended claims and their legal equivalents.
LIST OF REFERENCE NUMERALS
- [0077]1 cooling or heating system
- [0078]3 thermal energy source
- [0079]4 piping system
- [0080]5 thermal energy consumer
- [0081]7 circulation pump
- [0082]9 temperature-controlled valve
- [0083]11 pump housing
- [0084]13 suction inlet
- [0085]14 pressure outlet
- [0086]15 motor housing
- [0087]17 motor housing lead
- [0088]19 front face of motor housing lead
- [0089]R rotor axis
- [0090]21 valve position control
- [0091]23 opening degree estimation
- [0092]25 PI controller
- [0093]27 output Outff of the feed forward control
- [0094]28 output OutPI of the PI controller
- [0095]29 adaptive feed forward control
- [0096]31 pump characteristic curve of maximum speed
- [0097]33a-c system characteristic curves
- [0098]PP1 proportional pressure curve
- [0099]PP2 proportional pressure curve
- [0100]PP3 proportional pressure curve
- [0101]A shifting amount needed to avoid negative gradient
Claims
1. A method for controlling a circulation pump installed in a system for heating or cooling, wherein the system is equipped with one or more temperature-controlled valves, wherein the method comprises:
operating the pump at an operating point, wherein the current operating point is defined as the intersection point of an adaptable pump characteristic curve and a variable system characteristic curve, wherein the system characteristic curve varies with a common degree of openness of the one or more temperature-controlled valves, wherein the pump characteristic curve is adapted by setting the speed of the pump, wherein the speed of the pump is controlled such that the operating point follows an adjustable control curve; and
automatically adjusting the control curve when the system characteristic curve changes in order to keep the common degree of openness of the one or more temperature-controlled valves in a desired range between a minimum common degree of openness and a maximum common degree of openness, wherein automatically adjusting the control curve comprises determining a system variable being susceptible to system characteristic curve changes, and using the system variable as an input to provide a feed forward signal to automatically adjust the control curve in a feed forward control.
2. The method of
3. The method of
logging a maximum and a minimum of the system variable that has been determined over a past period of time; and
determining a common degree of openness value (?) indicative of the common degree of openness of the one or more temperature-controlled valves in dependence of the distance of the system variable from the logged maximum and/or logged minimum.
4. The method of
5. The method of
6. The method of
7. The method of
for the relative values at all higher pre-determined system variable points by shifting those relative values upward by an amount that is needed to avoid the updated mapping from having a negative gradient, and/or
for the relative values at all lower pre-determined system variable points by shifting those relative values downward by an amount that is needed to avoid the updated mapping from having a negative gradient.
8. The method of
9. The method of
10. The method of
11. The method of
12. The method of
the system variable is within a pre-determined speed boost area adjacent to a logged maximum of the system variable), and
a maximum control curve is currently applied, and
a pre-determined period of maximum boosting time has not lapsed.
13. A computer program comprising instructions which, when the program is executed by a computer, cause the computer to carry out the method of
14. A circulation pump configured to be installed in a system for heating or cooling, wherein the system is equipped with one or more temperature-controlled valves and wherein the circulation pump comprises control electronics configured to carry out a method comprising:
operating the pump at an operating point, wherein a current operating point is defined as an intersection point of an adaptable pump characteristic curve and a variable system characteristic curve, wherein the system characteristic curve varies with a common degree of openness of the one or more temperature-controlled valves, wherein the pump characteristic curve is adapted by setting a speed of the pump, wherein the speed of the pump is controlled such that the operating point follows an adjustable control curve; and
adjusting the control curve when the system characteristic curve changes so as to keep the common degree of openness of the one or more temperature-controlled valves in a desired range between a minimum common degree of openness and a maximum common degree of openness, wherein adjusting the control curve comprises determining a system variable that is susceptible to system characteristic curve changes, and using the system variable as an input to provide a feed forward signal to adjust the control curve in a feed forward control.
15. The circulation pump of
16. The circulation pump of
17. The circulation pump of
logging a maximum and a minimum of the system variable that has been determined over a past period of time; and
determining a common degree of openness value indicative of the common degree of openness of the one or more temperature-controlled valves in dependence of a distance of the system variable from the logged maximum and/or logged minimum.
18. The circulation pump of
19. The circulation pump of
wherein the stored adaptable mapping comprises a list of relative values defining which control curve is applied within a total range of applicable control curves at pre-determined system variable points, wherein the relative values are interpolated between the pre-determined system variable points,
wherein the stored adaptable mapping is updated only for the one or two relative value(s) at those pre-determined system variable point(s) that are closest to the currently determined system variable if the updated mapping has a throughout non-negative gradient, and wherein otherwise the stored adaptable mapping is updated in addition
for the relative values at all higher pre-determined system variable points by shifting those relative values upward by an amount that is needed to avoid the updated mapping from having a negative gradient, and/or
for the relative values at all lower pre-determined system variable points by shifting those relative values downward by an amount that is needed to avoid the updated mapping from having a negative gradient.
20. The circulation pump of