Pump drive that minimizes a pulse width based on voltage data to improve intake and discharge strokes

Abstract

The performance of a solenoid drive liquid pump can be very dependent on the magnitude and stability of an input voltage, with non-ideal input power resulting in loss of efficiency and potential damage to the pump. Pulse width of drive signals provided to the pump, which cause solenoids to alternately energize to move liquid through the pump, may be adjusted in duration in order to compensate for non-ideal input voltage. A drive control module of the pump gathers voltage information, determines an improved pulse width based upon that voltage information, and then provides drive signals based upon the improved pulse width. Operating in this manner, a pump can operate at or near peak efficiency despite both significant variances in input voltage and non-sinusoidal input voltage, and without customized components or adapters.

What is claimed is: 
     
         1 . A pump comprising:
 a liquid chamber comprising an intake valve and an output valve;   a set of solenoids that may be energized by a drive, in response to drive signals; a shaft configured to perform an intake stroke or a discharge stroke by operation of the set of solenoids, wherein the intake stroke increases a volume of the liquid chamber and allows liquid to flow through the intake valve and the discharge stroke decreases the volume of the liquid chamber and forces liquid through the output valve; and   a drive control module comprising a processor and memory and a voltage measuring circuit, wherein the drive control module is operable to provide drive signals to the set of solenoids;   wherein the drive control module is configured to:
 receive a set of voltage data via the voltage measuring circuit; 
 based on (1) the set of voltage data, (2) a corrected pulse width equation, and (3) an input voltage from the set of voltage data, a set of performance data, or a combination thereof, determine a corrected pulse width that is of a minimum duration that allows for completion of the intake stroke and the discharge stroke; and 
 generate a drive signal based upon the corrected pulse width and provide it to the drive. 
   
     
     
         2 . The pump of  claim 1 , wherein the drive control module is configured to determine the corrected pulse width by:
 determining a root mean squared of the input voltage; and   determine the corrected pulse width based on the corrected pulse width equation, the set of voltage data, and the root mean squared.   
     
     
         3 . The pump of  claim 1 , wherein the drive control module is configured to determine the corrected pulse width by:
 determining if the input voltage if clean or dirty;   selecting a noisy power equation as the corrected pulse width equation when the input voltage is determined to be dirty; and   selecting a clean power equation as the corrected pulse width equation when the input voltage is determined to be clean.   
     
     
         4 . The pump of  claim 3 , wherein the noisy power equation will produce a pulse width of a different duration than the clean power equation when each uses the same set of voltage data. 
     
     
         5 . The pump of  claim 4 , wherein the corrected pulse width equation is a third order polynomial equation. 
     
     
         6 . The pump of  claim 1 , wherein the drive control module is configured to:
 receive the set of performance data from the drive, the set of performance data being generated by a set of sensors of the drive during the discharge stroke and the intake stroke; and   determine the corrected pulse width based on the set of performance data.   
     
     
         7 . The pump of  claim 6 , wherein the set of performance data comprises three or more of:
 a pressure measurement of the liquid chamber; an intake stroke distance traveled;   a discharge stroke distance traveled;   an intake stroke velocity over time;   a discharge stroke velocity over time; and   a drive component temperature.   
     
     
         8 . The pump of  claim 6 , wherein the drive control module is configured to:
 receive a new set of performance data each time the corrected pulse width is determined; and   determine the corrected pulse width for each new set of performance data that is received.   
     
     
         9 . The pump of  claim 1 , wherein the drive control module is configured to:
 periodically receive a new set of voltage data; and   where the new set of voltage data differs from an immediately preceding set of voltage data, determine the corrected pulse width based on the new set of voltage data.   
     
     
         10 . The pump of  claim 9 , wherein the drive control module is configured receive the new set of voltage data based upon a test time interval. 
     
     
         11 . The pump of  claim 1 , wherein the drive control module is configured to determine the corrected pulse width for sets of voltage data having input voltage ranging from  110  volts to  240  volts. 
     
     
         12 . The pump of  claim 1 , wherein the volume of the liquid chamber changes due to one of:
 a flexible diaphragm in contact with the liquid chamber and the shaft;   a plunger in contact with the liquid chamber and the shaft; or   a displacement volume of the shaft itself entering the liquid chamber.   
     
     
         13 . The pump of  claim 1 , wherein the corrected pulse width is determined based upon the set of voltage data and a set of pump usage data, wherein the set of pump usage data comprises a pump service life and a pump drive activation time. 
     
     
         14 . A method for adapting drive signals for a pump comprising:
 receiving a set of voltage data via a voltage measuring circuit of a drive control module of the pump;   based on (1) the set of voltage data, (2.) a corrected pulse width equation, and (3) an input voltage from the set of voltage data, a set of performance data, or a combination thereof, determine a corrected pulse width that is of a minimum duration that allows for completion of an intake stroke and a discharge stroke; and   generating a drive signal based upon the corrected pulse width and providing the drive signal to a drive of the pump,   wherein the drive is configured to energize a set of solenoids in response to drive signals, and wherein energizing the set of solenoids causes a shaft of the pump to perform an intake strokes that causes liquid to flow into a liquid chamber and discharge strokes that causes liquid to flow out of the liquid chamber.   
     
     
         15 . The method of  claim 14 , wherein determining the corrected pulse width comprises:
 determining a root mean squared of the input voltage; and   determine the corrected pulse width based on the corrected pulse width equation, the set of voltage data, and the root mean squared.   
     
     
         16 . The method of  claim 14 , wherein determining the corrected pulse width comprises:
 determining if the input voltage if clean or dirty;   selecting a noisy power equation as the corrected pulse width equation when the input voltage is determined to be dirty; and   selecting a clean power equation as the corrected pulse width equation when the input voltage is determined to be clean.   
     
     
         17 . The method of  claim 16 , wherein the noisy power equation will produce a pulse width of a longer duration than the clean power equation when each uses the same set of voltage data. 
     
     
         18 . The method of  claim 14 , wherein determining the corrected pulse width comprises:
 receiving the set of performance data from the drive, the set of performance data being generated by a set of sensors of the drive during the discharge stroke and the intake stroke; and   determining the corrected pulse width based on the set of performance data.   
     
     
         19 . The method of  claim 18 , further comprising:
 receiving a new set of performance data each time the corrected pulse width is determined; and   determining the corrected pulse width for each new set of performance data that is received.   
     
     
         20 . The method of  claim 18 , further comprising:
 periodically receive a new set of voltage data; and   where the new set of voltage data differs from an immediately preceding set of voltage data, determine the corrected pulse width based on the new set of voltage data.