FLUID FLOW SYSTEMS AND METHODS OF USING THE SAME

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Application No. 63/699,582, filed Sep. 26, 2024, which is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to a pump system, and more specifically, to a pump system for providing a precise amount of fluid flow when missing ingredients.

BACKGROUND

Pump systems, such as fluid systems using piston pumps and motors, typically have large and bulky components. These components are usually installed in a small space of a pump system, thus not easily accessible for maintenance or replacement. Moreover, lack of sufficient protection such as guards around many rotating members poses safety concerns in such systems. Furthermore, in many applications, such as precise fluid delivering pump systems used in biopharmaceutical facilities, stock control programs for the pump systems are not flexible and cannot be modified to fit custom uses.

SUMMARY

According to some implementations of the present disclosure, a pump system is designed for providing a precision flow of a fluid. The pump system comprises a motor, a pump, a coupler, and a shroud. The motor has a motor shaft extending from a motor-coupling end of the motor. The pump has a pump shaft extending from a pump-coupling end of the pump. The coupler has a first portion configured to be coupled to the motor shaft in a non-rotational and fixed fashion. Additionally, the coupler has a second portion configured to be coupled to the pump shaft in a non-rotational and fixed fashion. The first portion of the coupler is configured to be non-rotationally coupled to the second portion of the coupler. The shroud has a first end configured to be coupled with the motor-coupling end of the motor and a second end configured to be coupled with the pump-coupling end of the pump such that (i) the shroud, (ii) the motor-coupling end, and (iii) the pump-coupling end enclose the coupler therein.

The above summary is not intended to represent each implementation or every aspect of the present disclosure. Additional features and benefits of the present disclosure are apparent from the detailed description and figures set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a pump system for providing a precision flow of a fluid, according to certain aspects of the present disclosure.

FIG. 2 is a back perspective view of the pump system, according to certain aspects of the present disclosure.

FIG. 3 is an exploded front view of the pump system, according to certain aspects of the present disclosure.

FIG. 4 is an exploded back view of the pump system, according to certain aspects of the present disclosure.

FIG. 5 is a front perspective view of the coupler of the pump system, according to certain aspects of the present disclosure.

FIG. 6 is a back perspective view of the coupler of the pump system, according to certain aspects of the present disclosure.

FIG. 7 is an exploded front view of the coupler of the pump system, according to certain aspects of the present disclosure.

FIG. 8 is an exploded back view of the coupler of the pump system, according to certain aspects of the present disclosure.

FIG. 9 is a front perspective view of a shroud of the pump system, according to certain aspects of the present disclosure.

FIG. 10 is a back perspective view of the shroud of the pump system, according to certain aspects of the present disclosure.

FIG. 11 is a schematic diagram showing electrical connections and signal/data flows between a control system, the motor, and the pump of the pump system, according to certain aspects of the present disclosure.

FIG. 12 is a flowchart showing a process of the pump system for providing the precision flow of a fluid, according to certain aspects of the present disclosure.

FIG. 13 is a flowchart showing a batching process, a dosing process, and a calibration program of the pump system, according to certain aspects of the present disclosure.

FIG. 14 is a flowchart showing a method for providing a precision flow of a fluid, according to certain aspects of the present disclosure.

While the present disclosure is susceptible to various modifications and alternative forms, specific implementations and implementations thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the present disclosure to the particular forms disclosed, but on the contrary, the present disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

DETAILED DESCRIPTION

A pump system is designed to deliver precise fluid flows. The pump system can be used in upstream mixing of ingredients, for example, in a clean biopharmaceutical facility. The output of the system is typically a large quantity of mixed ingredients that is used to fill vials and/or syringes by a different system. The pump system utilizes a motor to drive a four-piston pump. Both the motor and the pump are not contained in an enclosure, thus are easily accessible. The connection between shafts of the motor and the pump is fully guarded by a gasketed shroud for safety protection of the rotating parts. A programable control system precisely controls various parameters, such as pump flowrate, pump shaft revolution and start position, to achieve the desired output with high precision. Moreover, the control system monitors the motor by adjusting various motor variables, such as motor shaft revolution rate, motor shaft position, motor start/stop, and motor temperature. Further, the control system controls the motor and pump to deliver precise fluid flows in a batching process and a dosing process without the use of external devices such as flowmeters and valves that need to be controlled by another controller. The batching process provides large volumes of fluid flows in large intervals, while the dosing process can generate small volumes of fluid in short intervals. The control system includes a calibration program used to calibrate the pump system to achieve high precision of fluid flows. The target precision is achieved in a range of, for example, about 97% to about 103% of a target flowrate for a fluid at a certain operating pressure. The range of the target precision may include, but not be limited to, about 99% to about 101%, 95% to 105%, 90% to 100%, 85% to 115%, 80% to 120% and any other suitable ranges. The calibration program records specific motor variables and pump parameters in a calibration file for the specific fluid at the operating pressure. This file can be used in actual applications for delivering desired precision fluid flows.

FIG. 1 and FIG. 2 illustrate front and back perspective views, respectively, of a pump system 100 for providing a precision flow of a fluid. The pump system 100 includes a motor 110, a pump 120, a shroud 140 and a mounting bracket 190. The motor 110 is coupled to the pump 120. The motor 110 is configured to drive the pump 120 so that the pump 120 provides a precision flow of a fluid. The shroud 140 is coupled to the motor 110 on one end and coupled to the pump 120 on an opposite end of the shroud 140. Additionally, the shroud 140 is configured to seal (e.g., in an air-tight fashion) against the motor 110 and the pump 120. Accordingly, the connection between the motor 110 and the pump 120 is enclosed within the shroud 140 so that the connection is maintained in an air-tight environment.

In some implementations, the motor 110 is a servo motor, a high precision motor, a stepper motor, a step motor, a non-magnetic motor, a synchronous motor, a direct-current motor, or any combination thereof. For example, the motor 110, such as a servo motor, is an electronic device that utilizes a feedback mechanism to precisely control rotary or linear motion. The motor 110 can control the output via a motor shaft with high precision, e.g., using an optical encoder. In this example, the optical encoder has many positions, e.g., 400 positions. A photosensor that detects a specific position of the optical encoder sends a signal thereto. The optical encoder converts the signal into a square wave and transmits to a control device, such as a motion control system. The motion control system adjusts one or more of many variables of the motor to turn the motor on and off to achieve the desired precision of the motor shaft motion.

For example, the pump 120 may be a four-piston fluid system pump specifically designed for critical applications in the biopharmaceutical industry. In this example, a special design allows the pump 120 to gently, safely and securely convey aqueous solutions and biological products that are shear sensitive. The four-piston design does not include a mechanical shaft seal or wetted rotating parts, ensuring total product containment without abrasion. Additionally, the four-piston pumping principle enables risk-free dry running, low pulsation, self-priming, and minimal particle generation.

FIG. 3 and FIG. 4 show front and back exploded perspective views, respectively, of the pump system 100. The motor 110 includes a motor shaft 111 that extends from a motor-coupling end 112 of the motor 110. The pump 120 has a pump shaft 121 that extends from a pump-coupling end 122 of the pump 120. The coupler 130 has a first portion 131 and a second portion 132. The first portion 131 is configured to be coupled to the motor shaft 111 in a non-rotational and fixed fashion. And the second portion 132 is configured to be coupled to the pump shaft 121 in a non-rotational and fixed fashion. Additionally, the first portion 131 of the coupler 130 is configured to be non-rotationally coupled to the second portion 132 of the coupler 130. Further, the shroud 140 has a first end 141 and a second end 142. The first end 141 is configured to be coupled with the motor-coupling end 112 of the motor 110. The second end 142 is configured to be coupled with the pump-coupling end 122 of the pump 120 such that (i) the shroud 140, (ii) the motor-coupling end 112, and (iii) the pump-coupling end 122 enclose the coupler 130 therein. Thus, the shroud 140 provides, therewithin, a guard that completely encloses and maintains the rigid connection between the motor shaft 111 and the pump shaft 121 in a clean and dry environment.

The first end 141 of the shroud 140 may have an outer diameter that is smaller than an outer diameter of the second end 142 of the shroud 140. For example, the shroud 140 may have a general cone shape, as shown in FIG. a4 to FIG. 4. Additionally, the outer diameter of the first end 141 of the shroud 140 is about the same as an outer diameter of the motor-coupling end 112 and the outer diameter of the second end 142 of the shroud 140 is about the same as an outer diameter of the pump-coupling end 122 of the pump 120. Further, in response to the motor-coupling end 112 of the motor 110 being coupled to the first end 141 of the shroud 140, at least a portion of the motor-coupling end 112 is received within the first end 141 of the shroud 140.

In some implementations, the pump system 100 may further include a first gasket 181 and a second gasket 182. The first gasket 181, for example, is positioned between the first end 141 of the shroud 140 and the motor-coupling end 112 of the motor 110. Additionally, the second gasket 182 is positioned between the second end 142 of the shroud 140 and the pump-coupling end 122 of the pump 120. Both the first gasket 181 and a second gasket 182 provide air-tight seals between the shroud 140 and the motor 110 and the between the shroud 140 and the pump 120, respectively. Further, the motor shaft 111 of the motor 110 includes a first key 113 exteriorly and radially positioned on the motor shaft 111, as shown in FIG. 3. The first key 113 is configured to be interiorly coupled to the coupler 130. Additionally, the pump shaft 121 of the pump 120 may include a second key 123 that is exteriorly and radially positioned on the pump shaft 121, as shown in FIG. 4. The second key 123 of the pump shaft 121 is configured to be interiorly coupled to the coupler 130.

FIG. 5 and FIG. 6 show front and back perspective views, respectively, of the coupler of the pump system. The coupler 130 includes a first keyway 133, a second keyway 134, a first threaded hole 135, a second threaded hole 136, two or more first fingers 137, two or more second fingers 138, and an insert adaptor 171. Specifically, the first keyway 133 is positioned internally and radially within the first portion 131 of the coupler 130, as shown in FIG. 5. The second keyway 134 is positioned internally and radially within the second portion 132 of the coupler 130, as shown in FIG. 6. The first threaded hole 135 is defined by and radially positioned on the first portion 131. The first portion 131 of the coupler 130 is coupled to the motor shaft 111 by engaging the first key 113 of the motor shaft 111 with the first keyway 133 of the coupler 130. The first threaded hole 135 is configured to receive an external fastener (not shown), e.g., a set threw, to tighten the first key 113 against the first keyway 133 of the coupler 130. Accordingly, the connection between the first portion 131 of the coupler 130 and the motor shaft 111 is secured by the external fastener and the first threaded hole 135 of the coupler 130.

Similarly, the second threaded hole 136 is defined by and radially positioned on the second portion 132. The second portion 132 of the coupler 130 is coupled to the pump shaft 121 by engaging the second key 123 of the pump shaft 121 with the second keyway 134 (shown in FIG. 6) of the second portion 132 of the coupler 130. The second threaded hole 136 is configured to receive another external fastener, e.g., a set threw, to tighten the second key 123 against the second keyway 134 of the coupler 130. The connection between the second portion 132 of the coupler 130 and the pump shaft 121 is secured by the external fastener and the second threaded hole 136. Thus, the coupler 130 couples each of the motor shaft 111 and the pump shaft 121 in a non-rotationally and fixed fashion. Further, the first portion 131 and the second portion 132 are coupled with the insert adaptor 171 to enable the motor 110 to drive the pump 120 to deliver the desired precision fluid flow.

FIG. 7 and FIG. 8 show exploded front view and exploded back view, respectively, of the coupler of the pump system. The insert adaptor 171 of the coupler 130 includes four or more fingers 172. The insert adaptor 171 is positioned between the first portion 131 and the second portion 132 of the coupler 130. The two or more first fingers 137 of the coupler 130 are distally distributed on the first portion 131 and the two or more second fingers 138 are distally distributed on the second portion 132 of the coupler 130. Additionally, the four or more fingers 172 of the insert adaptor 171 are radially and externally distributed on the insert adaptor 171. The four or more fingers 172 of the insert adaptor 171 are configured to individually interlock with the two or more first fingers 137 of the first portion 131 and the two or more second fingers 138 of the second portion 132. For example, each of the four or more fingers 172 of the insert adaptor 171 is inserted into a corresponding gap between a finger of the two or more first fingers 137 of the first portion 131 and an adjacent finger of the two or more second fingers 138 of the second portion 132. Additionally, the insert adaptor 171 is configured to receive, in a corresponding gap between two adjacent fingers of the four or more fingers 172, one of the two or more first fingers 137 of the first portion 131, or one of the two or more second fingers 138 of the second portion 132. In this example, each of the two or more first fingers 137 of the first portion 131 is inserted into a corresponding gap between two adjacent fingers of the four or more fingers 172 of the insert adaptor 171. Further, each of the two or more second fingers 138 of the second portion 132 is inserted into a corresponding gap between two adjacent fingers of the four or more fingers 172 of the insert adaptor 171. Thus, the insert adaptor 171 is axially coupled to the first portion 131 and the second portion 132 of the coupler 130 to create a rigid and non-rotational connection therein.

In some examples, each of the four or more fingers 172 of the insert adaptor 171 includes a first button 173, as shown in FIG. 7. The first button 173 externally positioned on each of the four or more fingers 172 facing the first portion 131 of the coupler 130. Similarly, in other examples, each of the four or more fingers 172 of the insert adaptor 171 includes a second button 174, as shown in FIG. 8. The second button 174 externally positioned on each of the four or more fingers 172 facing the first portion 131 of the coupler 130. The first button 173 and the second button 174 are configured to maintain an air gap between the insert adaptor 171 and the first portion 131, and between the insert adaptor 171 and the second portion 132 of the coupler 130. The resulting air gaps can facilitate efficient disassembly of the coupler 130 for repair and/or maintenance.

FIG. 9 and FIG. 10 show front and back perspective views, respectively, of the shroud. The shroud 140 includes a flat portion 143. The flat portion 143 is externally and radially positioned on the shroud 140. The flat portion 143 of the shroud is used to conveniently attach the pump system 100 to an external structure. In this example, the pump system 100 includes a mounting bracket 190, as shown in FIG. 1 and FIG. 2. The mounting bracket 190 is configured to be coupled to the flat portion 143 of the shroud 140 to aid in attaching the pump system 100 to an external surface. Additionally, the mounting bracket 190 has a general H shape so that the pump system 100 can be conveniently and efficiently attached to a desired external structure.

FIG. 11 shows a schematic diagram of electrical connections and signal/data flows between a control system, the motor, and the pump of the pump system. The pump system 100 further comprises a control system 150 that controls various components of the pump system 100 to deliver a desired precision flow of a fluid. For example, the control system 150 may include one or more processors 151, a memory 152, and a storage 153. Alternatively, the control system 150 may include a plurality of converters 154 coupled with the motor 110 and the control system 150. The plurality of converters 154 may include analogue to digital converts (ADCs), digital to analogue converts (DACs), alternating current to direct current (AC/DC) converts, and/or direct current to alternating current (DC/AC) converts. The memory 152 may store machine-executable instructions for the one or more processors 151. The storage 153 may also store executable instructions and/or digital files for the control system 150 to control the motor 110 and the motor 110 drives the pump 120 of the pump system 100 to deliver the precision flow 127 of a fluid. Additionally, the pump 120 may have one or more input from one or more ingredient tanks 155. Further, the pump 120 may deliver the precision flow 127 to an output tank 156, as shown in FIG. 9. The motor 110 may have one or more variables 115 and the pump 120 may have one or more parameters 125.

FIG. 12 shows a flowchart of a process of the pump system for providing a precision flow of a fluid. The one or more processors of the control system 150 is configured to execute machine-executable instructions to cause the pump system to monitor the one or more parameters of the pump 301. For example, the pump system adjusts the one or more variables of the motor 303. Subsequently, based at least in part on the one or more variables of the motor, the control system causes the motor to switch between an ON state and an OFF state to deliver the precision flow of the fluid 305. In this process, the one or more parameters of the pump includes, but is not limited to, a revolution rate of the pump shaft or a start position of the pump shaft, or any combination thereof. The one or more variables of the motor includes, but is not limited to, a motor temperature, a motor current, a motor voltage, a revolution rate of the motor shaft, a start position of the motor shaft, a torque output of the motor shaft, a power output of the motor shaft, or any combination thereof.

FIG. 13 shows is a flowchart of a batching process, a dosing process, and a calibration program of the pump system. Specifically, the one or more processors of the control system is configured to execute machine-executable instructions to cause the pump system to monitor a batching process 311. The batching process is configured to deliver the precision flow in a plurality of first intervals with each of the plurality of first intervals having a first flow volume 313. Additionally, the one or more processors of the control system is configured to execute machine-executable instructions to cause the pump system to monitor a dosing process 321. The dosing process configured to deliver the precision flow in a plurality of second intervals with each of the plurality of second intervals having a second flow volume 323. Each of the plurality of first intervals in step 313 has a greater duration than each of the plurality of second intervals in step 323, and the first flow volume in step 313 is greater than the second flow volume in step 323. Further, the batching process in step 311 has a first flowrate and the dosing process in step 321 has a second flowrate, the first flowrate being greater than the second flowrate.

The one or more processors of the control system is configured to execute machine-executable instructions to cause the pump system to perform a calibration program for a specific fluid, the specific fluid having a process pressure and a delivery flowrate 331. For example, the control system is configured to cause the pump system to operate at the process pressure in the batching process 333. Additionally, the control system monitors the first flow volume per each of the plurality of first intervals to be within a target range of the delivery flowrate 335. Subsequently, the control system records the calibration program into a calibration registry for the specific fluid 337.

The target range in step 335 includes, but is not limited to, a range of about 97% to about 103% of the delivery flowrate. Alternatively, the target range in step 335 includes, but is not limited to, a range of about 95% to 105%, about 90% to 110%, 85% to 115%, or 80% to 120%, of the delivery flowrate.

FIG. 14 shows is a flowchart of a method for providing a precision flow of a fluid. Specifically, the method 500 provides a coupler having a first portion and a second portion 501. Using the coupler, the method 500 connects the first portion of the coupler to a motor shaft of a motor 503 and connects the second portion of the coupler to a pump shaft of a pump 505. Subsequently, the method 500, using a shroud, encloses therewithin the coupler, the motor shaft, and the pump shaft, in an air-tight fashion 507. Moreover, the method 500 monitors, via a control system, one or more parameters of the pump 509 by adjusting one or more variables of the motor 511. Further, based at least in part on the one or more variables of the motor, the method 500 causes the motor to switch between an ON state and an OFF state to deliver the precision flow of the fluid 513.

The method 500 uses the control system to monitor a batching process and a dosing process. In the batching process, the method 500 delivers the precision flow in a plurality of first intervals with each of the plurality of first intervals having a first flow volume. In the dosing process, the method 500 delivers the precision flow in a plurality of second intervals with each of the plurality of second intervals having a second flow volume. In this example, each of the plurality of first intervals having a greater duration than each of the plurality of second intervals, and the first flow volume being greater than the second flow volume. Additionally, the batching process has a first flowrate and the dosing process has a second flowrate. The first flowrate is greater than the second flowrate.

Further, the method 500 uses the control system to perform a calibration program for a specific fluid. In this example, the specific fluid has a process pressure and a delivery flowrate. The method 500 performs the calibration program at the process pressure in the batching process. During the calibration program, the method 500 monitors the first flow volume per each of the plurality of first intervals to be within a target range of the delivery flowrate. The target range includes, but is not limited to, a range of about 97% to about 103% of the delivery flowrate. Alternatively, the target range in step 335 includes, but is not limited to, a range of about 95% to 105%, about 90% to 110%, 85% to 115%, or 80% to 120%, of the delivery flowrate. Once the delivery flowrate falls within the required target range, the method 500 records the results of the calibration program into a calibration registry for the specific fluid. The results may include the process pressure, the delivery flowrate and the target range, the one or more variables of the motor, the one or more parameters of the pump, and the actual delivery flowrate achieved. The one or more parameters of the pump includes a revolution rate of the pump shaft or a start position of the pump shaft, or any combination thereof. The one or more variables of the motor includes a motor temperature, a motor current, a motor voltage, a revolution rate of the motor shaft, a start position of the motor shaft, a torque output of the motor shaft, a power output of the motor shaft, or any combination thereof.

Although the disclosed implementations have been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur or be known to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. One or more elements or aspects or steps, or any portion(s) thereof, from one or more of any of the above implementations and/or the below claims can be combined with one or more elements or aspects or steps, or any portion(s) thereof, from one or more of any of the other above implementations and/or below claims or combinations thereof, to form one or more additional implementations and/or claims of the present disclosure.

While the present disclosure has been described with reference to one or more particular implementations or implementations, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present disclosure. Each of these implementations and obvious variations thereof is contemplated as falling within the spirit and scope of the present disclosure. It is also contemplated that additional implementations according to aspects of the present disclosure may combine any number of features from any of the implementations described herein.