Eccentric Screw Pump And Method For Adapting The Operating State Of An Eccentric Screw Pump

Abstract

The invention pertains to an eccentric screw pump with a stator-rotor system, which includes a rotor with a rotor screw and a stator with an internal thread. The stator has a support element and an elastomer part, wherein the support element encloses the elastomer part sectionally over its entire circumference. The stator-rotor system has a mechanism for adjusting the stator, which is coupled to at least one sensor for determining actual operating parameters of the stator-rotor system by means of a control unit that activates the adjusting mechanism with consideration of the actual operating parameters determined with the aid of at least one sensor.

Claims

1. An eccentric screw pump with a stator-rotor system comprising a rotor with a rotor screw and a stator with an internal thread, wherein the stator comprises a support element and an elastomer part, and wherein the support element encloses the elastomer part at least sectionally over its entire circumference, characterized in that the stator-rotor system features an adjusting mechanism for adjusting the stator which is coupled to at least one sensor for determining actual operating parameters of the stator-rotor system with control unit that can activate the adjusting mechanism with consideration of the actual operating parameters determined with the aid of at least one sensor.

2. The eccentric screw pump according to claim 1, wherein the adjusting mechanism comprises two adjusting elements that are arranged on the stator-rotor system and variable with respect to their distance from one another, wherein a mechanical coupling and/or connection exists between the adjusting elements of the adjusting mechanism and the stator such that a change in the cross section and the length of the elastomer part of the stator can be realized by changing the relative distance between the two adjusting elements.

3. The eccentric screw pump according to claim 2, wherein the first adjusting element is arranged stationary on the stator-rotor system and the other, second adjusting element is arranged positionally variable on the stator-rotor system.

4. The eccentric screw pump according to claim 3, wherein the positionally variable second adjusting element can be repositioned by means of an actuator that is activated by the control unit in order to change its distance from the stationary first adjusting element.

5. The eccentric screw pump according to claim 1, wherein at least one first sensor is arranged on the eccentric screw pump and/or wherein at least one second sensor is arranged on the elastomer part of the stator and/or wherein at least one third sensor is arranged on the adjusting mechanism.

6. The eccentric screw pump according to claim 5, wherein the first sensor is designed for measuring the pressure, rotational speed, temperature and/or volumetric flow rate of the eccentric screw pump and/or wherein the second sensor is designed for measuring the prestress and/or reaction forces of the elastomer material of the elastomer part and/or wherein the third sensor is designed for measuring the position of the positionally variable second adjusting element and/or for measuring the distance between the stationary first adjusting element and the positionally variable second adjusting element.

7. A method for adapting the operating state of an eccentric screw pump with a stator-rotor system, wherein the stator-rotor system comprises a rotor, a stator and an adjusting mechanism for adjusting the stator, wherein the stator comprises an elastomer part and a support element, and wherein the method comprises the following steps: a. establishing an actual operating state of the eccentric screw pump by respectively determining at least one actual physical operating parameter concerning the eccentric screw pump and/or at least one actual physical operating parameter concerning the elastomer part and/or at least one actual physical operating parameter concerning the adjusting mechanism with the aid of suitable sensors; b. comparing the at least one actual operating parameter with known nominal operating parameters; c. activating the adjusting mechanism if the measured actual operating parameters deviate from the nominal operating parameters in order to adjust the stator, d. wherein the adjustment of the new operating state is monitored by controlling at least one actual physical operating parameter.

8. The method according to claim 7, wherein an adjustment travel of the adjusting mechanism is calculated if the measured actual operating parameters deviate from the nominal operating parameters, and wherein the adjusting mechanism is activated accordingly and the calculated adjustment travel is carried out in order to adjust an ideal operating point (iBP) of the stator.

9. The method according to claim 7, wherein the adaptation of the operating state in response to a deviation between the measured actual operating parameters and the nominal operating parameters is realized by adjusting an ideal operating point (iBP) by means of an incremental approximation.

10. The method according to claim 9, wherein the adjusting mechanism is transferred into an at least largely closed position, in which the prestress in the stator-rotor system is increased, and wherein the ideal operating point (iBP), at which the eccentric screw pump performs with maximum efficiency, is subsequently adjusted by opening the adjusting mechanism in a controlled fashion.

11. The method according to claim 7, wherein the actual operating parameters of the eccentric screw pump are after the adjustment of the adjusting mechanism established anew and compared with the nominal operating parameters once a defined time period has elapsed.

12. The method according to claim 11, wherein the adjusting mechanism is activated anew if the actual operating parameters deviate from the nominal operating parameters.

13. The method according to claim 11, wherein the adjusted operating state of the eccentric screw pump is checked anew after a defined time period (Δt3) if the deviation between the actual operating parameters and the nominal operating parameters was sufficiently reduced.

14. The method according to claim 7, wherein the actual operating parameters of the eccentric screw pump are established anew and compared with the nominal operating parameters after a defined time period (Δt1) if the actual operating parameters do not deviate from the nominal operating parameters.

15. The method according to claim 7, wherein the pressure, rotational speed, temperature and/or volumetric flow rate of the eccentric screw pump and/or the prestress between the rotor and the stator and/or reaction forces of the elastomer material of the elastomer part and/or the position of at least one adjusting element of the adjusting mechanism and/or the distance between two adjusting elements of the adjusting mechanism are respectively determined with the aid of suitable sensors.

16. The method according to claim 7, wherein the adjustment of the adjusting mechanism is realized by increasing or decreasing the distance between two adjusting elements of the adjusting mechanism, and wherein the cross section and the length of the coupled elastomer part of the stator-rotor system are changed due to the distance change between the two adjusting elements.

17. The method according to claim 7, wherein the determined deviation only triggers an activation of the adjusting mechanism if the determined deviation lies outside a defined tolerance range.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Exemplary embodiments of the invention and their advantages are described in greater detail below with reference to the attached figures. In these figures, the proportions of the individual elements relative to one another do not always correspond to the actual proportions because a few shapes are simplified and other shapes are enlarged in relation to other elements in order to provide a better overview.

[0045] FIG. 1 shows a schematic partial view of a conventional stator-rotor system (the prior art).

[0046] FIG. 2 shows a schematic partial view of a first embodiment of an inventive stator-rotor system with adjusting mechanism.

[0047] FIG. 3 schematically shows a sequence of a control mechanism for adjusting the stator-rotor system.

[0048] FIG. 4 shows the ideal operating point as a function of an adjustment travel of the adjusting mechanism.

DETAILED DESCRIPTION

[0049] Identical or identically acting elements of the invention are identified by identical reference symbols. In order to provide a better overview, the individual figures furthermore only show the reference symbols required for the description of the respective figure. The embodiments shown merely represent examples of the inventive device and/or the inventive method and not a conclusive restriction.

[0050] FIG. 1 shows a schematic partial view of a conventional stator-rotor system 1 for an eccentric screw pump. Such a system 1 comprises a typically metallic, single-threaded (not-shown) rotor and a stator 3 with a double thread. During the operation of the eccentric screw pump, the rotor carries out an eccentric rotational motion about the longitudinal stator axis X3 with its figure axis. The stator 3 comprises an elastomer part 4 and a stator casing 5, wherein no rigid connection exists between the elastomer part 4 and the stator casing 5.

[0051] FIG. 2 shows a schematic partial view of a first embodiment of an inventive stator-rotor system 10 with an adjusting mechanism 12 for respectively readjusting or adjusting the stator 3. The adjusting mechanism 12 comprises a stationary first adjusting element 13 and a positionally variable second adjusting element 14. A change in the distance between the two adjusting elements 13, 14 causes a deformation of the elastomer and therefore a change in the cross section and/or the length of the elastomer part 4 of the stator 3, as well as a respective readjustment or adjustment of the elastomer part 4 of the stator 3. A flange 23 on the stator casing 5 particularly serves as the stationary adjusting element 13 and an actuating element 24 arranged on the free end 8 of the elastomer part 4 serves as the positionally variable adjusting element 14.

[0052] The adjusting mechanism 12 is coupled to a control system 30 and activated and controlled thereby. The control system 30 comprises a control unit 32 and at least one sensor 35 for measuring physical operating parameters of the stator-rotor system 10 or the eccentric screw pump, respectively. At least one first sensor 36 is particularly provided on the eccentric screw pump in order to measure the pump pressure, rotational speed, temperature and/or volumetric flow rate. In addition, at least one second sensor 37 may be arranged on the elastomer part 4 and designed, for example, for determining the prestress between the rotor and the stator 3 or the reaction forces of the elastomer part. Furthermore, at least one third sensor 38 may be provided on the adjusting mechanism 12 and designed for respectively detecting, for example, the position of the positionally variable adjusting element 14 or the relative distance between the stationary adjusting element 13 and the positionally variable adjusting element 14. The data acquired with the aid of the sensors is transmitted to the control unit 32, which compares this data with nominal operating parameters and activates a corresponding adjustment of the adjusting system 12 if the measured actual operating parameters deviate from the nominal operating parameters, particularly an adjustment, during which the relative distance between the stationary adjusting element 13 and the positionally variable adjusting element 14 is changed such that the elastomer is deformed and the cross section and/or the length of the elastomer part 4 of the stator 3 changes.

[0053] FIG. 3 schematically shows a sequence of a control mechanism for adjusting the stator-rotor system 10 according to FIG. 2. The inventive control mechanism establishes a correlation between different physical parameters of the stator-rotor system 10 or the eccentric screw pump and the state of wear of the stator 3 or the prestress between the stator 3 and the rotor of the eccentric screw pump. For example, a correlation between the physical parameters pressure, volumetric flow rate, rotational speed and/or viscosity and the state of wear of the stator 3 or the prestress between the stator 3 and the rotor is established. The most direct parameter that combines these correlations with one another is the state of stress in the elastomer material. This stress can be to be determined directly by means of a corresponding sensor system 37 in the elastomer material or indirectly based on the reaction force of the elastomer on other components, for example on the stator wall, particularly the stator casing 5, on the end face of the elastomer part 4, on closure elements of the stator casing 5, on the rotor of the stator-rotor system 10, etc.

[0054] It is alternatively and/or additionally also possible to use parameters that can be measured on the eccentric screw pump such as the pump pressure, the rotational speed, with which the eccentric screw pump is operated, the temperature, the volumetric flow rate of the conveyed medium, etc.

[0055] A correlation, for example, between pressure, volumetric flow rate, rotational speed and the required prestress is established with the aid of the inventive control algorithm and a corresponding adjustment travel for the adjustment of the adjusting mechanism 12, which should be suitable for adjusting the optimal operating point, is subsequently determined. It is particularly conceivable to provide sensors 38 that determine the actual state of the adjusting system, particularly the position of the positionally variable adjusting element 14 or the relative distance between the stationary adjusting element 13 and the positionally variable adjusting element 14, and/or sensors 38 that monitor the adjustment of the desired nominal position when the position of the positionally variable adjusting element 14 is adjusted.

[0056] The operating parameters determined with the aid of the sensors provide information on the operating state of the eccentric screw pump. The control unit 32 (see FIG. 2) compares these operating parameters with defined operating parameters that are stored, for example, in a characteristic diagram or in a table in the control unit 32. The system does not react if the comparison shows no deviation between the actual operating parameters and the nominal operating parameters. Instead, the actual operating parameters are measured anew after a time interval Δt1 and subjected to a comparison such that the operating state of the eccentric screw pump or the stator-rotor system 10 is regularly monitored or controlled.

[0057] However, if the comparison shows a deviation between the actual operating parameters and the nominal operating parameters, the control unit 32 determines the required adjustment of the adjusting mechanism 12 based on a stored characteristic diagram or a stored table and activates the adjusting mechanism accordingly. After the automated adjustment of the adjusting mechanism 12, the physical operating parameters of the eccentric screw pump or the stator-rotor system 10 are measured anew once another time interval Δt2 has elapsed in order to once again determine whether the optimal operating state is respectively reached or maintained. If the measured operating parameters to not correspond to the desired nominal operating parameters, the control unit 32 once again calculates an adjustment travel and the adjusting mechanism 12 is readjusted accordingly. The control algorithm particularly carries out an incremental adjustment of the type described below with reference to FIG. 4.

[0058] Even if the desired optimal operating state of the eccentric screw pump was achieved with the adjustment, permanent monitoring takes place by regularly determining the operating parameters within defined time intervals Δt3 and, if applicable, readjusting the adjusting mechanism in order to achieve the optimal deformation of the elastomer and therefore the optimal operating state of the eccentric screw pump during its operation.

[0059] FIG. 4 shows the adjustment of an ideal operating point as a function of an adjustment travel n of the adjusting mechanism. A certain volumetric flow rate Q is assigned to a certain rotational speed of an eccentric screw pump. At a volumetric efficiency of 100%, the volumetric flow rate Q particularly would amount exactly to the volume, which is conveyed from the suction side to the pressure side of the eccentric screw pump by the individual transport elements (transport cavities) in accordance with the rotational speed.

[0060] The optimal adjustment of the ideal operating point iBP of the eccentric screw pump takes place as follows: an observation of the volumetric flow rate Q at a constant rotational speed over a certain adjustment travel n shows that this volumetric flow rate Q is nearly constant over an extended adjustment travel n. However, the required torque (not illustrated in the diagram in FIG. 4) is not constant. If the prestress is released by adjusting and/or repositioning the adjusting elements of the adjusting mechanism accordingly, the torque drops due to the lower frictional losses caused by the reduced prestress. The efficiency of the eccentric screw pump increases in a typically broad adjusting range, in which at least largely no change of the volumetric flow rate Q takes place because no backflow or only slight backflow occurs as yet. The efficiency of the eccentric screw pump does not drop until an operating point is reached, at which backflow increasingly occurs. The point of maximum efficiency represents the ideal operating point iBP and can be concretely defined as follows: the ideal operating point of the pump lies exactly in the range of the adjustment travel n of the adjusting mechanism, in which the prestress between the rotor and the stator is just sufficiently high such that no backflow or largely no backflow occurs. The ideal operating point iBP consequently is the point, at which just as much prestress as necessary for generating the required counterpressure with no backflow of the medium is generated in the rotor-stator system.

[0061] This functionality is used for the new control algorithm, wherein an incremental approximation to the ideal operating state iBP particularly takes place. According to an embodiment of the invention, the control algorithm utilizes the following measuring principle: [0062] 1. Measuring operating parameters of the eccentric screw pump such as pressure, rotational speed, torque (motor current) and, if applicable, measuring the volumetric flow rate Q, wherein the measurement is carried out, for example, by means of a volumetric flow meter, a measuring diaphragm or the like. [0063] 2. Adjusting the rotor-stator system by means of the adjusting mechanism: the adjustment is initially closed. The rubber of the elastomer part is compressed such that backflow=0 or largely 0. The volumetric flow rate Q particularly drops as the compression increases because the cavity volume of the pump cavities of the eccentric screw pump becomes smaller and smaller. [0064] 3. Reopening the adjustment once it is ensured that the range of sufficient compression has been reached. In this case, the volumetric flow rate Q initially remains constant up to a certain point. At this point, the volumetric flow rate Q drops because backflow in the stator-rotor system increases. The ideal operating point iBP lies shortly before this dropping point. [0065] The range of sufficient compression can be determined, for example, based on the measured values for the volumetric flow rate Q. The volumetric flow rate Q increases as the adjusting mechanism is closed. The maximum is exceeded once this volumetric flow rate Q no longer changes or slightly drops. [0066] 4. The adjustment according to item 3 is carried out autonomously in the rotor-stator system within certain time intervals such that an active adjustment or adaptation to varying operating conditions of the pump is ensured.

[0067] The invention was described with reference to a preferred embodiment. For a person skilled in the art, however, it is conceivable that the invention can be modified or changed without thereby deviating from the scope of protection of the following claims.