DEVICE FOR CONTROLLING SOLAR DRIVEN WATER PUMPS AND METHOD IN WHICH SUCH A DEVICE IS APPLIED

Abstract

Device for controlling solar driven water pumps with three selectable modes on the control panel being: I) speed mode with 100% use of the available solar DC power at all times; II) solar mode using available solar DC power only, and III) eco mode combining the use of the available solar DC power with the use of the AC power from a grid or a generator and/or batteries, by automatic switching between two stages, being (i) solar stage running on solar DC power only, and (ii) hybrid stage running with solar DC power and AC power from grid or generator and/or batteries like in speed mode. The purpose of the present disclosure is to preferentially use solar energy from solar panels over AC current from the electric grid or from a generator and/or batteries while ensuring sufficient pumping capacity.

Claims

1. A device for controlling solar driven water pumps, wherein the device allows an automated combination of a solar DC power from a solar photovoltaic array and an AC power from an AC grid or an AC generator and/or a set of batteries in three different and selectable modes on the device: I) a speed mode configured to ensure the use of 100% of the solar DC power available from the solar photovoltaic array at all times, by automatically taking the missing power from the AC grid or the AC generator and/or the set batteries in case the solar DC power is insufficient to keep driving a water pump at a requested speed; II) a solar mode configured to run on the available solar DC power only, and arranged to increase or decrease a water pump speed based on available solar DC power, and to shut off the water pump when the available solar power is insufficient; and III) an eco mode configured to use the available solar DC power together with the AC power from the AC grid or the AC generator and/or the set of batteries arranged to pump a minimum quantity of water to be pumped per day and that switches between two stages, being (i) a solar stage configured to run on solar DC power only, and (ii) a hybrid stage configured to run with solar DC power and AC power from the AC grid or the AC generator and/or the set of batteries like in the speed mode, delivering a constant water pressure from the water pump.

2. The device according to claim 1, wherein the combination of solar DC and grid AC is controlled by an electronic control unit configured to control a variable frequency drive that is responsible for converting input electric power into a three-phase power supply to a motor of the water pump and is arranged to adapt the DC power supply, coming from the solar photovoltaic array, to the AC power source, three phased, according to a motor expected voltage.

3. The device according to claim 2, wherein the electronic control unit is configured to continuously monitor the voltage and the current from the solar photovoltaic array and, based on an algorithm, to interact with the variable frequency drive, always trying to utilize maximum power available from solar radiation, and to monitor several inputs of the electronic control unit, including input from sensors, and to make decisions based on the inputs of the electronic control unit.

4. The device according to claim 3, wherein the electronic control unit is configured to use a maximum power point tracking algorithm enabling the electronic control unit to made all the decisions based on real-time analysis of the inputs of the electronic control unit and then to control the output of the device, being the energy supply to the motor of the water pump.

5. The device according to claim 1, wherein the electronic control unit is configured to run during the hybrid stage (ii) with solar DC power and AC power from the AC generator, arranged so that an output power of the AC generator set is always set higher than a safety power level of the AC generator, and so that any surplus of electric energy is fed to charge the set of batteries, which when the set of batteries are fully charged, cause the AC generator to be automatically cut, and in that the DC power of the set of batteries is then used to run the water pump when the solar power is not sufficient to run the water pump at a requested speed, until a power level of the set of batteries is too low, and the AC generator is automatically started again to provide extra AC power.

6. The device according to claim 5, wherein an extra load to the set of batteries when the AC generator is automatically cut, is controlled by an auxiliary controller, using a proprietary algorithm that avoids any interference with the device for controlling the water pump.

7. A method applied by the device for controlling a solar driven water pump in claim 1 wherein the eco mode is selected, the method comprising at least the following steps: turning a selector to the eco mode on an electronic control unit, whereafter the electronic control unit is configured to: monitor an amount of solar DC power captured by the solar photovoltaic array; make a programmed number of tries to start the water pump on solar energy only; when a solar radiation is not sufficient to pump water at a minimal hydraulic power required to safely operate the water pump, switch from the (i) solar stage to (ii) hybrid stage where missing power is now taken from the AC grid or the AC generator but where solar energy is also used when it is available; switch off the AC current after a programmed time span, and lets the water pump continue to run on solar energy only until available sun energy drops below a critical threshold and then stops the water pump; make a predefined number of tries again in a predefined number of minutes to switch on the water pump on solar energy only; when the switching on the water pump fails for lack of solar power, automatically switches to the (ii) hybrid stage again, bringing in AC energy from the AC grid or the AC generator and/or the set of batteries to bring a hydraulic power back to a required level, where both solar and the AC grid power are used. repeat an endless automatic switching between the (i) solar mode and the (ii) hybrid mode the selector is switched from the eco mode.

8. The method according to claim 7, wherein when, within a programmed time lapse, the solar energy remains too low for a minimum speed of the water pump, the electronic control unit switches to the (ii) hybrid stage and the AC power is brought in to drive the water pump to at least a minimal safe speed.

9. The method according to claim 8, wherein, after running the water pump for a programmed time lapse at a requested speed to maintain the constant water pressure, the (ii) hybrid stage is automatically switched off by the electronic control unit and the device returns to the (i) solar stage and the water pump is back on solar supply only, where the water pump will have to run between a full speed and the minimum speed.

10. The method according to claim 9, wherein after returning to the (i) solar stage, the (i) solar stage is maintained until the solar DC power decreases so much that a minimum power to run the water pump at the minimal safe speed is no longer available, whereafter the electronic control unit stops the water pump.

11. The method according to claim 10, wherein after a programmed time lapse after the water pump stops, the electronic control unit automatically tries to start the water pump again in the (i) solar stage on solar power only.

12. The method according to claim 11, wherein when, within a programmed time lapse, the solar energy remains too low for a minimum pump speed, the electronic control unit switches back to the (ii) hybrid stage and the AC power is brought in to run the water pump at the required speed.

13. The method according to claim 12, wherein the last step is the same as the above mentioned first step, and is followed by the same ensuing steps as the above mentioned first step in an endless and automated cycle providing the device that runs as much as possible on solar energy, but also ensures that a minimal amount of water is pumped up daily and calls in AC power in assistance only when needed, to provide a solution as ecological as possible in the given circumstances.

14. A method applied by the device for controlling a solar drive water pump according to claim 1, wherein the speed mode is selected, the method comprising: setting an output power of the AC generator always higher than a safety power level of the AC generator; feeding any surplus of electric energy to charge the set of batteries; automatically cutting the AC generator when the set of batteries are fully charged; running the water pump on DC power from the set of batteries when the solar power is not sufficient to run the water pump at the requested speed, until a power level of the set of batteries is too low; and automatically starting the AC generator up again to provide extra AC power.

15. The device according to claim 2, wherein the the motor expected voltage is 3×230 V or 3×400 V.

16. The device according to claim 5, wherein the safety power level of the AC generator is 30% of a nominal power of the AC generator.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0071] With the intention of better showing the characteristics of the present disclosure, hereafter, as an example using a water well installation without any limitative character, an embodiment of a device for controlling solar driven well pumps is described, with reference to the accompanying drawings, wherein:

[0072] FIG. 1A schematically represent a device for controlling a solar driven well pump connected to a water tank according to the present disclosure;

[0073] FIG. 1B schematically represent a device for controlling a solar driven well pump connected to an irrigation system according to the present disclosure;

[0074] FIG. 2 graphically shows successive time phases in driving a well pump in an ecological mode;

[0075] FIG. 3 graphically shows the relation between voltage and current at different levels of solar irradiation;

[0076] FIG. 4 schematically represents a device for managing solar energy and generator energy to drive a pump.

DETAILED DESCRIPTION

[0077] The device 1 for controlling a solar driven well pump 2 represented in FIG. 1A comprises a control box 3, containing an electronic control unit 4, a power supply 5, a selector 6 for selecting speed mode H, Solar mode S, or Eco mode E, a DC breaker switch 7 and an AC breaker switch 8 and is connected with a water tank 9 level sensor 9′ by a cable 10, with a well level probe 11 by a cable 12 and with the well pump motor 13 by a cable 14. The well pump 2 is positioned in a drilled shaft 15 below the ground water table 16 and is connected by a water pipe 17 to the water tank 9. The control box 3 is further connected to an array of solar cells 18 by two cables 19, 20. The well shaft 15 is protected by a removable mantle and lid 21.

[0078] FIG. 1B shows the same installation as FIG. 1A except that the pipe 17 delivers water to an irrigation system.

[0079] FIG. 2 shows a graph 22 of four measured parameters as a function of time of the day when driving a well pump in Ecological mode. The x-axis gives the hour of the day divided in 5 minute fractions, while the y-axis shows:

[0080] (i) measured solar radiation (SR) in Watt/m.sup.2;

[0081] (ii) solar power from the solar cells (SC) on a scale of 0-1600 Watt or J/s;

[0082] (iii) solar voltage (SV) from the solar cells on a scale of 0-400 V;

[0083] (iv) hydraulic power of the well pump (WP) on a scale of 0-100 Watt.

[0084] The time axis (h) is divided in four consecutive time blocks being [0085] I—a first time block using solar energy only, followed by [0086] II—a second time block using both solar energy and energy from an electric grid or generator and/or batteries, followed by [0087] III—a third time block using solar energy only, followed by [0088] IV—a fourth time block using both solar energy and energy from an electric grid or generator and/or batteries.

[0089] The method applied by the device 1 for controlling a solar driven well pump 2 in Eco-mode according to the present disclosure is as follows.

[0090] The device 1 for controlling the well pump is switched to Eco mode by turning the selector 6 to Eco mode E. The electronic control unit 4 will, starting from dawn when solar radiation is picking up in time block I, make a programmed number of tries to start the well pump 2 on solar energy only. In this particular case, the solar radiation is not sufficient yet to be able to pump water at the minimal hydraulic power required to safely operate the pump. After, in this case three tries, the electronic control unit 4 switches the operation mode automatically to Speed mode, where the missing power is now taken from an AC grid or generator and/or batteries.

[0091] During time block II the pump runs at the required speed and is fed by the AC grid but also by some solar energy at times when it is available. After a programmed time delay the AC current is switched off, in this case after 15 minutes, and the pump 2 continues to run on solar energy only in time block III, until the available sun energy drops below a critical threshold, e.g. because the sun is hidden behind a cloud, thus halting the well pump 2. The device now again makes up to three tries in 10 minutes to switch on the well pump using solar energy only. If this fails for lack of solar power, the control unit 4 will automatically switch to Speed mode again, bringing in AC energy from a grid or generator to bring the hydraulic power of the well pump 2 back to full speed in time block IV, where both DC solar and AC grid power is used.

[0092] The operation in time block IV now is similar to the operation in time block II and the control unit 4 will, after a programmed time delay, switch off the AC current again, followed by a purely solar driven time block V, etc.

[0093] The electronic control unit 4 ensures in this way that a minimum required quantity of water is pumped up daily, and that this is achieved by using as much solar energy as possible when it is available and by using AC energy from a grid or generator only to the extent that it is needed to ensure the required quantity of water.

[0094] FIG. 3 shows the relation between voltage (V) and current (I) at different levels of solar irradiation on photovoltaic cells. The X-axis represents the electric current I, while the Y-axis represents the electric voltage V. Curves are shown for different intensity levels of solar radiation, expressed as Watt/m2 of solar energy received by the photovoltaic cells.

[0095] The graph also shows the relation between voltage and current for an intensity level of 1000 W/m2 of solar energy received for three different ambient temperatures: 25° C., 50° C. and 75° C.

[0096] From the graph it is clear that the voltage-current relation is not linear and that when the solar power goes down, the available current for the same voltage also diminishes. The graph also reveals that changes in temperature of the photovoltaic cells have an influence on the available voltage: when the temperature increases, the available voltage goes down.

[0097] All this implies that the optimal point in the I-V curve where the power is maximum changes continuously and so it is necessary to track this maximal power point or MPP continuously to obtain the maximum efficiency of the system.

[0098] In the case of solar driven pumping systems, it is only possible to work on the right hand side of the curve, where the system acts as a voltage source. On the left hand side, the solar generator becomes a power source which is not suitable for operating systems with solar power only.

[0099] The desired voltage range or current can be obtained by connecting solar panels in series, which will increase the voltage, and by connection solar panels in parallel, which will increase the final current. This means the configuration of the solar panels needs to be tailored to the needs and requirements of the application, in this case of driving a water pump.

[0100] FIG. 4 schematically shows a device 23 for managing solar energy and generator energy to drive a pump that is supplied with AC. The device is controlled by a master electronic control unit 24, that is equipped with Maximal Power Point Tracking software (MPPT) and Automatic Power Compensation software (APC) and controls a slave Variable Frequency Drive (VFD) 25 that can receive sensor inputs from a temperature probe 26, a dry run switch 27, a water level switch 28 and a pressure transducer 29.

[0101] A solar array 30 delivers DC and feeds it to the VFD through cables 31, 32. A generator set 33 delivers AC to the VFD 25 through cables 34,35, or alternatively to a charger 36 through cables 37, 38. The charger 36 delivers DC to a battery pack 39 through cables 40, 41. The battery pack 39 can also provide DC directly to the VFD 25 through cables 41, 47, 32 or AC through the charger 36 and inverter 42 and through cables 41, 40, 43, 44, 35. The VFD 25 supplies AC to the pump 45 through cable 46.

[0102] The device 1 for controlling a solar driven well pump 2 according to the present disclosure can be used in several applications where water is needed and is not limited to agricultural irrigation or to water well installations.

[0103] It is also possible to apply the device to the production of drinking water where it can be steered by a water sensor in the storage tank for drinking water. In case the storage tank is full, the well pump can then be stopped and no more energy is then consumed.

[0104] It is evident that the device according to the present disclosure can be applied to be solar driven applications other than the present water well pump, where an optimal ecological balance is sought for the use of the solar energy or another variable green energy such as wind energy.

[0105] The present disclosure is in no way limited to the embodiment described by way of an example and represented in the figures, however, such a device for controlling solar driven water pumps can be realized in various forms without leaving the scope of the present disclosure, as it is defined in the following claims.