Diaphragm Pump Assemblies

Abstract

A diaphragm pump system that includes a pair of working fluid diaphragm pump assemblies that are each fluidly connected to working fluid flows. Each working fluid diaphragm pump assembly is operationally associated with a drive arrangement that is fluidly isolated from the working fluid flow that is moved during operation of the pump system. A manifold assembly connects the discrete drive arrangements and is constructed to control the cyclic operation of the pair of working fluid diaphragm pump assemblies to mitigate pulsatile effects in the combined working fluid flow when the discharges of the working fluid flows associated with operation of the pair of working fluid diaphragm pump assemblies is combined and independent of the contributions of the discrete diaphragm pumps to the resultant combined output fluid flow.

Claims

1. A diaphragm pump assembly comprising: a first working fluid diaphragm and a second working fluid diaphragm that are operationally connected to one another; a gas manifold disposed between first working fluid diaphragm and the second working fluid diaphragm and constructed to communicate a gas signal to each of a first gas chamber to effectuate a discharge stroke of the first working fluid diaphragm and a second gas chamber to effectuate a discharge stroke of the second working fluid diaphragm; and a rocker switch supported by the gas manifold and configured to interrupt the gas signal communicated to each of the first gas chamber and the second gas chamber as a respective one of the first working fluid diaphragm and the second working fluid diaphragm approaches an end of a respective discharge stroke during each discharge stroke.

2. The diaphragm pump assembly of claim 1 further comprising another diaphragm pump assembly operationally connected to the diaphragm pump assembly such that an output of the diaphragm pump assembly and the another of the diaphragm pump assembly and communicated to a common fluid discharge manifold.

3. The diaphragm pump assembly of claim 2 further comprising a gas regulator assembly connected to the gas manifold of the diaphragm pump assembly and another gas regulator assembly connected to the gas manifold of the another diaphragm pump assembly.

4. The diaphragm pump assembly of claim 3 further comprising a gas connection between the gas regulator assembly and another gas regulator assembly.

5. The diaphragm pump assembly of claim 3 further comprising a first control arrangement connected to each of the gas regulator assembly and another gas regulator assembly when each control arrangement is constructed to electronically detect a position of a respective one of the first working fluid diaphragm and the second working fluid diaphragm.

6. The diaphragm pump assembly of claim 5 further comprising a linear transducer constructed to detect the position of the respective one of the first working fluid diaphragm and the second working fluid diaphragm.

7. The diaphragm pump assembly of claim 6 further comprising a linear transducer constructed to detect the position of each of the first working fluid diaphragm and the second working fluid diaphragm.

8. A diaphragm pump assembly comprising: a first diaphragm pump assembly and a second diaphragm pump assembly wherein each of the first diaphragm pump assembly and the second diaphragm pump assembly each include a first working fluid diaphragm and a second working fluid diaphragm that are each constructed to move a working fluid through the respective one of the first diaphragm pump assembly the second diaphragm pump assembly; a detection system constructed to detect a position of each of the first working fluid diaphragm and the second working fluid diaphragm of each of the first diaphragm pump assembly and the second diaphragm pump assembly; and an air regulator assembly connected to the first diaphragm pump assembly, the second diaphragm pump assembly and the detection system and constructed to adjust an air pressure communicated to a respective one of the first diaphragm pump assembly and the second diaphragm pump assembly based on the position of a respective one of the first working fluid diaphragm and the second working fluid diaphragm of a respective one of the first diaphragm pump assembly and the second diaphragm pump assembly.

9. The diaphragm pump assembly of claim 8 wherein the air regulator assembly is further defined as four-way valve assembly associated with the first diaphragm pump assembly and another four-way valve assembly associated with the second diaphragm pump assembly and connected to the four-way valve assembly associated with the first diaphragm pump assembly.

10. The diaphragm pump assembly of claim 9 further comprising an intake manifold connected to each of the first diaphragm pump assembly and the second diaphragm pump assembly.

11. The diaphragm pump assembly of claim 10 further comprising a discharge manifold connected to each of the first diaphragm pump assembly and the second diaphragm pump assembly.

12. The diaphragm pump assembly of claim 8 wherein the detection system is further defined as a linear transducer associated with at least one of the first working fluid diaphragm and the second working fluid diaphragm of each of the first diaphragm pump assembly and the second diaphragm pump assembly.

13. The diaphragm pump assembly of claim 12 wherein the linear transducer associated with at least one of the first diaphragm pump assembly and the second diaphragm pump assembly is disposed between the first working fluid diaphragm and the second working fluid diaphragm of the respective one of the first diaphragm pump assembly and the second diaphragm pump assembly.

14. The diaphragm pump assembly of claim 13 wherein the linear transducer is configured to detect a relative position of each of the first working fluid diaphragm and the second working fluid diaphragm relative to a respective pump chamber of the respective one of the first diaphragm pump assembly and the second diaphragm pump assembly.

15. A method of operating a diaphragm pump assembly, the method comprising: connecting a first diaphragm pump assembly to a second diaphragm pump assembly wherein each of the first diaphragm pump assembly and the second diaphragm pump assembly have a respective first working fluid pumping diaphragm and a second working fluid pumping diaphragm that are configured to move fluid through the respective one of the first diaphragm pump assembly and the second diaphragm pump assembly; determining a position of the respective one of the first working fluid pumping diaphragm and the second working fluid pumping diaphragm of each of the first diaphragm pump assembly and the second diaphragm pump assembly; and manipulating operation of a gas valve assembly configured to effectuate an intake stroke and a discharge stroke of the first diaphragm pump assembly and the second diaphragm pump assembly in response to the determined position of the respective one of the first working fluid pumping diaphragm and the second working fluid pumping diaphragm.

16. The method of claim 15 wherein manipulating operation of the gas valve assembly is further defined as manipulating a position of a rocker arm that effectuates a switch of a gas flow communication to a respective one of the first diaphragm pump assembly and the second diaphragm pump assembly.

17. The method of claim 16 further comprising providing a plurality of rocker arms that interchangeably cooperate with the gas valve assembly and wherein the discrete rocker arms manipulate a ratio of fluid pumped by a respective one of the first diaphragm pump assembly and second diaphragm pump assembly.

18. The method claim 15 wherein the gas valve assembly is further defined as a four-way gas valve assembly that is associated with the first diaphragm pump assembly and another four-way gas valve assembly that is associated with the second diaphragm pump assembly.

19. The method of claim 18 further comprising fluidly connecting the four-way gas valve assembly associated with the first diaphragm assembly to the another four-way gas valve assembly associated with the second diaphragm assembly.

20. The method claim 15 further comprising manipulating operation of the first diaphragm pump assembly in response to a relative position of one of the first working fluid diaphragm pump and the second working fluid diaphragm of the second diaphragm pump assembly.

Description

DESCRIPTION OF THE DRAWINGS

[0024] A clear conception of the advantages and features constituting the present invention, and of the construction and operation of typical mechanisms provided with the present invention, will become more readily apparent by referring to the exemplary, and therefore non-limiting, embodiments illustrated in the drawings accompanying and forming a part of this specification, wherein like reference numerals designate the same elements in the several views, and in which:

[0025] FIG. 1 is a top plan view of a portion of a diaphragm pump system according to one embodiment of the present invention;

[0026] FIG. 2 is a front elevation view of the diaphragm pump system shown in FIG. 1;

[0027] FIG. 3 is a schematic representation of a diaphragm pump system according to another embodiment of the invention;

[0028] FIG. 4 is a schematic representation of another embodiment of the diaphragm pump system according to another embodiment of the invention;

[0029] FIG. 5 is a perspective view of one of the working fluid diaphragm pump assemblies and respective working fluid diaphragm retracting assemblies of the diaphragm pump system shown in FIG. 4;

[0030] FIG. 6 is a view similar to FIG. 5 and shows a portion of the housing removed from the diaphragm pump system and exposing a diaphragm disposed therein;

[0031] FIG. 7 is a perspective view of the working fluid and retracting diaphragm pump assemblies of the system shown in FIG. 4;

[0032] FIG. 8 is a top plan view of the working fluid and retracting diaphragm pump assemblies shown in FIG. 7;

[0033] FIG. 9 is a schematic view of the diaphragm pump system shown in FIG. 1 with an alternate diaphragm position detection system according to a further aspect of the present invention;

[0034] FIG. 10 is a view similar to FIG. 9 and shows another alternate diaphragm position detection system associated to another aspect of the present invention;

[0035] FIG. 11 is a trend plot showing the cyclic operation associated with the first working fluid diaphragm pump assembly and the second working fluid diaphragm pump assembly generated during the operation of the diaphragm pump assemblies show in the FIGS. above;

[0036] FIG. 12 is a perspective view of a ball valve assembly usable with the diaphragm pump assemblies disclosed above;

[0037] FIG. 13 is a side elevation view of the ball valve assembly shown in FIG. 12;

[0038] FIG. 14 is an elevational cross section view along line A-A of the ball valve assembly shown in FIG. 13;

[0039] FIG. 15 is a detailed cross section view of the ball valve assembly taken along line B shown in FIG. 14;

[0040] FIG. 16 is a top plan view of the ball valve assembly shown in FIG. 12;

[0041] FIG. 17 is a perspective view of a diaphragm pump assembly according to another embodiment of the invention having discrete position detection devices associated therewith and wherein each discrete diaphragm pump assembly includes two working fluid moving chambers;

[0042] FIG. 18 is a graphical cross section view of the diaphragm pump assembly shown in FIG. 17 taken along line 18-18 shown therein;

[0043] FIG. 19 is a graphical cross section view of the diaphragm pump assembly shown in FIG. 17 taken along line 19-19;

[0044] FIG. 20 is a graphical cross section view of the diaphragm pump assembly shown in FIG. 17 taken along line 20-20;

[0045] FIG. 21 is a image of a diaphragm pump assembly according to another embodiment of the invention and having the discrete air flow valves and manifold assemblies associated therewith;

[0046] FIG. 22 is a perspective view of one of the two working fluid diaphragm pump assemblies shown in FIG. 21 with the other two working fluid diaphragm pump assembly removed therefrom; and

[0047] FIG. 23 is a partially exploded view of the two working fluid diaphragm pump assembly shown in FIG. 22.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] Referring to FIGS. 1-2, a diaphragm pump system 50 according to a first embodiment of the present invention includes a first working fluid pumping diaphragm pump assembly 52 and a second working fluid pumping diaphragm pump assembly 54. Each working fluid pumping diaphragm pump assembly includes a respective working fluid pumping diaphragm pump housing 56, 58 that is constructed to enclose a respective working fluid pumping diaphragm as disclosed further below. As is commonly understood, translation of the respective working fluid pumping diaphragms in respective back and forth working directions effectuates the respective intake and discharge strokes associated with communicating a working fluid through the discrete diaphragm pump assemblies 52, 54. As used herein, reference to the respective working fluid diaphragm pump assemblies refers to the portions of system 50 wherein operation of the respective diaphragms associated therewith effectuate translation of the fluid intended to be moved via the cyclic operation of the respective diaphragms associated therewith.

[0049] The housing 56, 58 associated with each working fluid pumping diaphragm pump assembly 52, 54 defines a discrete working fluid inlet 64, 66 and a discrete working fluid outlet 68, 70. An inlet manifold 74 fluidly connects the inlets 64, 66 associated with respective diaphragm pump assemblies 52, 54 to a common working fluid inlet 76. Working fluid inlet 76 is constructed to be connected to a bulk fluid source that is intended to be moved by operation of diaphragm pump system 50. A working fluid outlet manifold 78 fluidly connects the respective outlets 68, 70 associated with discrete diaphragm pump assemblies 52, 54 to a common fluid outlet 80. During operation of the respective working fluid diaphragms 60, 62, fluid is drawn from manifold inlet 76 and directed toward the corresponding inlet 64, 66 of a respective working fluid pumping diaphragm pump assembly 52, 54 and associated with a respective intake stroke of a respective working fluid diaphragm. Once drawn into the working fluid chamber associated with each diaphragm pump assembly 52, 54, during a respective discharge stroke of a respective working fluid diaphragm, the working fluid is communicated to a respective outlet 68, 70 and therefrom toward manifold outlet 80. As disclosed further below, diaphragm pump system 50 is configured to provide a substantially uniform pressure and flow signal associated with the working fluid flow even though the resultant working fluid flow associated with discharge manifold 78 is created by combination of the discrete fluid flows associated with operation of respective discrete diaphragm pump assemblies 52, 54.

[0050] System 50 includes a first diaphragm retracting assembly or working fluid diaphragm pump operator 100 in the form of a piston assembly 100 and a second diaphragm retracting assembly or working fluid diaphragm pump operator 102 in the form of a second piston assembly 102 which are each discreetly associated with a respective working fluid diaphragm pump assembly 52, 54. Each piston assembly 100, 102 includes a piston shaft 104, 106 that is attached to a respective piston 108, 110 that is slideably disposed within a respective piston shaft 112, 114. Each respective piston 108, 110, and the corresponding piston shaft 104, 106 associated therewith, is slidable in an axial direction, as indicated by arrows 120, 122 to effectuate the discrete cyclic operation of the respective diaphragm 60, 62 of the underlying diaphragm pump assembly 52, 54.

[0051] An air manifold 124, 126 is disposed between respective diaphragm assemblies 52, 54 and a corresponding piston assembly 100, 102 and configured to effectuate the desired sequential or controlled operation of discrete diaphragm pump assemblies 52, 54 as described further below. Each piston assembly 100, 102 includes a respective limit control or piston position indication arrangement 140, 142 that cooperates with a respective piston shaft 104, 106. Arrangements 140, 142 provide an indication as to the relative position of the respective pistons 108, 110 and thereby an indication as to the relative position of the respective piston shaft 112, 114, and thereby an indication as to the relative operational position associated with the respective working fluid diaphragm pump assemblies 52, 54. Said in another way, arrangements 140, 142 provide an indication as to the relative intake and/or discharge stroke associated with the respective diaphragms associated with working fluid diaphragm assemblies 52, 54.

[0052] Referring to FIG. 1, in one embodiment, each limit switch assembly or control arrangement 140, 142 includes a first limit switch 144, 146 and a second limit switch 148, 150 that are configured to provide an indication as to the position of piston 108, 110 relative to the respective piston sleeve 112, 114. Such an indication is also indicative of an underlying position associated with operation of respective working fluid diaphragm associated with the respective working fluid diaphragm pump assemblies 52, 54. FIGS. 3 and 4 show a diaphragm pump system 200 according to another embodiment of the present invention. Similar reference numbers are used in FIGS. 1-10 to refer to similar structures between diaphragm pump system 50 and diaphragm pump system 200 and/or interchangeable features therebetween. As set forth further below, it is appreciated that various modalities of a control arrangement are possible and can be desirably configured to achieve the desired operation of a respective diaphragm system 50, 200 in accordance with one or more discrete features disclosed in the present application.

[0053] Referring to FIGS. 3-8, diaphragm pump system 200 preferably includes a control, controller, or control arrangement 160 having one or more inputs 162 and is connected to one or more sensors 164, 166 and/or limit switch assemblies or control arrangements 140, 142 associated with assessing the underlying operational condition of the respective working fluid diaphragm pump assemblies 52, 54 and the respective diaphragm retracting assemblies 100, 102 associated with the respective diaphragm pump system 50, 200.

[0054] Unlike system 50, diaphragm pump system 200 includes a first diaphragm retracting assembly or working fluid diaphragm pump operator 100 and a second diaphragm retracting assembly or working fluid diaphragm pump operator 102 that are formed as respective non-working fluid diaphragm pump assemblies. Said in another way, a respective diaphragm 163, 165 associated with the pump operators 100, 102 of system 200 are fluidly isolated from the working fluid flow associated with working fluid diaphragm pump assemblies 52, 54 but operationally connected thereto via respective connecting rods 169, 171 such that the cyclic operation of respective diaphragms 163, 165 effectuates the desired cyclic operation of diaphragms 60, 62 but do not directly effectuate movement of the working fluid flow during operation of system 200.

[0055] Like system 50, system 200 includes one or more connections 170, 172, 174, 176 that extend between one or more sensors 164, 166 and/or limit switch assemblies 140, 142 so as to provide the desired indication and/or communication of information associated with the desired operation of the underlying respective diaphragm pump system 50, 200. It is further appreciated that, depending on the configuration of the discrete sensors 164, 166 and/or limit switch assemblies and/or control arrangements 140, 142, inputs 170, 172, 174, 176 can be configured to communicate any of an electrical and/or pneumatic operational signals to controller 160 to achieve the desired cyclic operation of respective diaphragm pump assemblies 52, 54 to achieve a generally uniform flow volume and pressure of the working fluid output 80 associated with working fluid flow discharge manifold 78. As disclosed further below with respect to FIGS. 9 and 10, it is further appreciated that the operational functionality associated with the sensors 164, 166 can be provided in various modalities. Although shown as being associated with the working fluid diaphragm retracting assembly, it is further appreciated that the working fluid diaphragm retracting assemblies shown therein could be equivalently be formed as diaphragm retracting assemblies as disclosed above in FIGS. 3-4.

[0056] As shown schematically in FIGS. 3 and 4, diaphragm pump working fluid inlets 64, 66 are preferably fluidly connected to one another via intake or inlet manifold 74 which is fluidly connected to a bulk fluid source 180. It is appreciated that source 180 may take many forms such as a bulk container. As disclosed further below, it is envisioned that systems 50, 200 are usable in various environments. For instance, source 180 can be configured as an unpressurized source of bulk material. Although such tanks are commonly referred to in the industry as pressure pots wherein the volume of the tank is pressurized to effectuate communication of the bulk materials to the delivery system, there is no need to pressurize the source of bulk material when the same is communicated to an application device via respective systems 50, 200. Such a consideration provides for ready inspection of volume of material that remains available for use and allows for construction of the bulk container system in a lighter form factor in as much as the container is not subjected to pressurization. Systems 50, 200 are configured to be useable in both manual and automatic coating applications including automotive and equipment manufacturing painting operations, application of ultraviolet (UV) coatings such as in the manufacture of wood furniture, cabinets, auto lamp covers, metal furniture, application of ceramic coatings such as in mold making processes common to aerospace applications, application of porcelain coatings such as used in the manufacture and conditioning of bathroom fixtures, as well as the application of chemical agent resistant coatings (CARC) typical to military applications. It should be appreciated that the applications provided above are merely exemplary rather than exhaustive of the uses associated with systems 50, 200.

[0057] Regardless of the intended application, operation of respective working fluid diaphragms 60, 62, of systems 50, 200 in response to operation of the respective first and second working fluid diaphragm retracting assemblies 100, 102, whether formed as a piston operational modality, as in system 50, or a diaphragm operational modality, as in system 200, effectuates communication of the working fluid flow from respective inlets 64, 66, to respective discharges 68, 70, and therefrom to the common working fluid flow discharge outlet 80 associated with discharge manifold 78. The sequential operation of working fluid diaphragms 60, 62 associated with generation of the respective discharge strokes is effectuated by operation of respective pistons 108, 110 associated with piston assemblies 102, 104 of system 50 or operation of the respective non-working fluid diaphragms 163, 165 in response to the various pressure and fluid flow signals associated with the controlled operation of the respective diaphragm pump system 50, 200.

[0058] In an alternate aspect as shown in FIG. 9, limit or position switches 140, 142 associated with the respective position of piston shaft 104, 106 are further provided as a gear limit arrangement 192, 194 associated with providing and/or ascertaining the desired or actual relative axial position of respective pistons 108, 110 relative to respective cylinders 112, 114. Like limit switch assemblies 140, 142, it is further appreciated that gear position indicators 192, 194 be operationally connected to controller 160 so as to provide the desired indication as to the relative position of respective pistons 108, 110 relative to the underlying diaphragm piston pump assemblies 52, 54.

[0059] Referring to FIG. 10, when provided in a gear driven arrangement, it is further appreciated that respective limit assemblies 140, 142 can include a cam arrangement 201 having one or more lobes 202 that are configured and oriented to interact with one or more axial limit switches 204, 206, 208. The relative position and/or signal associated with switches 204, 206, 208 provides an indication as to the relative orientation of respective piston shaft 104, 106, and the respective piston 108, 110 associated therewith, relative to the corresponding cylinder 112, 114, and thereby a current operating condition associated with a respective working fluid diaphragm 60, 62.

[0060] Each of the limit or position indicating configurations disclosed above provides an indication as to the relative orientation associated with a respective diaphragm 60, 62 relative to the respective intake and/or discharge stroke associated therewith. During operation of diaphragm pump systems 50, 200, respective operational instructions are communicated to the chamber associated with a dry, air, or non-working fluid side of respective diaphragm 60, 62 and/or a respective pressure chamber 220, 222 associated with respective piston assemblies 100, 102 so as to effectuate the desired cyclic operation of respective diaphragm 60, 62 at least in part in response to the operating pressure associated with the discharge flow and/or pressure associated with the working fluid flow moved via operation of the respective diaphragm pump system 50, 200.

[0061] It is appreciated that the cyclic operation associated with each of discrete pistons 108, 110 or diaphragms 163, 165 associated with the respective working fluid diaphragm retracting assembly can be effectuated with either of a pressure or vacuum signal being communicated to the laterally outboard facing side or the diaphragm facing side associated with each of pistons 108, 110 or non-working fluid diaphragms 163, 165. That is, it is appreciated that a vacuum pressure signal or a position pressure instruction signal can be communicated to a desired respective side of each of respective pistons 108, 110, the non-working fluid side of diaphragm 60, 62, and/or a respective side of non-working fluid diaphragms 163, 165 to achieve the desired intake or discharge stroke of a respective working fluid diaphragm 60, 62.

[0062] As disclosed further below with respect to FIG. 11, the respective intake and discharge strokes associated with the operation of diaphragms 60, 62 is effectuated in such a manner so as to generally balance the working fluid pressure and flow characteristics associated with common working fluid output or outlet 80 of discharge manifold 78. The cyclic sequential operation associated with operation of diaphragm assemblies 52, 54 is configured to mitigate pressure and flow spikes associated with respective differentials between the working fluid intake and discharge flows and pressures in response to the sequential operation attributable to the contribution of the discrete diaphragm pump assembly 52, 54 to the resultant overall working fluid flow. That is, diaphragm pump systems 50, 200 are constructed to accommodate and mitigate the fluid flow pressure deviations associated with the cyclic nature innate to the operation of diaphragm pump assemblies 52, 54 wherein each of the discrete diaphragm chambers are associated with translating the working fluid flow through the respective diaphragm pump assembly.

[0063] As disclosed further below, the operation of controller 160 that operates to reduce the fluid pressure surges associated with the cyclic operation of diaphragms 60, 62. Referring to FIG. 11, control arrangement 160 is configured to briefly apply a pumping pressure or partial air pressure signal to both of dry side chambers at the same time near the full compression stroke associated with the discharge stroke of each respective diaphragm 60, 62. As disclosed further below with respect to FIG. 11, discrete diaphragm pump assemblies 52, 54, whether the operation is driven by a piston assembly or non-working fluid diaphragm assembly, whose position is monitored via a LVDT sensor or other sensor construction, are constructed to accommodate introduction of an operating air pressure flow, or a portion thereof, concurrently for a brief period, or overlap when one working fluid diaphragm approaches an end of a discharge stroke and the other working fluid diaphragm approaches an end of the intake stroke.

[0064] FIG. 11 shows an exemplary operating sequence associated with control of the operation airflow to achieve the desired sequential cyclic operation associated with diaphragm pump system 50, 200. Communication to the air side of diaphragm 60 effectuates a discharge operation associated with diaphragm 60 and translation of piston 108, 212, or a respective non-working fluid diaphragm 163, 165 toward the working fluid side associated with diaphragm 60. Upon completion of the discharge stroke associated with diaphragm 60, 214, communication of the signal associated with nonworking fluid side of diaphragm 60, 216 terminates when an intake instruction 218 is communicated to piston 108 or the respective non-working fluid diaphragm 163, 165 to effectuate an intake stroke 220 associated with diaphragm 60 and piston 108 or a respective non-working fluid diaphragm 163, 165.

[0065] Upon completion of the intake stroke 222 associated with operation of non-working fluid diaphragm 165 or piston 108 and diaphragm 60, discharge stroke instructions 224, 226 associated with diaphragm 60 and piston 108, or non-working fluid diaphragm 165, are initiated until initiation 228 of a discharge stroke 230 of diaphragm 60 and associated piston 108 or diaphragm 165. Operation of diaphragm 62 and piston 110, or diaphragm 165, are effectuated in a similar but timewise shifted or offset manner so as to effectuate multiple intake operations 232, 234 and multiple sequential discharge operations 236, 238 associated with operation of diaphragm 62 and piston 110 or diaphragm 163. That is, the discharge strokes associated with operation of diaphragms 60, 62 are timewise offset from one another so as to generate a generally uniform working fluid flow discharge pressure and flow parameters.

[0066] Multiple pressure signal overlap areas 240, 242 are provided at the discrete intervals during the cyclic operation of diaphragm 62 and piston 110 or non-working fluid diaphragm 163 and diaphragm 60 and piston 108 or non-working fluid diaphragm 165. Pressure overlaps 240, 242 associated with operation of diaphragms 60, 62 and pistons 108, 110, or non-working fluid diaphragms 163, 165 allows transitioning of each of the respective diaphragms 60, 62 during the respective intake and discharge strokes so as to maintain a generally uniform working fluid discharge flow and pressure associated with the cyclic operation of diaphragm pump system 50, 200 such that system 50, 200 mitigates the flow and pressure spikes associated with the discrete intake and discharge strokes inherent to operation of discrete ones of diaphragms 60, 62 during continued operation of system 50, 200.

[0067] It should be appreciated that although first and second working fluid diaphragm retracting operator or assembly 100, 102 are provided as respective diaphragm assemblies rather than piston assemblies as described above with respect to FIGS. 1-2, the respective diaphragm assemblies associated with the first and second working fluid diaphragm retracting pump operator or assembly 100, 102 as shown in FIGS. 3-8 are fluidly isolated from communication of the working fluid flow through system 200 and are each operable to effectuate manipulation of the respective working fluid diaphragm 60, 62. Referring to FIG. 8, each diaphragm retracting assembly 100, 102 includes a retracting diaphragm shaft 104, 106 that is attached to a respective retracting diaphragm 108, 110 that is slideably disposed within a respective retracting diaphragm shaft 112, 114. Each respective retracting diaphragm 108, 110, and the corresponding retracting diaphragm shaft 104, 106 associated therewith, is slidable in an axial direction, as indicated by arrows 120, 122 to effectuate the discrete cyclic operation of the respective working fluid pumping diaphragm 60, 62 of the underlying working fluid pumping diaphragm pump assembly 52, 54.

[0068] An air manifold 124, 126 is disposed between respective working fluid pumping diaphragm assemblies 52, 54 and a corresponding respective retracting diaphragm assembly 100, 102 and configured to effectuate the desired sequential or controlled operation of discrete pumping diaphragm pump assemblies 52, 54 as described above and described further below. Each retracting diaphragm assembly 100, 102 includes a respective limit control or retracting diaphragm position indication arrangement 140, 142 that cooperates with a respective retracting diaphragm shaft 104, 106. Position indication arrangements 140, 142 provide an indication as to the relative position of the respective retracting diaphragms 108, 110 and thereby an indication as to the relative position of the respective retracting diaphragm shaft 112, 114, and thereby an indication as to the relative operational position associated with the respective pumping diaphragm pump assemblies 52, 54. Said in another way, position indication arrangements 140, 142 provide an indication as to the relative intake and/or discharge stroke associated with operation of the respective working fluid pumping diaphragms 60, 62.

[0069] Position indication arrangements 140, 142 are constructed to communicate and control operation of working fluid pumping diaphragm pump assemblies 52, 54 and retracting diaphragm assemblies 100, 102 in the same manner as described above with respect to diaphragm pump system 50. As described above, each limit switch assembly or control arrangement 140, 142 includes a first limit switch and a second limit switch that are configured to provide an indication as to the position associated with the respective operation and position of retracting diaphragm 108, 110 relative to a respective retracting diaphragm sleeve 112, 114. Such an indication is also indicative of an underlying position associated with operation of respective working fluid pumping diaphragm 60, 62.

[0070] Although not shown in FIGS. 5-8, the diaphragm pump system 200 shown therein includes a control or control arrangement 160 as described above having one or more inputs and is connected to one or more sensors and/or limit switch assemblies or control arrangements 140, 142 associated with assessing the underlying operational condition of the respective working fluid pumping diaphragm pump assemblies 52, 54 and the respective retracting diaphragm assemblies 100, 102. One or more connections 170, 172, 174, 176 extend between one or more sensors and/or limit switch assemblies 140, 142 so as to provide the desired indication and/or communication of information associated with the desired operation of the underlying diaphragm pump system 50. It is further appreciated that, depending on the configuration of the discrete sensors and/or limit switch assemblies and/or control arrangements 140, 142, inputs 170, 172, 174, 176 can be configured to communicate any of an electrical and/or pneumatic operational signals to controller 160 to achieve the desired cyclic operation of respective working fluid pumping diaphragm pump assemblies 52, 54 to achieve a generally uniform flow volume and pressure of the working fluid output 80 associated with working fluid flow discharge manifold 78 in a manner similar to that described above with respect to FIGS. 1-6.

[0071] Like the arrangement shown schematically in FIGS. 1-2, the working fluid diaphragm pumps associated with diaphragm pump system 200 shown in FIGS. 3-8 include working fluid inlets that are fluidly connected to one another via an intake manifold which is fluidly connected to a bulk fluid source. Operation of respective working fluid pumping diaphragms 60, 62 in response to operation of respective retracting diaphragm assemblies 100, 102 effectuates communication of the working fluid flow from respective inlets to respective outlets associated with respective working fluid diaphragm pump assemblies 52, 54, and therefrom to the common working fluid flow discharge outlet 80 associated with discharge manifold 78. The sequential operation of working fluid pumping diaphragms associated with generation of the respective discharge strokes is effectuated by operation of respective retracting diaphragms 108, 110 associated with retracting diaphragm assemblies 102, 104 in response to the various pressure and fluid flow signals associated with the controlled operation of diaphragm pump system 50. It is appreciated that operation of the embodiment of the diaphragm pump system shown in FIGS. 3-8 is operable with either of the displacement and control arrangements 140, 142, 160 as described above to achieve the desired cyclic operation of working fluid pumping diaphragm assemblies 52, 54 as shown in FIGS. 3-8 wherein motion of the discrete working fluid diaphragms 60, 62 is provided by operation of the respective retracting diaphragm assemblies 100, 102 and the respective retracting diaphragm shafts 104, 106 associated therewith.

[0072] Each of the limit or position indicating configurations disclosed above provides an indication as to the relative orientation associated with a respective working fluid pumping diaphragms 60, 62 relative to the respective intake and/or discharge stroke associated therewith. With respect to the embodiment of diaphragm pump system 200 as shown in FIGS. 3-8, during operation of diaphragm pump assembly 200, respective operational instructions are communicated to the chamber associated with a dry, air, or non-working fluid side of respective working fluid pumping diaphragm 60, 62 and/or a respective pressure chamber 220, 222 associated with respective retracting diaphragm assemblies 100, 102 so as to effectuate the desired cyclic operation of respective working fluid pumping diaphragm 60, 62 at least in part in response to the operating pressure associated with the discharge flow and/or pressure associated with the working fluid flow moved via operation of diaphragm pumping system 200.

[0073] It is appreciated that the cyclic operation associated with each of discrete retracting diaphragms 108, 110 can be effectuated with either of a pressure or vacuum signal being communicated to the laterally outboard facing side or the working fluid pumping diaphragm facing side associated with each of retracting diaphragms 108, 110. That is, it is appreciated that a vacuum pressure signal or a position pressure instruction signal can be communicated to a desired side of each of respective retracting diaphragms 108, 110 and/or the non-working fluid side of the working fluid pumping diaphragm 60, 62 to achieve the desired intake or discharge stroke of a respective working fluid pumping diaphragm 60, 62.

[0074] As disclosed above with respect to FIG. 10, and with respect to the embodiment of system 200 shown in FIGS. 3-8, it is appreciated that the respective intake and discharge strokes associated with the operation of working fluid pumping diaphragms 60, 62 is effectuated in such a manner so as to generally balance the working fluid pressure and flow characteristics associated with common working fluid output 80 of discharge manifold 78. The cyclic sequential operation associated with operation of diaphragm pump assemblies 50, 52 is configured to mitigate pressure and flow spikes associated with respective differentials between the working fluid intake and discharge flows and pressures in response to the sequential operation attributable to the contribution of the discrete pump assembly 52, 54 to the resultant overall working fluid flow. That is, diaphragm pump systems 50, 200 are each constructed to accommodate and mitigate the fluid flow and fluid flow pressure deviations associated with the cyclic nature innate to the operation of diaphragm pump assemblies 52, 54 as disclosed above.

[0075] As alluded to above, the operation of controller 160 associated with the diaphragm pumping system 200 shown in FIGS. 3-8 also operates to reduce the fluid pressure surges associated with the cyclic operation of working fluid flow pumping diaphragms 60, 62. Referring to FIG. 10, control arrangement 160 associated with system 200 shown in FIGS. 3-8 is configured to briefly apply a pumping pressure or partial air pressure signal to both of the respective dry side chambers at the same time near the full compression stroke associated with the discharge stroke of each respective working fluid pumping diaphragm 60, 62. Discrete diaphragm pump assemblies 52, 54 are constructed to accommodate introduction of an operating air pressure flow, or a portion thereof, concurrently for a brief period, or overlap when one working fluid pumping diaphragm approaches an end of a discharge stroke and the other working fluid pumping diaphragm approaches an end of the intake stroke.

[0076] FIG. 10 shows an exemplary operating sequence associated with airflow control to achieve the desired sequential cyclic operation associated with working fluid pumping diaphragm pump system 50, 200. Communication to the air side of working fluid pumping diaphragm 60 effectuates a discharge operation associated with working fluid pumping diaphragm 60 and translation of retracting diaphragm 108, 212 toward the working fluid side associated with working fluid pumping diaphragm 60. Upon completion of the discharge stroke associated with working fluid pumping diaphragm 60, 214, communication of the signal associated with nonworking fluid side of working fluid pumping diaphragm 60, 216 terminates when an intake instruction 218 is communicated to retracting diaphragm 108 to effectuate an intake stroke 220 associated with working fluid pumping diaphragm 60 and retracting diaphragm 108.

[0077] Upon completion of the intake stroke 222 associated with operation of retracting diaphragm 108 and working fluid pumping diaphragm 60, discharge stroke instructions 224, 226 associated with working fluid pumping diaphragm 60 and retracting diaphragm 108 are initiated until initiation 228 of a discharge stroke 230 of working fluid pumping diaphragm 60 and associated retracting diaphragm 108. Operation of working fluid pumping diaphragm 62 and retracting diaphragm 110 are effectuated in a similar but timewise shifted or offset manner so as to effectuate multiple intake operations 232, 234 and multiple sequential discharge operations 236, 238 associated with operation of working fluid pumping diaphragm 62 and retracting diaphragm 110. That is, the discharge strokes associated with operation of working fluid pumping diaphragms 60 and timewise offset or shift relative to one another so as to generate a generally uniform working fluid flow discharge.

[0078] As shown in FIG. 10, multiple pressure signal overlap areas 240, 242 are provided at the discrete intervals during the cyclic operation of working fluid pumping diaphragm 62 and retracting diaphragm 110 and working fluid pumping diaphragm 60 and retracting diaphragm 108, respectively. Pressure overlaps 240, 242 associated with operation of working fluid pumping diaphragms 60, 62 and retracting diaphragms 108, 110 allows transitioning of each of the respective working fluid pumping diaphragms 60, 62 during the respective intake and discharge strokes so as to maintain a generally uniform working fluid discharge flow and flow pressure associated with the cyclic operation of working fluid pumping diaphragm pump system 200 such that system 200 mitigates the flow and pressure spikes associated with the discrete intake and discharge strokes inherent to operation of discrete ones of working fluid pumping diaphragms 60, 62 during continued operation of system 200 and/or for those configurations wherein the working fluid pumping diaphragms are physically connected to one another such that operation of one working fluid pumping diaphragm is physically contingent upon operation of an opposing working fluid pumping diaphragm.

[0079] It should further be appreciated that system 200 as disclosed in FIGS. 3-8 can be conveniently provided by manipulation of the construction of what is considered two discrete double working fluid diaphragm pump assemblies. However, as disclosed above, it should be further appreciated that only one discrete side of each double diaphragm pump assembly is associated with the communication of the working fluid flow through system 200. Such considerations present several novel aspects as to the control and operation of the underlying system.

[0080] For instance, the retraction speed associated with operation of retracting diaphragm assemblies 100, 102 determines the suction pressure and volume loaded into the working fluid diaphragm pumps 52, 54. In one embodiment, the linear variable differential transformer (LVDT) 140, 142 incorporates a LVDT transducer which provides controller 160 with an analog travel measurement. The measure of travel over time is used by controller 160 to determine speed and flow rate associated with operation of diaphragm pump assemblies 52, 54. Air pressure associated with driving the retraction rate associated with operation of retracting diaphragm assemblies 100, 102 is programmable such that system 200 can be configured to provide a constant retraction rate associated with retracting diaphragm assemblies 100, 102 and thereby working fluid pumping diaphragms 60, 62. Preferably, the speed of retraction associated with operation of the retracting diaphragm assemblies 100, 102 is controlled independently of the speed associated with the working fluid discharge stroke associated with each of the respective working fluid diaphragm pump assemblies. Such a consideration allows control of the retraction or working fluid pump load speed at a constant rate to allow optimization of the discrete working fluid load volumes. Similar considerations provide for control of the working fluid flow rates associated with combined contributions of the discrete working fluid flow diaphragm pump assemblies.

[0081] Whether provided as a piston retraction control arrangement or a diaphragm retraction control arrangement, working fluid pumping diaphragms 60, 62 includes some degree of hysteresis associated with the operation of the working fluid pumping diaphragm during each of the working fluid intake and discharge strokes. Accordingly, the pressure required to generate a constant or steady state working fluid flow rate as related to a current stroke condition changes with travel. Controller 160, LVDT 140, 142, and the programmable pneumatic pressure instructions provide a more constant or steady state working fluid delivery rate through adjustment, usually an increase, to the drive pressure as the respective working fluid pumping diaphragm 60, 62 approaches the respective ends of their respective operating strokes.

[0082] In a further aspect, systems 200 as disclosed above mitigates instances of reduced working fluid flow rates attributable to inadequate sealing or seating of the check valves associated with the discrete working fluid discharge strokes. During operation with low working fluid output pressures, failure of a discrete check valve associated with respective working fluid flow diaphragm 60, 62 to adequately seal can create a situation wherein a portion of the working fluid discharge flow is contributed to the volume associated and, although the system does not achieve a desired flow rate, the underlying working fluid pumping diaphragm pump assembly continues cyclic operation. Using an activate signal, such as actuation of a spray gun or the like associated with the discharge 80 of manifold 78 allows controller 160 can monitor LVDT's 140, 142 and provide a check valve leak signal or automatically reduce a respective pump assemblies 52, 54 compressed air pressure signal until working fluid pumping stops thereby automatically correcting the discharge check valve blow-by or bleed flows.

[0083] Accordingly, systems 50, 200, whether configured in accordance with the aspects shown in FIGS. 1-2 or the aspects shown in FIGS. 3-8, provides a diaphragm pump control arrangement having a more universal flow and pressure signal indicia associated with the cyclic operation of the underlying system 50, 200. Whereas pumping diaphragms 60, 62 provide the fluid pressure signal associated with operation of system 50, 200, respective retracting piston and diaphragm retracting diaphragm assemblies 100, 102 provide a pump suction speed associated with determining the pump volumetric output. Discrete pneumatic control of the working fluid pumping diaphragm operating air pressure and retracting piston or diaphragm suction pressure, and the timed pneumatic sequence associated therewith, provides for a selective overlap of the piston and/or diaphragm operating pressure when shifting between the intake and discharge strokes associated with operation of working fluid pumping diaphragm 60 and working fluid pumping diaphragm 62, respectively. The discrete overlap associated with respective pressure signals 240, 242 reduces flow and pressure value pulsatile effects associated with the discharge flow and pressure signal associated with the working fluid flow such that system 50, 200 provides dynamic control of both the suction and pressure speed control associated therewith. Further, each of systems 50, 200 negates the need for refilled and non-recirculated pressure potentiometers as well as fluid flow surge suppressors and/or pressure regulators commonly associated with fluid pump output ports thereby providing a generally robust system having fairly negligible flow surge signals during operation.

[0084] FIGS. 12-16 show various views of an optional ball valve assembly 250 usable with at least one, and preferably each, of the respective intake and discharge ports associated with the respective working fluid diaphragm assemblies 52, 54 associated with systems 50, 200. Those skilled in the art will readily appreciate the construction of ball valve assemblies 250 as being commonly disposed between at least one of an inlet passage and a discharge passage between the discrete diaphragm chamber associated with the working fluid and the manifold structure associated therewith. Such ball valve assemblies are commonly configured to prevent flows in the opposite operational flow direction or between discrete inlet and outlet passages during operation of the discrete the diaphragm pump assemblies.

[0085] Each ball valve assembly 250 includes a seat 252 that is commonly defined by a portion of the housing 254 or a manifold associated with the discrete working fluid diaphragm pump assembly. Unlike known diaphragm pump assemblies, ball valve assembly 250 includes a seal 256 that is supported by a groove 258 formed in seat 252. Seal 256 is configured to engage an exterior surface 261 of a ball 260 associated with each ball valve assembly 250 when the ball is oriented in a closed orientation relative to a respective working fluid flow passage 262 defined by housing 254 or a manifold associated therewith. Ball 260 includes an optional weight 264 that is oriented to gravitationally bias ball 260 into sealed engagement with seal 256.

[0086] Whereas rubber ball valves have proved unsatisfactory when systems 50, 200 are used for communicating paint materials to an application device, particularly at the low flow pressure values customary thereto, ball valve assemblies wherein the ball is formed of materials like Teflon and stainless steel are commonly selected but frequently do not seat properly at low pressure differentials between the opposing intake and discharge passages associated with the working fluid diaphragm pump assemblies and tend to result is cross contamination of the fluid flow signals from respective intake and discharge sides of the pump assembly. Such occurrences reduce the ability to accurately control the flow parameters at low flow pressures and volumes as disclosed above. Providing seal 256 and the additional weighting of ball 260 via weight 264 allows the working fluid diaphragm pump assemblies to be constructed in a manner that allows for the placement of a solvent resistant seal 256 in the form of an O-ring to improve the sealing performance associated with operation of ball valve assembly 250 at low working fluid diaphragm chamber conditions prior to development of a desired pressure differential relative to the opposing fluid sides of the ball valve assembly 250 and thereby more accurate control associated with the working fluid flow and working fluid flow pressure associated with operation of systems 50, 200.

[0087] FIGS. 17-23 show various views of a diaphragm pump system or diaphragm pump assembly 300 according to another alternate embodiment of the invention. Although assembly 300 is generally operable in the same manner as diaphragm pump systems 50, 200 with respect to generating substantially uniform working fluid flow pressure and flow volumes associated with movement of the working fluid flows therethrough, diaphragm pump assembly 300 is constructed to provide a discharge stroke with each oscillation of discrete diaphragm pump shafts associated with each of a pair of discrete dual diaphragm diaphragm pump assemblies 302, 304 that are fluidly connected to one another and whose operation is monitored and manipulated by a position detection system, such as a linear variable differential transformer (LVDT) 306, 308, and a control, controller, or control arrangement similar to control arrangement 160 in a manner similar to that described above with respect to systems 50, 200.

[0088] Referring to FIGS. 17-20, each dual diaphragm pump assembly 302, 304 includes a pair of discrete working fluid diaphragms 310, 312 that are each respectively disposed in discrete working fluid chambers 314, 316 associated with each of discrete diaphragm pump assemblies 302, 304. Discrete pairs of working fluid diaphragms 310, 312 can be operationally connected to one another via respective diaphragm shafts 318 of each discrete dual diaphragm pump assembly 302, 304. Alternatively, it is further appreciated that discrete shafts 318 may be secured to discrete gas diaphragms 320, 322 associated with each pump assembly 302, 304 such that respective pressurization and depressurization of respective gas chambers 324, 326 may effectuate the relative translation or motion of working fluid diaphragms 310, 312 relative to the respective working fluid chamber 314, 316 to effectuate the movement of the working fluid flow through diaphragm pump assemblies 302, 304.

[0089] A working fluid inlet manifold 330 includes a working fluid inlet 332 and a plurality of working fluid outlets 334 that are each fluidly connected to a respective one of working fluid diaphragm chambers 314, 316 of each discrete diaphragm pump assembly 302, 304. A working fluid discharge manifold 338 includes a plurality of working fluid inlets 340 that are each connected to a respective working fluid diaphragm chamber 314, 316 of each of diaphragm pump assembly 302, 304 and a working fluid outlet 342 that is associated with the collective fluid movement associated to operation of diaphragms 310, 312 of each of diaphragm pump assemblies 302, 304 during the cyclic operation of dual diaphragm diaphragm pump assembly 300.

[0090] Each diaphragm pump assembly 302, 304 includes in air distributor body 348 that supports respective shafts 318. An air inlet 350 is connected to each distributor body 348 and is supported by a manifold body 352 that is secured thereto. Each distributor body 348 includes a respective passage 354 that is formed therethrough and which is constructed to communicate at least a portion of an air flow through discreet distributor bodies 348 to a respective relay valve assembly (FIG. 21) as disclosed further below with respect to FIGS. 21-23 and to provide a desired cyclic operation of discrete working fluid diaphragms 310, 312 in a manner that is, based at least in part, on the discrete relative position of the discrete working fluid diaphragms 310, 312 and based on information attained from the discrete position detection systems 306, 308 associated therewith and in a manner consistent with the disclosure above regarding systems 50, 200.

[0091] FIGS. 21-23 show a dual diaphragm pump assembly 400 constructed in a manner similar to dual diaphragm diaphragm pump assembly 300 and according to another embodiment of the present invention and wherein the diaphragm pump assembly includes a plurality of discrete working fluid diaphragms whose relative motion also contributes to an overall working fluid output of the diaphragm pump assembly 400. Like diaphragm pump assembly 300, diaphragm pump assembly 400 includes an air distribution or pump body 402, 404 that is disposed between respective diaphragm working fluid chambers 406, 408 associated with the respective dual diaphragm pump assemblies 410, 412. Although shown as discrete distribution bodies 402, 404 associated with discrete working fluid diaphragm pairs associated with each of the discrete diaphragm pump assembly 410, 412, it is appreciated that distribution bodies 402, 404 could be provided as a unitary assembly or a single distribution body that is constructed to cooperate with multiple discrete dual diaphragm pumps 410, 412.

[0092] It is further appreciated that discrete pump bodies 402, 404 can be constructed to cooperate with discrete diaphragm working fluid chambers 406, 408 defined by discrete diaphragm bell housings having discrete working fluid volumes and/or various volumes and/or discrete diaphragm bell housings having dissimilar fluid pumping volumes. In a preferred aspect of the present invention, pump bodies 402, 404 are constructed to cooperate with and be secured to working fluid diaphragm bell housings manufactured by one or more original equipment manufacturers (OEM's) of single and dual diaphragm pump assemblies that are not constructed to allow the effectuate alignment of operation of the working fluid diaphragms in a manner as disclosed in the present application wherein pressure differentials associated with the near end of stroke operation of the discrete working fluid diaphragms is manipulated to mitigate the generation of pressure differentials and flow value differentials at the resultant working fluid flow outputs associated with the collective output generated by the cyclic operation of the discrete working fluid flow diaphragms.

[0093] Still referring to FIGS. 22-23, at least one of dual diaphragm assemblies 410, 412 includes a regulator assembly 420 having an air input 422 associated with communicating a desired air operating pressure to one or more of pump bodies 402, 404. During operation of dual diaphragm pump assembly 400, air delivered to discrete pump bodies 402, 404 is communicated to air manifold 412 and one or more discrete valve assemblies 424, 426 associated therewith. Discrete valve assemblies 424, 426 interact with a flow valve such as a rocker 428 of the like. Manifold 412 include one or more connections 430 associated with communicating air moved through manifold 412 toward respective regulator valves, as disclosed further below with respect to FIG. 21, and/or to other dual diaphragm pump bodies 402, 404 and/or the discrete manifolds 412 associated therewith to achieve both the cyclic and output working fluid flow pressure and flow value associated with cyclic operation of diaphragm pump assembly 400 in a manner similar to diaphragm pump systems 50, 200.

[0094] Referring back to FIG. 21, in a preferred aspect to the present invention, and when provided in a discrete two dual diaphragm pump assembly configuration, diaphragm pump assembly 400 includes a respective regulator valve assembly 440, 442 associated with each of the dual diaphragm pump assemblies 410, 412 that are associated therewith. In a preferred aspect of the present invention, each of the discrete pump bodies 402, 404; respective regulator valve assemblies 420, 440, 442; and respective manifold valve assemblies 424, 426 are independently serviceable and can be individually configured for operation with discrete dual diaphragm pump assemblies whether provided as discrete dual diaphragm pump assemblies or multiple dual diaphragm pump assemblies whose operation collectively contributes to the resultant fluid flow output of the resultant assembly.

[0095] Operation of rocker 428 and the interaction of rocker 428 with valve assembly 424, 426 facilitates the desired switching of the respective intake and discharge stroke of the respect working fluid flow diaphragms associated with each of the respective pump bodies 402, 404 associated therewith. In a preferred aspect of the present invention, diaphragm pump assembly 400 includes a plurality of rockers 428 wherein each rocker has a unique construction relative to the interaction of the discrete rocker 428 with the respective switching valve assemblies 424, 426. Such a consideration allows the user to uniquely configure diaphragm pump assembly 400 to provide discrete working fluid stroke volumes of a given working fluid diaphragm associated with the respective diaphragm pump assembly 400. That is, interchangeable rockers 428 allow the user to adjust or otherwise manipulate a respective ratio of discrete fluids communicated to a combined output of diaphragm pump assembly 400 when the discrete constituent fluids are communicated to the respective working fluid inputs of the discrete dual diaphragm pump assemblies 410, 412 of diaphragm pump assembly 400.

[0096] Whether constructed as a dual diaphragm pump assembly wherein the discrete working fluid inputs and outputs are fluidly connected to each discrete dual diaphragm working fluid chamber and each discrete diaphragm pump assembly includes two discrete working fluid moving chambers, such as diaphragm pump assembly 300, or whether provided as discrete diaphragm chambers that are constructed to move discrete working fluids to a unitary output as diaphragm pump assembly 400, each of diaphragm pump assemblies 300, 400 provide diaphragm pump assemblies that mitigate pressure differentials and fluid flow volume differentials attributable to the cyclic operation of the discrete working fluid diaphragm operation and whether each discrete working fluid diaphragm is configured to communicate common or different working fluids.

[0097] Still further, the orientation of position detection systems 306, 308 being disposed and engaged with a common shaft 318 whose position can be associated with and/or assignable so as to determine the relative position of multiple discrete working fluid diaphragms 310, 312 during the cycle operation of the discrete dual diaphragm diaphragm pump assemblies 302, 304 presents several additional benefits. For instance, working fluid flow pressure drops attributable to mechanical and fluid flow aspects such as fluid flow and diaphragm deflection frictional forces, hysteresis of the diaphragm material, and changes to the working fluid flow diaphragm cavity size on can be accommodated to maintain a desired working fluid flow output pressure and flow value via the timely switching of the operational direction of translation of discrete shafts 318 associated with discrete dual diaphragm diaphragm pump assemblies 302, 204. That is, the discrete air flow regulators 440, 442 and attenuate dual mode regulator pump shaft mechanical bias associated with the discrete directional operation of the discrete connected respective working fluid diaphragm pairs 310, 312 associated with fluidly connected dual diaphragm diaphragm pump assemblies 302, 304 provides a dynamic counteracting pressure offset from the static pump pressure via increasing the pump diaphragm air pressure and thereby providing a constant pressure working fluid output pressure and working fluid flow value in a manner consistent with systems 50, 200 as disclosed above albeit in a multiple dual diaphragm diaphragm pump assembly methodology.

[0098] Therefore, one embodiment of the present invention includes a diaphragm pump assembly that includes a first working fluid diaphragm and a second working fluid diaphragm that are operationally connected to one another. A gas manifold is disposed between the first working fluid diaphragm and the second working fluid diaphragm and is constructed to communicate a gas signal to each of a first gas chamber to effectuate a discharge stroke of the first working fluid diaphragm and a second gas chamber to effectuate a discharge stroke of the second working fluid diaphragm. A rocker switch is supported by the gas manifold and is configured to interrupt the gas signal communicated to each of the first gas chamber and the second gas chamber as a respective one of the first working fluid diaphragm and the second working fluid diaphragm approaches an end of a respective discharge stroke during each discharge stroke.

[0099] Another embodiment of the invention that is useable or combinable with one or more of the features, objects, or aspects of the above embodiments includes diaphragm pump assembly having a first diaphragm pump assembly and a second diaphragm pump assembly wherein each of the first diaphragm pump assembly and the second diaphragm pump assembly each include a first working fluid diaphragm and a second working fluid diaphragm that are each constructed to move a working fluid through the respective one of the first diaphragm pump assembly the second diaphragm pump assembly. The diaphragm pump assembly includes a detection system constructed to detect a position of each of the first working fluid diaphragm and the second working fluid diaphragm of each of the first diaphragm pump assembly and the second diaphragm pump assembly during operation thereof. An air regulator assembly is connected to the first diaphragm pump assembly, the second diaphragm pump assembly, and the detection system and constructed to adjust an air pressure communicated to a respective one of the first diaphragm pump assembly and the second diaphragm pump assembly based on the position of a respective one of the first working fluid diaphragm and the second working fluid diaphragm of a respective one of the first diaphragm pump assembly and the second diaphragm pump assembly during operation of the diaphragm pump assembly.

[0100] A further embodiment of the invention that is useable or combinable with one or more of the features, objects, or aspects and/or above embodiments includes a method of operating a diaphragm pump assembly that includes connecting a first diaphragm pump assembly to a second diaphragm pump assembly wherein each of the first diaphragm pump assembly and the second diaphragm pump assembly have a respective first working fluid pumping diaphragm and a second working fluid pumping diaphragm that are configured to move fluid through the respective one of the first diaphragm pump assembly and the second diaphragm pump assembly. The method further determines a position of the respective one of the first working fluid pumping diaphragm and the second working fluid pumping diaphragm of each of the first diaphragm pump assembly and the second diaphragm pump assembly. manipulating Operation of a gas valve assembly configured to effectuate an intake stroke and a discharge stroke of the first diaphragm pump assembly and the second diaphragm pump assembly is manipulated in response to the determined position of the respective one of the first working fluid pumping diaphragm and the second working fluid pumping diaphragm during operation of the diaphragm pump assembly.

[0101] Of course, specific details of the preferred embodiment as described herein are not to be interpreted as limiting the scope of the invention, but are provided merely as a basis for the claims and for teaching one skilled in the art to variously practice and construct the present invention in any appropriate manner. Changes may be made in the details of the construction of various components of the discrete pumping diaphragm pump assembly, without departing from the spirit of the invention as defined in the following claims.