Method and apparatus for increasing compressed air efficiency in a pump

A pump that improves efficiency of an amount of supply compressed air utilized during operation of the pump, comprising:

• a first diaphragm assembly disposed in a first diaphragm chamber, the first diaphragm assembly comprising a first end-of-stroke position (EOS1) and a predetermined first turndown position (XSL), the predetermined first turndown position (XSL) comprising a preset and different position in the first diaphragm assembly than the first end-of-stroke position (EOS1);
• a second diaphragm assembly disposed in a second diaphragm chamber, the second diaphragm assembly comprising a second end-of-stroke position (EOS2) and a predetermined second turndown position (XSR), the predetermined second turndown position (XSR) comprising a preset and different position in the second diaphragm assembly than the second end-of-stroke position (EOS2);
• a first sensor, at least a portion of which is disposed in the first diaphragm chamber, configured to detect the first diaphragm assembly at the first predetermined turndown position (XSL) when a portion of the first diaphragm assembly contacts a portion of the first sensor, the pump configured to decrease supply compressed air to the first diaphragm chamber upon the first sensor detecting the first diaphragm assembly at the predetermined first turndown position (XSL);
• and
• a second sensor, at least a portion of which is disposed in the second diaphragm chamber, configured to detect the first diaphragm assembly at the first end-of-stroke position (EOS1) when a portion of the first diaphragm assembly contacts a portion of the second sensor, the pump configured to increase supply compressed air to the second diaphragm chamber upon the second sensor detecting the first diaphragm assembly at the first end-of-stroke position (EOS1).

A compressed air efficiency device for operation with a compressed air driven pump, comprising:

• a first sensor, at least a portion of which is disposed in a first diaphragm chamber comprising a first diaphragm assembly, the first sensor configured to detect the first diaphragm assembly at a first predetermined turndown position (XSL) in the first diaphragm chamber when a portion of the first diaphragm assembly contacts a portion of the first sensor;
• a second sensor configured to detect the first diaphragm assembly at a first end-of-stroke position (EOS1) when a portion of the first diaphragm assembly contacts a portion of the second sensor, the first end-of-stroke position (EOS1) comprising a different position in the first diaphragm chamber than the first predetermined turndown position (XSL);
• a third sensor, at least a portion of which is disposed in a second diaphragm chamber comprising a second diaphragm assembly, the third sensor configured to detect the second diaphragm assembly at the predetermined second turndown position (XSR) when a portion of the second diaphragm assembly contacts a portion of the third sensor;
• a fourth sensor, configured to detect the second diaphragm assembly at a second end-of-stroke position (EOS2) when a portion of the second diaphragm assembly contacts a portion of the fourth sensor, the second end-of-stroke position (EOS2) comprising a different position in the second diaphragm chamber than the second predetermined turndown position (XSR);
• and
• a valve configured to:
• decrease supply compressed air to the first diaphragm chamber upon the first sensor detecting the first diaphragm assembly at the predetermined first turndown position (XSL);
• increase supply compressed air to the second diaphragm chamber upon the second sensor detecting the first diaphragm assembly at the first end-of-stroke position (EOS1);
• decrease supply compressed air to the second diaphragm chamber upon the third sensor detecting the second diaphragm assembly at the predetermined second turndown position (XSR);
• and
• increase supply compressed air to the first diaphragm chamber upon the fourth sensor detecting the second diaphragm assembly at the second end-of-stroke position (EOS2).