Water supply pump state detection device and method

Abstract

The application relates to the technical field of water supply, in particular to a water supply pump state detection device and method. The water supply pump state detection device comprises a water supply pump, a pressure detection unit, a vibration detection unit and a water pressure pulsation detection unit; the pressure detection unit is connected with the water supply pump and is used for detecting the pressure of the inlet and outlet of the water supply pump; the vibration detection unit is connected with the water supply pump and is used for detecting the vibration of the water supply pump; the water pressure pulsation detection unit is connected with the water supply pump and is used for detecting the water pressure pulsation of the water supply pump. The water supply pump state detection device can monitor the inlet and outlet pressure, water pressure pulsation data and mechanical vibration data in real time, and can analyze the data, comprehensively consider the rated parameters such as the lift and the net positive suction head of the water supply pump, thereby giving potential fault early warning and cause diagnosis of the water supply pump, so as to propose corresponding predictive maintenance solutions.

Description

Technical Field

[0001] This application relates to the field of water supply technology, and more specifically, to a water supply pump status detection device and method. Background Technology

[0002] Currently, the main technologies used in the field of water supply pump status monitoring are: using electrical measurement data such as current, voltage, power factor and frequency output from the water supply pump control cabinet, and employing signal threshold management; when these data exceed the threshold, an alarm is triggered or the pump is shut down.

[0003] The main drawback of this method is that fault detection is too delayed: when the absolute value or change of electrical measurement data such as current, voltage, power factor and frequency has exceeded the standard, the equipment will enter a functional failure state in a short time, or even have already failed, resulting in shutdown or failure to achieve the expected water supply; at this time, maintenance work can no longer guarantee water supply safety in a timely manner. Summary of the Invention

[0004] This application provides a water supply pump status detection device and method to improve the above-mentioned problems.

[0005] The present invention is as follows:

[0006] A water supply pump status detection device includes a water supply pump, a pressure detection unit, a vibration detection unit, and a water pressure pulsation detection unit; the pressure detection unit is connected to the water supply pump and is used to detect the pressure at the inlet and outlet of the water supply pump; the vibration detection unit is connected to the water supply pump and is used to detect the vibration of the water supply pump; the water pressure pulsation detection unit is connected to the water supply pump and is used to detect the water pressure pulsation of the water supply pump.

[0007] In one embodiment of the present invention, the water supply pump includes a base, a pump body, and a motor. The pump body and the motor are both connected to the base, and the motor is drivenly connected to the pump body.

[0008] The pressure detection unit includes a first pressure sensor and a second pressure sensor, which are respectively located at the inlet and outlet of the pump body to detect the pressure at the inlet and outlet respectively.

[0009] The water supply pump status monitoring device also includes a speed sensor, which is used to detect the motor speed.

[0010] In one embodiment of the present invention, the vibration detection unit includes a first vibration sensor and a second vibration sensor, wherein the first vibration sensor is connected to the base to detect the vibration of the base;

[0011] The second vibration sensor is connected to the transmission connection between the motor and the pump body to detect vibration at the transmission connection between the motor and the pump body.

[0012] In one embodiment of the present invention, the water pressure pulsation detection unit includes a first water pressure pulsation sensor and a second water pressure pulsation sensor. The first water pressure pulsation sensor is connected to the inlet and is used to detect water pressure pulsation at the inlet. The second water pressure pulsation sensor is connected to the volute tongue of the pump body and is used to detect water pressure pulsation at the volute tongue.

[0013] A method for detecting the condition of a water supply pump, implemented using the aforementioned water supply pump condition detection device, includes:

[0014] Obtain basic data on the water supply pump and determine its operating performance and cavitation performance;

[0015] Collect the operating parameters and operating status of the water supply pump;

[0016] Based on the operating parameters and operating status of the water supply pump, determine the operating characteristics of the water supply pump.

[0017] Based on the time-domain data of the operating status, spectral analysis is performed to determine the spectral data of the vibration signal and the water pressure pulsation signal;

[0018] Based on the basic data, operating condition characteristics, vibration data, and spectral data of water pressure pulsation of the water supply pump, output fault warnings or fault causes;

[0019] Based on the fault warning or the cause of the fault, determine the corresponding predictive maintenance plan.

[0020] In one embodiment of the present invention, the steps of acquiring basic data of the water supply pump and determining the operating performance and cavitation performance of the water supply pump include:

[0021] Based on the product manual and installation data of the water supply pump, determine the number of impeller blades Z and the rated speed n of the water supply pump. d Rated flow rate Q d Rated head H d Performance curves of flow rate Q-head H at various speeds, and flow rate Q-NPSH. r Cavitation curve, installation height h g Installation center height h a Inhalation tube damage h c Local atmospheric pressure p a and the vaporization pressure of water p v The net positive suction head (NPSH) of the unit is determined based on the installation height of the water supply pump and the suction pipe loss. a ;

[0022] Curve fitting was performed using a quadratic polynomial with the least squares method to determine the equation of the flow rate Q-head H performance curve as shown in equation (1), where flow rate Q is the net positive suction head (NPSH). r The equation for the cavitation curve is given by equation (2);

[0023]

[0024] NPSH r =B0+B i Q+B2Q 2 (2)

[0025] Net Positive Suction Head (NPSH) a The calculation method is as shown in equation (3);

[0026]

[0027] Where Q, H, and n are the actual flow rate, head, and speed of the water supply pump, respectively, and A i B i p is a constant a and p v These are the local atmospheric pressure and the vaporization pressure of water, respectively, h g It refers to the installation height of the water supply pump, h. c Damage to the suction pipe of the water supply pump.

[0028] In one embodiment of the present invention, the step of collecting the operating parameters and operating status of the water supply pump includes:

[0029] The multi-channel transmitter receives pressure signals from the pressure detection unit, which represent the fluid pressure data at the inlet and outlet of the water supply pump; vibration signals from the vibration detection unit, which represent the vibration data of the water supply pump; water pressure pulsation signals from the water pressure pulsation detection unit, which represent the water pressure pulsation data of the water supply pump; and speed signals from the speed sensor, which represent the speed data of the water supply pump, thus integrating them into a data source.

[0030] The multichannel transmitter converts the received data source into Modbus protocol data based on 485 and transmits it to the Modbus server.

[0031] In one embodiment of the present invention, the step of determining the operating condition characteristics of the water supply pump based on its operating parameters and operating status includes:

[0032] Based on the water pressure data and rotational speed data, and the equation (1) of the flow rate Q-head H performance curve, the flow rate Q-NPSH r The equation (2) of the cavitation curve determines the operating conditions of the water supply pump;

[0033] Let the measured pressure at the inlet be P. in The pressure value at the outlet is P. out (All units are Pa), then the operating head of the water supply pump is as shown in equation (4);

[0034]

[0035] Let the rotational speed data be n, and the operating head H of the water supply pump obtained by equation (4) be substituted into equation (1) of the flow rate Q-head H performance curve to calculate the operating flow rate Q of the water supply pump.

[0036] Calculate the characteristic value x of the water supply pump's operating condition according to equation (5);

[0037]

[0038] Substitute the operating flow rate Q into the flow rate Q - net positive suction head (NPSH). r Equation (2) of the cavitation curve yields the net positive suction head (NPSH) of the water supply pump. r .

[0039] In one embodiment of the present invention, the step of determining the spectral data of vibration signal and water pressure pulsation signal by performing spectral analysis based on the time-domain data of the operating state includes:

[0040] The time-domain data of the vibration data and water pressure pulsation data of the water supply pump measured in real time by the vibration detection unit and the water pressure pulsation detection unit are processed and analyzed. The time-domain data volume is required to include at least 50 rotation cycles.

[0041] The processing and analysis of the time-domain data of the water supply pump's vibration data and water pressure pulsation data includes: performing fast Fourier transform analysis on the time-domain data of the water pressure pulsation data and vibration data to obtain the spectral data of these two signals, and determining their main frequency, secondary frequency, and the amplitude corresponding to each frequency based on the spectral data of the water pressure pulsation data and vibration data.

[0042] In one embodiment of the present invention, the step of outputting a fault warning or fault cause based on the spectrum data of the water supply pump's basic data, operating condition characteristics, vibration data, and water pressure pulsation data includes:

[0043] Based on the classification of vibration levels, determine the vibration intensity boundary AV of the water supply pump. RMS Then, calculate the vibration amplitude limit AV according to equation (6). max ;

[0044] AV max =AV RMs ÷0.707 (6)

[0045] The limit value of water pressure pulsation amplitude of the water supply pump is determined according to the operating head H of the water supply pump, as shown in formula (7);

[0046] AW max =10% × H × 9810 (7)

[0047] Based on the vibration data of the water supply pump and the amplitude corresponding to the main frequency AV0, and the amplitude corresponding to the main frequency AW0 of the water pressure pulsation data of the water supply pump, respectively compared with AV0... max and AW max Compare, if AV0 ≥ AV max or AW0≥AW max If so, a warning will be issued;

[0048] After a warning is issued, the cause of the fault is determined by comprehensively considering the operating characteristics of the water supply pump and the main frequency, secondary frequency, main frequency, and secondary frequency of the output vibration data, as well as the main and secondary frequencies of the water pressure pulsation data.

[0049] The beneficial effects of this invention are:

[0050] The water supply pump status detection device includes a water supply pump, a pressure detection unit, a vibration detection unit, and a water pressure pulsation detection unit. The pressure detection unit is connected to the water supply pump and is used to detect the pressure at the inlet and outlet of the water supply pump. The vibration detection unit is connected to the water supply pump and is used to detect the vibration of the water supply pump. The water pressure pulsation detection unit is connected to the water supply pump and is used to detect the water pressure pulsation of the water supply pump.

[0051] This water supply pump condition monitoring device can monitor inlet and outlet pressure, water pressure pulsation data, and mechanical vibration data in real time. By analyzing the data and combining the rated parameters of the water supply pump such as head and net positive suction head, it can provide early warning and cause diagnosis of potential faults in the water supply pump, so as to propose corresponding predictive maintenance solutions. Attached Figure Description

[0052] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0053] Figure 1 An installation diagram of the pressure detection unit provided in this application;

[0054] Figure 2 An installation diagram of the vibration detection unit and water pressure pulsation detection unit provided in this application;

[0055] Figure 3 A schematic diagram of the water supply pump status monitoring device provided in this application;

[0056] Figure 4 The logic diagram for early warning and cause judgment of water supply pump failure provided in this application.

[0057] Icons: 100 - Water supply pump status detection device; 110 - Water supply pump; 120 - Pressure detection unit; 130 - Vibration detection unit; 140 - Water pressure pulsation detection unit; 111 - Base; 112 - Pump body; 113 - Motor; 121 - First pressure sensor; 122 - Second pressure sensor; 131 - First vibration sensor; 132 - Second vibration sensor; 141 - First water pressure pulsation sensor; 142 - Second water pressure pulsation sensor; 151 - Speed ​​sensor. Detailed Implementation

[0058] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0059] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0060] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other.

[0061] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0062] In the description of the embodiments of this application, it should be noted that the indicated orientation or positional relationship is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use, or the orientation or positional relationship commonly understood by those skilled in the art, and is only for the convenience of describing this application and simplifying the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. In addition, the terms "first," "second," "third," etc. are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0063] In the description of the embodiments of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set," "install," and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0064] Please refer to Figure 1 and Figure 2 This embodiment provides a water supply pump status detection device 100, including a water supply pump 110, a pressure detection unit 120, a vibration detection unit 130, and a water pressure pulsation detection unit 140; the pressure detection unit 120 is connected to the water supply pump 110 and is used to detect the water pressure at the inlet and outlet of the water supply pump 110; the vibration detection unit 130 is connected to the water supply pump 110 and is used to detect the vibration of the water supply pump 110; the water pressure pulsation detection unit 140 is connected to the water supply pump 110 and is used to detect the water pressure pulsation of the water supply pump 110.

[0065] Please refer to Figure 1 and Figure 2 The working principle of the water supply pump status detection device 100 is as follows:

[0066] The water supply pump condition monitoring device 100 includes a water supply pump 110, a pressure detection unit 120, a vibration detection unit 130, and a water pressure pulsation detection unit 140. The pressure detection unit 120 is used to detect the fluid pressure at the inlet and outlet of the water supply pump 110; the vibration detection unit 130 is used to detect the vibration of the water supply pump 110; and the water pressure pulsation detection unit 140 is used to detect the water pressure pulsation of the water supply pump 110. Therefore, the water supply pump condition monitoring device 100 can monitor inlet and outlet fluid pressure, water pressure pulsation data, and mechanical vibration data in real time. Furthermore, by analyzing the data and considering the rated parameters of the water supply pump 110, such as its head and net positive suction head (NPSH), the device can provide early warning and cause diagnosis of potential faults in the water supply pump 110, thereby facilitating the development of corresponding predictive maintenance solutions.

[0067] Further, please refer to Figure 1 and Figure 2In this embodiment, the water supply pump 110 includes a base 111, a pump body 112, and a motor 113. Both the pump body 112 and the motor 113 are connected to the base 111, and the motor 113 is drivenly connected to the pump body 112. Therefore, based on the aforementioned structure of the water supply pump 110, when the pressure detection unit 120 is provided, the pressure detection unit 120 includes a first pressure sensor 121 and a second pressure sensor 122. The first pressure sensor 121 and the second pressure sensor 122 are respectively disposed at the inlet and outlet of the pump body 112 to detect the pressure at the inlet and outlet, respectively. In addition, the water supply pump status detection device 100 also includes a speed sensor 151, which is used to detect the speed of the motor 113.

[0068] When the vibration detection unit 130 is set, the vibration detection unit 130 includes a first vibration sensor 131 and a second vibration sensor 132. The first vibration sensor 131 is connected to the base 111 to detect the vibration of the base 111; the second vibration sensor 132 is connected to the transmission connection between the motor 113 and the pump body 112 to detect the vibration of the transmission connection between the motor 113 and the pump body 112.

[0069] When the water pressure pulsation detection unit 140 is set, the water pressure pulsation detection unit 140 includes a first water pressure pulsation sensor 141 and a second water pressure pulsation sensor 142. The first water pressure pulsation sensor 141 is connected to the inlet and is used to detect the water pressure pulsation at the inlet. The second water pressure pulsation sensor 142 is connected to the volute tongue of the pump body 112 and is used to detect the water pressure pulsation at the volute tongue.

[0070] In addition, the water supply pump status detection device 100 also includes a power supply module and a control module; the power supply module, pressure detection unit 120, vibration detection unit 130 and water pressure pulsation detection unit 140 are all electrically connected to the control module.

[0071] In summary, please refer to Figure 1 and Figure 2 The purpose of the water supply pump status monitoring device 100 is to install sensors to monitor inlet and outlet pressure, speed, vibration, and water pressure pulsation, and transmit data through a stable communication method and control module. Then, it performs signal processing and combines it with a mechanism model to achieve a comprehensive diagnosis of the cause of the fault. Based on the cause of the fault, it provides a predictive maintenance solution, thereby ensuring that potential faults are detected in the early stage of performance degradation of the water supply pump 110, and timely prompting of predictive maintenance solutions, so as to achieve the purpose of maintenance before the equipment malfunctions and avoid downtime due to faults.

[0072] Therefore, please refer to Figures 1-3The water supply pump status monitoring device 100 is used to perform predictive maintenance on the pump units in the water intake, water delivery, and pressurization stages of the water supply system, thereby ensuring water supply safety. The water supply pump status monitoring device 100 includes a pressure detection unit 120, a vibration detection unit 130, and a water pressure pulsation detection unit 140, which are used to monitor inlet and outlet pressures, mechanical vibrations, and water pressure pulsations, respectively, and in conjunction with operating parameters such as rotational speed. In addition, the control module may include a data acquisition module and a data analysis module, enabling the pressure detection unit 120, vibration detection unit 130, and water pressure pulsation detection unit 140 to be connected to the data acquisition module via an RS485 interface, and then to the data analysis module via the Modbus TCP protocol. A power supply module is also included to power the pressure detection unit 120, vibration detection unit 130, water pressure pulsation detection unit 140, data acquisition module, and data analysis module.

[0073] Finally, the data analysis module performs data calculations, comprehensively considering the rated parameters of the water supply pump 110 such as head and net positive suction head, operating condition monitoring parameters such as inlet and outlet pressure and speed, and status monitoring signals such as water pressure pulsation signals and vibration signals. Combined with the mechanism model, potential fault warnings and cause diagnosis are performed, and corresponding predictive maintenance solutions are suggested.

[0074] Specifically, as can be seen from the above content, please refer to... Figures 1-3 The water supply pump status detection device 100 includes a sensor module, a data acquisition module and a data analysis module. The sensor module consists of a pressure detection unit 120, a vibration detection unit 130 and a water pressure pulsation detection unit 140.

[0075] During operation, when the sensor module collects analog signals, the water supply pump status monitoring device 100 transmits them to the data acquisition module via RS485. The data acquisition module can store the data and transmit it to the data analysis module via the Modbus TCP protocol. The data analysis module provides fault diagnosis results through intelligent data analysis and outputs a predictive maintenance plan for the water supply pump 110.

[0076] In the above-mentioned components, the pressure detection unit 120, vibration detection unit 130, and water pressure pulsation detection unit 140 respectively realize real-time signal sensing of operating condition parameters such as inlet and outlet pressure and speed of water supply pump 110, as well as status monitoring parameters such as water pressure pulsation signal and vibration signal. The data acquisition module mainly realizes the conversion, collection, and storage of real-time signals sensed by the sensor module, and periodically uploads the data to the data analysis module. The data analysis module analyzes the massive amount of real-time data uploaded by the data acquisition module to complete the analysis of equipment operating condition parameters and status monitoring parameters, monitor the operating status of water supply pump 110, diagnose the causes of water supply pump 110 failures, and provide predictive maintenance solutions based on the causes. The power supply module provides power to the sensor module, data acquisition module, and data analysis module.

[0077] Based on the above, when configuring the pressure detection unit 120, the pressure detection unit 120 includes a first pressure sensor 121 and a second pressure sensor 122. The first pressure sensor 121 and the second pressure sensor 122 are respectively installed at the inlet and outlet of the pump body 112 to detect the pressure at the inlet and outlet respectively. Specifically, the first pressure sensor 121 and the second pressure sensor 122 are installed in the inlet pipe and outlet pipe of the water supply pump 110 respectively, so as to sense the inlet and outlet pressure signals of the water supply pump 110 as the data source for calculating the operating head and cavitation characteristics of the water supply pump 110. Among them, the frequency response range of the first pressure sensor 121 and the second pressure sensor 122 is 0.1~1kHz, and the linearity error is ≤0.5%.

[0078] When configuring the vibration detection unit 130, the vibration detection unit 130 includes a first vibration sensor 131 and a second vibration sensor 132. The first vibration sensor 131 is connected to the base 111 to detect the vibration of the base 111; the second vibration sensor 132 is connected to the transmission connection between the motor 113 and the pump body 112 to detect the vibration at the transmission connection between the motor 113 and the pump body 112. Specifically, the first vibration sensor 131 and the second vibration sensor 132 can be installed at the base 111 and the bearing of the water pump 110, respectively, to sense the mechanical vibration signals at key locations of the water pump 110, serving as a data source for monitoring the fault status and determining the cause of the fault in the water pump 110; the frequency response range of the first vibration sensor 131 and the second vibration sensor 132 is 0.1~10kHz, and the linearity error is ≤1%.

[0079] When configuring the water pressure pulsation detection unit 140, the water pressure pulsation detection unit 140 includes a first water pressure pulsation sensor 141 and a second water pressure pulsation sensor 142. The first water pressure pulsation sensor 141 is connected to the inlet and is used to detect water pressure pulsation at the inlet. The second water pressure pulsation sensor 142 is connected to the volute tongue of the pump body 112 and is used to detect water pressure pulsation at the volute tongue. Specifically, the first water pressure pulsation sensor 141 and the second water pressure pulsation sensor 142 are installed at the volute tongue and the inlet of the water supply pump 110, respectively. The purpose is to sense the water pressure pulsation signal at key locations of the water supply pump 110, serving as the data source for monitoring the fault status and determining the cause of the fault in the water supply pump 110. The frequency response range of the first water pressure pulsation sensor 141 and the second water pressure pulsation sensor 142 is 0.5~100kHz, and the linearity error is ≤1%.

[0080] In addition, it should be noted that, besides the aforementioned structure, a speed sensor 151 is installed at the connection point between the motor 113 and the pump body 112 of the water supply pump 110. This sensor detects the rotational speed of the water supply pump 110, serving as a data source for calculating the operating conditions and fault causes of the pump. The speed sensor 151 has a frequency response range of 0.1–5 kHz and a linear error ≤1%. The sensor module is hardwired and connected to the data acquisition module via an RS485 interface. The data acquisition module is connected to the data analysis module via wired communication using the Modbus TCP protocol. Given that the pump room where the water supply pump 110 is located may be tens of meters underground, this connection method ensures high stability of data transmission and aggregation, unaffected by network conditions. The data analysis module monitors and calculates all collected real-time data. Through pre-set fault warning and fault cause judgment logic for the water supply pump 110, it uses intelligent algorithms to perform status monitoring, fault diagnosis, and cause analysis of the water supply pump 110. Based on the cause analysis, it provides predictive maintenance solutions, which is beneficial for operation and maintenance personnel to carry out targeted maintenance work. This enables the prediction of the deterioration trend of water supply pump 110 before a functional failure occurs, the diagnosis of the cause of potential failures, and the provision of corresponding predictive maintenance solutions. Through predictive maintenance, unplanned downtime due to failures is avoided, thus ensuring water supply safety.

[0081] In summary, please refer to Figures 1-3 The water supply pump status monitoring device 100 aims to provide early warning and predictive maintenance solutions before the water supply pump 110 malfunctions. It employs sensor modules capable of monitoring key operating parameters and status monitoring parameters of the water supply pump 110, achieving accurate perception of these signals and providing a solid data foundation for fault diagnosis and predictive maintenance of the water supply pump 110. Furthermore, based on the operating environment and operating conditions of the water supply pump 110, the communication method from the sensor module to the data acquisition module and then to the data transmission module ensures effective data transmission even in harsh environments.

[0082] Therefore, the water supply pump status monitoring device 100 comprehensively collects and analyzes parameters that characterize the operating conditions of the water supply pump 110, such as inlet and outlet pressure and speed, and parameters that characterize the operating status of the water supply pump 110, such as vibration at key locations and water pressure pulsation. Combined with the fault early warning and fault cause judgment logic of the water supply pump 110, it can detect the deterioration trend of the equipment when the water supply pump 110 has potential faults, and provide potential fault cause diagnosis and predictive maintenance strategies. Therefore, it can maintain the water supply pump 110 earlier, avoid functional failures that lead to equipment failure, and effectively ensure water supply safety.

[0083] Based on the above, please refer to Figures 1-3 In this embodiment, based on the aforementioned water supply pump status detection device 100, the present invention also provides a water supply pump 110 status detection method, which is implemented using the aforementioned water supply pump status detection device 100, and includes:

[0084] Step 1: Obtain the basic data of water supply pump 110 and determine the operating performance and cavitation performance of water supply pump 110;

[0085] Step 2: Collect the operating parameters and operating status of water supply pump 110;

[0086] Step 3: Determine the operating characteristics of water supply pump 110 based on its operating parameters and operating status;

[0087] Step 4: Based on the time-domain data of the operating status, perform spectrum analysis to determine the spectrum data of the vibration signal and the water pressure pulsation signal;

[0088] Step 5: Based on the basic data, operating condition characteristics, vibration data, and spectral data of water pressure pulsation data of water supply pump 110, output fault warning or fault cause;

[0089] Step 6: Determine the corresponding predictive maintenance plan based on the fault warning or fault cause.

[0090] Furthermore, in this embodiment, the steps of acquiring basic data of the water supply pump 110 and determining the operating performance and cavitation performance of the water supply pump 110 include:

[0091] Please refer to Table 1 and determine the number of impeller blades Z and rated speed n of water pump 110 based on the product manual and installation data. d Rated flow rate Q d Rated head H d Performance curves of flow rate Q-head H at various speeds, and flow rate Q-NPSH. r Cavitation curve, installation height h g Installation center height h aInhalation tube damage h c Local atmospheric pressure p a and the vaporization pressure of water p v The net positive suction head (NPSH) of the device is determined based on the installation height of the water supply pump 110 and the suction pipe loss. a ;

[0092]

[0093]

[0094] Table 1

[0095] Curve fitting was performed using a quadratic polynomial with the least squares method to determine the equation of the flow rate Q-head H performance curve as shown in equation (1), where flow rate Q is the net positive suction head (NPSH). r The equation for the cavitation curve is given by equation (2);

[0096]

[0097] NPSH r =B0+B1Q+B2Q 2 (2)

[0098] Net Positive Suction Head (NPSH) a The calculation method is as shown in equation (3);

[0099]

[0100] Where Q, H, and n are the actual flow rate, head, and speed of water supply pump 110, respectively, and A i B i p is a constant a and p v These are the local atmospheric pressure and the vaporization pressure of water, respectively, h g The installation height of the water supply pump is 110, h. c Damage to the suction pipe of water pump 110.

[0101] Furthermore, in this embodiment, the steps for collecting the operating parameters and operating status of the water supply pump 110 include:

[0102] Please refer to Table 2. The multi-channel transmitter receives the pressure signal output by the pressure detection unit 120, which represents the fluid pressure data at the inlet and outlet of the water supply pump 110; the vibration signal output by the vibration detection unit 130, which represents the vibration data of the water supply pump 110; the water pressure pulsation signal output by the water pressure pulsation detection unit 140, which represents the water pressure pulsation data of the water supply pump 110; and the speed signal output by the speed sensor 151, which represents the speed data of the water supply pump 110, and integrates them into a data source.

[0103]

[0104] Table 2

[0105] The multichannel transmitter converts the received data source into Modbus protocol data based on 485 and transmits it to the Modbus server.

[0106] Furthermore, in this embodiment, the step of determining the operating condition characteristics of the water supply pump 110 based on its operating parameters and operating status includes:

[0107] Please refer to Table 3. Based on the water pressure data, rotational speed data, and equation (1) of the flow rate Q-head H performance curve, the flow rate Q-NPSH is calculated as follows: r The equation (2) of the cavitation curve determines the operating conditions of the water supply pump 110;

[0108]

[0109] Table 3

[0110] Let the measured pressure at the inlet be P. in The pressure value at the outlet is P. out (All units are Pa), then the operating head of the water supply pump 110 is as shown in equation (4);

[0111]

[0112] Let the rotational speed data be n, and the operating head H of the water supply pump 110 obtained by equation (4) be substituted into equation (1) of the flow rate Q-head H performance curve to calculate the operating flow rate Q of the water supply pump 110.

[0113] Calculate the characteristic value x of the operating condition of water supply pump 110 according to formula (5);

[0114]

[0115] Substitute the operating flow rate Q into the flow rate Q - net positive suction head (NPSH). r Equation (2) of the cavitation curve yields the net positive suction head (NPSH) of the water supply pump 110. r .

[0116] Furthermore, in this embodiment, the step of performing spectrum analysis based on the time-domain data of the operating state to determine the spectrum data of the vibration signal and the water pressure pulsation signal includes:

[0117] Please refer to Table 4 to process and analyze the time-domain data of the vibration data and water pressure pulsation data of the water supply pump 110 measured in real time by the vibration detection unit 130 and the water pressure pulsation detection unit 140. The time-domain data should contain at least 50 rotation cycles.

[0118]

[0119]

[0120] Table 4

[0121] Referring to Table 5, the time-domain data processing and analysis of the vibration data and water pressure pulsation data of the water supply pump 110 includes: performing fast Fourier transform analysis on the time-domain data of the water pressure pulsation data and vibration data to obtain the spectrum data of these two signals; and determining the main frequency, secondary frequency, and amplitude corresponding to each frequency based on the spectrum data of the water pressure pulsation data and vibration data.

[0122] Signal clock speed The amplitude corresponding to the main frequency Second frequency The amplitude corresponding to the second frequency Vibration signal <![CDATA[FV0]]> <![CDATA[AV0]]> <![CDATA[FV1,FV2]]> <![CDATA[AV1,AV2]]> Water pressure pulsation signal <![CDATA[FW0]]> <![CDATA[AW0]]> <![CDATA[FW1,FW2]]> <![CDATA[AW1,AW2]]>

[0123] Table 5

[0124] Furthermore, in this embodiment, the step of outputting a fault warning or fault cause based on the basic data, operating condition characteristics, vibration data, and spectral data of the water supply pump 110 includes:

[0125] Please refer to Table 6, based on the installation center height h. a and rated speed n d To determine the classification of the vibration level of water supply pump 110;

[0126]

[0127] Table 6

[0128] Step A: Please refer to Table 7 and determine the vibration intensity boundary AV of water supply pump 110 according to the vibration level classification. RMS Then, calculate the vibration amplitude limit AV according to equation (6). max ;

[0129]

[0130] Table 7

[0131] AV max =AV RMs ÷0.707 (6)

[0132] Step B: Determine the limit value of water pressure pulsation amplitude of water supply pump 110 according to the operating head H of water supply pump 110, as shown in formula (7);

[0133] AW max =10% × H × 9810 (7)

[0134] Step C: Based on the vibration data of water supply pump 110, the amplitude corresponding to the main frequency AV0, and the amplitude corresponding to the main frequency of water pressure pulsation data of water supply pump 110, respectively, compare them with AV0... max and AW max Compare, if AV0 ≥ AV max or AW0≥AW max If so, a warning will be issued;

[0135] Step D: After the warning message appears, based on the operating characteristics of the water supply pump 110 and the main frequency, secondary frequency, main frequency, and secondary frequency of the output vibration data, determine the cause of the fault. Please refer to [the relevant documentation]. Figure 4 , Figure 4 This step demonstrates the logic for determining the fault warning and cause of the water supply pump 110.

[0136] Furthermore, in this embodiment, a corresponding predictive maintenance plan is determined based on the fault warning or fault cause, as shown in Table 8;

[0137]

[0138] Table 8

[0139] Based on the above, taking the condition diagnosis and predictive maintenance of a secondary pumping station unit in a water supply plant as an example, the process of applying the above-mentioned water supply pump 110 testing method is as follows:

[0140] Step 1: Input the basic data of water supply pump 110 (as shown in Table 9), and calculate and output the operating performance and cavitation performance of water supply pump 110 using this method (as shown in Table 10).

[0141] Input water pump basic data numerical values Number of impeller blades Z 5 <![CDATA[Rated speed n d > 740rpm <![CDATA[Rated flow rate Q d > <![CDATA[3600m 3 / h]]> <![CDATA[Rated head H d > 36m <![CDATA[Installation height h g > 1.475m <![CDATA[Installation center height h a > 960mm <![CDATA[Inlet pipe loss h c > 670mm <![CDATA[Local atmospheric pressure p a > 101325Pa <![CDATA[Vaporization pressure p of water v > 3169Pa

[0142] Table 9

[0143]

[0144]

[0145] Table 10

[0146] Step 2: Deploy the water supply pump 110 operating parameter and operating status monitoring terminal to collect operating parameters and operating status of the system.

[0147] Deploy the monitoring terminal according to the monitoring terminal content, system architecture, sensor installation location, and parameter requirements in step two, and collect operating parameters and operating status.

[0148] Step 3: Input operating parameters and operating status, and output the operating characteristics of water supply pump 110.

[0149] Based on the calculation logic and formula in step three, under a certain monitored operating condition, the operating head of the output water supply pump 110 is H = 29.6m, corresponding to an operating flow rate Q = 4217m³ / h. 3 / h, speed is rated speed, operating condition characteristic value x = 1.17, net positive suction head (NPSH) r =7.47m.

[0150] Step 4: Input the time-domain data of the operating status (vibration signal and water pressure pulsation signal), perform spectrum analysis, and output the spectrum data of the vibration signal and water pressure pulsation signal.

[0151] Based on the time-domain data of the vibration signal and water pressure pulsation signal collected by the monitoring terminal in step two, a spectrum analysis was performed, and the results are shown in Table 11:

[0152]

[0153] Table 11

[0154] Step 5: Input the basic data of water supply pump 110, operating condition characteristics, and spectrum data of vibration signal and water pressure pulsation signal, and output the fault warning and fault cause.

[0155] Based on the spectrum data output from step four, Figure 4 The fault warning and fault cause judgment logic of the water supply pump 110 can determine that the main fault cause under this working condition is water pump cavitation, and output fault cause diagnosis.

[0156] Step 6: Input the fault diagnosis results and output the predictive maintenance plan for each fault.

[0157] Based on the fault diagnosis output in step five, the corresponding predictive maintenance plan was "adjust the pump's operating conditions, or disassemble and overhaul the pump, and spray the impeller with a polymer material." The water plant immediately adjusted its pump operation plan, reducing the flow rate of pump 110 by frequency conversion regulation and adding a smaller pump to prevent it from continuing to operate under cavitation conditions. The pump will be disassembled and repaired during the next planned overhaul, and the severely cavitation-damaged parts of the impeller will be sprayed with repair material.

[0158] This enables the prediction of the deterioration trend of water supply pump 110 before a functional failure occurs, the diagnosis of the cause of potential failures, and the provision of corresponding predictive maintenance solutions. Through predictive maintenance, unplanned downtime due to failures is avoided, thus ensuring water supply safety.

[0159] The above are merely preferred embodiments of this application and are not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A water supply pump state detection method, implemented by a water supply pump state detection device, characterized in that: the water supply pump state detection device comprises a water supply pump, a pressure detection unit, a vibration detection unit, a water pressure pulsation detection unit and a rotating speed sensor; the pressure detection unit is connected with the water supply pump and used for detecting the pressure of the inlet and outlet of the water supply pump; the vibration detection unit is connected with the water supply pump and used for detecting the vibration of the water supply pump; the water pressure pulsation detection unit is connected with the water supply pump and used for detecting the water pressure pulsation of the water supply pump; the rotating speed sensor is used for detecting the rotating speed of the motor; the water supply pump state detection method comprises: acquiring the basic data of the water supply pump and determining the running performance and cavitation performance of the water supply pump, specifically comprising: NPSH, NPSH, NPSH, NPSH, collecting the running parameters and running state of the water supply pump, specifically comprising: a multi-channel transmitter receiving the pressure signal output by the pressure detection unit, the vibration signal output by the vibration detection unit, the water pressure pulsation signal output by the water pressure pulsation detection unit and the rotating speed data output by the rotating speed sensor, which represent the fluid pressure data of the inlet and outlet of the water supply pump, the vibration data of the water supply pump, the water pressure pulsation data of the water supply pump and the rotating speed data of the water supply pump, and integrating the data sources; the multi-channel transmitter converts the received data sources into Modbus protocol data based on 485 and transmits to the Modbus server; determining the running condition characteristics of the water supply pump according to the running parameters and the running state of the water supply pump, specifically comprising: NPSH, NPSH, NPSH, performing frequency spectrum analysis according to the time domain data of the running state, determining the frequency spectrum data of the vibration signal and the water pressure pulsation signal, specifically comprising: processing and analyzing the time domain data of the vibration data and the water pressure pulsation data of the water supply pump measured by the vibration detection unit and the water pressure pulsation detection unit in real time, and the time domain data amount is required to contain at least 50 rotating periods; wherein the processing and analyzing of the time domain data of the vibration data and the water pressure pulsation data of the water supply pump comprises: performing fast Fourier transform analysis on the time domain data of the water pressure pulsation data and the vibration data to obtain the frequency spectrum data of the two signals, and determining the main frequency, the secondary frequency and the amplitude corresponding to each frequency of the water pressure pulsation data and the vibration data according to the frequency spectrum data; outputting the fault warning or the fault reason according to the basic data of the water supply pump, the running condition characteristics, the frequency spectrum data of the vibration data and the water pressure pulsation data of the water supply pump, specifically comprising: AV, AV, AV, AW, AV, AW, AV, AV, AW, AW; after the prompt warning appears, comprehensively judging the fault reason according to the running condition characteristics of the water supply pump and the main frequency of the output vibration data, the secondary frequency of the vibration data, the main frequency of the water pressure pulsation data and the secondary frequency of the water pressure pulsation data; determining the corresponding predictive maintenance scheme according to the fault warning or the fault reason. 2.The water supply pump state detection method according to claim 1, characterized in that: ​ ​ ​ determining the number of impeller blades of the water supply pump according to the product manual and installation data of the water supply pump Z , rated rotational speed n d , rated flow rate Q d , rated head H d , flow rate at each rotational speed Q - head H performance curve, flow rate Q - net positive suction head ​ r cavitation curve, installation height h g , installation center height h a , suction pipe loss h c , local atmospheric pressure p a and vaporization pressure of water p v , and determining the net positive suction head of the device according to the installation height and suction pipe loss of the water supply pump ​ a ; The flow rate is determined by curve fitting using a second order polynomial by the least square method Q - head H The equation of the performance curve is given by equation (1) and the flow rate Q - net positive suction head ​ r The equation of the cavitation curve is given by equation (2); (1) (2) Device net positive suction head ​ a The calculation method is as formula (3); (3) wherein, Q , H , n Q, H, N are the actual flow rate, head and rotational speed of the water supply pump respectively, A i , B i are constants, p a and p v are the local atmospheric pressure and the vapor pressure of water respectively, h g is the installation height of the water supply pump, h c is the suction pipe loss of the water supply pump; ​ ​ ​ According to the pressure data and the rotational speed data, and the flow Q - head H Equation (1) of the performance curve, flow Q - net positive suction head ​ r Equation (2) of the cavitation curve determines the operating condition of the water supply pump; Wherein, set the import of the measured pressure value is P in , the export of the pressure value is P out , unit is Pa, the operation of the water supply pump head as formula (4); (4) Let the rotational speed data be n , and the operating head of the water supply pump obtained from equation (4) H , and the flow rate Q - head H of the performance curve (1) of the water supply pump Q ; The water supply pump operating condition characteristic value is calculated according to formula (5) x ; (5) substituting the operating flow rate Q substituting the flow rate Q - net positive suction head ​ r the equation (2) of the cavitation curve, obtaining the net positive suction head of the feed pump ​ r ; ​ ​ ​ determining a classification of a vibration level of the water supply pump based on the installation center height h a and the rated rotational speed n d ​ determining a vibration intensity demarcation limit of the water supply pump according to the vibration level classification ​ RMS calculating the vibration amplitude limit value according to formula (6) ​ max ; (6) According to the operating head of the water supply pump H Determine the limit value of the water pressure pulsation amplitude of the water supply pump, as shown in formula (7). (7) According to the vibration data dominant frequency corresponding amplitude of the water supply pump ​ 0 And the water pressure pulsation data dominant frequency corresponding amplitude of the water supply pump ​ 0 Respectively with ​ max And ​ max If ​ 0 ≥ ​ max Or ​ 0 ≥ ​ max Then prompt warning; ​ ​ ​ The water supply pump comprises a base, a pump body and a motor, the pump body and the motor are connected with the base, and the motor is in transmission connection with the pump body; The pressure detection unit comprises a first pressure sensor and a second pressure sensor, the first pressure sensor and the second pressure sensor are respectively arranged at the inlet and the outlet of the pump body to detect the pressure of the inlet and the outlet.

3. The water supply pump state detection method according to claim 2, characterized in that: The vibration detection unit comprises a first vibration sensor and a second vibration sensor, the first vibration sensor is connected with the base to detect the vibration of the base; The second vibration sensor is connected at the transmission connection position of the motor and the pump body to detect the vibration at the transmission connection position of the motor and the pump body.

4. The water supply pump state detection method according to claim 2, characterized in that: The water pressure pulsation detection unit comprises a first water pressure pulsation sensor and a second water pressure pulsation sensor, the first water pressure pulsation sensor is connected at the inlet and is used to detect the water pressure pulsation of the inlet, and the second water pressure pulsation sensor is connected at the volute tongue of the pump body and is used to detect the water pressure pulsation at the volute tongue.

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