A diaphragm pump diaphragm break monitoring system and method

Abstract

This invention relates to a diaphragm pump monitoring method, specifically a diaphragm pump diaphragm damage monitoring system and method, solving the technical problem that existing diaphragm damage monitoring methods are difficult to accurately and timely monitor diaphragm damage. The diaphragm pump diaphragm damage monitoring system includes a diaphragm pump body and a piston; the diaphragm pump body includes a housing, a diaphragm chamber, a diaphragm, and a guide rod; an external drive mechanism uses the piston and hydraulic oil located in the hydraulic chamber to cause the diaphragm to move undulatingly, thereby driving the guide rod connected to it to reciprocate axially within the hydraulic chamber; it also includes a magnetic ring, a control module, an oil discharge detector and an oil replenishment detector electrically connected to the control module; the oil discharge detector and the oil replenishment detector are sequentially arranged on the housing on the side wall of the hydraulic chamber in a direction away from the diaphragm, with their detection ends located within the hydraulic chamber and corresponding to the guide rod; the magnetic ring is coaxially arranged at the end of the guide rod near the piston. This invention's method can monitor the diaphragm's operating status in real time.

Description

Technical Field

[0001] This invention relates to a diaphragm pump monitoring system and method, specifically to a diaphragm pump diaphragm damage monitoring system and method. Background Technology

[0002] Damage to the rubber diaphragm inside the diaphragm chamber can cause hydraulic oil to mix with materials, preventing the diaphragm pump from functioning properly and even damaging the piston assembly. Therefore, timely and effective detection of diaphragm damage is crucial for ensuring the reliable and stable operation of the diaphragm pump.

[0003] Currently, the common method for monitoring diaphragm damage is to install an oil contamination sensor in the hydraulic chamber. The sensor's feedback value determines the degree of hydraulic oil contamination, thus indicating whether the diaphragm is damaged. While this method seems intuitive, its accuracy is poor for two reasons: First, the quality characteristics of the hydraulic oil change after prolonged operation of the diaphragm pump unit, causing changes in the sensor's readings. These changes may not be due to material contamination from diaphragm damage, leading to false alarms. Second, even when diaphragm damage contaminates the hydraulic oil, the large volume of the hydraulic chamber and the generally solid-liquid mixture of contaminants make them difficult to dissolve and diffuse. If the location of the diaphragm damage is far from the sensor's installation location, even if the sensor detects contamination, damage to the piston assembly may have already occurred, preventing timely and effective monitoring of diaphragm damage. Summary of the Invention

[0004] The purpose of this invention is to solve the technical problem that existing diaphragm damage monitoring methods are difficult to accurately and timely monitor diaphragm damage, and to provide a diaphragm pump diaphragm damage monitoring system and method.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0006] A diaphragm pump diaphragm damage monitoring system includes a diaphragm pump body and a piston. The diaphragm pump body includes a housing, a diaphragm chamber disposed within the housing, a diaphragm disposed within the diaphragm chamber, and a guide rod connected to the diaphragm. One end of the piston is connected to the end of the housing away from the diaphragm, and the other end of the piston is used to connect to an external drive mechanism. A hydraulic cavity is formed between the diaphragm, the housing, and the piston. The diaphragm, the guide rod, the piston, and the hydraulic cavity are coaxially arranged. The external drive mechanism causes the diaphragm to move convexly and concavely through the piston and hydraulic oil located in the hydraulic cavity, thereby driving the guide rod connected to it to reciprocate axially within the hydraulic cavity.

[0007] Its special feature is:

[0008] It also includes a magnetic ring, a control module, an oil drain detector and an oil replenishment detector that are electrically connected to the control module;

[0009] The oil drain detector and the oil replenishment detector are sequentially installed on the housing on the side wall of the hydraulic chamber in a direction away from the diaphragm. Their detection ends are all located inside the hydraulic chamber and correspond to the end of the guide rod.

[0010] The magnetic ring is coaxially mounted on the end of the guide rod near the piston.

[0011] When the magnetic ring passes through the corresponding positions of the oil drain detector and the oil replenishment detector, it sends a signal to the control module to drain oil from the hydraulic chamber and replenish oil, respectively.

[0012] The oil drain detector and the oil replenishment detector are positioned on the housing of the hydraulic chamber sidewall to meet the following conditions:

[0013] When the hydraulic oil in the hydraulic chamber is within a preset pressure range, the magnetic ring is located between the drain detector and the replenishment detector; when the hydraulic oil in the hydraulic chamber is greater than the preset pressure range, the magnetic ring is located at the corresponding position of the drain detector, or at the position of the drain detector that is away from the replenishment detector; when the hydraulic oil in the hydraulic chamber is less than the preset pressure, the magnetic ring is located at the corresponding position of the replenishment detector, or at the position of the replenishment detector that is away from the drain detector.

[0014] Furthermore, the plane containing the magnetic ring coincides with the central axis of the oil drain detector or the oil replenishment detector.

[0015] Meanwhile, the present invention also provides a method for monitoring diaphragm damage in a diaphragm pump, which is characterized by including the following steps:

[0016] 1) Construct the aforementioned diaphragm pump diaphragm damage monitoring system;

[0017] 2) Set the delay time and preset time in the control module;

[0018] 3) Start the external drive mechanism to make the diaphragm pump body run normally through the piston;

[0019] 4) Use the oil drain detector and oil replenishment detector to detect the position of the magnetic ring;

[0020] 5) Determine whether the magnetic ring passes the corresponding position of the oil drain detector or the oil replenishment detector. If yes, the magnetic ring triggers the oil drain detector or the oil replenishment detector to send an oil drain signal or an oil replenishment signal, and proceed to step 6); otherwise, return to step 4).

[0021] 6) After receiving the oil discharge signal or oil replenishment signal, if the control module receives the oil discharge signal or oil replenishment signal again triggered by the magnetic ring within the delay time, then execute step 7); otherwise, clear the delay time to zero, the control module determines that the diaphragm pump is operating normally, and returns to step 4).

[0022] 7) The oil replenishment signal or oil discharge signal activates the delay timer in the control module to start counting down to the preset time, and at the same time returns to step 4);

[0023] If the delay timer remains active for the preset time, the control module determines that the diaphragm of the diaphragm pump is damaged and shuts down the diaphragm pump due to malfunction; otherwise, the preset time is reset to zero, the control module determines that the diaphragm pump is operating normally, and returns to step 4).

[0024] Furthermore, in step 2), the delay time is 12-20 seconds.

[0025] Furthermore, in step 3), the specific positions of the magnetic ring and the oil drain detector or oil replenishment detector are as follows:

[0026] The position when the plane of the magnetic ring coincides with the central axis of the oil drain detector or the oil replenishment detector.

[0027] Furthermore, in step 2), the preset time is 180s.

[0028] Furthermore, in step 2), the delay time is 15 seconds.

[0029] Compared with the prior art, the beneficial effects of the technical solution of the present invention are:

[0030] (1) The diaphragm pump diaphragm damage monitoring system of the present invention, under the premise of unchanged installation structure, uses a magnetic ring to trigger an oil discharge detector or an oil replenishment detector to send an oil discharge signal or an oil replenishment signal, and then uses a control module to realize real-time monitoring of the diaphragm pump diaphragm, saving the cost of additional installation of oil pollution sensors and their accessories.

[0031] (2) The diaphragm pump diaphragm damage monitoring method of the present invention can set the delay time and preset time according to the different operating conditions of the diaphragm pump, achieve the best monitoring effect through on-site debugging, avoid false alarms, and can monitor the working status of the diaphragm pump in a timely and effective manner. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of an embodiment of the diaphragm pump diaphragm damage monitoring system of the present invention;

[0033] Figure 2 This is a flowchart illustrating an embodiment of the diaphragm pump diaphragm damage monitoring method of the present invention.

[0034] The attached figures are labeled as follows:

[0035] 1-Diaphragm pump body, 2-Diaphragm chamber, 3-Diaphragm, 4-Guide rod, 5-Piston, 6-Hydraulic chamber, 7-Oil discharge detector, 8-Oil replenishment detector, 9-Magnetic ring. Detailed Implementation

[0036] like Figure 1 As shown, a diaphragm pump diaphragm damage monitoring system includes a diaphragm pump body 1 and a piston 5. The diaphragm pump body 1 includes a housing, a diaphragm chamber 2 disposed within the housing, a diaphragm 3 disposed within the diaphragm chamber 2, and a guide rod 4 connected to the diaphragm 3. One end of the piston 5 is connected to the end of the housing away from the diaphragm 3, and the other end of the piston 5 is used to connect to an external drive mechanism. A hydraulic cavity 6 is formed between the diaphragm 3, the housing, and the piston 5. The diaphragm 3, the guide rod 4, the piston 5, and the hydraulic cavity 6 are coaxially arranged. The external drive mechanism causes the diaphragm 3 to move convexly and concavely through the piston 5 and the hydraulic oil located in the hydraulic cavity 6, thereby driving the guide rod 4 connected thereto to reciprocate axially within the hydraulic cavity 6. The system also includes a magnetic ring 9, a control module, an oil discharge detector 7 electrically connected to the control module, and an oil replenishment detector 8.

[0037] Oil drain detector 7 and oil replenishment detector 8 are sequentially arranged on the housing of the side wall of hydraulic chamber 6 along the direction away from diaphragm 3, with their detection ends located inside hydraulic chamber 6 and corresponding to the end of guide rod 4. Magnetic ring 9 is coaxially arranged at the end of guide rod 4 near piston 5, and the planes of magnetic ring 9 and guide rod 4 coincide with the central axes of oil drain detector 7 and oil replenishment detector 8. When magnetic ring 9 passes the corresponding positions of oil drain detector 7 and oil replenishment detector 8, oil drain detector 7 and oil replenishment detector 8 respectively send signals to the control module to drain or replenish oil in hydraulic chamber 6. The arrangement of oil drain detector 7 and oil replenishment detector 8 on the housing of the side wall of hydraulic chamber 6 meets the following conditions:

[0038] When the hydraulic oil in the hydraulic chamber 6 is within the preset pressure range, the magnetic ring 9 is located between the drain detector 7 and the replenishment detector 8; when the hydraulic oil in the hydraulic chamber 6 is greater than the preset pressure range, the magnetic ring 9 is located at the corresponding position of the drain detector 7, or at the position of the drain detector 7 away from the replenishment detector 8; when the hydraulic oil in the hydraulic chamber 6 is less than the preset pressure, the magnetic ring 9 is located at the corresponding position of the replenishment detector 8, or at the position of the replenishment detector 8 away from the drain detector 7.

[0039] This invention utilizes the oil replenishment detector 8 and oil discharge detector 7 installed in the hydraulic chamber 6 to achieve real-time monitoring and determination of whether the diaphragm 3 is damaged through the control module.

[0040] The working principle of the above embodiments is as follows:

[0041] When the diaphragm pump is running normally, the diaphragm 3 is in the diaphragm chamber 2 and reciprocates with the piston 5 due to changes in oil pressure.

[0042] When the diaphragm pump is working, the guide rod 4 moves together with the diaphragm 3. Under normal circumstances, the magnetic ring 9 on the guide rod 4 is between the oil replenishment detector 8 and the oil discharge detector 7. As the pressure of the hydraulic oil changes, the diaphragm 3 will increase or decrease its deformation, thereby triggering the oil discharge detector 7 or the oil replenishment detector 8. By properly draining and replenishing the hydraulic chamber 6, the volume of hydraulic oil in the hydraulic chamber 6 is kept constant, and the operating position of the diaphragm 3 can be controlled within the optimal range (i.e., between the oil discharge detector 7 and the oil replenishment detector 8).

[0043] When the diaphragm 3 is intact and operating normally, the diaphragm pump's oil replenishment and discharge actions are regular and infrequent as the piston 5 reciprocates. However, if the diaphragm 3 is damaged, the oil replenishment / discharge actions become frequent. This is because when the piston 5 moves from position A to position B, the hydraulic oil in the hydraulic chamber 6 is compressed and leaks in large quantities into the diaphragm chamber 2 through the damaged hole in the diaphragm 3. The magnetic ring 9 on the guide rod 4 then moves to below the discharge detector 7, triggering the discharge signal. Then, when the piston 5 returns from position B to position A, insufficient hydraulic oil in the hydraulic chamber 6 causes the diaphragm 3 to absorb excessively, causing the magnetic ring 9 on the guide rod 4 to move to below the replenishment detector 8, triggering the replenishment signal. Simultaneously, some hydraulic oil leaks into the diaphragm chamber 2 through the damaged hole in the diaphragm 3, contaminating the hydraulic oil and altering its properties.

[0044] like Figure 2 As shown, the present invention also provides a method for monitoring diaphragm damage in a diaphragm pump, comprising the following steps:

[0045] 1) Construct the aforementioned diaphragm pump diaphragm damage monitoring system;

[0046] 2) Set a 15s delay and a 180s timer in the control module;

[0047] 3) Start the external drive mechanism to make the diaphragm pump body 1 run normally through piston 5;

[0048] 4) Detect the position of the magnetic ring 9 using the oil drain detector 7 and the oil replenishment detector 8;

[0049] 5) Determine whether the magnetic ring 9 passes the corresponding position of the oil drain detector 7 or the oil replenishment detector 8. If yes, the magnetic ring 9 triggers the oil drain detector 7 or the oil replenishment detector 8 to send an oil drain signal or an oil replenishment signal, and proceed to step 6); otherwise, return to step 4).

[0050] 6) After receiving the oil discharge signal or oil replenishment signal, if the control module receives the oil discharge signal or oil replenishment signal again within 15 seconds triggered by the magnetic ring, then execute step 7); otherwise, reset the 15-second delay to zero, determine that the diaphragm pump is operating normally, and return to step 4).

[0051] 7) The oil replenishment signal or oil discharge signal activates the delay timer in the control module to start counting down to a 180s delay, and at the same time returns to step 4);

[0052] If the delay timer remains active for 180 seconds, the control module determines that the diaphragm of the diaphragm pump is damaged and shuts down the diaphragm pump due to a fault; otherwise, the 180-second timer is reset, the control module determines that the diaphragm pump is operating normally, and returns to step 4).

[0053] In the control module, by measuring the triggering timing and frequency of the oil replenishment detector 8 and the oil discharge detector 7 during the operation of the diaphragm pump, it is possible to diagnose whether the hydraulic oil is excessively consumed, thereby determining whether the diaphragm 3 is damaged.

[0054] During the operation of the diaphragm pump, when the control module receives a replenishment signal or a discharge signal, a 15-second delay is set in the control module to extend this signal, and the system monitors whether a replenishment signal or a discharge signal continues to appear within 15 seconds. If no replenishment signal or discharge signal appears within 15 seconds, the 15-second delay timer is reset to zero, and the diaphragm pump operates normally.

[0055] If a replenishment or discharge signal is received within 15 seconds, the delay timer in the control module is activated and starts timing for 180 seconds. If the delay timer remains active for 180 seconds, the control module determines that the diaphragm 3 of the diaphragm pump is damaged after the timing time expires, and the diaphragm pump stops due to malfunction. If the delay timer does not remain active for 180 seconds, it is considered normal replenishment or discharge, and the diaphragm pump can continue to operate normally.

[0056] When diaphragm 3 is damaged, each reciprocating motion of piston 5 will trigger the oil replenishment detector 8 or the oil discharge detector 7 to send an oil replenishment signal or an oil discharge signal. Therefore, the delay timer will keep counting for each time within the 15s delay period. Thus, the 180s delay timer will remain active. After the counting time is up, the control module will be triggered to alarm the hydraulic oil fault, and the control module will determine that the diaphragm 3 of the diaphragm chamber 2 is damaged.

Claims

1. A method for monitoring diaphragm damage in a diaphragm pump, characterized in that, Includes the following steps: 1) Construct a diaphragm pump diaphragm damage monitoring system, the system including a diaphragm pump body (1) and a piston (5); the diaphragm pump body (1) includes a housing, a diaphragm chamber (2) disposed in the housing, a diaphragm (3) disposed in the diaphragm chamber (2), and a guide rod (4) connected to the diaphragm (3); one end of the piston (5) is connected to the end of the housing away from the diaphragm (3), and the other end of the piston (5) is used to connect to an external drive mechanism; a hydraulic cavity (6) is formed between the diaphragm (3), the housing, and the piston (5); the diaphragm (3), the guide rod (4), the piston (5) and the hydraulic cavity (6) are coaxially arranged; the external drive mechanism causes the diaphragm (3) to move concave and convex through the piston (5) and the hydraulic oil located in the hydraulic cavity (6), thereby driving the guide rod (4) connected to it to reciprocate along the axial direction in the hydraulic cavity (6); It also includes a magnetic ring (9), a control module, an oil drain detector (7) electrically connected to the control module, and an oil replenishment detector (8); the plane where the magnetic ring (9) is located coincides with the central axis of the oil drain detector (7) or the oil replenishment detector (8); The oil drain detector (7) and the oil replenishment detector (8) are sequentially arranged on the housing of the side wall of the hydraulic cavity (6) in a direction away from the diaphragm (3). Their detection ends are located inside the hydraulic cavity (6) and correspond to the end of the guide rod (4). The magnetic ring (9) is coaxially disposed at one end of the guide rod (4) near the piston (5); When the magnetic ring (9) passes through the corresponding positions of the oil drain detector (7) and the oil replenishment detector (8), the oil drain detector (7) and the oil replenishment detector (8) respectively send signals to the control module to drain oil from the hydraulic chamber (6) and replenish oil. The positions of the oil drain detector (7) and the oil replenishment detector (8) on the housing of the side wall of the hydraulic chamber (6) meet the following conditions: When the hydraulic oil in the hydraulic chamber (6) is within the preset pressure range, the magnetic ring (9) is located between the drain detector (7) and the replenishment detector (8); when the hydraulic oil in the hydraulic chamber (6) is greater than the preset pressure range, the magnetic ring (9) is located at the corresponding position of the drain detector (7), or the corresponding position of the drain detector (7) is away from the replenishment detector (8); when the hydraulic oil in the hydraulic chamber (6) is less than the preset pressure, the magnetic ring (9) is located at the corresponding position of the replenishment detector (8), or the corresponding position of the replenishment detector (8) is away from the drain detector (7). 2) Set the delay time and preset time in the control module; 3) Start the external drive mechanism to make the diaphragm pump body (1) run normally through the piston (5); 4) Use the oil drain detector (7) and the oil replenishment detector (8) to detect the position of the magnetic ring (9); 5) Determine whether the magnetic ring (9) passes the corresponding position of the oil drain detector (7) or the oil replenishment detector (8). If yes, the magnetic ring (9) triggers the oil drain detector (7) or the oil replenishment detector (8) to send an oil drain signal or an oil replenishment signal, and proceed to step 6); otherwise, return to step 4). 6) After receiving the oil discharge signal or oil replenishment signal, if the control module receives the oil discharge detector (7) or oil replenishment detector (8) triggered by the magnetic ring (9) again within the delay time, then step 7) is executed; otherwise, the delay time is cleared, the control module determines that the diaphragm pump is operating normally, and returns to step 4). 7) The oil replenishment signal or oil discharge signal activates the delay timer in the control module to start counting down to the preset time, and simultaneously returns to step 4). If the delay timer remains active for the preset time, the control module determines that the diaphragm (3) of the diaphragm pump is damaged and stops the diaphragm pump; otherwise, the preset time is cleared, the control module determines that the diaphragm pump is running normally, and returns to step 4).

2. The method for monitoring diaphragm damage in a diaphragm pump according to claim 1, characterized in that: In step 2), the delay time is 12-20 seconds.

3. The method for monitoring diaphragm damage in a diaphragm pump according to claim 2, characterized in that, In step 3), the specific positions of the magnetic ring (9) and the oil drain detector (7) or oil replenishment detector (8) are as follows: The position when the plane of the magnetic ring (9) coincides with the central axis of the oil drain detector (7) or the oil replenishment detector (8).

4. The method for monitoring diaphragm damage in a diaphragm pump according to claim 3, characterized in that: In step 2), the preset time is 180s.

5. The method for monitoring diaphragm damage in a diaphragm pump according to claim 4, characterized in that: In step 2), the delay time is 15 seconds.

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