Detection method, system and device suitable for abnormal operation state of pump

Abstract

The invention discloses a detection method, system and device suitable for the abnormal operation state of a pump. The method comprises the steps that at least three pieces of first data corresponding to the abnormal operation state detection of the pump are obtained in real time; wherein the first data is rotating speed data of pump operation; generating second data corresponding to the first data in real time based on the first data; wherein the second data is pulse signal data corresponding to the pump operation rotating speed data; according to the second data, whether the pump runs in an abnormal state or not is judged in real time, and third data corresponding to the second data is generated; wherein the third data is early warning data of the running state of the pump, and the system and the device corresponding to the method adopt a high-speed signal detection and wheel disc time difference calculation method to judge the rotating direction and the rotating speed of the pump and provide abnormal state detection data of the pump for unmanned operation of the pump.

Description

Technical Field

[0001] The present invention belongs to the technical field of pump speed and reverse alarm detection, and in particular relates to a detection method, system and device suitable for abnormal operation of a pump. Background Art

[0002] In the field of industrial manufacturing, with the continuous development of science and technology, various automation technologies are becoming more and more mature. Intelligence, automation and unmanned operation are the general trend of future industrial development. In order to achieve automation and unmanned operation, various detection and sensing devices must be configured. Pumps are indispensable production equipment in the industrial field, especially in heavy industry, and unmanned pump rooms are the future development trend.

[0003] In large-scale modern underground iron ore mines, various types of pumps are used to transport slurry, water and other media during the mineral processing process. According to the overall policy of green, deep and intelligent mine development and construction, with the continuous implementation of mechanization and automation, it is very important to monitor and detect abnormal pump reversal in the process of unmanned operation and remote operation of the pump. If the pump reversal is not discovered in time, it will cause a large current output when the pump starts, which is very likely to burn the motor or break the shaft due to excessive load, thereby increasing production costs and seriously affecting the organization of normal production.

[0004] Therefore, in view of the above technical problems and defects, it is urgent to design and develop a detection method, system and device suitable for abnormal operation of a pump. Summary of the invention

[0005] In order to overcome the shortcomings and difficulties of the above-mentioned prior art, the purpose of the present invention is to provide a detection method, system and device suitable for the abnormal operation state of a pump, which adopts high-speed signal detection and roulette time difference calculation method to judge the rotation direction and rotation speed of the pump, and provide abnormal state detection data of the pump for unmanned operation of the pump.

[0006] The first object of the present invention is to provide a detection method suitable for abnormal operation of a pump; the second object of the present invention is to provide a detection system suitable for abnormal operation of a pump; the third object of the present invention is to provide a detection device suitable for abnormal operation of a pump.

[0007] The first object of the present invention is achieved in that the method comprises the following steps: Acquire in real time at least three first data corresponding to the abnormal operation state detection of the pump to be tested; wherein the first data is the speed data of the pump operation; Based on the first data, second data corresponding to the first data is generated in real time; wherein the second data is pulse signal data corresponding to the pump running speed data; According to the second data, it is determined in real time whether the pump operation is in an abnormal state, and third data corresponding to the second data is generated; wherein the third data is early warning data of the pump operation state.

[0008] Furthermore, the real-time acquisition of at least three first data corresponding to the abnormal operation state detection of the pump to be pumped also includes: Generate and obtain fourth data corresponding to the abnormal operation state of the pump to be detected, and generate corresponding first control data in real time based on the fourth data; wherein the fourth data is the activation signal data for starting the detection of the abnormal operation state of the pump; and the first control data is the control command data for detecting the abnormal operation state of the pump.

[0009] Further, the generating, based on the first data, second data corresponding to the first data in real time also includes: Based on the second data, the corresponding fifth data is calculated and generated; wherein the fifth data is the time difference data of two adjacent signals; the pump speed calculation formula is as follows: (1) In the formula, t1, t2, and t3 are the signal times; The rotation direction and rotation speed of the pump are determined in real time according to the fifth data.

[0010] Further, the method of determining in real time whether the pump is in an abnormal state according to the second data and generating third data corresponding to the second data also includes: respectively generating and acquiring rotation speed threshold data, reversal time data and reversal time threshold data corresponding to the operation of the pump; Based on the rotation speed threshold data, the reversal time data and the reversal time threshold data, corresponding sixth data is generated; wherein the sixth data is pump reversal alarm information data.

[0011] The second object of the present invention is achieved in this way: the system is applied to the detection method applicable to the abnormal operation state of the pump, and the system comprises: A data acquisition unit, used for acquiring in real time at least three first data corresponding to the abnormal operation state of the pump to be detected; wherein the first data is the speed data of the pump operation; A first data generating unit is used to generate second data corresponding to the first data in real time based on the first data; wherein the second data is pulse signal data corresponding to the pump running speed data; The second data generating unit is used to determine in real time whether the pump operation is in an abnormal state according to the second data, and to generate third data corresponding to the second data; wherein the third data is early warning data of the pump operation state.

[0012] Furthermore, the data acquisition unit further includes: The first generating module is used to generate and obtain fourth data corresponding to the abnormal operation state of the pump to be detected, and generate corresponding first control data in real time according to the fourth data; wherein the fourth data is the activation signal data for starting the detection of the abnormal operation state of the pump; and the first control data is the control command data for detecting the abnormal operation state of the pump.

[0013] Furthermore, the first data generating unit further includes: The second generating module is used to calculate and generate corresponding fifth data based on the second data; wherein the fifth data is the time difference data of two adjacent signals; the pump speed calculation formula is as follows: (1) In the formula, t1, t2, and t3 are the signal times; The first determination module is used to determine the rotation direction and rotation speed of the pump in real time according to the fifth data.

[0014] Furthermore, the second data generating unit further includes: a third generating module, for respectively generating and acquiring rotation speed threshold data, reversal time data and reversal time threshold data corresponding to the operation of the pump; The fourth generating module is used to generate corresponding sixth data based on the rotation speed threshold data, the reversal time data and the reversal time threshold data; wherein the sixth data is pump reversal alarm information data.

[0015] The third object of the present invention is achieved as follows: the system is applied to the detection method applicable to the abnormal operation state of the pump, the device comprising: a detection turntable for detecting the rotation direction of the pump speed, and a Hall switch installed on one side of the detection turntable and perpendicular to the detection turntable; The signal of the Hall switch is connected to the high-speed pulse input terminal of the controller, and the controller outputs a switch signal, which is a reverse alarm signal of the pump.

[0016] The controller main control chip model is STM32F405; The detection turntable has a diameter of 300mm and is installed on the non-drive end shaft of the pump to rotate with the shaft; at least three cylindrical magnets with a diameter of 8mm are installed at the same radius position on the outer ring of the detection turntable, and the installation angles of the three cylindrical magnets are respectively: 0 degrees, 60 degrees and 180 degrees.

[0017] The present invention uses a method to obtain at least three first data corresponding to the abnormal state detection of the pump operation in real time; wherein the first data is the speed data of the pump operation; Based on the first data, second data corresponding to the first data is generated in real time; wherein the second data is pulse signal data corresponding to the pump running speed data; Based on the second data, it is determined in real time whether there is an abnormal state in the operation of the pump, and third data corresponding to the second data is generated; wherein the third data is early warning data of the pump operation status, and the system and device corresponding to the method use high-speed signal detection and roulette time difference calculation methods to determine the rotation direction and rotation speed of the pump, and provide abnormal state detection data of the pump for unmanned operation of the pump.

[0018] That is to say, the present invention adopts a simple method to solve the problem of detecting the rotation speed and rotation direction of the pump, and issues an alarm message when reversal occurs, thereby eliminating the equipment risks and production risks caused by the reversal of the pump, and avoiding large current output when the pump starts, which may cause the motor to burn out due to excessive load or break the shaft, thereby increasing production costs and seriously affecting the organization of normal production. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0020] Figure 1 A schematic flow chart of the steps of a detection method for abnormal pump operation according to the present invention; Figure 2 A schematic diagram of the architecture of a detection system suitable for abnormal pump operation is provided for the present invention; Figure 3 This is a schematic diagram of the structure of a detection device suitable for detecting abnormal operation of a pump according to the present invention; In the figure: 1-Hall switch; 2-detection turntable; 3-pump non-drive end shaft; 4-cylindrical magnet; 5-detection turntable; 6-controller. DETAILED DESCRIPTION

[0021] In order to better understand the purpose, technical solutions and advantages of the present invention, the present invention is further described below in conjunction with the accompanying drawings and specific implementation methods. Those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.

[0022] The present invention may also be implemented or applied through other different specific examples, and the details in this specification may also be modified and changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention.

[0023] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back...), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0024] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or suggesting their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. Secondly, the technical solutions between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in the field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0025] The present invention will be further described in detail below in conjunction with the accompanying drawings. Figure 1-Figure 3 As shown, the present invention provides a method for detecting an abnormal state of pump operation, wherein the method comprises the following steps: S01, acquiring in real time at least three first data corresponding to the abnormal operation state detection of the pump to be tested; wherein the first data is the speed data of the pump operation; S02. Based on the first data, generating second data corresponding to the first data in real time; wherein the second data is pulse signal data corresponding to the pump running speed data; S03. According to the second data, determine in real time whether the pump is in an abnormal state, and generate third data corresponding to the second data; wherein the third data is early warning data of the pump operation state.

[0026] The real-time acquisition of at least three first data corresponding to the abnormal operation state detection of the pump to be pumped also includes: S011. Generate and obtain fourth data corresponding to the abnormal operation state of the pump to be detected, and generate corresponding first control data in real time based on the fourth data; wherein the fourth data is the activation signal data for starting the detection of the abnormal operation state of the pump; and the first control data is the control command data for detecting the abnormal operation state of the pump.

[0027] The step of generating second data corresponding to the first data in real time based on the first data further includes: S021. Based on the second data, calculate and generate corresponding fifth data; wherein the fifth data is the time difference data of two adjacent signals; the pump speed calculation formula is as follows: (1) In the formula, t1, t2, and t3 are the signal times; S022. Determine the rotation direction and rotation speed of the pump in real time according to the fifth data.

[0028] The step of determining in real time whether the pump is in an abnormal state according to the second data and generating third data corresponding to the second data further includes: S031, respectively generate and obtain rotation speed threshold data, reversal time data and reversal time threshold data corresponding to the operation of the pump; S032. Generate corresponding sixth data based on the rotation speed threshold data, the reversal time data and the reversal time threshold data; wherein the sixth data is pump reversal alarm information data.

[0029] Specifically, in an embodiment of the present invention, the present invention provides a pump speed and direction detection device based on a Hall switch, which is composed of a Hall switch, a detection turntable, and a controller.

[0030] The diameter of the detection turntable is 300mm, installed on the non-drive end shaft of the pump, and rotates with the shaft. Three magnets with a diameter of 8mm are installed at the same radius on the outer ring of the detection turntable. The installation angles of the three magnets are: 0 degrees, 60 degrees, and 180 degrees.

[0031] The Hall switch uses a 5V, PNP type switch with a diameter of DN8. The Hall switch is perpendicular to the detection turntable and the head of the Hall switch is aligned with the magnet.

[0032] The controller is an electronic integrated controller. The main control chip of the controller is STM32F405. The Hall switch signal is connected to the high-speed pulse input terminal of the controller. The controller outputs a switch signal, which is the reverse alarm signal of the pump. It outputs a 4~20mA analog signal, which is the speed signal of the pump. The controller is equipped with a photoelectric isolation RS485 communication interface, and the communication protocol is Modbus RTU. The monitoring device parameters can be set and the monitoring data can be read through the communication interface.

[0033] Working principle: Install the detection turntable at the non-driving end of the pump, and align the Hall switch with the cylindrical magnet, with a distance of no more than 10mm from the cylindrical magnet. The controller is powered by 24VDC, and the output end is connected to PLC or other signal collectors to detect the direction and speed of the pump.

[0034] That is to say, after the pump rotates, the detection disk rotates accordingly. When the magnet on the detection disk passes the Hall switch, the controller receives a signal. In order to improve the accuracy of signal detection, the controller uses an interrupt to receive high-speed pulse signals from the Hall switch and calculates the time difference t1, t2, and t3 of two adjacent signals in ms, where t1~t3 is the time difference detected in sequence. When t2>t1 or t3>t2 or t1>t3, the count is increased by 1. When the final count value = 2, it is forward rotation, and when the count value = 1, it is reverse rotation.

[0035] The pump speed calculation formula is as follows: (1) speed: pump speed, in rpm; Pump reverse alarm logic judgment: When the pump stops, due to the water hammer effect, a short-term reverse is normal, and a low-speed reverse is also a normal phenomenon, but a long-term high-speed reverse is an abnormal scene. The pump reverse judgment logic of this device is as follows: Direction=Reverse&speed>S L &Tr>Ts In the above formula, Direction: rotation direction, forward / reverse; Speed: rotation speed, rpm; S L : Rotation speed threshold setting, rpm, default 10rpm, adjustable; Tr: Reverse time, S, when Direction = reverse, reset and start timing, when Direction = forward, stop timing; Ts: Reverse time threshold setting, S, default 6s, adjustable; In the above formula, when the three conditions are met at the same time, it can be determined that the pump is in an abnormal reverse state and a reverse alarm message is issued.

[0036] Input and output device: In order to adapt to the application scenarios of various systems, this device is equipped with a hard contact output interface and a communication interface. The communication interface adopts a photoelectric isolation RS485 interface and ModbusRTU communication protocol. The functions of the communication interface are as follows: Communication interface parameters can be set, including station address, baud rate, check bit and other parameters; Ts (reversal time threshold setting) and S L (rotation speed threshold setting); the speed range can be set; the reverse alarm status bit can be read, 1 is alarm, 0 is normal; the speed value can be read, the unit is rpm; The hard contact interface uses DO and AO interfaces, among which the DO interface is a 1-way reverse alarm output interface, relay type, with an electric shock capacity of 5A / 220V; the AO interface is 4~20mA output, and the speed range defaults to 2900rpm and can be set.

[0037] To achieve the above object, the present invention also provides a detection system suitable for abnormal operation of a pump, such as Figure 2 As shown, the system is applied to the detection method applicable to the abnormal operation state of the pump, and the system includes: A data acquisition unit, used for acquiring in real time at least three first data corresponding to the abnormal operation state of the pump to be detected; wherein the first data is the speed data of the pump operation; A first data generating unit is used to generate second data corresponding to the first data in real time based on the first data; wherein the second data is pulse signal data corresponding to the pump running speed data; The second data generating unit is used to determine in real time whether the pump operation is in an abnormal state according to the second data, and to generate third data corresponding to the second data; wherein the third data is early warning data of the pump operation state.

[0038] The data acquisition unit further includes: The first generating module is used to generate and obtain fourth data corresponding to the abnormal operation state of the pump to be detected, and generate corresponding first control data in real time according to the fourth data; wherein the fourth data is the activation signal data for starting the detection of the abnormal operation state of the pump; and the first control data is the control command data for detecting the abnormal operation state of the pump.

[0039] The first data generating unit further includes: The second generating module is used to calculate and generate corresponding fifth data based on the second data; wherein the fifth data is the time difference data of two adjacent signals; the pump speed calculation formula is as follows: (1) In the formula, t1, t2, and t3 are the signal times; The first determination module is used to determine the rotation direction and rotation speed of the pump in real time according to the fifth data.

[0040] The second data generating unit further includes: a third generating module, for respectively generating and acquiring rotation speed threshold data, reversal time data and reversal time threshold data corresponding to the operation of the pump; The fourth generating module is used to generate corresponding sixth data based on the rotation speed threshold data, the reversal time data and the reversal time threshold data; wherein the sixth data is pump reversal alarm information data.

[0041] In the system solution embodiment of the present invention, the specific details of the method steps involved in the detection of abnormal operation status of a pump have been described above, that is, the functional modules in the system are used to implement the steps or sub-steps in the above method embodiment, which will not be repeated here.

[0042] In order to achieve the purpose of the present invention, a detection device suitable for abnormal operation of a pump is also provided. Figure 3 As shown, the device is applied to the detection method applicable to the abnormal operation state of the pump, and the device comprises: a detection turntable for detecting the rotation speed and direction of the pump, and a Hall switch installed on one side of the detection turntable and perpendicular to the detection turntable; The signal of the Hall switch is connected to the high-speed pulse input terminal of the controller, and the controller outputs a switch signal, which is the reverse alarm signal of the pump. The main control chip model of the controller is STM32F405; The detection turntable has a diameter of 300mm and is installed on the non-drive end shaft of the pump to rotate with the shaft; at least three cylindrical magnets with a diameter of 8mm are installed at the same radius position on the outer ring of the detection turntable, and the installation angles of the three cylindrical magnets are respectively: 0 degrees, 60 degrees and 180 degrees.

[0043] The present invention uses a method to obtain in real time at least three first data corresponding to the abnormal operation state detection of the pump to be tested; wherein the first data is the speed data of the pump operation; based on the first data, second data corresponding to the first data is generated in real time; wherein the second data is pulse signal data corresponding to the speed data of the pump operation; according to the second data, it is determined in real time whether the pump operation is in an abnormal state, and third data corresponding to the second data is generated; wherein the third data is early warning data of the pump operation state, as well as the system and device corresponding to the method, which adopt high-speed signal detection and roulette time difference calculation method to judge the rotation direction and rotation speed of the pump, and provide abnormal state detection data of the pump for unmanned operation of the pump.

[0044] That is to say, the present invention adopts a simple method to solve the problem of detecting the rotation speed and rotation direction of the pump, and issues an alarm message when reversal occurs, thereby eliminating the equipment risks and production risks caused by the reversal of the pump, and avoiding large current output when the pump starts, which may cause the motor to burn out due to excessive load or break the shaft, thereby increasing production costs and seriously affecting the organization of normal production.

[0045] The above-mentioned embodiments only express several implementation methods of the present invention, and the description thereof is relatively specific and detailed, but it cannot be understood as limiting the scope of the patent of the present invention. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A method for detecting abnormal operation of a pump, characterized in that: The method comprises the steps of: Acquire in real time at least three first data corresponding to the abnormal operation state detection of the pump to be tested; wherein the first data is the speed data of the pump operation; Based on the first data, second data corresponding to the first data is generated in real time; wherein the second data is pulse signal data corresponding to the pump running speed data; According to the second data, it is determined in real time whether the pump operation is in an abnormal state, and third data corresponding to the second data is generated; wherein the third data is early warning data of the pump operation state.

2. A method for detecting abnormal pump operation according to claim 1, characterized in that: The real-time acquisition of at least three first data corresponding to the abnormal operation state detection of the pump to be pumped also includes: Generate and obtain fourth data corresponding to the abnormal operation state of the pump to be detected, and generate corresponding first control data in real time based on the fourth data; wherein the fourth data is the activation signal data for starting the detection of the abnormal operation state of the pump; and the first control data is the control command data for detecting the abnormal operation state of the pump.

3. A method for detecting abnormal pump operation according to claim 1, characterized in that: The step of generating second data corresponding to the first data in real time based on the first data further includes: Based on the second data, the corresponding fifth data is calculated and generated; wherein the fifth data is the time difference data of two adjacent signals; the pump speed calculation formula is as follows: （1） In the formula, t1, t2, and t3 are the signal times; The rotation direction and rotation speed of the pump are determined in real time according to the fifth data.

4. A method for detecting abnormal pump operation according to claim 1, characterized in that: The step of determining in real time whether the pump is in an abnormal state according to the second data and generating third data corresponding to the second data further includes: respectively generating and acquiring rotation speed threshold data, reversal time data and reversal time threshold data corresponding to the operation of the pump; Based on the rotation speed threshold data, the reversal time data and the reversal time threshold data, corresponding sixth data is generated; wherein the sixth data is pump reversal alarm information data.

5. A detection system suitable for abnormal operation of a pump, characterized in that: The system is applied to the detection method for abnormal operation of a pump as claimed in any one of claims 1 to 4, and the system comprises: A data acquisition unit, used for acquiring in real time at least three first data corresponding to the abnormal operation state of the pump to be detected; wherein the first data is the speed data of the pump operation; A first data generating unit is used to generate second data corresponding to the first data in real time based on the first data; wherein the second data is pulse signal data corresponding to the pump running speed data; The second data generating unit is used to determine in real time whether the pump operation is in an abnormal state according to the second data, and to generate third data corresponding to the second data; wherein the third data is early warning data of the pump operation state.

6. A detection system for abnormal pump operation according to claim 5, characterized in that: The data acquisition unit further includes: The first generating module is used to generate and obtain fourth data corresponding to the abnormal operation state of the pump to be detected, and generate corresponding first control data in real time according to the fourth data; wherein the fourth data is the activation signal data for starting the detection of the abnormal operation state of the pump; and the first control data is the control command data for detecting the abnormal operation state of the pump.

7. A detection system for abnormal pump operation according to claim 5, characterized in that: The first data generating unit further includes: The second generating module is used to calculate and generate corresponding fifth data based on the second data; wherein the fifth data is the time difference data of two adjacent signals; the pump speed calculation formula is as follows: （1） In the formula, t1, t2, and t3 are the signal times; The first determination module is used to determine the rotation direction and rotation speed of the pump in real time according to the fifth data.

8. A detection system for abnormal pump operation according to claim 5, characterized in that: The second data generating unit further includes: a third generating module, for respectively generating and acquiring rotation speed threshold data, reversal time data and reversal time threshold data corresponding to the operation of the pump; The fourth generating module is used to generate corresponding sixth data based on the rotation speed threshold data, the reversal time data and the reversal time threshold data; wherein the sixth data is pump reversal alarm information data.

9. A detection device suitable for abnormal operation of a pump, characterized in that: The device is applied to the detection method for abnormal operation of a pump as claimed in any one of claims 1 to 4, and the device comprises: a detection turntable for detecting the rotation speed and direction of the pump, and a Hall switch installed on one side of the detection turntable and perpendicular to the detection turntable; The signal of the Hall switch is connected to the high-speed pulse input terminal of the controller, and the controller outputs a switch signal, which is a reverse alarm signal of the pump.

10. A detection device for abnormal pump operation according to claim 9, characterized in that: The controller main control chip model is STM32F405; The detection turntable has a diameter of 300mm and is installed on the non-drive end shaft of the pump to rotate with the shaft; at least three cylindrical magnets with a diameter of 8mm are installed at the same radius position on the outer ring of the detection turntable, and the installation angles of the three cylindrical magnets are respectively: 0 degrees, 60 degrees and 180 degrees.

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