Drainage pump dynamic priority control method and device integrated with equipment health monitoring

Abstract

The invention provides a drainage pump dynamic priority control method and device fusing equipment health monitoring, and the method comprises the steps: collecting the operation state of each drainage pump through a PLC system, and carrying out the automatic statistics of the single operation time Trun, the operation time interval Tint and the operation number N; calculating an intermediate variable s based on the ratio of Trun to Tint, and carrying out normalization processing on the intermediate variable s; function fusion is carried out on the intermediate variable s and the operation times N, a pump starting priority parameter q is calculated, and the pump starting priority of the drainage pump is determined according to the q value; according to the real-time calculation result of the pump starting priority parameter q, the drainage pump with the highest priority is selected for pump starting operation, and dynamic alternation and load balancing of the drainage pumps are achieved. Dynamic priority control and load balancing of the drainage pump can be achieved, the service life of equipment is prolonged, energy waste and fault risks caused by frequent starting and stopping are reduced, and the operation reliability and the intelligent level of the drainage system are improved.

Description

Technical Field

[0001] The present invention relates to the field of control systems, and in particular to a method and device for dynamic priority control of a drainage pump integrating equipment health monitoring. Background Art

[0002] As a core component of leakage and drainage control in hydropower stations, drainage pump systems are widely used in hydropower generation, water conservancy facilities, and industrial water treatment. With the development of industrial automation and intelligent control technology, traditional control methods based on fixed water levels or timed start and stop are gradually being replaced by PLC (Programmable Logic Controller) systems. Related technologies integrate DI modules, time counting function blocks, and SCADA systems to build a complete process from data acquisition, operating status monitoring to control decision-making. Specifically, the system includes key links such as liquid level detection, equipment operating parameter statistics, health status assessment, and pump start priority scheduling, aiming to improve the operating efficiency and equipment reliability of the drainage system.

[0003] However, the existing pump start control methods directly adopt static threshold setting or single parameter comparison, and do not fully consider the health status and load balancing requirements of the drainage pump in a dynamic operating environment. This may lead to frequent start and stop of the equipment, uneven use or long-term idleness, thus affecting the stability of the system and the life of the equipment. Specifically, the control strategies based on the number of operations, the duration of a single operation or the start and stop interval have logical conflicts in actual applications, making it difficult to directly compare priorities; at the same time, the weight distribution method relies on a large number of experimental verifications, is highly subjective and complex to implement. In addition, due to the lack of online monitoring and early warning mechanisms for the pump start frequency, the system responds laggingly when faced with fluctuations in seepage volume, making it difficult to adapt to real-time scheduling requirements under complex working conditions. Summary of the Invention

[0004] The present invention aims to solve one of the technical problems in the related art at least to a certain extent.

[0005] To this end, the first object of the present invention is to propose a dynamic priority control method for a drainage pump integrating equipment health monitoring.

[0006] The second object of the present invention is to provide a dynamic priority control device for a drainage pump integrating equipment health monitoring.

[0007] To achieve the above-mentioned purpose, the first embodiment of the present invention proposes a dynamic priority control method for drainage pumps integrating equipment health monitoring, including: S1, collecting the operating status of each drainage pump through the PLC system, and automatically counting the single operation time T_run, the operation time interval T_int and the number of operations N; S2, calculating the intermediate variable s based on the ratio of the T_run and T_int, and normalizing the intermediate variable s; S3, performing function fusion on the intermediate variable s and the number of operations N, calculating the pump start priority parameter q, where q = s / (2N), and determining the pump start priority of the drainage pump according to the size of the q value; S4, according to the real-time calculation result of the pump start priority parameter q, selecting the drainage pump with the highest priority to start the pump operation, so as to realize dynamic rotation and load balancing of the drainage pumps.

[0008] In one embodiment of the present invention, the operating status of each drainage pump is collected through the PLC system, and the single operation time T_run, the operation time interval T_int and the number of operations N are automatically counted, and the following also includes: S11, when the equipment starts to run, the time counting function block in the PLC is used to record the start time of the operation and start timing, and the number of operations N is increased by 1 at the same time; S12, when the equipment stops running, the time counting function block stops timing and outputs the single operation time T_run, and then starts recording the operation time interval T_int until the next time the equipment is started, stops timing and outputs T_int, and the number of operations N is automatically reset at the end of each month.

[0009] In one embodiment of the present invention, the intermediate variable s is calculated based on the ratio of T_run to T_int, and the intermediate variable s is normalized so that its numerical range is controlled between (0, 1), and further includes: S21, when T_int is not 0, the intermediate variable s is calculated as the ratio of T_run to T_int, and the numerical range of s is limited to between (0, 1) through normalization; S22, when T_int is 0, the intermediate variable s is set to 0 to avoid calculation anomalies caused by division by zero.

[0010] In one embodiment of the present invention, the intermediate variable s is functionally fused with the number of operations N to calculate the pump start priority parameter q, where q = s / (2N), and the pump start priority of the drainage pump is determined according to the size of the q value, and also includes: S31, dividing the intermediate variable s by 2 times the number of operations N to obtain the pump start priority parameter q to ensure that the number of operations N has a negative impact on the priority; S32, when the number of operations N is less than 2, the pump start priority parameter q takes the drainage pump number n as the initial value to ensure the fairness of the initial pump start.

[0011] In one embodiment of the present application, further comprising: S5, calculating the pump starting frequency f based on the ratio of the number of operations N and the operation time interval T_int, wherein f=N / T_int, and comparing the pump starting frequency f with a preset frequency threshold, when f exceeds the frequency threshold, triggering a frequency too high alarm signal.

[0012] To achieve the above object, the second aspect of the embodiment of the present application provides a drainage pump dynamic priority control device integrating equipment health monitoring, comprising: an operating state acquisition module, configured to acquire the operating state of each drainage pump through a PLC system, and automatically count the single operation time T_run, the operation time interval T_int and the number of operations N; an intermediate variable calculation and normalization module, configured to calculate an intermediate variable s based on the ratio of the T_run and the T_int, and perform normalization processing on the intermediate variable s; a pump starting priority parameter calculation module, configured to functionally fuse the intermediate variable s and the number of operations N, calculate a pump starting priority parameter q, wherein q=s / (2N), and determine the pump starting priority of the drainage pump according to the q value; and a pump starting control module, configured to select the drainage pump with the highest priority for pump starting operation according to the real-time calculation result of the pump starting priority parameter q, so as to realize dynamic rotation and load balancing of the drainage pump.

[0013] The method and device of the embodiment of the present application realize dynamic priority control and online health monitoring of the drainage pump, effectively balance the equipment load, prolong the service life, and reduce frequent starting and stopping and manual intervention.

[0014] Additional aspects and advantages of the present application will be in part apparent and in part pointed out hereinafter. BRIEF DESCRIPTION OF DRAWINGS

[0015] The above and / or additional aspects and advantages of the present application will become apparent and be readily appreciated from the following description, including the appended drawings.

[0016] Figure 1 A flowchart of a drainage pump dynamic priority control method integrating equipment health monitoring provided by the embodiment of the present application;

[0017] Figure 2 A principle diagram of a leakage drainage system provided by the embodiment of the present application;

[0018] Figure 3 A control principle diagram of an equipment health monitoring system provided by the embodiment of the present application;

[0019] Figure 4 A flowchart of an improved intelligent pump starting control method of a leakage drainage pump provided by the embodiment of the present application;

[0020] Figure 5 This is a structural diagram of a dynamic priority control device for a drainage pump that integrates equipment health monitoring, provided in an embodiment of the present application. DETAILED DESCRIPTION

[0021] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0022] In order to enable those skilled in the art to better understand the solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of the present invention.

[0023] The following describes a method and apparatus for dynamic priority control of a drainage pump integrating equipment health monitoring according to an embodiment of the present invention with reference to the accompanying drawings.

[0024] Figure 1 FIG. 1 is a flow chart of a method for dynamic priority control of a drainage pump integrating equipment health monitoring according to an embodiment of the present invention. Figure 1 Shown, including:

[0025] S1, collect the operating status of each drainage pump through the PLC system, and automatically count the single operation time T_run, operation time interval T_int and operation number N.

[0026] Specifically, this step collects the operating status of each drainage pump through the PLC system, and automatically counts the single running time T_run, the running time interval T_int and the number of operations N. It is the core data collection and processing link for realizing the dynamic priority control of the drainage pump. At the technical implementation level, this step relies on the real-time monitoring of the running status of the drainage pump motor by the digital input (DI) module of the PLC. When the drainage pump starts, the DI module detects the signal change (such as from 0 to 1), triggers the time counting function block (such as TON or CTU) inside the PLC, and starts recording the running time T_run; when the drainage pump stops running, the timing stops and the current running time is output. At the same time, the number of operations N is accumulated through the counting function block (CTU), and the count is increased by 1 for each start-stop cycle, and the N value is automatically cleared by the timer trigger at the end of each month to achieve periodic statistics.

[0027] At the parameter level, T_run, measured in minutes, reflects the duration of a single drainage pump run; T_int, also measured in minutes, represents the interval between two consecutive runs and is used to assess the system's load balancing status; and N is an integer counter that records the number of times the drainage pump has run in the current cycle. These three parameters enable the construction of a pump-start frequency model (f = N / T_int), which is used to determine whether the equipment is operating at an abnormally high frequency, thereby triggering an early warning mechanism. A frequency threshold (e.g., f > 0.05 times / minute) can be set in the PLC program. When this threshold is exceeded, the system sends an alarm signal to the SCADA server via a communication interface (such as Modbus TCP or OPC UA).

[0028] At the application scenario level, this step is applicable to the leakage drainage system of a hydropower station, especially under conditions where the water level in the collection well fluctuates frequently, and can effectively prevent the premature aging of a single drainage pump due to frequent start and stop. The PLC system is deployed in the on-site control cabinet and is directly connected to the drainage pump motor control circuit to ensure the real-time and accuracy of data collection. The statistical results are uploaded to the SCADA system via industrial Ethernet for real-time monitoring and decision support by operators. It is understandable that in the leakage drainage system, a liquid level switch is usually set in the leakage water collection well. When the water level rises to the first warning water level, the first drainage pump is started. When the water level continues to rise to the second warning water level, the second drainage pump is started, and so on, until the last drainage pump is started. The pump starting principle is as follows Figure 2 In this method, the priority of starting the pump is determined by introducing the drainage pump health condition parameters of single operation duration (T_run), operation time interval (T_int) and operation times (N).

[0029] The technical benefit of this step is to provide accurate, real-time equipment health data for the subsequent pump startup priority calculation model, enabling a quantitative assessment of the drainage pump's operating status. Through automatic statistical and normalization processing, the parameters s and q are ensured to be within a reasonable range (0, 1), thereby improving the scientific and operational nature of the priority sorting process, ultimately achieving the comprehensive control goals of balancing equipment load, extending service life, and reducing failure rates.

[0030] Furthermore, S1 includes:

[0031] S11, when the equipment starts running, the time counting function block in the PLC is used to record the start time of the operation and start timing, and the number of operations N is increased by 1.

[0032] Specifically, when the device starts running, the time counting function block in the PLC is used to record the start time and start timing, and the running number N is added by 1, which is one of the key steps to realize the online monitoring and dynamic priority control of the drainage pump health status in the present application. This step collects the running state signal of the drainage pump in real time through the DI (Digital Input) module of the PLC. When the pump motor start signal (such as contactor closing or running relay action) is detected, the time counting function block (such as TON or CTU function block in IEC 61131-3 standard) is triggered to start timing, record the starting time of the current running cycle, and simultaneously add the running number counter N by 1, so as to realize the automatic statistics of the running number of the drainage pump.

[0033] In terms of technical implementation, this step is usually realized by combining the timer and counter function blocks of the PLC. For example, the TON (On-Delay Timer) function block is used to record the single running time T_run. When the pump start signal input is "ON", the TON starts timing; when the signal becomes "OFF", the TON outputs the current cumulative running time. At the same time, the CTU (CountUp) function block is used to incrementally count the running number N. The counting operation is triggered once every time the pump starts. In order to ensure the accuracy and real-time performance of the data, the counter N is automatically cleared at the end of each month through the PLC program, which meets the common practice of periodic data statistics in industrial automation systems.

[0034] In terms of parameter index, the running number N is an integer variable (INT), the initial value is 0, and the maximum value is set according to system requirements, usually not more than 32767 times; the time base of the time counting function block can be set to 10ms or 100ms to meet the high-precision timing requirements. The units of T_run and T_int are minutes (min), and the millisecond-level timing results are converted to minute values through the internal time conversion module of the PLC, which is convenient for subsequent health parameter calculation and comparison.

[0035] The single running time (T_run), running time interval (T_int) and running number (N) of the working condition parameters reflect the health status of the device to different degrees, and the associated health characteristics are shown in Table 1. This method realizes the online monitoring of the drainage pump device health through the automatic statistics and online monitoring of the single running time (T_run), running time interval (T_int) and running number (N) of the drainage pump working condition parameters, and pre-warns the devices with too high pump starting frequency.

[0036] Table 1 Monitoring parameter associated health characteristics

[0037] Monitoring parameter Associated health feature Single run length Mechanical wear effect Operation time interval System load balancing state Operation number Fatigue aging degree

[0038] The system adopts a layered architecture based on PLC, and collects the operating status of the equipment through the DI module. When the equipment starts running, the time counting function block in the PLC starts timing, and the counting function block adds 1 at the same time, automatically counting the number of operations N, and automatically clearing the number of operations after each month. When the equipment stops running, the time counting stops and the output time T_run is the duration of a single operation. When the PLC collects the stopped status of the equipment, the time counting function block starts timing until the PLC collects the running status of the equipment, then the counting stops and the output time is the last running time interval T_int. Finally, each health condition parameter is transmitted to the SCADA server through network communication and displayed on the monitoring system screen to achieve real-time health monitoring. The equipment health monitoring control principle is as follows Figure 3 As shown in the figure, only one level switch is shown. At the same time, according to the frequency calculation model f = N / T_int, the pump start frequency f is calculated in the PLC, and a custom threshold is set to issue a high frequency warning.

[0039] At the application level, this step is applicable to the intelligent start-stop control of multiple drainage pumps in a hydropower station's seepage drainage system. The PLC monitors and collects data on each pump's operating status in real time, providing basic data support for subsequent pump start priority calculation models. This ensures that pump start decisions are based on actual equipment operating conditions rather than fixed thresholds.

[0040] The technical benefit of this step is that it enables the automated collection and statistics of drainage pump operating data, providing a reliable data foundation for equipment health assessment and dynamic priority control. By accurately recording the start time and number of each run, the system can accurately calculate T_run, T_int, and N, thereby establishing the pump start priority parameter q, achieving load balancing and optimizing equipment life, thereby improving the intelligence level and operational efficiency of the drainage system.

[0041] S12, when the device stops running, the time counting function block stops timing and outputs the single running time T_run, and then starts recording the running time interval T_int until the next time the device is started, stops timing and outputs T_int, and the number of runs N is automatically reset to zero at the end of each month.

[0042] Specifically, in some implementations, when the device stops running, the time counting function block will automatically stop timing and output the single running time T_run based on the device running status signal collected by the PLC (programmable logic controller). This function block usually uses a timer instruction (such as TON or CTU) to accumulate time, and its timing accuracy can be set to milliseconds (such as 100ms) to ensure the statistical accuracy of the running time. During the operation of the device, the time counting function block continuously records the running time. Once it detects that the device status changes from "running" to "stopped", the timing stop is triggered, and the accumulated time value is output as T_run for subsequent health status assessment.

[0043] Furthermore, when the equipment stops, the timer function block switches to recording the operating time interval, T_int. At this point, the timer begins recording the interval between the equipment stop and the next start. The PLC detects the equipment entering the "Run" state again, at which point it stops counting and outputs T_int. Recording this interval helps assess the frequency of equipment starts and stops, thereby determining whether it is operating abnormally. In practice, the minimum T_int recording interval can be set to 1 minute, and the maximum can be set to several hours, depending on the system configuration and the drainage pump's operating cycle.

[0044] Furthermore, the number of runs, N, is automatically accumulated by a counter module within the PLC. Each time the device completes a complete start-stop cycle (i.e., from start to stop), the counter increments by 1. To implement periodic counting and resetting, the system automatically resets N to zero at the end of each month (typically 00:00 on the 1st of each month) through a time-triggered mechanism. This ensures that the periodicity of run count statistics aligns with the equipment maintenance cycle. This reset operation can be implemented using the PLC's built-in date and time functions (such as DATE_AND_TIME) in conjunction with timer interrupts (such as T_INTERRUPT).

[0045] This step plays a key role in the entire dynamic priority control method. By accurately collecting and processing healthy operating parameters such as T_run, T_int, and N, it provides a real-time, reliable data foundation for the pump start priority calculation model. Combined with the subsequent function fusion algorithm, it enables intelligent rotation control of drainage pumps, effectively improving system operating efficiency, extending equipment life, and reducing the risk of mechanical failure caused by frequent starts and stops.

[0046] S2: Calculate an intermediate variable s based on the ratio of T_run to T_int, and perform normalization processing on the intermediate variable s.

[0047] Specifically, in the present invention's pump startup priority calculation model, calculating the intermediate variable s based on the ratio of the single run duration T_{\text{run}} to the run interval T_{\text{int}} and normalizing it is a key step in implementing dynamic priority control for drainage pumps. This step quantifies the device's operating status and load balancing characteristics, providing the fundamental input for the subsequent calculation of the priority parameter q, thereby enabling intelligent pump startup scheduling.

[0048] In some implementations, the intermediate variable s is calculated as s = \frac{T_{\text{run}}}{T_{\text{int}}}. Its physical meaning is to reflect the "operation intensity" of the drainage pump during its most recent run: when T_{\text{run}} is small and T_{\text{int}} is large, a low s value indicates that the device operates for short periods of time, with long intervals, and is under a light load. Conversely, a high s value indicates frequent or long runs, with a heavy load. Because T_{\text{int}} is typically much larger than T_{\text{run}}, a directly calculated s value may exceed the reasonable range, affecting the comparability of subsequent priority parameters. Therefore, it needs to be normalized.

[0049] Normalization is done by linear mapping, mapping s to the interval (0,1). In the specific implementation, the normalization function can be set to s min s max s min , where s min and s max are the minimum and maximum s values ​​of all drainage pumps in the system. min and s max The data can be collected and updated dynamically online through PLC to ensure the real-time and adaptability of the normalization process. min , s max , then when s = 0.5, after normalization, s = 0.625.

[0050] In practical applications, this step is typically implemented in a PLC controller. Combined with equipment start and stop signals collected by the DI module, a time counting function block (such as TON or TOF) accurately records T_{\text{run}} and T_{\text{int}}. This data is then displayed and analyzed in a SCADA system. After normalization, s' is used as a component of the pump start priority parameter q and functionally integrated with the number of runs N to form the final priority ranking criteria.

[0051] This step allows the system to dynamically assess the operating status of each drainage pump, avoiding misjudgments of priority due to a single parameter and improving the scientific and rational nature of pump activation decisions. Furthermore, normalization ensures the comparability of the intermediate variable s under different operating conditions, providing a quantitative basis for achieving load balancing and extending equipment life, with significant engineering value.

[0052] Furthermore, S2 includes:

[0053] S21, when T_int is not 0, calculate the intermediate variable s as the ratio of T_run to T_int, and limit the value range of s to (0, 1) through normalization processing.

[0054] Specifically, in some implementations, when T_int is not 0, calculating the intermediate variable s as the ratio of T_run to T_int and normalizing s to a value between (0, 1) is a key step in the pump start priority calculation model of the present invention. This step aims to quantify the relative activity of the drainage pump between the running and stopped states, thereby providing standardized input parameters for subsequent priority calculations.

[0055] From the perspective of technical implementation, the calculation formula of s is: s = T_run / T_int, where T_run represents the duration of a single operation of the drainage pump, and T_int represents the time interval between the end of the last operation and the start of the current operation. Since T_int may be much larger than T_run in actual operation, directly calculating s may result in an excessively large value, affecting the stability and comparability of subsequent calculation models. Therefore, the present invention introduces a normalization processing strategy to limit the value range of s to between (0, 1). The normalization method can optionally adopt linear scaling or exponential compression. In specific implementation, an exponential compression function is preferred, such as s' = 1-e^(-k·s), where k is the normalization coefficient, usually in the range of 0.01 to 0.1, to ensure that s' can remain within a reasonable range when s changes significantly.

[0056] At the parameter level, the acquisition accuracy of T_run and T_int directly impacts the accuracy of s. In PLC systems, time counting function blocks (such as TON or CTU) typically maintain millisecond-level accuracy, meeting the requirements of the industrial control standard IEC 61131-3. The normalization coefficient k must be optimized based on system response speed and parameter sensitivity, typically determined through simulation testing or historical data regression analysis, to ensure that s' maintains good discrimination and stability under different operating conditions.

[0057] At the application level, this step is applicable to the intelligent start-stop control of multiple drainage pumps in a hydropower station's seepage drainage system. When the water level in the sump reaches the set pump start level, the PLC compares the current s' values ​​of each pump and selects the pump with the highest priority for start. This process is displayed in real time in the SCADA system, allowing operations and maintenance personnel to monitor equipment health and the execution of the pump start strategy.

[0058] In terms of technical effectiveness, normalizing s to the range (0, 1) effectively avoids numerical overflow issues caused by excessively large T_int, enhances comparability across drainage pumps, and provides a stable, standardized input for the subsequent calculation of the priority parameter q. This step enhances the intelligence of pump startup decisions and helps achieve dynamic optimization of load balancing and equipment health.

[0059] S22, when T_int is 0, the intermediate variable s is set to 0 to avoid calculation exceptions caused by division by zero.

[0060] Specifically, when T_int is 0, the intermediate variable s is set to 0 to avoid calculation anomalies caused by division by zero. This is one of the key fault-tolerance mechanisms in the pump start priority calculation model of the present invention. The technical implementation principle of this step is based on the stability of mathematical operations and the reliability of logical control. It aims to ensure that during actual operation, when the operating interval T_int is 0 due to reasons such as the drainage pump not yet completing its first start-stop cycle or system initialization, the intermediate variable s can still remain within a reasonable numerical range. This ensures that the subsequent calculation of the priority parameter q will not cause anomalies or interruptions due to division by zero.

[0061] In a specific implementation, T_int represents the time interval between the end of the drainage pump's last run and the start of its current run. This interval is automatically recorded by the time counting function block in the PLC after detecting a change in the device's state (from running to stopped). When the system is just starting up or a drainage pump has not yet completed two start and stop operations, T_int may be 0 or undefined. Directly substituting the formula s = T_run / T_int in this case will result in a division by zero mathematical error, thus affecting the stability and accuracy of the entire pump start priority calculation model. To avoid this problem, the present invention introduces a conditional judgment mechanism into the algorithm logic: when T_int = 0 is detected, the system automatically assigns the intermediate variable s to 0 instead of performing a division operation.

[0062] The parameter setting of this step strictly follows the real-time and reliability requirements of PLC programming in industrial control systems. In the PLC program, the collection accuracy of T_int is usually in milliseconds, and the system supports a maximum timing range of 32767 seconds (about 9 hours), which meets the definition of the time counting function block in IEC 61131-3 standard. The normalization processing range of the intermediate variable s is (0, 1), and its calculation formula is s = T_run / T_int (when T_int ≠ 0), and when T_int = 0, s = 0. This setting ensures that the s value does not interfere with the pump start priority parameter q during the system initialization phase or when the data is not ready.

[0063] In actual application scenarios, this step is mainly applied in the initial stage of the drainage pump system startup or the stage when the device state data has not been completely collected. For example, when the system is just put into operation, T_int of all drainage pumps is 0, at this time, the s value is uniformly set to 0, so that the pump start priority parameter q = 1-s / (2N) = 1 / (2N), thereby ensuring that each pump is started in order according to the number sequence in the initial stage, and uniform start and stop is realized. With the passage of system running time, T_int is gradually recorded and updated, the s value enters the normal calculation process, and the pump start priority parameter q is dynamically adjusted according to the real-time running data, realizing load balancing and healthy rotation.

[0064] The technical effect of this step is to effectively improve the robustness and fault tolerance of the pump start control system, avoiding program crashes or control failures caused by abnormal data. At the same time, by setting the s value to 0, the system can still maintain an orderly pump start logic in the initial stage, laying a foundation for the accumulation of subsequent health parameters and the stable operation of the priority model. This mechanism embodies the scientificity and practicality of the present application in dynamic priority control, and is an important guarantee link for realizing intelligent rotation control of drainage pumps.

[0065] S3, function fusion is performed on the intermediate variable s and the number of running times N to calculate a pump start priority parameter q, wherein q = s / (2N), and the pump start priority of the drainage pump is determined according to the value of q.

[0066] Specifically, in the pump start priority calculation model of the present application, the intermediate variable s and the number of running times N are functionally fused to calculate the pump start priority parameter q, and the expression of q = s / (2N) is one of the core steps to realize dynamic rotation control of the drainage pump. This step quantifies the health status and running frequency of the device to provide a comparable priority index for subsequent pump start decision-making.

[0067] At the technical implementation level, the intermediate variable s is derived by fusing the normalized single-run duration T_{\text{run}} and the run interval T_{\text{int}}. Its value range is controlled within the range (0,1) and is used to reflect the drainage pump's comprehensive performance in terms of operating efficiency and system load balancing. The number of runs N is collected by the PLC system through the DI module, automatically counted at each start and stop event, and periodically reset to zero monthly to reflect the device's recent usage frequency. s and N are functionally fused, and s is weighted using the inverse form of 1 / (2N). This ensures that pumps with more runs have lower priority, thus achieving load balancing.

[0068] Regarding parameter indicators, the calculation of s must meet normalization requirements. Maximum-minimum normalization or Z-score standardization is typically used to ensure comparability of s values ​​across different pumps. The number of runs, N, is calculated over a calendar month, with an initial value of 0 and incremented by 1 each time the pump is started. The denominator uses 2N rather than N to avoid excessively large q values ​​when N is small (e.g., 1 or 2). This prevents overactivation of new pumps due to a low number of runs and ensures proper rotation of the system even in the initial stages.

[0069] In actual application scenarios, this step is embedded in the PLC control logic, with real-time data collection and display performed through the SCADA system. When the water level in the sump reaches the set pump start level, the PLC sorts the pumps according to their current q values ​​and selects the pump with the highest priority for startup. This method is suitable for scenarios such as hydropower stations and industrial plants where multiple pumps are required for coordinated drainage. It is particularly effective in conditions with frequent seepage fluctuations, effectively preventing the frequent startup and shutdown of a single pump and improving system stability.

[0070] The technical benefit of this step is that by quantifying and integrating health status with operating frequency, dynamic adjustment of pump activation priorities is achieved, eliminating the need for manual threshold setting and reducing system maintenance complexity. Furthermore, the Q-value calculation mechanism ensures balanced utilization of each pump over the long term, thereby extending equipment life, reducing failure rates, and improving the overall efficiency and reliability of the drainage system.

[0071] Furthermore, S3 includes:

[0072] S31 , dividing the intermediate variable s by twice the number of operations N to obtain a pump start priority parameter q, to ​​ensure that the number of operations N has a negative impact on the priority.

[0073] Specifically, in the proposed pump startup priority calculation model, dividing the intermediate variable s by twice the number of runs N yields the pump startup priority parameter q, a core step in implementing dynamic drainage pump rotation control. This step quantifies the equipment's operating status and integrates the health parameters T_{\text{run}} (single run duration) and T_{\text{int}} (running interval) with the number of runs N to form a comparable priority indicator, thereby guiding the startup sequence of drainage pumps.

[0074] In some implementations, the intermediate variable s is calculated based on the normalized T_{\text{run}} and T_{\text{int}}, and its value range is controlled in the range of (0,1) to eliminate the interference of different dimensions and numerical ranges on priority judgment. Specifically, the calculation formula of s is:

[0075]

[0076] s represents the intermediate variable, and n represents the pump number. Generally, the pump start interval T_int is much longer than the single run duration T_run. To prevent the pump start priority parameter s from becoming excessively large due to a large pump start interval T_int, and thus losing its upper limit, a normalization strategy is employed to keep the intermediate parameter s within the range (0, 1) when T_int is not equal to 0. This leads to the intermediate variable calculation method.

[0077] Then, we perform a superposition calculation on the intermediate variable s and the number of operations N to obtain the final pump start priority calculation model. The intermediate variable calculation model shows that the larger the intermediate variable s, the higher the priority, while the larger N, the lower the priority. Since N is much larger than s, we can perform a reciprocal conversion based on the intermediate variable model. Furthermore, to control q within the range of (0, 1) and avoid the situation where the q value is infinitely close to 1 due to an excessively large N, we use 2N as the denominator, resulting in the initial pump start priority calculation model:

[0078]

[0079] The denominator is 2N to keep q within the range of (0, 1) while preventing q from approaching zero due to an excessively large N, which would result in a loss of priority differentiation. By combining s with N, pumps with more runs have lower priorities, thus achieving load balancing and equipment rotation.

[0080] In practice, this step is embedded in a PLC-based hierarchical control system. The DI module collects the start and stop status of the drainage pumps and, combined with the time counting function block, automatically calculates T_{\text{run}}, T_{\text{int}}, and N. When the water level in the sump reaches the set pump start level, the system sorts the pumps according to their current q values ​​and selects the pump with the highest priority for startup.

[0081] The technical benefit of this step is that by quantifying the inhibitory effect of the number of runs on priority, it effectively avoids the uneven utilization of equipment caused by fixed rotation strategies or static thresholds in traditional control methods. Furthermore, this method eliminates the need for manual parameter setting and exhibits excellent adaptability and real-time response capabilities, making it suitable for dynamically changing industrial scenarios such as hydropower stations. It significantly improves the operational efficiency and equipment reliability of drainage systems.

[0082] S32, when the number of operations N is less than 2, the pump start priority parameter q takes the drainage pump number n as the initial value to ensure fairness in the initial pump start.

[0083] Specifically, in some implementations, when the number of operations N is less than 2, the pump start priority parameter q takes the drainage pump number n as the initial value. This step is intended to ensure fairness and predictability in the pump start sequence during the initial operation phase of the system, thereby laying the foundation for subsequent dynamic priority calculation based on health condition parameters. When the system is first put into operation or a drainage pump has not yet completed two start-stop cycles, due to the operation time interval T int Valid data has not yet been formed and cannot accurately reflect the load balancing status of the device. Therefore, the number n is used as the initial priority parameter to avoid priority calculation deviation caused by missing data.

[0084] Specifically, this step is implemented in the PLC program through logical judgment: when the number of times a drainage pump has run N is less than 2, the system will directly read the pump number n and assign it to the pump start priority parameter q. The number n is usually an integer, representing the unique identification of the drainage pump in the system, such as pump 1, pump 2, etc. At this time, the value range of q is N max , where N max The highest number of drainage pumps in the system. Because there's a one-to-one correspondence between number n and the number of runs N, and the order of the numbers typically aligns with installation or maintenance priority, this strategy allows for rotating equipment startup in the early stages, preventing a pump from being frequently activated due to inadequate priority calculation logic.

[0085] At the parameter level, key parameters involved in this step include the drainage pump number n and the number of runs N. N is automatically counted by the PLC's internal counter module, incrementing by 1 after each start-stop cycle and automatically clearing to zero at the end of each month to accommodate periodic operation requirements. Furthermore, this step ensures data consistency for the subsequent normalization and function fusion in the pump priority calculation model, ensuring that all drainage pumps participate in the priority sorting process under the same initial conditions.

[0086] In the application scenario, this step is applicable to the initial startup of the hydropower station leakage drainage system or the cold start phase after the equipment is restarted. In this phase, the system has not yet accumulated enough operating data, so the number is used as the initial priority parameter to effectively prevent the control logic from failing due to incomplete data. When the number of operations N reaches 2 or more, the system will automatically switch to the T-based run 、T int The dynamic priority calculation model of N can achieve more refined load balancing control.

[0087] The technical benefit of this step is that, by introducing the serial number as the initial priority parameter, the system maintains a fair order for pump startup even when historical operating data is lacking, thereby avoiding uneven device utilization caused by incomplete priority parameter calculation. Furthermore, this strategy simplifies the logical judgment process during the system initialization phase, improving the robustness and adaptability of the control system and providing a stable data foundation for subsequent dynamic priority control.

[0088] S4, according to the real-time calculation result of the pump start priority parameter q, selecting the drainage pump with the highest priority to start the pump operation, so as to realize dynamic rotation and load balancing of the drainage pumps.

[0089] Specifically, this step "selecting the drainage pump with the highest priority to start the pump according to the real-time calculation result of the pump start priority parameter q, so as to realize dynamic rotation and load balancing of the drainage pump" is the core control logic link in the "dynamic priority control method and system of drainage pumps integrating equipment health monitoring" of the present invention. Its technical implementation is based on real-time monitoring of the operating status of the drainage pump and function fusion calculation of health parameters.

[0090] At the technical implementation level, this step uses the PLC system to perform online statistics and calculations on the number of times each drainage pump runs N, the duration of a single run T_run, and the operating time interval T_int, and then substitutes them into the calculation model of the pump start priority parameter q. Specifically, considering that T_int cannot be calculated when the drainage pump is started for the first two times, each pump is started in sequence according to the numbering order for the first two times. Therefore, the initial value of the pump start priority parameter of each pump is set to the serial number n of the corresponding pump, so that each drainage pump can be started evenly twice at the beginning. In summary, the final pump start priority calculation model is obtained:

[0091]

[0092] Substitute the intermediate variable calculation model into the formula, and the following formula is obtained:

[0093]

[0094] According to the pump starting priority parameter size, the greater the q value, the higher the priority.

[0095] In actual operation, when the water level of the water collecting well reaches the set pump starting water level, the PLC system will calculate the q value of each pump in real time, and select the drainage pump with the maximum q value to start the pump operation, so as to realize dynamic rotation.

[0096] At the parameter index level, T_run is usually the duration of a single operation of the drainage pump, the unit is minute, and the range is generally between 10-120 min; T_int is the interval time between two pump starting operations, the unit is minute, and the range is usually between 60-300 min; N is the cumulative number of operations of the drainage pump in the current period, the range is 0-100 times. The q value is normalized to the interval (0, 1) for comparison and control. In addition, the system supports customizing the frequency threshold (such as f=N / T_int>0.5 times / hour) for triggering the high frequency warning.

[0097] At the application scene level, this step is suitable for the scenes such as hydropower stations, underground pumping stations and industrial drainage systems that need multiple drainage pumps to work together. Especially in the working condition of frequent seepage fluctuation and uncertain water level change, this method can effectively avoid the frequent starting and stopping of a single pump, realize the reasonable rotation among multiple pumps, and thus improve the system stability and equipment life.

[0098] At the technical effect level, through the dynamic priority calculation model, this step realizes the intelligent decision of the drainage pump starting sequence, does not need to manually set a fixed threshold, reduces the system maintenance complexity. At the same time, by balancing the operation number and operation interval of each pump, the equipment service life is effectively prolonged, the mechanical wear and failure rate are reduced, and the overall operation efficiency and reliability of the drainage system are improved.

[0099] In summary, the dynamic priority control method of the leakage drainage pump fusing the equipment health monitoring of the present application is as shown in Figure 4 .

[0100] The equipment health monitoring system can automatically and online count the single operation duration (T_run), operation time interval (T_int) and operation number (N), and display them in real time on the host computer of the monitoring system. At the same time, the frequency calculation model can be used for high frequency alarm, the equipment health condition is concerned, and the operation reliability of the equipment is improved.

[0101] The dynamic priority pump start control method based on health condition parameters can achieve load balancing of drainage pump operation and extend the service life of the equipment. When the water level reaches the pump start water level of the water collection well, it will be Figure 4 The process starts the pump. The first two times the pump is started, the operation time interval T_int cannot be calculated. The pumps will be started in sequence according to the equipment serial number. When all drainage pumps have been started twice, the pump start priority parameter q will be updated according to the real-time working conditions, and the pump will be started according to the updated pump start priority parameter q. Figure 2 For example, if drainage pump 1 was last started with a time interval of T_int = 230 minutes, a running time of T_run = 60 minutes, and a number of runs N = 3, q ​​= 0.632; drainage pump 2 was last started with a time interval of T_int = 210 minutes, a running time of T_run = 40 minutes, and a number of runs N = 2, q = 0.710; and drainage pump 3 was last started with a time interval of T_int = 250 minutes, a running time of T_run = 50 minutes, and a number of runs N = 2, q = 0.707. Using this method, the starting priority parameters q for the three drainage pumps are calculated, as shown in Table 2. When the water level in the collection well reaches the low level first, drainage pump 2 will be started first according to the starting priority parameter. If the water level rises further to the mid-level, drainage pump 3 will be started first, and pumps 2 and 3 will operate simultaneously. After the equipment stops running, even if the water level drops in a short period of time and then rises immediately, it will not be started again because the running time or number of times of drainage pump No. 2 and drainage pump No. 3 does not reach the threshold. This avoids frequent start and stop of the same drainage pump and ensures that the work of each drainage pump is fully rotated, which can effectively reduce resource waste and reduce equipment failure rate.

[0102] Table 2 Calculation results of pump start priority parameters

[0103] Drain pump serial number 1 2 3 T_int 230 min 210 min 250 min T_run 60 min 40 min 50 min N 3 2 2 q 0.632 0.710 0.707

[0104] In summary, the present invention uses PLC to conduct online monitoring and statistics of the health operating parameters of the drainage pump to achieve health monitoring and early warning of the equipment, and performs function fusion on the health operating parameters to obtain the pump start priority parameters. By comparing the pump start priority parameters and selecting the drainage pump to start the pump, multiple drainage pumps can be made to work alternately, reducing the situation where some drainage pumps in the drainage system are damaged due to long-term lack of work. At the same time, this method can effectively avoid the situation in the previous method where the same drainage pump is frequently started when the water level in the collection well frequently changes. In addition, this method does not require manual setting of thresholds or parameters, and the pump start priority parameters are calculated from the operating condition data, so it has better adaptability in applications in various scenarios. Through this method and system, real-time monitoring of equipment health can be achieved, and the load balance of equipment operation can be ensured, the reliability of equipment operation can be improved, and the life cycle of equipment can be extended.

[0105] The dynamic priority control method for drainage pumps integrated with equipment health monitoring in an embodiment of the present invention realizes load balancing and real-time monitoring of the health status of the drainage pumps, extends the service life of the equipment, and reduces the failure rate and energy waste caused by frequent starting and stopping.

[0106] In order to implement the above embodiment, Figure 5 As shown, this embodiment also provides a drainage pump dynamic priority control device 10 integrating equipment health monitoring, including:

[0107] The operation status acquisition module 100 is used to collect the operation status of each drainage pump through the PLC system and automatically count the single operation time T_run, the operation time interval T_int and the number of operations N;

[0108] An intermediate variable calculation and normalization module 200 is configured to calculate an intermediate variable s based on the ratio of T_run to T_int, and perform normalization processing on the intermediate variable s;

[0109] The pump start priority parameter calculation module 300 is used to perform a function fusion on the intermediate variable s and the number of operations N to calculate the pump start priority parameter q, where q = s / (2N), and determine the pump start priority of the drainage pump according to the value of q;

[0110] The pump start control module 400 is used to select the drainage pump with the highest priority to start the pump according to the real-time calculation result of the pump start priority parameter q, so as to realize dynamic rotation and load balancing of the drainage pumps.

[0111] Furthermore, the operating status acquisition module is also used to:

[0112] When the equipment starts running, the time counting function block in the PLC is used to record the start time of the operation and start timing, and the number of operations N is increased by 1;

[0113] When the device stops running, the time counting function block stops timing and outputs the single running time T_run, and then starts recording the running time interval T_int until the next time the device starts, stops timing and outputs T_int, and the number of runs N is automatically cleared at the end of each month.

[0114] Furthermore, the intermediate variable calculation and normalization module is also used for:

[0115] When T_int is not 0, the intermediate variable s is calculated as the ratio of T_run to T_int, and the value range of s is limited to (0, 1) through normalization;

[0116] When T_int is 0, the intermediate variable s is set to 0 to avoid calculation exceptions caused by division by zero.

[0117] Further, the pump starting priority parameter calculation module is further configured to:

[0118] Divide the intermediate variable s by 2 times the running number N to obtain the pump starting priority parameter q, so as to ensure that the running number N has a negative impact on the priority;

[0119] When the running number N is less than 2, the pump starting priority parameter q takes the number n of the drainage pump as an initial value, so as to ensure the fairness of the initial pump starting.

[0120] Further, the drainage pump dynamic priority control device further comprises:

[0121] A frequency calculation and alarm module is configured to calculate a pump starting frequency f based on a ratio of the running number N and the running time interval T_int, wherein f=N / T_int, and compare the pump starting frequency f with a preset frequency threshold, and trigger a frequency too high alarm signal when f exceeds the frequency threshold.

[0122] The drainage pump dynamic priority control device of the fusion device health monitoring according to the embodiments of the present application realizes load balancing and real-time monitoring of the health status of the drainage pump, prolongs the service life of the device, and reduces the failure rate and energy waste caused by frequent starting and stopping.

[0123] In the description of the present specification, the description of the terms "one embodiment", "some embodiments", "an example", "a specific example", or "some examples" and the like means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any appropriate manner in any one or more embodiments or examples. In addition, the person skilled in the art can combine and combine the different embodiments or examples described in the present specification and the features of the different embodiments or examples without contradiction.

[0124] In addition, the terms "first", "second" are only for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Therefore, the features defined with "first", "second" can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "a plurality of" is at least two, for example, two, three, etc., unless otherwise specifically limited.

Claims

1. A dynamic priority control method for drainage pumps integrating equipment health monitoring, characterized in that: include: S1, collect the operating status of each drainage pump through the PLC system, and automatically count the single operation time T_run, operation time interval T_int and operation number N; S2, calculating an intermediate variable s based on the ratio of T_run to T_int, and normalizing the intermediate variable s; S3, performing a function fusion on the intermediate variable s and the number of operations N to calculate a pump start priority parameter q, where q = s / (2N), and determining the start priority of the drainage pump according to the value of q; S4, based on the real-time calculation result of the pump start priority parameter q, the drainage pump with the highest priority is selected to start the pump operation, thereby realizing dynamic rotation and load balancing of the drainage pumps.

2. The method according to claim 1, wherein The PLC system collects the operating status of each drainage pump and automatically counts the single operation time T_run, the operation time interval T_int and the number of operations N, and also includes: S11, when the equipment starts running, the time counting function block in the PLC is used to record the start time of the operation and start timing, and the number of operations N is increased by 1; S12, when the device stops running, the time counting function block stops timing and outputs the single running time T_run, and then starts recording the running time interval T_int until the next time the device is started, stops timing and outputs T_int, and the number of runs N is automatically reset to zero at the end of each month.

3. The method according to claim 1, wherein The calculating of the intermediate variable s based on the ratio of T_run to T_int and normalizing the intermediate variable s further includes: S21, when T_int is not 0, calculate the intermediate variable s as the ratio of T_run to T_int, and limit the value range of s to (0, 1) through normalization processing; S22, when T_int is 0, the intermediate variable s is set to 0 to avoid calculation exceptions caused by division by zero.

4. The method according to claim 1, wherein The intermediate variable s is functionally integrated with the number of operations N to calculate a pump start priority parameter q, where q=s / (2N), and the start priority of the drainage pump is determined according to the value of q, further comprising: S31, dividing the intermediate variable s by 2 times the number of operations N to obtain the pump start priority parameter q, to ​​ensure that the number of operations N has a negative impact on the priority; S32, when the number of operations N is less than 2, the pump start priority parameter q takes the drainage pump number n as the initial value to ensure fairness in the initial pump start.

5. The method according to claim 1, wherein Also includes: S5, calculate the pump start frequency f based on the ratio of the number of operations N to the operation time interval T_int, where f = N / T_int, and compare the pump start frequency f with a preset frequency threshold. When f exceeds the frequency threshold, trigger a high frequency alarm signal.

6. A dynamic priority control device for drainage pumps integrating equipment health monitoring, characterized in that: include: The operation status acquisition module is used to collect the operation status of each drainage pump through the PLC system and automatically count the single operation duration T_run, operation time interval T_int and operation number N; An intermediate variable calculation and normalization module, configured to calculate an intermediate variable s based on the ratio of T_run to T_int, and perform normalization processing on the intermediate variable s; A pump start priority parameter calculation module is used to perform a function fusion on the intermediate variable s and the number of operations N to calculate the pump start priority parameter q, where q = s / (2N), and determine the pump start priority of the drainage pump according to the value of q; The pump start control module is used to select the drainage pump with the highest priority to start the pump according to the real-time calculation result of the pump start priority parameter q, so as to realize dynamic rotation and load balancing of the drainage pumps.

7. The device according to claim 6, characterized in that The operating status acquisition module is also used for: When the equipment starts running, the time counting function block in the PLC is used to record the start time of the operation and start timing, and the number of operations N is increased by 1; When the device stops running, the time counting function block stops timing and outputs the single running time T_run, and then starts recording the running time interval T_int until the next time the device starts, stops timing and outputs T_int, and the number of runs N is automatically cleared at the end of each month.

8. The device according to claim 6, wherein The intermediate variable calculation and normalization module is also used for: When T_int is not 0, the intermediate variable s is calculated as the ratio of T_run to T_int, and the value range of s is limited to (0, 1) through normalization; When T_int is 0, the intermediate variable s is set to 0 to avoid calculation exceptions caused by division by zero.

9. The device according to claim 6, wherein The pump start priority parameter calculation module is also used for: Divide the intermediate variable s by 2 times the number of operations N to obtain the pump start priority parameter q to ensure that the number of operations N has a negative impact on the priority; When the number of operations N is less than 2, the pump start priority parameter q takes the drainage pump number n as the initial value to ensure fairness in the initial pump start.

10. The device according to claim 6, wherein Also includes: The frequency calculation and alarm module is used to calculate the pump start frequency f based on the ratio of the number of operations N to the operation time interval T_int, where f = N / T_int, and compare the pump start frequency f with a preset frequency threshold. When f exceeds the frequency threshold, a high frequency alarm signal is triggered.

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