Pump room intelligent control node and internet-of-things water pump intelligent control system formed by same

Abstract

The invention discloses a pump room intelligent control node, which comprises a shell, a display screen, a manual intervention key, an equipment data acquisition interface, a water pump driving interface, a communication interface and a control circuit board, the control circuit board is used for receiving pool water level data information and motor temperature data information collected by the equipment data collection interface, outputting the information to the communication interface for wireless transmission and outputting work stopping and starting instructions to the water pump according to received wireless control instructions. The intelligent control node can monitor the water volume of the water pool, can monitor the operation state of the motor in the pump room, and can give an early warning when the movement temperature of the motor is too high, so that a worker can maintain the motor in time. The internet-of-things water pump intelligent control system composed of the pump room intelligent control nodes of all the pump stations and the data service center can achieve reliable communication of nodes such as water pumps and water towers through the internet-of-things technology.

Description

Technical Field

[0001] This invention relates to the field of intelligent control technology for pump stations, specifically to intelligent control nodes for pump stations and the Internet of Things (IoT) intelligent control system for water pumps composed of them. Background Technology

[0002] A pump house is a building that houses water pumps, motors, pump control cabinets, and other auxiliary equipment. It is the main structure of a water pumping station project, and its primary function is to provide good working conditions for the pump units, auxiliary equipment, and operation and management personnel. Because pump houses, especially water supply pump houses, are located close to water sources, most of which are situated in the suburbs, most pump houses are scattered across rivers, reservoirs, and other similar areas in the urban and rural areas.

[0003] Currently, most small pumping stations still rely on traditional manual operation, with staff controlling the pumps based on instrument parameters and experience. Some stations use water level floats with simple remote control devices for basic semi-automatic operation, but this method only monitors the water level in the tank, is susceptible to external interference, and is unreliable. Some control systems use PLCs or microcontrollers as the control core, enabling basic judgments about equipment and water level to achieve partial automatic control. While this method achieves automation, it still requires manual assistance. Simple, mechanical, single-level water level control cannot automatically predict and adjust operating parameters based on water usage, lacks multi-detection fault-tolerance mechanisms, and cannot provide timely emergency handling when sensors malfunction. Furthermore, it lacks monitoring and fault warning functions for the operating status of pumps, motors, and frequency converters, failing to detect and address abnormal equipment conditions early, which can easily lead to equipment damage or even fires.

[0004] Because the various pumping stations lack corresponding intelligent networking equipment and operate independently, this independent operation makes it difficult to comprehensively manage each water source. This can lead to situations where some pumping stations shut down due to low water levels, causing even stations with sufficient water supply to stop as well, failing to meet the demand for maximizing water supply. Often, staff need to mechanically test pumping and shut down each independent pumping station, generating a huge workload. This method also makes it difficult to accurately assess water demand, resulting in slow circulation in the elevated water tanks during periods of low water consumption, making the water quality susceptible to pollution. Conversely, during periods of high water consumption, the elevated water tanks may not have sufficient storage, leading to a drop in water pressure or even water outages. Summary of the Invention

[0005] To address the aforementioned technical issues, this invention provides an intelligent control node for pump stations. This node monitors the water volume in the reservoir and the operating status of the motors within the pump station, issuing warnings when the motor temperature is too high so that staff can promptly perform maintenance. The IoT-based intelligent pump control system, comprised of the intelligent control nodes for each pump station and a data service center, utilizes IoT technology to achieve reliable communication between pumps, water towers, and other nodes. This system employs big data technology to comprehensively analyze current water usage and predict future water consumption. When water consumption is low, it lowers the pumping trigger level, extending equipment downtime and reducing startup frequency to minimize equipment wear. When water consumption is high, it raises the pumping trigger level to potentially increase storage capacity and ensure stable water supply. Furthermore, the system comprehensively considers the water source conditions of each pump station, enabling scientific scheduling and effectively improving water resource utilization and water supply security.

[0006] To achieve the above-mentioned technical effects, the present invention is implemented through the following technical solution: Intelligent control nodes for pump stations, including Housing, used to encapsulate the control circuit board; The display screen is used to show the input water level information in the pool and the motor operating temperature information; Manual intervention buttons, including emergency stop button, manual start button and parameter setting knob, are used to stop / restore the working status of water pump and motor in case of equipment failure. The parameter setting knob is used to set the operating data parameters of motor and water pump. The equipment data acquisition interface includes a water level sensor data acquisition interface and a motor temperature sensor interface, which are used to collect water level data and motor temperature data. The water pump drive interface includes several wiring terminals, which are connected to the frequency converter one by one, so as to control and adjust the working status of the water pump through the frequency converter; The communication interface, including the antenna connector, is used to wirelessly transmit and receive water level information from the pump room and motor operating temperature information. The control circuit board is used to receive water level data and motor temperature data collected by the equipment data acquisition interface and output them to the communication interface for wireless transmission. Based on the received wireless control commands, it can output stop and start commands for the water pump. The display screen, manual intervention button, equipment data acquisition interface, water pump drive interface, and communication interface are fixed on the housing, and the control circuit board is encapsulated in the housing. The display screen, manual intervention button, equipment data acquisition interface, water pump drive interface, and communication interface are all connected to the control circuit board.

[0007] Furthermore, the control circuit board is fixed with an MCU, a power module, a clock module, a communication module, a first analog-to-digital converter (ADC), a second ADC, a first sensor driver module, a second sensor driver module, and several relays. The display screen, emergency stop button, manual start button, parameter setting knob, power module, clock module, communication module, first ADC, and second ADC are all connected to the MCU. Several of the terminal blocks are connected one-to-one with several of the relays, and several of the relays are connected to the MCU.

[0008] Furthermore, the housing consists of a U-shaped outer shell and a base plate. The display screen, emergency stop button, manual start button, and parameter setting knob are located on the top of the U-shaped outer shell. One side wing of the U-shaped outer shell has a terminal protrusion opening, and the other side wing of the U-shaped outer shell has a sensor signal acquisition connector protrusion opening and an antenna connector protrusion opening. The U-shaped outer shell has screw holes, and the four corners of the base plate are fixed with threaded connecting posts. The threaded connecting posts have threaded holes, and locking screws pass through the screw holes and are threaded into the threaded connecting posts to fix the U-shaped outer shell to the base plate.

[0009] Meanwhile, this invention also discloses an IoT-based intelligent control system for water pumps, including an intelligent control node for the pump house, a frequency converter, a water level sensor, a motor temperature sensor, and a data service center. The water pump is connected to the intelligent control node for the pump house via a terminal block connected to the frequency converter. The water level sensor and the motor temperature sensor are respectively connected to the water level sensor data acquisition interface and the motor temperature sensor interface. The water level sensor is installed in the water tank of the pump house, and the motor temperature sensor is fixed to the motor of the water pump. The intelligent control node for the pump house is wirelessly connected to the data service center via a communication module. The data service center includes a gateway, a server, and a host computer. The gateway is connected to the server, and the host computer is connected to the server. Each intelligent control node for the pump house sends the collected data information to the gateway via the communication module. The gateway uploads the received information to the server. The host computer can obtain the pump house data information stored on the server. When there is an unreasonable situation in the pump house data information, the host computer can send a warning message to the mobile terminal through the server. The host computer can issue water pump adjustment commands through the server and send them wirelessly to the intelligent control node for the pump house through the gateway. The intelligent control node for the pump house controls the working status of the water pump through the frequency converter.

[0010] Furthermore, the communication module is a LoRa wireless communication module.

[0011] The beneficial effects of this invention are as follows: The intelligent control node can monitor the water volume of the water tank and the operating status of the motor in the pumping station, and issue an early warning when the motor operating temperature is too high so that staff can carry out timely maintenance; the Internet of Things (IoT) intelligent water pump control system, composed of the intelligent control nodes of each pumping station and the data service center, can use IoT technology to achieve reliable communication between nodes such as pumps and water towers. The system can use big data technology to comprehensively analyze the current water consumption and predict the water consumption in the future. When the water consumption is low, the pumping trigger water level is lowered to extend the equipment downtime and reduce the number of starts to reduce equipment wear. When the water consumption is high, the pumping trigger water level is raised to potentially increase the water storage capacity and ensure a stable water supply; at the same time, the system can comprehensively consider the water source conditions of each pumping station, scientifically schedule operations, and effectively improve the water source utilization rate and water supply guarantee capacity. Attached Figure Description

[0012] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used 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 those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1 This is a front structural diagram of the intelligent control node of the pump station; Figure 2 This is a schematic diagram of the rear structure of the intelligent control node in the pump room; Figure 3 This is a schematic diagram of the composition structure of the intelligent control node in the pump station; Figure 4 This is a structural block diagram of the intelligent control node of the pump room; Figure 5 This is a schematic diagram of the MCU's package structure; Figure 6 This is a circuit diagram of the clock module; Figure 7 This is the circuit diagram of the power supply module; Figure 8 This is the circuit diagram of the LoRa communication module; Figure 9 This is a circuit diagram of four relays; Figure 10 This is a schematic diagram of the circuit structure of the first sensor driving module; Figure 11 This is a schematic diagram of the circuit structure of the second sensor driving module; Figure 12 This is a structural block diagram of an IoT-based intelligent control system for water pumps.

[0014] The attached diagram lists the components represented by each number as follows: 1-Housing, 2-Display screen, 3-Emergency stop button, 4-Manual start button, 5-Parameter setting knob, 6-Terminal block, 7-Antenna connector, 8-Water level sensor data acquisition interface, 9-Motor temperature sensor interface, 10-U-shaped housing, 11-Terminal block protrusion opening, 12-Base plate, 13-Threaded connecting post, 14-Control circuit board, 15-MCU, 16-Communication module, 17-Relay, 18-Power supply module, 19-Clock module, 20-First analog-to-digital converter module, 21-First sensor driver module, 22-Second analog-to-digital converter module, 23-Second sensor driver module. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] like Figure 1-2 As shown, the intelligent control node of the pump station includes... Housing 1, used to encapsulate the control circuit board; Display screen 2 is used to display the input water level information of the pool and the motor operating temperature information; The manual intervention buttons include an emergency stop button 3, a manual start button 4, and a parameter setting knob 5, which are used to stop / restore the working status of the water pump and motor in case of equipment failure. The parameter setting knob is used to set the operating data parameters of the motor and water pump. The equipment data acquisition interface includes a water level sensor data acquisition interface 8 and a motor temperature sensor interface 9, which are used to collect water level data and motor temperature data. The water pump drive interface includes four terminals 6, which are connected to the frequency converter one by one to control and adjust the working status of the water pump through the frequency converter. The communication interface, including antenna connector 7, is used to wirelessly transmit and receive water level information and motor operating temperature information collected by the pump room. The control circuit board 14 is used to receive water level data and motor temperature data collected by the equipment data acquisition interface and output them to the communication interface for wireless transmission. Based on the received wireless control commands, it outputs stop and start commands to the water pump. The display screen 2, manual intervention button, equipment data acquisition interface, water pump drive interface and communication interface are fixed on the housing 1. The control circuit board 14 is encapsulated in the housing. The display screen, manual intervention button, equipment data acquisition interface, water pump drive interface and communication interface are all connected to the control circuit board.

[0017] The housing consists of a U-shaped outer shell 10 and a base plate 12. The display screen, emergency stop button, manual start button, and parameter setting knob are located on the top of the U-shaped outer shell. A terminal protrusion opening 11 is opened on one side wing plate of the U-shaped outer shell, and a sensor signal acquisition connector protrusion opening and an antenna connector protrusion opening are opened on the other side wing plate of the U-shaped outer shell. Screw holes are opened on the U-shaped outer shell, and threaded connecting posts 13 are fixed at the four corners of the base plate. Threaded connecting posts have threaded holes, and locking screws pass through the screw holes and are threaded into the threaded connecting posts to fix the U-shaped outer shell to the base plate.

[0018] like Figure 3-4 As shown, the control circuit board 14 is fixed with an MCU 15, a power module 18, a clock module 19, a communication module 16, a first analog-to-digital converter 20, a second analog-to-digital converter 22, a first sensor driver module 21, a second sensor driver module 23, and four relays 17. The display screen, emergency stop button, manual start button, parameter setting knob, power module, clock module, communication module, first analog-to-digital converter module, and second analog-to-digital converter module are all connected to the MCU. The four terminals are connected one-to-one with the four relays, and the four relays are all connected to the MCU.

[0019] like Figure 5 As shown, in this embodiment, the MCU selected is the STC15W4K48S4 chip. This chip is a purely domestically produced MCU with independent intellectual property rights in China, featuring low power consumption, high reliability, high performance, abundant on-chip resources, and low cost. The microcontroller communicates with the real-time clock through the high 3 bits of port P2 to obtain accurate time data. It connects to the LoRa wireless communication module through COM1 to establish an air interface for communication and data exchange with other nodes. The low 4 bits of port P4 control four relays. Port P1 is configured to operate in high-impedance mode, mapping the on-chip AD to read the water level signal collected by the sensor drive circuit.

[0020] As shown in Figure 6, in this embodiment, the clock module consists of a real-time clock chip DS1302, a 23.768kHz crystal oscillator, and a 3V backup battery. The 23.768kHz crystal oscillator provides the time reference signal, which is divided by the frequency divider inside the DS1302 to obtain a 1-second signal, driving the clock operation. Time data is stored in the internal registers of the DS1302. The backup battery is used to ensure the clock continues to run even in the event of power failure.

[0021] like Figure 7 As shown, in this embodiment, the power module adopts a back-topology DC-DC power converter with LM2596 as the main controller, which features high efficiency, small size, high output power, and low ripple. In the circuit, Schottky diodes, high-frequency inductors, and capacitors form a resonant circuit, and the LM2596 acts as a high-frequency switch, providing a stable 5V voltage for each module in the node through feedback control.

[0022] like Figure 8 As shown, in this embodiment, the communication module uses the LoRa wireless communication module SX1278, which has the advantages of low power consumption, high sensitivity, and anti-interference. The LoRa driver circuit consists of an electronic power switch, a mode selection DIP switch, indicator lights, and a communication interface. The electronic power switch mainly consists of an NPN transistor S8050 and a P-channel MOSFET IRF5210, and can control the power supply of the LoRa module through the P4.5 pin of the microcontroller. The module power can be turned off when communication is not needed to save battery power. The mode selection DIP switch is used to configure the module's operating mode. The indicator lights indicate the module's operating status and data transmission status. The communication interface is connected to the MCU's COM port for data transmission.

[0023] like Figure 9 As shown, in this embodiment, the four sets of relays use the same circuit structure, which reduces the types of circuit components and lowers costs. A high-level signal from the microcontroller's I / O port drives the NPN transistor S8050 to connect the relay winding circuit, the relay is energized, and the switching quantity is set to 1. When the I / O port outputs a low level, the relay is de-energized, and the switching quantity is set to 0. The diodes and capacitors in the circuit form a surge absorption circuit to absorb the back electromotive force generated when the relay coil is de-energized, preventing interference to the circuit. The resistor is used to limit the relay coil current, reducing the heat generated by the coil.

[0024] like Figure 10-11 As shown in this embodiment, both the first sensor driving module and the second sensor driving module include an LM358 amplifier, which can amplify the analog electrical signal input by the sensor to collect relevant water level and temperature information.

[0025] like Figure 12As shown, the IoT-based intelligent water pump control system includes an intelligent control node for the pump house, a frequency converter, a water level sensor, a motor temperature sensor, and a data service center. The water pump is connected to the intelligent control node via the terminal block of the frequency converter. The water level sensor and the motor temperature sensor are connected to the water level sensor data acquisition interface and the motor temperature sensor interface, respectively. The water level sensor is installed in the water tank of the pump house, and the motor temperature sensor is fixed to the motor of the water pump. The intelligent control node for the pump house is wirelessly connected to the data service center via a communication module. The data service center includes a gateway, a server, and a host computer. The gateway is connected to the server, and the host computer is connected to the server. Each intelligent control node for the pump house sends the collected data information to the gateway via the communication module. The gateway uploads the received information to the server. The host computer can obtain the pump house data information stored on the server. When there is an unreasonable situation in the pump house data information, the host computer can send a warning message to the mobile terminal through the server. The host computer can also send water pump adjustment commands through the server and wirelessly send them to the intelligent control node for the pump house through the gateway. The intelligent control node for the pump house controls the working status of the water pump through the frequency converter.

[0026] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

Claims

1. A smart control node for a pumping station, characterized in that, include Housing, used to encapsulate the control circuit board; The display screen is used to show the input water level information in the pool and the motor operating temperature information; Manual intervention buttons, including emergency stop button, manual start button and parameter setting knob, are used to stop / restore the working status of water pump and motor in case of equipment failure. The parameter setting knob is used to set the operating data parameters of motor and water pump. The equipment data acquisition interface includes a water level sensor data acquisition interface and a motor temperature sensor interface, which are used to collect water level data and motor temperature data. The water pump drive interface includes several wiring terminals, which are connected to the frequency converter one by one, so as to control and adjust the working status of the water pump through the frequency converter; The communication interface, including the antenna connector, is used to wirelessly transmit and receive water level information from the pump room and motor operating temperature information. The control circuit board is used to receive water level data and motor temperature data collected by the equipment data acquisition interface and output them to the communication interface for wireless transmission. Based on the received wireless control commands, it can output stop and start commands for the water pump. The display screen, manual intervention button, equipment data acquisition interface, water pump drive interface, and communication interface are fixed on the housing, and the control circuit board is encapsulated in the housing. The display screen, manual intervention button, equipment data acquisition interface, water pump drive interface, and communication interface are all connected to the control circuit board.

2. The intelligent control node for pumping stations according to claim 1, characterized in that, The control circuit board is equipped with an MCU, a power module, a clock module, a communication module, a first analog-to-digital converter (ADC), a second ADC, a first sensor driver module, a second sensor driver module, and several relays. The display screen, emergency stop button, manual start button, parameter setting knob, power module, clock module, communication module, first ADC, and second ADC are all connected to the MCU. Several terminal blocks are connected to several relays one by one, and several relays are connected to the MCU.

3. The intelligent control node for pumping stations according to claim 2, characterized in that, The housing consists of a U-shaped outer shell and a base plate. The display screen, emergency stop button, manual start button, and parameter setting knob are located on the top of the U-shaped outer shell. One side wing of the U-shaped outer shell has a terminal protrusion opening, and the other side wing of the U-shaped outer shell has a sensor signal acquisition connector protrusion opening and an antenna connector protrusion opening. The U-shaped outer shell has screw holes, and the four corners of the base plate are fixed with threaded connecting posts. The threaded connecting posts have threaded holes, and locking screws pass through the screw holes and are threaded into the threaded connecting posts to fix the U-shaped outer shell to the base plate.

4. An IoT-based intelligent control system for water pumps, characterized in that: The system includes a pump house intelligent control node, a frequency converter, a water level sensor, a motor temperature sensor, and a data service center. The water pump is connected to the pump house intelligent control node via a terminal block connected to the frequency converter. The water level sensor and motor temperature sensor are connected to the water level sensor data acquisition interface and the motor temperature sensor interface, respectively. The water level sensor is installed in the water tank of the pump house, and the motor temperature sensor is fixed to the pump motor. The pump house intelligent control node is wirelessly connected to the data service center via a communication module. The data service center includes a gateway, a server, and a host computer. The gateway and the host computer are connected to the server. Each pump house intelligent control node sends the collected data information to the gateway via the communication module. The gateway uploads the received information to the server. The host computer can obtain the pump house data information stored on the server. If there are any unreasonable situations in the pump house data information, the host computer can send a warning message to the mobile terminal through the server. The host computer can also send water pump adjustment commands through the server and wirelessly send them to the pump house intelligent control node through the gateway. The pump house intelligent control node controls the working status of the water pump through the frequency converter.

5. The IoT-based intelligent control system for water pumps according to claim 4, characterized in that, The communication module used is a LoRa wireless communication module.

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