Vertical pump all-in-one machine controller and control system thereof

Abstract

The application provides a vertical pump integrated machine controller and a control system thereof, which comprises a power driving module, a protective cover arranged outside the power driving module, a pump body fluid conveying module connected with the power driving module, and a connecting and fixing module connected with the pump body fluid conveying module. The system adopts a permanent magnet synchronous motor and a speed sensorless vector control, combines embedded edge computing and an adaptive algorithm, and improves control precision. A dynamic energy efficiency optimization module adjusts operation parameters in real time according to sensor data and a pump characteristic curve, and ensures efficient operation. A multi-modal fault prediction module fuses current, pressure difference and vibration data, identifies early faults such as bearing wear and cavitation in advance through a lightweight convolutional neural network, gives a graded early warning, displays on a liquid crystal screen, and is convenient for rapid maintenance. An intelligent valve linkage module realizes closed-loop cooperation of exhaust and drainage valves and a pump body, automatically optimizes start-stop processes, eliminates cavitation and residual damage, and guarantees execution reliability through digital feedback.

Description

Technical Field

[0001] This invention relates to the field of vertical pump technology, and more specifically, to a vertical pump integrated controller and its control system. Background Technology

[0002] Vertical pumps are core fluid transport equipment in industrial production, urban water supply, and agricultural irrigation. The performance of their controllers directly determines the operating efficiency, stability, and adaptability of the pump set. Application No. 202210832640.3 proposes a controller structure for a vertical pump, including a pump motor and a controller assembly mounted on top of the pump motor. A cooling system is provided between the pump motor and the controller assembly, supplying airflow from the controller assembly to the pump motor. The pump motor and controller assembly share a common cooling system. The cooling system drives airflow from the bottom of the controller assembly to the motor, forming an intake end at the bottom of the controller assembly and an outlet end on the outside of the pump motor. The intake and outlet ends each carry heat from the controller assembly and the pump motor for heat transfer and dissipation, thereby significantly reducing the manufacturing cost of large-size heat dissipation components in traditional solutions.

[0003] Existing vertical pump controllers have several shortcomings that require improvement: The existing power drive unit lacks integration with the pump body, control module, and valve assembly, resulting in a large installation space requirement and complex wiring between components. This makes them prone to malfunctions due to loose wiring, requiring multiple devices to be checked individually during maintenance, leading to low maintenance efficiency. Furthermore, the power drive module lacks a dedicated protective structure, making it susceptible to corrosion in humid and dusty industrial environments, thus shortening the equipment's lifespan.

[0004] Existing controllers use ordinary asynchronous motors with V / F control mode, lacking adaptive algorithms for the characteristics of vertical pumps. They cannot dynamically adjust operating parameters according to actual flow and pressure requirements, resulting in the pump often operating in an inefficient range and significant energy waste. Furthermore, most control schemes do not incorporate pump characteristic curve databases, and the acceleration and deceleration adjustment methods are rigid, which can easily generate water hammer effects and exacerbate pipeline and pump wear.

[0005] Existing controllers can only provide feedback through alarm signals after a fault occurs, lacking the ability to predict early faults such as bearing wear, impeller cavitation, and flow channel blockage. This often leads to minor faults escalating into equipment shutdowns and causing production interruptions. At the same time, fault diagnosis relies heavily on manual on-site inspections and lacks data-driven and intelligent analysis methods, resulting in delayed operation and maintenance responses and high costs.

[0006] Existing controllers use LED indicator lights or simple digital tube displays, which can only show a limited number of operating parameters and provide vague fault information. The button design lacks protection and logical partitioning, making it prone to accidental operation. Furthermore, the lack of a panel unlocking function allows unauthorized personnel to arbitrarily modify parameters, affecting the stability of equipment operation. Therefore, this paper proposes a vertical pump integrated controller and its control system. Summary of the Invention

[0007] The purpose of this invention is to address the problems raised in the existing background technology. To achieve the above-mentioned objective, this invention provides the following technical solution: A vertical pump integrated controller, comprising a power drive module, a protective cover surrounding the power drive module, the power drive module being connected to a pump body fluid delivery module, the pump body fluid delivery module being connected to a connecting and fixing module, a valve assembly being provided on the pump body fluid delivery module, the power drive module being connected to a control module, the control module being connected to a display and operation module, and the control module being connected to a high-voltage interface module and a low-voltage interface module.

[0008] As a preferred technical solution of the present invention, the pump body fluid conveying module includes a pump head, a pump shaft, an impeller, a guide vane, a pressure-resistant cylinder, and an inlet / outlet water cavity. The pump head is provided with a pump shaft, the pump shaft is provided with an impeller and a guide vane outside the pump shaft, the guide vane is provided with a pressure-resistant cylinder outside the guide vane, and the impeller is provided with an inlet / outlet water cavity below the impeller.

[0009] As a preferred technical solution of the present invention, the power drive module is equipped with a permanent magnet synchronous motor, which is connected to the pump shaft.

[0010] As a preferred technical solution of the present invention, the connection and fixing module includes a pull rod, an inlet connection flange, and an outlet connection flange. The pressure-resistant cylinder is provided with a pull rod on its outside, and the inlet connection flange and the outlet connection flange are provided on both sides of the inlet and outlet cavity.

[0011] As a preferred embodiment of the present invention, the valve assembly includes an air release valve and a water drain valve, with the air release valve located above the pump head and the water drain valve located on the outer side of the inlet and outlet water chambers.

[0012] As a preferred technical solution of the present invention, the control module is adapted to a permanent magnet synchronous motor and realizes motor drive control, adopts sensorless vector control, and is adapted to linear acceleration and deceleration adjustment.

[0013] As a preferred technical solution of the present invention, the high-voltage interface module is provided with a three-phase power input terminal, a power grounding terminal, a frequency converter output terminal and a motor grounding terminal, and the low-voltage interface module integrates a power port, an analog input port, a digital input port and a relay terminal for connecting external sensors, control signals and relay loads.

[0014] As a preferred technical solution of the present invention, the power port simultaneously outputs three low-voltage power supplies of different voltage levels, namely the first power supply, the second power supply and the third power supply. The analog input port includes a voltage signal input terminal and a current signal input terminal. The voltage signal input terminal is adapted to at least two three-wire sensors with different voltage output ranges, and the current signal input terminal is adapted to a sensor with a preset current range. The digital input port includes three digital signal terminals for inputting external switch control signals; The relay terminal is an independent control terminal, including a normally closed terminal, a common terminal and a normally open terminal, used to realize the on-off control of the relay load; As a preferred technical solution of the present invention, the display operation module includes an LCD screen and a mechanical tactile button group; the LCD screen is an industrial-grade protective display screen, used to display controller operating parameters, equipment status and fault information in real time. The mechanical touch button group includes equipment operation control, shutdown control, parameter adjustment, menu switching, fault reset, and panel unlocking.

[0015] A control system for a vertical pump integrated controller, wherein the control module integrates an embedded edge computing unit, is configured with an adaptive sensorless vector control algorithm based on the pump's operating state, and further includes the following collaborative working modules: Multimodal fault prediction module: Real-time acquisition of three-phase waveforms of stator current of permanent magnet synchronous motor, pressure difference signal of inlet and outlet water chamber and vibration spectrum data of pump shaft. Through a lightweight convolutional neural network model, early signs of bearing wear, impeller cavitation or flow channel blockage are identified online and displayed on the LCD screen in a graded warning manner. Dynamic energy efficiency optimization module: Based on the external flow / pressure sensor signal connected to the low-voltage interface module, combined with the built-in pump characteristic curve database, the linear acceleration / deceleration slope and output frequency are dynamically adjusted to ensure that the system always operates in the high-efficiency zone while meeting process requirements, and the optimized operating parameters are automatically stored in non-volatile memory. Dual-redundant low-voltage power supply management module: The power port in the low-voltage interface module not only outputs three low-voltage power supplies of different voltage levels, but also at least one of the power supplies is composed of a main control power supply and a backup supercapacitor energy storage unit connected in parallel. When the main power supply drops abnormally, the supercapacitor seamlessly takes over the power supply of the critical circuit within 10ms to ensure that the control logic is not interrupted and the operating status is not lost. Intelligent valve linkage control module: During startup or shutdown, the control module automatically triggers electromagnetic drive commands to the vent valve and drain valve according to a preset timing sequence, realizing a closed-loop operation logic of venting before starting the pump and shutting down the pump before emptying. The actual opening and closing status of the valves is fed back through digital input terminals to verify the reliability of the execution.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention integrates the power drive module, pump body fluid conveying module, control module, display operation module and connection and fixing module into one integrated unit. The power drive module is equipped with a protective cover to effectively resist moisture and dust corrosion and extend the service life of the equipment. The connection and fixing module achieves quick installation and positioning through tie rods and inlet / outlet flanges. The internal wiring of each module is standardized, reducing external wiring and lowering the difficulty of installation and the risk of failure.

[0017] This invention employs a permanent magnet synchronous motor with sensorless vector control, combined with an embedded edge computing unit and adaptive algorithms, which significantly improves control accuracy. The dynamic energy efficiency optimization module dynamically adjusts the linear acceleration / deceleration slope and output frequency based on external sensor signals and a built-in pump characteristic curve database, ensuring that the system always operates in the high-efficiency zone and maintains high-efficiency operation even after the equipment restarts.

[0018] The multimodal fault prediction module of this invention collects stator current three-phase waveforms, pressure difference signals, and vibration spectrum data. With the help of a lightweight convolutional neural network model, it can identify early fault signs such as bearing wear and impeller cavitation in advance, and provide graded early warning prompts to avoid downtime losses caused by the expansion of faults. Fault information is displayed on the LCD screen in real time to assist maintenance personnel in quickly troubleshooting and reduce maintenance time and labor costs.

[0019] The intelligent valve linkage control module of this invention realizes closed-loop coordination between the vent valve, the drain valve and the pump body. When starting the pump, the vent is released before operation, and when stopping the pump, the pump is turned off before emptying. This completely solves the cavitation problem caused by incomplete venting and the equipment damage caused by failure to empty the pump. The valve opening and closing status is fed back through digital input terminals to ensure that the command is executed in place and to avoid the risk of loss of coordination control. Attached Figure Description Figure 1 This is a front view schematic diagram provided for the present invention; Figure 2 This is a three-dimensional structural schematic diagram provided by the present invention; Figure 3 This is a schematic diagram of the left-side structure provided by the present invention; Figure 4 A schematic diagram of the pump body fluid delivery module structure provided by the present invention; Figure 5 This is a top view structural diagram provided by the present invention; Figure 6This is a schematic diagram of the valve assembly structure provided by the present invention.

[0020] The image shows: 1. Power drive module; 101. Permanent magnet synchronous motor; 2. Protective cover; 3. Pump body fluid delivery module; 301. Pump head; 302. Pump shaft; 303. Impeller; 304. Guide vane; 305. Pressure-resistant cylinder; 306. Inlet and outlet water chambers; 4. Connecting and fixing module; 401. Tie rod; 402. Inlet connection flange; 403. Outlet connection flange; 5. Valve assembly; 501. Air vent valve; 502. Drain valve; 6. Control module; 7. Display and operation module. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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 specific implementations of the present invention and are not limited to all embodiments.

[0022] Therefore, the following detailed description of embodiments of the present invention is not intended to limit the scope of the claimed invention, but merely illustrates some embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0023] It should be noted that, in the absence of conflict, the embodiments and features and technical solutions in the embodiments of the present invention can be combined with each other. It should be noted that similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0024] Example 1: A vertical pump integrated controller includes a power drive module 1, a protective cover 2 on the outside of the power drive module 1, the power drive module 1 is connected to a pump body fluid delivery module 3, the pump body fluid delivery module 3 is connected to a connection and fixing module 4, a valve assembly 5 is provided on the pump body fluid delivery module 3, the power drive module 1 is connected to a control module 6, the control module 6 is connected to a display and operation module 7, and the control module 6 is connected to a high-voltage interface module and a low-voltage interface module.

[0025] The pump body fluid transport module 3 includes a pump head 301, a pump shaft 302, an impeller 303, a guide vane 304, a pressure-resistant cylinder 305, and an inlet / outlet water chamber 306. The pump head 301 is equipped with a pump shaft 302, and the impeller 303 and guide vane 304 are arranged outside the pump shaft 302. The pressure-resistant cylinder 305 is arranged outside the guide vane 304, and the inlet / outlet water chamber 306 is arranged on the lower side of the impeller 303.

[0026] The power drive module 1 is equipped with a permanent magnet synchronous motor 101, which is connected to the pump shaft 302.

[0027] The connecting and fixing module 4 includes a pull rod 401, an inlet connecting flange 402, and an outlet connecting flange 403. The pull rod 401 is provided on the outside of the pressure-resistant cylinder 305, and the inlet connecting flange 402 and the outlet connecting flange 403 are provided on both sides of the inlet and outlet water chamber 306.

[0028] The valve assembly 5 includes an air release valve 501 and a water drain valve 502. The air release valve 501 is located above the pump head 301, and the water drain valve 502 is located on the outside of the inlet / outlet water chamber 306.

[0029] The control module 6 is adapted to the permanent magnet synchronous motor 101 and realizes motor drive control. It adopts sensorless vector control and is adapted to linear acceleration and deceleration adjustment.

[0030] The high-voltage interface module is equipped with three-phase power input terminals, power grounding terminals, inverter output terminals, and motor grounding terminals. The low-voltage interface module integrates power ports, analog input ports, digital input ports, and relay terminals for connecting external sensors, control signals, and relay loads.

[0031] The power port simultaneously outputs three low-voltage power supplies of different voltage levels, namely the first power supply, the second power supply, and the third power supply. The analog input port includes a voltage signal input terminal and a current signal input terminal. The voltage signal input terminal is compatible with at least two three-wire sensors with different voltage output ranges, and the current signal input terminal is compatible with sensors with a preset current range. The digital input port includes three digital signal terminals for inputting external switch control signals; The relay terminal is an independent control terminal, including a normally closed terminal, a common terminal and a normally open terminal, used to realize the on and off control of the relay load; The display operation module 7 includes an LCD screen and a mechanical tactile button group; the LCD screen is an industrial-grade protective display screen, used to display controller operating parameters, equipment status and fault information in real time; The mechanical touch button group includes equipment operation control, shutdown control, parameter adjustment, menu switching, fault reset and panel unlocking.

[0032] A control system for a vertical pump integrated controller includes a control module 6 that integrates an embedded edge computing unit, is configured with an adaptive sensorless vector control algorithm based on the pump's operating status, and further includes the following collaborative modules: Multimodal fault prediction module: Real-time acquisition of three-phase waveforms of stator current of permanent magnet synchronous motor 101, pressure difference signal of inlet and outlet water chamber 306 and vibration spectrum data of pump shaft 302. Through a lightweight convolutional neural network model, early signs of bearing wear, impeller cavitation or flow channel blockage are identified online and displayed on the LCD screen in a graded warning manner. Dynamic energy efficiency optimization module: Based on the external flow / pressure sensor signal connected to the low-voltage interface module, combined with the built-in pump characteristic curve database, the linear acceleration / deceleration slope and output frequency are dynamically adjusted to ensure that the system always operates in the high-efficiency zone while meeting process requirements, and the optimized operating parameters are automatically stored in non-volatile memory. Dual-redundant low-voltage power supply management module: The power port in the low-voltage interface module not only outputs three low-voltage power supplies of different voltage levels, but also at least one of the power supplies is composed of the main control power supply and the backup supercapacitor energy storage unit connected in parallel. When the main power supply drops abnormally, the supercapacitor seamlessly takes over the power supply of the critical circuit within 10ms to ensure that the control logic is not interrupted and the operating status is not lost. Intelligent valve linkage control module 6: During startup or shutdown, control module 6 automatically triggers electromagnetic drive commands to vent valve 501 and drain valve 502 according to a preset timing sequence, realizing a closed-loop operation logic of venting before pumping and shutting off the pump before emptying, and feeding back the actual opening and closing status of the valves through digital input terminals to verify the reliability of execution.

[0033] Example 2: A vertical pump integrated controller includes a control module 6, a display and operation module 7, a high-voltage interface module, a low-voltage interface module, and a communication module; the core control object of the control module 6 is a permanent magnet synchronous motor 101, which adopts a sensorless vector control method, with a carrier frequency setting range of 5KHz-15KHz, a maximum adjustable speed of 3600rpm-60.00Hz, a speed setting resolution of 1rpm-0.01Hz, a speed stability accuracy of ±1%, and supports linear acceleration and deceleration curves, with an adjustable acceleration and deceleration time range of 3S~300S; The display operation module 7 includes an LCD screen and a set of 8 mechanical tactile buttons. The button functions include running, stopping, parameter modification, menu switching, and fault reset. The high-voltage interface module includes three-phase power input terminals R, S, T, power grounding terminal, inverter output terminals U, V, W, and motor grounding terminal; the input rated voltage / frequency is 3PH: 380V~440V 50Hz / 60Hz, the allowable voltage operating range is 3PH: 220V~530V ±5% frequency, and the output voltage range is 0V to rated input voltage; The low-voltage interface module includes power ports +10V-GND, +24V-COM, +5V-GND, analog input ports AI1 and AI2, digital input ports DI1, DI2, and DI3, and relay terminals TA, TB, and TC. The communication module has 485 communication terminals A+ and B-, supports multi-pump networking, has a default communication rate of 9600bps, 8 data bits, 1 stop bit, and 0 parity bits.

[0034] The power port is specifically configured as follows: the +10V-GND port provides +10V power to the outside, with a maximum output current of 100mA, and is compatible with 1KΩ~5KΩ external potentiometers. The +24V-COM port provides +24V power with a maximum output current of 200mA, serving as a power supply for digital input / output terminals and external sensors. The +5V-GND port provides +5V power with a maximum output current of 100mA, serving as the power supply for external serial communication.

[0035] The analog input port is specifically compatible with the following types of sensors: 24V current-type pressure sensor: the positive terminal connects to the +24V port, and the negative terminal connects to the AI2 port. The AI2 supports 0-20mA signal input. The sensor model 0 / 1 / 2 can be set to correspond to 1.0Mpa / 1.6Mpa / 2.5Mpa respectively via parameter P3-11, and the channel, range, current upper and lower limits, and filtering parameters can be configured via P0-08, P0-09, P3-13, P3-14, and P3-15. Number; +10V power supply three-wire voltage type pressure sensor: positive terminal connected to +10V port, negative terminal connected to GND port, output terminal connected to AI1 port. AI1 supports 0-10V signal input. The sensor model 0 / 1 / 2 can be set to 1.0Mpa / 1.6Mpa / 2.5Mpa respectively through parameter P3-06, and the channel, range, voltage upper and lower limits and filtering parameters can be configured through P0-10, P0-11, P3-08, P3-09 and P3-10. +5V powered three-wire voltage-type pressure sensor: the positive terminal is connected to the +5V port, the negative terminal is connected to the GND port, and the output terminal is connected to the AI1 port. AI1 supports 0.5-4.5V signal input. The sensor model 3 / 4 / 5 can be set to correspond to 1.0Mpa / 1.6Mpa / 2.5Mpa respectively through parameter P3-06, and the range, adjustment parameters and filtering parameters can be configured through P0-11, P0-12, P3-08, P3-09 and P3-10.

[0036] The digital input ports DI1, DI2, and DI3 have an input impedance of 2.4KΩ and an input voltage range of 9~30V. DI1 can be configured in default mode, DI2 can be configured in forced high-speed mode, and DI3 can be configured in forced low-speed mode.

[0037] The relay terminal is a single control terminal, with TA being a normally closed terminal, TB being a common terminal, and TC being a normally open terminal. The software is compatible by default with 24V, 4-20mA, 16Ba current-type pressure sensors.

[0038] A vertical pump integrated control system supports single pump independent control and multi-pump online control. Single pump independent control is achieved through controller panel operation or external PLC signals: the PLC inputs a 0-10V speed regulation signal through port AI1, a switch signal through port DI1, and DI2 / DI3 can be selected as forced high-speed / low-speed signals. Control is completed in conjunction with parameters P0-02 (constant speed mode), P0-04 (DI1 start / stop), P0-05 (AI1 target value), P3-00 / P3-02 / P3-04 (digital input functions), and P3-08 / P3-09 (AI1 voltage upper and lower limits). When multiple pumps are connected for control, each controller is connected in series via the 485 communication terminals A+ and B-. The host side sets parameter P1-00 to enable the connection, P1-01 to set the number of motors, and P1-02 to assign a unique pump group ID. The slave side only needs to set P1-02 to realize the host's unified scheduling and status monitoring of multiple pumps.

[0039] The controller supports local and remote communication control, specifically including: write command control: sending Modbus commands via the 485 interface, where byte 1 is the target station address (default 0x03), byte 2 is the write command (0x06), bytes 3-4 are the function code address (0x1001), bytes 5-6 are the function code parameters (high-order bits first), and bytes 7-8 are CRC checks; it can realize functions such as password verification, serial port data setting, control command start / deceleration stop / fault reset, target pressure / frequency setting, and operating mode switching; Read command control: Send Modbus read command byte 2 as 0x03, function code address 0xB001, read number 1-20, can read software version, running status, input / output power / current / voltage, speed, temperature, pressure value, fault code, water level status, online master / slave status and online pump group operating data.

[0040] The controller panel has status indication and operation lock functions: the indicator lights include a power indicator light that is always on when the device is on / standby, a running indicator light that is always on when the device is running, an alarm indicator light that is on when the device is alarming, and a fault indicator light that is on when the device is faulty. The panel supports automatic locking when there is no operation. Press and hold the return / unlock button for 3 seconds to unlock. In the locked state, only the fault reset and unlock functions are retained.

[0041] Example 3: The vertical pump integrated controller of the present invention includes a control module 6, a display and operation module 7, a high-voltage interface module, a low-voltage interface module, and a communication module. The modules work together to achieve precise control and flexible networking of the vertical pump.

[0042] Control Module 6: The core is a control chip adapted for the permanent magnet synchronous motor 101, which adopts sensorless vector control technology. The core performance parameters are as follows: carrier frequency 5KHz-15KHz, maximum adjustable speed 3600rpm 60.00Hz, speed setting resolution 1rpm 0.01Hz, speed stability ±1%, supports linear acceleration and deceleration curves, and the adjustable acceleration and deceleration time range is 3S~300S; the input rated voltage / frequency is 3PH: 380V~440V 50Hz / 60Hz, the allowable voltage operating range is 3PH: 220V~530V ±5% frequency, and the output voltage range is 0V to the rated input voltage.

[0043] Display operation module 7: equipped with 480 The 272-pixel LCD screen can display real-time operating parameters such as speed, power, pressure, current, voltage, temperature, running time, setting parameters, and fault information; it is equipped with 8 mechanical touch buttons, with functions covering operation, shutdown, parameter increase / decrease, menu switching, cursor movement, confirmation and saving, fault reset, and panel unlocking (press and hold for 3 seconds). It also supports automatic locking function when there is no operation, improving operational safety.

[0044] High-voltage interface module: includes three-phase power input terminals R, S, T, power grounding terminal, inverter output terminals U, V, W and motor grounding terminal. The high-voltage terminals adopt an anti-misinsertion design to meet the safety requirements of high current transmission in industrial sites.

[0045] Low-voltage interface module, power ports: +10V-GND+10V / 100mA, for potentiometer; +24V-COM+24V / 200mA, for sensor / digital I / O; +5V-GND+5V / 100mA, for communication module. Analog input ports: AI1 voltage signal input, compatible with 0-10V / 0.5-4.5V sensors; AI2 current signal input, compatible with 0-20mA sensors. Digital input ports: DI1, DI2, DI3, input impedance 2.4KΩ, input voltage 9~30V, supports start / stop, forced high speed / low speed and other function configurations; Relay terminals: 1 control terminal TA normally closed, TB common, TC normally open, suitable for relay control scenarios.

[0046] Communication module: It adopts 485 communication terminals A+ and B-, supports differential signal transmission, and the default communication parameters are 9600bps, 8 data bits, 1 stop bit, and 0 parity bits. The baud rate can be adjusted through parameter P4-01 and the slave address can be adjusted through parameter P4-02 to meet the needs of multi-pump online operation and remote communication.

[0047] The controller provides standardized parameter configuration schemes for different types of pressure sensors, with strong adaptability, as follows: 24V current type pressure sensor: connect the positive terminal to the +24V port, the negative terminal to the AI2 port, select the model corresponding to 1.0 / 1.6 / 2.5Mpa through parameter P3-110-2, select the AI2 channel through P0-08, set the range through P0-09, set the upper and lower limits of the current of 4.0mA / 20.0mA through P3-13 / P3-14, and set the 10ms filter parameters through P3-15.

[0048] +10V three-wire voltage type pressure sensor: positive terminal connects to +10V port, negative terminal connects to GND, output terminal connects to AI1, select the corresponding 1.0 / 1.6 / 2.5Mpa through P3-060-2, select AI1 channel through P0-10, set the range through P0-11, set the upper and lower voltage limits of 0.0V / 10.0V through P3-08 / P3-09, and set 10ms filtering through P3-10.

[0049] +5V three-wire voltage type pressure sensor: positive terminal connects to +5V port, negative terminal connects to GND, output terminal connects to AI1, select the corresponding 1.0 / 1.6 / 2.5Mpa through P3-063-5, set the range through P0-11, set the adjustment parameters through P0-12, set the upper and lower voltage limits of 0.0V / 10.0V through P3-08 / P3-09, and set the 10ms filter through P3-10.

[0050] PLC Control Interface: The controller supports external PLC control. Specific wiring and parameter configuration are as follows: Wiring specifications: Connect the PLC speed control signal 0-10V to AI1, and connect the reference ground to GND; connect the PLC switch signal to DI1, connect the forced high speed / low speed selectable signal to DI2 / DI3, and connect the switch signal ground to COM.

[0051] Parameter configuration: P0-02 is set to constant speed mode, P0-04 is set to DI1 start / stop, P0-05 is set to AI1 target value, P3-00 is set to DI1 default mode, P3-02 is set to DI2 forced high speed, P3-04 is set to DI3 forced low speed, and P3-08 / P3-09 are set to AI1 voltage upper and lower limits of 0.0V / 10.0V.

[0052] Multi-pump integrated control system: The control system of the present invention includes at least one vertical pump integrated controller and a vertical pump integrated machine. The structure of the vertical pump integrated machine includes a permanent magnet synchronous motor 101, a protective cover 2, an air release valve 501, a pump head 301, a tie rod 401, a pressure-resistant cylinder 305, a pump shaft 302, a guide vane 304, an impeller 303, a drain valve 502, an inlet / outlet water chamber 306, an inlet connection flange 402, and an outlet connection flange 403. The output shaft of the permanent magnet synchronous motor 101 is connected to the pump shaft 302. The impeller 303 is installed on the pump shaft 302. The guide vane 304 is located inside the pressure-resistant cylinder 305. The inlet / outlet water chamber 306 is connected to an external pipeline through a flange. The air release valve 501 / drain valve 502 is used for air release / drainage. The protective cover 2 protects the motor. The tie rod 401 fixes the pump head 301 and the pressure-resistant cylinder 305.

[0053] The control system supports independent control of a single pump and multi-pump online control. When connected in a network, each controller is connected in series through the 485 terminals A+ and B-. The master unit is configured with P1-00 to enable online connection, P1-01 to set the number of motors, and P1-02 to assign a unique ID with consecutive non-repeating numbers. The slave unit only needs to be configured with P1-02 to achieve unified scheduling of multiple pumps by the master unit. The master unit can read data such as the online status, operating frequency, power, current, fault code, and running time of each pump.

[0054] Local and remote communication control: Local operation: The panel can modify parameters, control operation / stop, and reset faults. It can display the water level, operating mode, running time and other statuses in real time. The water level status is fed back through the float switch, and the red icon indicates a float malfunction.

[0055] Remote communication control: Write command: Using the Modbus protocol, the command format is [target station address (0x03)][write command (0x06)][function code address (0x1001)][function code parameter][CRC check]. It can realize password unlocking, target pressure / frequency setting, start / stop / reset, and operation mode switching, etc. Read command: The command format is [target station address (0x03)][read command (0x03)][function code address (0xB001)][number of reads][CRC check]. It can read software version, running status, input / output power / current / voltage, speed, temperature, pressure value, fault code, water level status, online master and slave status, and online pump group data.

[0056] The above embodiments are only used to illustrate the present invention and are not intended to limit the technical solutions described herein. Although the present invention has been described in detail with reference to the above embodiments, the present invention is not limited to the specific embodiments described above. Therefore, any modifications or equivalent substitutions to the present invention, as well as all technical solutions and improvements that do not depart from the spirit and scope of the invention, are covered within the scope of the claims of the present invention.

Claims

1. A vertical pump integrated controller, comprising a power drive module (1), characterized in that, The power drive module (1) is provided with a protective cover (2). The power drive module (1) is connected to the pump body fluid delivery module (3). The pump body fluid delivery module (3) is connected to the connection and fixing module (4). The pump body fluid delivery module (3) is provided with a valve assembly (5). The power drive module (1) is connected to the control module (6). The control module (6) is connected to the display operation module (7). The control module (6) is connected to the high-voltage interface module and the low-voltage interface module.

2. The vertical pump integrated controller according to claim 1, characterized in that, The pump body fluid transport module (3) includes a pump head (301), a pump shaft (302), an impeller (303), a guide vane (304), a pressure-resistant cylinder (305), and an inlet / outlet water chamber (306). The pump head (301) is equipped with a pump shaft (302), and the pump shaft (302) is equipped with an impeller (303) and a guide vane (304) outside the pump shaft (302). The pressure-resistant cylinder (305) is equipped on the outer side of the guide vane (304), and the inlet / outlet water chamber (306) is equipped on the lower side of the impeller (303).

3. A vertical pump integrated controller according to claim 2, characterized in that, The power drive module (1) is equipped with a permanent magnet synchronous motor (101), which is connected to the pump shaft (302).

4. A vertical pump integrated controller according to claim 3, characterized in that, The connection and fixing module (4) includes a pull rod (401), an inlet connection flange (402), and an outlet connection flange (403). The pressure-resistant cylinder (305) is provided with a pull rod (401), and the inlet and outlet water chambers (306) are provided with an inlet connection flange (402) and an outlet connection flange (403) on both sides.

5. A vertical pump integrated controller according to claim 4, characterized in that, The valve assembly (5) includes an air release valve (501) and a water drain valve (502). The air release valve (501) is provided above the pump head (301), and the water drain valve (502) is provided on the outside of the inlet and outlet water chamber (306).

6. A vertical pump integrated controller according to claim 5, characterized in that, The control module (6) is adapted to the permanent magnet synchronous motor (101) and realizes motor drive control. It adopts sensorless vector control and is adapted to linear acceleration and deceleration adjustment.

7. A vertical pump integrated controller according to claim 6, characterized in that, The high-voltage interface module is equipped with a three-phase power input terminal, a power grounding terminal, a frequency converter output terminal, and a motor grounding terminal. The low-voltage interface module integrates a power port, an analog input port, a digital input port, and a relay terminal for connecting external sensors, control signals, and relay loads.

8. A vertical pump integrated controller according to claim 7, characterized in that, The power port simultaneously outputs three low-voltage power supplies of different voltage levels, namely the first power supply, the second power supply, and the third power supply. The analog input port includes a voltage signal input terminal and a current signal input terminal. The voltage signal input terminal is adapted to at least two three-wire sensors with different voltage output ranges, and the current signal input terminal is adapted to a sensor with a preset current range. The digital input port includes three digital signal terminals for inputting external switch control signals; The relay terminal is an independent control terminal, including a normally closed terminal, a common terminal and a normally open terminal, used to realize the on-off control of the relay load.

9. A vertical pump integrated controller according to claim 8, characterized in that, The display operation module (7) includes an LCD screen and a mechanical touch button group; the LCD screen is an industrial-grade protective display screen used to display the controller's operating parameters, equipment status and fault information in real time; the mechanical touch button group includes equipment operation control, shutdown control, parameter adjustment, menu switching, fault reset and panel unlocking.

10. The control system of a vertical pump integrated controller according to any one of claims 1-9, characterized in that, The system is equipped with an adaptive sensorless vector control algorithm based on the pump's operating status. The control module (6) integrates an embedded edge computing unit and further includes the following collaborative system modules: The multimodal fault prediction module is used to collect the stator current three-phase waveform of the permanent magnet synchronous motor (101), the pressure difference signal of the inlet and outlet water chamber (306) and the vibration spectrum data of the pump shaft (302). It uses a lightweight convolutional neural network model to identify early signs of bearing wear, impeller (303) cavitation or flow channel blockage online, and provides warnings in a graded manner on the LCD screen. The dynamic energy efficiency optimization module dynamically adjusts the linear acceleration / deceleration slope and output frequency based on the external flow or pressure sensor signals connected to the low-voltage interface module and the built-in pump characteristic curve database, so that the system always operates in the high-efficiency zone and automatically stores the optimized operating parameters to non-volatile memory. The intelligent valve linkage control module (6) automatically triggers electromagnetic drive commands to the vent valve (501) and the drain valve (502) according to a preset timing sequence during startup or shutdown, and performs closed-loop operation logic of venting first and then starting the pump, and shutting down the pump first and then venting the air. The actual opening and closing status of the valve is fed back through the digital input terminal to verify the execution command.

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