Intelligent pump integrated with multi-parameter monitoring and early warning feedback

Abstract

This invention relates to the field of intelligent sensing and detection technology, and discloses an intelligent pump integrating multi-parameter monitoring and early warning feedback. The pump includes a base, an inlet pipe, four pump bodies, four sets of second valves, and a power control cabinet. Each pump body has a first valve at its input end and a second valve at its output end, achieving modular layout and centralized control. By constructing a closed-loop control link from data acquisition and fault diagnosis to decision execution, and combining dynamic and comprehensive deviation based on operating conditions for state determination, the invention overcomes the shortcomings of fixed thresholds in adapting to changes in operating conditions, improving the accuracy of early fault identification. Through judgment of the liquid supply capacity before fault isolation and frequency reconstruction allocation after isolation, automatic fault-tolerant operation under fault conditions is achieved. Simultaneously, by combining hierarchical early warning and dynamic boundary optimization, the system's adaptive capability and intelligence level are improved, ensuring continuous liquid supply and operational stability.

Description

Technical Field

[0001] This invention relates to the field of intelligent sensing and detection technology, specifically to an intelligent pump that integrates multi-parameter monitoring and early warning feedback. Background Technology

[0002] With the continuous improvement of industrial automation and intelligent manufacturing, fluid transport systems are increasingly widely used in key fields such as chemical engineering, power generation, municipal water supply, and HVAC, placing higher demands on the safety, continuity, and intelligence of system operation. As the core power equipment of fluid transport systems, the pump's operating status directly affects the overall system's production efficiency and safety stability. In actual working conditions, long-term operation of the pump body is susceptible to various factors such as load fluctuations, medium changes, and mechanical wear, leading to potential faults such as abnormal current, increased vibration, and elevated temperature. If these faults are not detected and addressed in a timely manner, they may cause equipment damage, fluid supply interruption, or even safety accidents.

[0003] Currently, extensive research and applications have been conducted both domestically and internationally in the monitoring and control of pump equipment. Traditional pump control systems often use a single parameter (such as pressure or flow rate) as the control basis, supplemented by simple overcurrent and overload protection devices, capable of shutting down the system in the event of significant anomalies. In recent years, with the continuous advancement of sensor technology, embedded systems, and industrial communication technology, some high-end pump equipment has begun to integrate multi-parameter sensors (such as vibration, temperature, and current), and achieve data acquisition and remote monitoring through programmable logic controllers or fieldbuses. Simultaneously, fault diagnosis technology has been gradually introduced, enabling alarms to be issued in the early stages of some faults based on threshold comparison or simple feature extraction methods. Regarding system redundancy, in some critical applications, multiple pumps operate in parallel, with backup pumps activated through manual switching or simple interlocking logic to improve the reliability of fluid supply.

[0004] While existing technologies have improved the monitoring capabilities of pump systems to some extent, several shortcomings remain. Firstly, most monitoring schemes rely on fixed thresholds for a single parameter, lacking adaptability to multi-parameter fusion analysis and dynamic changes in operating conditions. This makes it difficult to accurately distinguish between normal operating fluctuations and early fault symptoms, leading to missed or false alarms. Secondly, when multiple pumps are configured in parallel, the post-fault handling methods are mostly shutdown alarms or manual intervention switching. There is a lack of automated mechanisms for isolating faulty pumps and reconfiguring the operating frequency of remaining pump units, making it impossible to achieve non-stop maintenance and system self-healing while ensuring continuous fluid supply. Summary of the Invention

[0005] This invention provides an intelligent pump that integrates multi-parameter monitoring and early warning feedback, solving the problems mentioned in the background art.

[0006] This invention provides the following technical solution: an intelligent pump integrating multi-parameter monitoring and early warning feedback, comprising a base, a support frame fixedly installed on the top of the base, and further comprising: an inlet pipe installed on the front side of the base, four sets of first valves provided on the rear side of the inlet pipe, and a monitoring component provided above the inlet pipe; four sets of pump bodies, the input end of each set of pump bodies being fixedly connected to the end of one set of first valves, and a control component installed on the top of each set of pump bodies; four sets of second valves, the end of each set of second valves being fixedly connected to the output end of one set of pump bodies, and the other end of each second valve being connected to an outlet pipe; and a power control cabinet installed above the support frame, an early warning indicator installed on the front side of the power control cabinet, and a signal receiver fixedly installed inside the power control cabinet, the signal receiver being electrically connected to each of the control components and the early warning indicator.

[0007] Preferably, the first valve cooperates with the second valve to independently isolate and maintain either of the pump bodies.

[0008] Preferably, the control unit includes an operation status acquisition and fault feature extraction module, a dynamic deviation calculation and fault determination module, an isolation decision and system reconstruction module, a maintenance mode control module, and a status feedback and hierarchical early warning module; the output of the operation status acquisition and fault feature extraction module is connected to the input of the dynamic deviation calculation and fault determination module; the output of the dynamic deviation calculation and fault determination module is connected to the input of the isolation decision and system reconstruction module; the output of the isolation decision and system reconstruction module is connected to the inputs of the maintenance mode control module and the status feedback and hierarchical early warning module, respectively; the output of the maintenance mode control module is connected to the input of the status feedback and hierarchical early warning module; the output of the status feedback and hierarchical early warning module is fed back to the input of the dynamic deviation calculation and fault determination module through a historical normal operation database.

[0009] Preferably, the operation status acquisition and fault feature extraction module is used to collect the operation parameters of each group of pumps and the water inlet parameters of the monitoring components in real time, calculate the basic fault feature values ​​of each pump, and transmit the calculation results to the dynamic deviation calculation and fault judgment module.

[0010] The dynamic deviation calculation and fault determination module is used to receive the basic fault characteristic value, and combine the current working condition of each pump with the historical normal operation database to calculate the dynamic deviation and comprehensive deviation of each monitoring parameter, determine the pump operating status based on the comprehensive deviation and its changing trend, and output the fault determination result to the isolation decision and system reconstruction module.

[0011] The isolation decision and system reconfiguration module is used to selectively isolate the faulty pump based on the received fault determination result, and reconfigure the operating frequency of the remaining available pumps after isolation. The isolation result and reconfiguration status are sent to the maintenance mode control module and the status feedback and hierarchical early warning module, respectively.

[0012] The maintenance mode control module is used to receive manual maintenance instructions, and in conjunction with the available pump information from the isolation decision and system reconstruction module, to perform isolation and restoration of the specified pump without shutting down the system, lock the control permissions during maintenance, and synchronize the maintenance status to the status feedback and hierarchical early warning module.

[0013] The status feedback and hierarchical early warning module is used to collect the execution results of the isolation decision and system reconstruction module and the maintenance mode control module, generate the operating status vector, output hierarchical early warning signals to the early warning indicator according to the comprehensive deviation, and feed back the normal operation data to the historical normal operation database for the dynamic deviation calculation and fault judgment module to call and update.

[0014] Preferably, the operation status acquisition and fault feature extraction module calculates the basic fault feature values ​​of each pump body, and the calculation formula is as follows:

[0015] ,

[0016] Among them, I i Let I be the real-time current of the i-th pump body. i，rated V is the rated current of the i-th pump body. i V represents the real-time vibration amplitude of the i-th pump body. i，base Let T be the reference vibration amplitude of the i-th pump body under normal operating conditions. p，i Let T be the real-time temperature of the i-th pump body. base The reference temperature for normal operation of the pump body is λ1, λ2, and λ3 are weighting coefficients that satisfy λ1+λ2+λ3=1.

[0017] Preferably, the historical normal operation database called by the dynamic deviation calculation and fault determination module is stored in compartments according to the pump body operating points, with the operating point interval being a frequency of 5Hz and a flow rate of 5m³ / h, and each operating point storing no less than 1000 sets of normal operation data.

[0018] The dynamic deviation calculation and fault judgment module establishes a dynamic boundary based on the current operating conditions for each monitored parameter, including current, vibration, and temperature. The dynamic boundary is determined by taking the mean of historical normal data at the corresponding operating point as a benchmark, combined with the dynamic confidence coefficient k and standard deviation. It is updated once every 500 hours of operation based on newly added normal data using the Bayesian formula.

[0019] The dynamic deviation calculation and fault determination module calculates the comprehensive deviation based on the deviation of each parameter relative to the dynamic boundary, and determines the pump's operating status into three categories in sequence: normal operation, early warning status, and fault status based on the comprehensive deviation and its changing trend.

[0020] Preferably, before the isolation decision and system reconfiguration module performs the isolation of the faulty pump, it first determines the liquid supply capacity. The isolation operation is only performed when the maximum liquid supply capacity of the remaining available pump after isolation is greater than or equal to the current required flow rate.

[0021] The isolation decision and system reconfiguration module executes the isolation of the faulty pump body in the following order: first, it sends a closing command to the first valve corresponding to the faulty pump body; after receiving the feedback signal that the valve is closed, it sends a closing command to the corresponding second valve; after receiving the feedback signal that the valve is closed, it finally sends a shutdown command to the corresponding control unit.

[0022] After isolation is completed, the isolation decision and system reconfiguration module updates the set of available pumps and recalculates and allocates the operating frequency of each available pump according to the current demand flow, thus completing the system operation reconfiguration.

[0023] Preferably, before performing non-stop maintenance, the maintenance mode control module first determines that there are at least two currently available pumps, and that the maximum liquid supply capacity of the remaining pumps after removing the pump to be maintained can still meet the current required flow rate. If the conditions are not met, the maintenance mode is refused.

[0024] After the maintenance mode control module completes the isolation of the pump body to be maintained, it sets a valve lock flag to prohibit automatic control operations on the pump body and its corresponding valves. Upon receiving a recovery command, it controls the corresponding valves to open sequentially, controls the soft start of the pump body to be maintained, and after the operation stabilizes, it adds it back to the set of available pump bodies, redistributes the operating frequency of each pump body, and clears the valve lock flag.

[0025] Preferably, the status feedback and hierarchical early warning module calculates the early warning level based on the comprehensive deviation degree, and divides the early warning into three levels: Level 1, Level 2, and Level 3, with Level 3 being the highest early warning level; at the same time, based on the contribution ratio of the deviation degree of each parameter, it determines the fault type as electrical fault, mechanical fault, abnormal temperature, or compound fault, and controls the early warning indicator to output the corresponding mode of audible and visual alarm signal.

[0026] The status feedback and hierarchical early warning module feeds back the collected data under normal operating conditions to the historical normal operating database for dynamic boundary update calculation, and at the same time synchronizes all operating status data to the host computer or monitoring center through the signal receiver.

[0027] The present invention has the following beneficial effects:

[0028] 1. This invention sets up multiple sets of pumps in parallel, and sets a first valve and a second valve at the input and output ends of each pump respectively. With the centralized control of the power control cabinet and signal receiver, it realizes the modular layout and centralized management of the multi-pump parallel system, effectively improving the overall operational flexibility and redundancy of the system.

[0029] 2. This invention, through the cooperation of the first valve and the second valve, can independently isolate and restore any pump body. Combined with the control of the valve locking mark by the maintenance mode control module, it realizes safe maintenance of a designated pump body without shutting down the system, ensuring the continuous operation of the liquid supply system.

[0030] 3. This invention constructs a closed-loop control link from data acquisition and fault identification to decision execution and status feedback by setting up a module for operation status acquisition and fault feature extraction, a module for dynamic deviation calculation and fault judgment, a module for isolation decision and system reconstruction, a module for maintenance mode control, and a module for status feedback and hierarchical early warning within the control component, thereby realizing intelligent management of the entire process of pump unit operation.

[0031] 4. This invention establishes a dynamic boundary based on operating conditions through a dynamic deviation calculation and fault determination module, and determines the operating status by combining the comprehensive deviation and its changing trend. This overcomes the shortcomings of fixed threshold judgment, which is difficult to adapt to changes in operating conditions, and improves the accuracy and reliability of early fault identification.

[0032] 5. This invention uses an isolation decision and system reconfiguration module to determine the liquid supply capacity before fault isolation, and reconfigures and allocates the operating frequency of the remaining available pumps according to the current demand flow rate after isolation, thereby achieving automatic fault-tolerant operation under fault conditions and ensuring the stability of liquid supply capacity and system operation.

[0033] 6. This invention outputs graded early warning signals based on the comprehensive deviation degree through a status feedback and graded early warning module, and determines the fault type by combining the contribution ratio of the deviation degree of each parameter. At the same time, it feeds back normal operation data to update the historical normal operation database, realizing accurate identification of early warning level and fault type and dynamic optimization of the discrimination boundary, thereby improving the system's adaptability and intelligence level. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0035] Figure 2 This is a side view of the present invention;

[0036] Figure 3 This is a schematic diagram of the structure of the bracket of the present invention;

[0037] Figure 4 This is a diagram showing the internal module connections of the control component of the present invention;

[0038] Figure 5 This is a flowchart of the fault isolation and system reconfiguration process of the present invention.

[0039] In the diagram: 1. Base; 11. Support frame; 2. Inlet pipe; 21. First valve; 22. Monitoring component; 3. Pump body; 31. Control component; 4. Second valve; 41. Outlet pipe; 5. Power control cabinet; 51. Early warning indicator; 52. Signal receiver. Detailed Implementation

[0040] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. In addition, the forms of the various structures described in the following embodiments are merely illustrative. The intelligent pump integrating multi-parameter monitoring and early warning feedback involved in the present invention is not limited to the structures described in the following embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] Please see Figures 1-3 The illustrated intelligent pump integrating multi-parameter monitoring and early warning feedback includes a base 1, with a support frame 11 fixedly mounted on the top of the base 1. A water inlet pipe 2 is installed on the front side of the base 1, and four sets of first valves 21 are provided on the rear side of the water inlet pipe 2 for controlling the flow of water into each branch. A monitoring component 22 is provided above the water inlet pipe 2 for real-time monitoring of inlet pressure, flow rate, or water quality parameters, and feeding the monitoring data back to the control system. The system also includes four pump bodies 3, with the input end of each pump body 3 fixedly connected to the end of one set of first valves 21 to achieve independent multi-channel water inlet control. Each pump body 3 is equipped with a control unit 31 on its top. The control unit 31 is used to adjust the start / stop, frequency, or output power of the corresponding pump body 3 according to the operation command. The control unit 31 adopts a 32-bit ARM Cortex-M4 core embedded microcontroller (MCU) with a main frequency of 168MHz. It has a built-in 12-bit ADC acquisition interface, 2 RS485 communication interfaces, and 8 digital I / O interfaces. The control unit 31 is electrically connected to the frequency converter driver of the corresponding pump body 3 through the RS485 bus to realize real-time control of the pump body's operating frequency and start / stop status and acquisition of operating parameters. At the same time, it establishes real-time communication with the signal receiver 52 through the CAN bus with a communication cycle of 100ms to ensure low-latency transmission of control commands and feedback data.

[0042] Each pump body 3 has a set of second valves 4 fixedly connected to its output end. The other end of each second valve 4 is connected to a water outlet pipe 41, thereby realizing the parallel flow output of multiple pumps. Through the cooperation of the first valve 21 and the second valve 4, the independent isolation and maintenance of any pump body 3 can be achieved. A power control cabinet 5 is installed above the support frame 11. An early warning indicator 51 is installed on the front of the power control cabinet 5 to issue an audible and visual alarm signal when the system is malfunctioning. A signal receiver 52 is fixedly installed inside the power control cabinet 5. The signal receiver 52 is electrically connected to each of the control components 31 and the early warning indicator 51. During operation, the signal receiver 52 receives external control commands or feedback signals from the monitoring component 22 and sends operation commands to each control component 31 according to preset logic. At the same time, it controls the early warning indicator 51 to provide status prompts based on the operating status of the pump body 3 and the monitoring data. The power control cabinet 5 can integrate a remote communication module to realize linkage control with the host computer or monitoring center.

[0043] During operation, after the system is powered on, the signal receiver 52 inside the power control cabinet 5 initializes and establishes electrical connections with each group of control components 31. The monitoring component 22 begins to collect multi-parameter data at the water inlet pipe 2 in real time, including water pressure, flow rate, temperature, and water quality parameters, and transmits the collected data to the signal receiver 52. The early warning indicator 51 performs a self-check and enters standby mode after confirming that there are no abnormalities. According to external control commands or preset operating logic, the signal receiver 52 comprehensively analyzes the multi-parameter data fed back by the monitoring component 22, calculates the optimal operating parameters, and sends them to one or more groups of control components 31. Upon receiving a start command, the corresponding controller 31 starts the corresponding pump body 3, and simultaneously opens the corresponding first valve 21 and second valve 4, forming an independent liquid supply path. Liquid enters the pump body 3 from the inlet pipe 2 via the first valve 21, and after being pressurized by the pump body 3, it flows into the outlet pipe 41 through the second valve 4 for output. In the multi-pump parallel operation mode, the signal receiver 52 dynamically adjusts the operating frequency or start / stop status of each group of controllers 31 based on the multi-parameter data fed back in real time by the monitoring component 22 and the output demand of the outlet pipe 41, thereby achieving balanced scheduling and energy-saving operation of each pump body 3. The signal receiver 52 receives feedback from each group of controllers 31 in real time. The operating status information of pump body 3 includes current, temperature, vibration, and operating time. This information is fused and analyzed with the influent parameter data collected by monitoring component 22. When any pump body 3 experiences an abnormal operating condition or monitoring component 22 detects any parameter exceeding a preset threshold range, signal receiver 52 sends a graded warning signal to warning indicator 51. Warning indicator 51 issues different modes of audible and visual alarms according to the level of abnormality. At the same time, signal receiver 52 sends corresponding processing instructions to the corresponding control component 31 according to the fault type, including frequency reduction operation, shutdown protection, or automatic switching to standby pump body 3, and shutting down the corresponding first pump body 3. Valve 21 and second valve 4 isolate the faulty pump body 3, while the remaining pump bodies 3 continue to maintain liquid supply, ensuring the overall continuity of system operation. When single pump maintenance is required, an isolation command is issued through the power control cabinet 5, and the signal receiver 52 controls the corresponding first valve 21 and second valve 4 to close and stops the operation of the corresponding control component 31, so that the pump body 3 is completely isolated from the inlet pipe 2 and outlet pipe 41. Other pump bodies 3 can still work normally, achieving maintenance without shutting down the system. During system operation, the signal receiver 52 continuously records all monitoring parameters and operating data to form a historical database for subsequent fault diagnosis and operation optimization.

[0044] refer to Figure 4The control unit (31) includes a running status acquisition and fault feature extraction module, a dynamic deviation calculation and fault determination module, an isolation decision and system reconstruction module, a maintenance mode control module, and a status feedback and hierarchical early warning module. The output of the running status acquisition and fault feature extraction module is connected to the input of the dynamic deviation calculation and fault determination module. The output of the dynamic deviation calculation and fault determination module is connected to the input of the isolation decision and system reconstruction module. The output of the isolation decision and system reconstruction module is connected to the input of the maintenance mode control module and the input of the status feedback and hierarchical early warning module, respectively. The output of the maintenance mode control module is connected to the input of the status feedback and hierarchical early warning module. The output of the status feedback and hierarchical early warning module is fed back to the input of the dynamic deviation calculation and fault determination module through the historical normal operation database.

[0045] The operation status acquisition and fault feature extraction module is used to collect the operation parameters of each pump body (3) and the water inlet parameters of the monitoring component (22) in real time, calculate the basic fault feature values ​​of each pump body (3), and transmit the calculation results to the dynamic deviation calculation and fault judgment module.

[0046] This module receives operating parameters from each group of pumps 3 in real time, relayed by the signal receiver 52, including current, temperature, vibration amplitude, and operating time t. i The subscripts i=1, 2, 3, 4 correspond to the four pump bodies. Simultaneously, this module receives the inlet water pressure P and inlet water flow rate Q collected by the monitoring component 22.

[0047] This module normalizes each parameter; the normalization formula is as follows: , where x is the original parameter value, and xmin and xmax are the minimum and maximum range values ​​of the parameter, respectively.

[0048] This module calculates the basic fault characteristic values ​​for each pump body:

[0049] ,

[0050] Among them, I i Let I be the real-time current of the i-th pump body. i，rated V is the rated current of the i-th pump body. i V represents the real-time vibration amplitude of the i-th pump body. i，base Let T be the reference vibration amplitude of the i-th pump body under normal operating conditions. p，i Let T be the real-time temperature of the i-th pump body. base The reference temperature for normal operation of the pump body; in this embodiment, the rated current I of a single pump body i，rated The amplitude is 3.8A, and the reference vibration amplitude V under normal operating conditions is... i，base The flow rate is 2.5 mm / s, and the normal operating reference temperature of the pump body is T.base The temperature is 45℃. This parameter can be adjusted according to the pump model and rated power. λ1, λ2, and λ3 are weighting coefficients, satisfying λ1+λ2+λ3=1. The initial value for each is set to 1 / 3, and subsequent adjustments can be made based on historical fault data. The specific adjustment method for the weighting coefficients is as follows: after each fault confirmation, the deviation percentages of the three parameters—current, vibration, and temperature—at the time of the fault occurrence are statistically analyzed, and then calculated according to the formula... Update the corresponding weights, where n=1, 2, and 3 correspond to the current, vibration, and temperature parameters, respectively. After updating, normalization is required to ensure that the sum of the three is always 1.

[0051] This module will calculate the basic fault characteristic value F. i and each original parameter I i V i T p，i Output to the dynamic deviation calculation and fault determination module.

[0052] The dynamic deviation calculation and fault determination module is used to receive the basic fault characteristic value, and combine the current working condition and historical normal operation database of each pump body (3) to calculate the dynamic deviation and comprehensive deviation of each monitoring parameter, determine the pump body operating status based on the comprehensive deviation and its changing trend, and output the fault determination result to the isolation decision and system reconstruction module.

[0053] This module receives the basic fault feature value F output by the operation status acquisition and fault feature extraction module. i and original parameter I i V i T p，i At the same time, the current operating condition parameters of the pump body are introduced—operating frequency f. i and output flow Q i These two parameters are provided by signal receiver 52. The module also calls the historical normal operation database stored in the power control cabinet 5. This database records the current, vibration, and temperature statistics of each pump under different operating conditions (f, Q). The historical normal operation database is stored in compartments according to operating conditions, with an interval of 5Hz frequency and 5m³ / h flow rate. 3 / h, storing no less than 1000 sets of normal operation data for each operating point to ensure the statistical significance of dynamic boundaries.

[0054] This module establishes dynamic boundaries based on operating conditions for each monitored parameter. Taking current I as an example... i For example, at the operating point (f, Q), its normal operating range is defined as:

[0055] ,

[0056] Where: μI(f, Q) is the average current at this operating point in the historical normal operation database; σ I (f, Q) represents the standard deviation of the current at this operating point; k is the dynamic confidence coefficient, initially set to 3, and updated every 500 hours based on newly added normal data using the Bayesian formula; the specific steps of the Bayesian update are as follows:

[0057] Step 1: Define the prior distribution:

[0058] The prior distribution of k follows a normal distribution N(μ0, σ0). 2 ), initial prior parameters μ0=3, σ0 2 =0.25;

[0059] Step 2: Calculate the sample statistics for the newly added normal data:

[0060] Using the most recent 500 hours of normal operating data, calculate the false alarm rate p when parameters exceed the initial 3σ boundary at each operating point. e The effective sample size is N;

[0061] Step 3: Calculate the posterior distribution:

[0062] Based on the likelihood function , where a is the number of normal data samples falling within the boundary, b is the number of samples exceeding the boundary, the posterior mean μ1 is calculated in combination with the prior distribution, the updated k value is taken as μ1, and the range of k is limited to [2, 5] to avoid the boundary being too wide or too strict.

[0063] Similarly, establish the vibration V i dynamic boundary and temperature T p，i dynamic boundary .

[0064] This module calculates the deviation of each parameter from the dynamic boundary:

[0065] ,

[0066] ,

[0067] ,

[0068] Where ε=10 -6 , is a very small positive number, used to prevent the denominator from being zero;

[0069] This module calculates the overall deviation: D i =w I ·d I，i +w V ·d V，i +w T ·dT，i weight w I w V w T The sensitivity of each parameter is dynamically adjusted based on the historical fault modes. The initial values ​​are each weighted equally at 1 / 3. After each fault occurs and is confirmed, the weights are updated according to the contribution ratio of the deviation of each parameter at the time of the fault.

[0070] This module is based on the overall deviation. Fault determination is based on the trend of its changes:

[0071] If D i ≤D base D base The upper limit of normal fluctuations is determined by the maximum comprehensive deviation of normal operating conditions in the historical normal operation database, and then it is judged as normal operation;

[0072] If D i >D base And the deviation growth rate dD i / dt>0 continues for more than time τ obs If the time is less than 10 seconds, it is considered a warning state and marked as "to be observed";

[0073] If D i >D base If any of the following conditions are met, the condition is determined to be in a fault state and marked as "pending isolation":

[0074] Condition 1: D i >1.5·max(D history ), where max(D history The value represents the maximum overall deviation in the pump's historical normal operation records.

[0075] Condition 2: Deviation rate growth dD i / dt is greater than the set threshold S for three consecutive sampling periods (each sampling period is 2 seconds). crit =0.1.

[0076] This module will integrate the deviation D i The judgment results and the markers to be isolated are output to the isolation decision and system reconstruction module;

[0077] The isolation decision and system reconfiguration module is used to selectively isolate the faulty pump based on the received fault determination result, and reconfigure the operating frequency of the remaining available pumps after isolation. The isolation result and reconfiguration status are sent to the maintenance mode control module and the status feedback and hierarchical early warning module, respectively.

[0078] This module receives the comprehensive deviation D output by the dynamic deviation calculation and fault determination module. iAnd mark the pumps to be isolated, and maintain the set of currently available pumps A, initially A={1,2,3,4}.

[0079] For pump i marked "to be isolated", this module performs a capacity determination: calculates the maximum liquid supply capacity of the remaining usable pump after isolation. Q j，max The maximum output flow rate of the j-th pump; obtain the current required flow rate Q. demand This value is determined by the signal receiver 52 based on the influent flow rate collected by the monitoring component 22 and the system set value.

[0080] like ≥Q demand If so, isolation is permitted;

[0081] If the conditions are not met, a degraded operation warning will be triggered, and a comprehensive deviation D will be selected from the currently available pump set A. i The largest pump is selected as the priority for isolation, meaning the pump with the most severe failure is isolated, and an "insufficient liquid supply" alarm message is sent to the signal receiver 52.

[0082] When the isolation conditions are met, the module performs faulty pump isolation in the following order:

[0083] (1) Send a closing command to the corresponding first valve 21, which is connected to the input end of the pump body i;

[0084] (2) Wait for the valve status feedback signal. Let the first valve status feedback be V. in，i ∈{0,1}, where 1 represents on and 0 represents off;

[0085] (3) Send a closing command to the corresponding second valve 4, which is connected to the output end of pump body i;

[0086] (4) Wait for the valve status feedback signal. Let the second valve status feedback be V. out，i ∈{0,1};

[0087] (5) When V is received in，i =0 and V out，i After receiving the confirmation signal of =0, a stop command is sent to the corresponding control unit 31 to stop the operation of pump body i.

[0088] After isolation is complete, the module updates the set of available pumps A=A{i} and recalculates the operating frequency allocation of the remaining available pumps:

[0089] ,

[0090] Where f ratedThis is the rated operating frequency of the pump body. The module sends frequency adjustment commands to each available pump body to achieve system reconfiguration and load redistribution.

[0091] This module outputs the isolation results (including success or failure status and the updated set of available pumps) and the refactoring status to the maintenance mode control module;

[0092] The maintenance mode control module is used to receive manual maintenance instructions, and in conjunction with the available pump information from the isolation decision and system reconstruction module, to perform isolation and restoration of the specified pump without shutting down the system, lock the control permissions during maintenance, and synchronize the maintenance status to the status feedback and hierarchical early warning module.

[0093] This module receives manual maintenance commands from the power control cabinet 5. These commands are input by the operator through the interactive interface of the power control cabinet 5 and include the pump body number i to be maintained.

[0094] This module performs non-stop maintenance procedures, such as... Figure 5 As shown, the specific steps are as follows:

[0095] Step 1, Conditional Judgment:

[0096] Check whether the currently available pump set A meets the following two conditions:

[0097] Condition 1: |A|≥2, meaning at least two pump bodies are available;

[0098] Condition two: ≥Q demand This means that even after removing the pump body to be maintained, the maximum liquid supply capacity of the remaining pump body can still meet the current flow demand.

[0099] If any condition is not met, the system will refuse to enter maintenance mode and send a text message "Unable to isolate for maintenance" to the warning indicator 51.

[0100] Step 2, Isolation Operation:

[0101] If the conditions are met, perform the following operations in sequence:

[0102] (1) Send a closing command to the first valve 21 corresponding to the pump body i to be maintained;

[0103] (2) Wait for the status feedback V of the first valve in，i =0 Confirmation;

[0104] (3) Send a closing command to the second valve 4 corresponding to the pump body i to be maintained;

[0105] (4) Wait for the status feedback V of the second valve. out，i =0 Confirmation;

[0106] (5) Send a shutdown command to the control unit 31 of the pump body i to be maintained.

[0107] Step 3: Lock maintenance status:

[0108] After isolation is completed, the module marks the pump body as being in maintenance status and sets the valve lock flag V. lock，i =1, prohibit any automatic control operation of the pump body and corresponding valves until maintenance is completed.

[0109] Step 4, Maintenance and Recovery:

[0110] When the operator inputs a recovery command through power control cabinet 5, the module performs the following operations:

[0111] (1) Send an opening command to the first valve 21 corresponding to the pump body i to be maintained;

[0112] (2) Wait for the status feedback V of the first valve in，i =1 Confirm;

[0113] (3) Send an opening command to the second valve 4 corresponding to the pump body i to be maintained;

[0114] (4) Wait for the status feedback V of the second valve. out，i =1 Confirm;

[0115] (5) Send a soft start command to the control unit 31 of the pump body i to be maintained, start at 30% of the rated frequency, run for 30 seconds and then gradually increase to the current required frequency;

[0116] (6) After the pump body is running stably (the current fluctuation does not exceed ±5% within 10 consecutive seconds), add i back to the available pump body set A;

[0117] (7) Based on the updated set of available pumps, redistribute the operating frequencies of each pump:

[0118] , ;

[0119] (8) Clear the valve lock mark V lock，i =0.

[0120] The status feedback and graded early warning module is used to collect the execution results of the isolation decision and system reconstruction module and the maintenance mode control module, generate the operating status vector, output graded early warning signals to the early warning indicator (51) according to the comprehensive deviation, and feed back the normal operation data to the historical normal operation database for the dynamic deviation calculation and fault judgment module to call and update.

[0121] This module receives the execution results from the isolation decision and system reconfiguration module and the maintenance mode control module, and generates the operating state vector of each pump:

[0122] Z i =[D i status i V in，i V out，i V lock，i ],

[0123] Among them, D i For overall deviation; status i ∈{0, 1, 2}, representing the three states of normal, warning, and fault, respectively; V in，i V out，i These are the status feedbacks for the first valve and the second valve, respectively; V lock，i To maintain the locked status flag.

[0124] When any pump body satisfies D i >D base At that time, the module outputs a graded warning signal to the warning indicator 51. The formula for calculating the warning level is:

[0125] ,

[0126] Where D max The preset maximum allowable deviation is set to 5.0; L alarm =1, 2, 3 correspond to Level 1, Level 2, and Level 3 warnings, respectively, with Level 1 being the lowest level and Level 3 being the highest level.

[0127] This module is based on the comprehensive deviation D. i The composition and fault determination results determine the fault type:

[0128] If d I，i If the contribution rate is greater than 50%, it is determined to be an electrical fault, and a continuous buzzing sound will be emitted.

[0129] If d V，i If the contribution rate is greater than 50%, it is determined to be a mechanical fault, and an intermittent buzzing sound will be output.

[0130] If d T，i If the contribution rate is greater than 50%, it is judged as an abnormal temperature, and a high-frequency buzzer sound is output.

[0131] If the contribution of each parameter is less than or equal to 50%, it is judged as a compound fault, and an alternating beeping sound is output.

[0132] For pumps that the dynamic deviation calculation and fault determination module determines to be "to be isolated" but have not yet been isolated, the module will continuously output an alarm until the isolation is completed.

[0133] When the maintenance mode control module issues a "cannot isolate for maintenance" message, the module simultaneously converts the message into a first-level warning signal and outputs it to the warning indicator 51 for text and audio-visual prompts.

[0134] The status feedback and hierarchical early warning module synchronizes all status data to the host computer or monitoring center via signal receiver 52 for remote monitoring and historical data storage. Simultaneously, the status feedback and hierarchical early warning module transmits data under normal operating conditions (i.e., D...) i ≤D base (And the duration exceeds 1 minute) Feedback is sent to the historical normal operation database of the dynamic deviation calculation and fault determination module for subsequent dynamic boundary update calculation.

[0135] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0136] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A smart pump integrating multi-parameter monitoring and early warning feedback, comprising a base (1), wherein a support frame (11) is fixedly mounted on the top of the base (1), characterized in that, Also includes: A water inlet pipe (2) is installed on the front side of the base (1). Four sets of first valves (21) are provided on the rear side of the water inlet pipe (2). A monitoring component (22) is provided above the water inlet pipe (2). Four sets of pump bodies (3) are provided. The input end of each set of pump bodies (3) is fixedly connected to the end of a set of first valves (21). A control component (31) is installed on the top of each set of pump bodies (3). Four sets of second valves (4) are provided. The end of each set of second valves (4) is fixedly connected to the output end of a set of pump bodies (3). The other end of each second valve (4) is connected to a water outlet pipe (41). A power control cabinet (5) is installed above the support frame (11). A warning indicator (51) is installed on the front side of the power control cabinet (5). A signal receiver (52) is fixedly installed inside the power control cabinet (5). The signal receiver (52) is electrically connected to each of the control components (31) and the warning indicator (51).

2. The intelligent pump integrating multi-parameter monitoring and early warning feedback according to claim 1, characterized in that: The first valve (21) works in conjunction with the second valve (4) to independently isolate and maintain any of the pump bodies (3).

3. The intelligent pump integrating multi-parameter monitoring and early warning feedback according to claim 1, characterized in that, The control unit (31) includes an operation status acquisition and fault feature extraction module, a dynamic deviation calculation and fault judgment module, an isolation decision and system reconstruction module, a maintenance mode control module, and a status feedback and hierarchical early warning module. The output of the operation status acquisition and fault feature extraction module is connected to the input of the dynamic deviation calculation and fault determination module; the output of the dynamic deviation calculation and fault determination module is connected to the input of the isolation decision and system reconstruction module; the output of the isolation decision and system reconstruction module is connected to the input of the maintenance mode control module and the status feedback and hierarchical early warning module, respectively; the output of the maintenance mode control module is connected to the input of the status feedback and hierarchical early warning module; the output of the status feedback and hierarchical early warning module is fed back to the input of the dynamic deviation calculation and fault determination module through the historical normal operation database.

4. The intelligent pump integrating multi-parameter monitoring and early warning feedback according to claim 3, characterized in that: The operation status acquisition and fault feature extraction module is used to collect the operation parameters of each group of pumps (3) and the water inlet parameters of the monitoring component (22) in real time, calculate the basic fault feature values ​​of each pump (3), and transmit the calculation results to the dynamic deviation calculation and fault judgment module. The dynamic deviation calculation and fault determination module is used to receive the basic fault characteristic value, and combine the current working condition and historical normal operation database of each pump body (3) to calculate the dynamic deviation and comprehensive deviation of each monitoring parameter, determine the pump body operating status based on the comprehensive deviation and its changing trend, and output the fault determination result to the isolation decision and system reconstruction module. The isolation decision and system reconfiguration module is used to selectively isolate the faulty pump based on the received fault determination result, and reconfigure the operating frequency of the remaining available pumps after isolation. The isolation result and reconfiguration status are sent to the maintenance mode control module and the status feedback and hierarchical early warning module, respectively. The maintenance mode control module is used to receive manual maintenance instructions, and in conjunction with the available pump information from the isolation decision and system reconstruction module, to perform isolation and restoration of the specified pump without shutting down the system, lock the control permissions during maintenance, and synchronize the maintenance status to the status feedback and hierarchical early warning module. The status feedback and hierarchical early warning module is used to collect the execution results of the isolation decision and system reconstruction module and the maintenance mode control module, generate the operating status vector, output hierarchical early warning signals to the early warning indicator (51) according to the comprehensive deviation, and feed back the normal operation data to the historical normal operation database for the dynamic deviation calculation and fault judgment module to call and update.

5. The intelligent pump integrating multi-parameter monitoring and early warning feedback according to claim 3, characterized in that: The operation status acquisition and fault feature extraction module calculates the basic fault feature values ​​of each pump body using the following formula: ， Among them, I i Let I be the real-time current of the i-th pump body. i，rated V is the rated current of the i-th pump body. i V represents the real-time vibration amplitude of the i-th pump body. i，base Let T be the reference vibration amplitude of the i-th pump body under normal operating conditions. p，i Let T be the real-time temperature of the i-th pump body. base The reference temperature for normal operation of the pump body is λ1, λ2, and λ3 are weighting coefficients that satisfy λ1+λ2+λ3=1.

6. The intelligent pump integrating multi-parameter monitoring and early warning feedback according to claim 3, characterized in that: The historical normal operation database called by the dynamic deviation calculation and fault judgment module is stored in compartments according to the pump body operating points. The operating point interval is 5Hz frequency and 5m³ / h flow rate. Each operating point stores no less than 1000 sets of normal operation data. The dynamic deviation calculation and fault judgment module establishes a dynamic boundary based on the current operating conditions for each monitored parameter, including current, vibration, and temperature. The dynamic boundary is determined by taking the mean of historical normal data at the corresponding operating point as a benchmark, combined with the dynamic confidence coefficient k and standard deviation. It is updated once every 500 hours of operation based on newly added normal data using the Bayesian formula. The dynamic deviation calculation and fault determination module calculates the comprehensive deviation based on the deviation of each parameter relative to the dynamic boundary, and determines the pump's operating status into three categories in sequence: normal operation, early warning status, and fault status based on the comprehensive deviation and its changing trend.

7. The intelligent pump integrating multi-parameter monitoring and early warning feedback according to claim 3, characterized in that: Before the isolation decision and system reconfiguration module performs faulty pump isolation, it first determines the liquid supply capacity. The isolation operation is only performed when the maximum liquid supply capacity of the remaining available pump after isolation is greater than or equal to the current required flow rate. The isolation decision and system reconfiguration module executes the isolation of the faulty pump body in the following order: first, it sends a closing command to the first valve (21) corresponding to the faulty pump body. After receiving the feedback signal that the valve is closed, it sends a closing command to the corresponding second valve (4). After receiving the feedback signal that the valve is closed, it finally sends a shutdown command to the corresponding control unit (31). After isolation is completed, the isolation decision and system reconfiguration module updates the set of available pumps and recalculates and allocates the operating frequency of each available pump according to the current demand flow, thus completing the system operation reconfiguration.

8. The intelligent pump integrating multi-parameter monitoring and early warning feedback according to claim 3, characterized in that: Before performing non-stop maintenance, the maintenance mode control module first determines that there are at least two available pumps and that the maximum liquid supply capacity of the remaining pumps after removing the pump to be maintained can still meet the current flow requirements. If the conditions are not met, the maintenance mode will not be entered. After the maintenance mode control module completes the isolation of the pump body to be maintained, it sets a valve lock flag to prohibit automatic control operations on the pump body and its corresponding valves. Upon receiving a recovery command, it controls the corresponding valves to open sequentially, controls the soft start of the pump body to be maintained, and after the operation stabilizes, it adds it back to the set of available pump bodies, redistributes the operating frequency of each pump body, and clears the valve lock flag.

9. The intelligent pump integrating multi-parameter monitoring and early warning feedback according to claim 3, characterized in that: The status feedback and graded early warning module calculates the early warning level based on the comprehensive deviation and divides the early warning into three levels: Level 1, Level 2, and Level 3, with Level 3 being the highest level. At the same time, based on the contribution ratio of the deviation of each parameter, it determines the fault type as electrical fault, mechanical fault, abnormal temperature, or composite fault, and controls the early warning indicator (51) to output the corresponding mode of audible and visual alarm signal. The status feedback and hierarchical early warning module feeds back the collected data under normal operating conditions to the historical normal operating database for dynamic boundary update calculation, and at the same time synchronizes all operating status data to the host computer or monitoring center through the signal receiver (52).

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