A water pump controller with high temperature protection

Abstract

This invention relates to the field of water pump controller technology, specifically a water pump controller with high-temperature protection, comprising an evaluation mechanism and a load reduction mechanism. The evaluation mechanism includes a water pump body and a housing located on one side of the water pump body. In this invention, three levels of warning parameters are set for the water pump body via a human-machine interface. When the temperature reaches the first warning level, the MCU140 reduces the carrier frequency of the PWM drive module, and the audible and visual alarm emits a green light. When the temperature reaches the second warning level, soft load reduction is implemented—the output frequency is reduced by 5% every 10 seconds, the audible and visual alarm emits a yellow light, accompanied by a short, high-frequency buzzer, while the human-machine interface displays "Overload load reduction in progress." When the temperature reaches the third warning level, the MCU immediately blocks the output of the PWM drive module, and the water pump body stops freely; the audible and visual alarm emits a red light and a long buzzer. This tiered intervention method effectively avoids direct shutdown of the water pump body and also avoids repeated restarts, ensuring pumping efficiency.

Description

Technical Field

[0001] This invention relates to the field of water pump controller technology, specifically a water pump controller with high-temperature protection. Background Technology

[0002] The water pump controller is suitable for remote monitoring and management of water intake pumping stations, water plant booster pumping stations, intermediate booster pumping stations, and community booster pumping stations in urban water supply systems. Pumping station managers can remotely monitor the working status and operating parameters of on-site equipment from the monitoring center; remotely control the start and stop of water supply equipment; and provide panoramic image monitoring of the station or key workstations.

[0003] Traditional water pump controllers are rather rigid in their control methods. Once the operating temperature of the water pump or the internal temperature of the controller is detected to reach a threshold, the system will directly issue a shutdown command. Then, after the temperature drops to a safe value, it will continue to work. This control method not only easily causes the water pumping task to be interrupted, but also significantly reduces the water pumping effect with repeated restarts. Summary of the Invention

[0004] The present invention aims to solve one of the technical problems existing in the prior art or related technologies.

[0005] Therefore, the technical solution adopted in this invention is as follows: A water pump controller with high-temperature protection includes an evaluation mechanism and a load-reducing mechanism. The evaluation mechanism includes a water pump body, a housing disposed on one side of the water pump body, a PCB fixed to the inner bottom surface of the housing, an MCU fixed to the top center of the PCB, a three-phase power line fixed between the water pump body and the PCB, a current transformer movably sleeved on the outside of the three-phase power line and fixed to the housing, a circuit detection module disposed on the outside of the PCB and fixed to the inner bottom surface of the housing, a temperature sensor 1, a temperature sensor 2 fixed to the outside of the housing, and a thermocouple inserted into the top of the water pump body. The current transformer, circuit detection module, temperature sensor one, temperature sensor two, and thermocouple are all electrically connected to the MCU. The load reduction mechanism includes a PWM drive module fixed to the top of the PCB, a front cover fixed to the top of the housing, a human-machine interface embedded in the top of the front cover, a non-volatile memory inserted into one side of the housing, a real-time clock module embedded in one side wall inside the housing, and an audible and visual alarm fixed to one end of the housing. The PWM drive module, human-machine interface, non-volatile memory, real-time clock module, and audible and visual alarm are all electrically connected to the MCU.

[0006] By adopting the above technical solution, and setting three-level warning parameters for the water pump body through the human-machine interface, when the temperature reaches the first warning level, the MCU140 reduces the carrier frequency of the PWM drive module, and the audible and visual alarm emits a green light; when the temperature reaches the second warning level, soft load reduction is implemented—the output frequency is reduced by 5% every 10 seconds, the audible and visual alarm emits a yellow light, accompanied by a short, high-frequency buzzer, and the human-machine interface displays "Overload load reduction in progress"; when the temperature reaches the third warning level, the MCU immediately blocks the output of the PWM drive module, and the water pump body stops freely; the audible and visual alarm emits a red light and emits a long buzzer. This graded intervention method effectively avoids the water pump body from stopping directly, and also avoids its repeated restarts, ensuring the water pumping effect.

[0007] In a preferred embodiment, the present invention can be further configured such that: the housing is composed of a housing body and a Z-shaped plate, the Z-shaped plate extends through one end of the housing body, and the current transformer is located on the outside of the housing body and is fixedly connected to the top of the Z-shaped plate.

[0008] In a preferred embodiment, the present invention can be further configured such that: one end of the Z-shaped plate is bent, and the second temperature sensor is snapped onto the inside of the bent position.

[0009] In a preferred embodiment, the present invention can be further configured such that: the three-phase power lines and the current transformers are each set to three, and the three current transformers are equally spaced and arranged in a row.

[0010] In a preferred embodiment, the present invention can be further configured such that the audible and visual alarm has three built-in lights, which are respectively set to green, yellow and red.

[0011] In a preferred embodiment, the present invention may be further configured such that a rear cover is snapped onto the top of the box sleeve, and the rear cover is fitted together with the front cover.

[0012] In a preferred embodiment, the present invention can be further configured such that: the back cover is composed of a plastic plate and multiple buckles, the multiple buckles are fixed to the bottom of the plastic plate, and the top of the box sleeve is provided with multiple buckle grooves suitable for buckle engagement.

[0013] In a preferred embodiment, the present invention can be further configured such that: the top of the back cover is provided with two recessed areas, the two recessed areas being vertically symmetrical about the vertical center plane of the back cover.

[0014] In a preferred embodiment, the invention may be further configured such that a plurality of sheaths, made of an elastic material, are sleeved between the three three-phase power lines.

[0015] By adopting the above technical solution, the beneficial effects achieved by the present invention are as follows: 1. In this invention, a three-level warning parameter is set for the water pump body through a human-machine interface. When the temperature reaches the first-level warning, the MCU140 reduces the carrier frequency of the PWM drive module, and the audible and visual alarm emits a green light. When the temperature reaches the second-level warning, soft load reduction is performed—the output frequency is reduced by 5% every 10 seconds, the audible and visual alarm emits a yellow light, accompanied by a short, high-frequency buzzer, and the human-machine interface displays "Overload load reduction in progress". When the temperature reaches the third-level warning, the MCU immediately blocks the output of the PWM drive module, and the water pump body stops freely. The audible and visual alarm emits a red light and a long buzzer. This graded intervention method effectively avoids the water pump body from stopping directly and also avoids its repeated restarts, ensuring the water pumping effect.

[0016] 2. In this invention, by setting up a current transformer, a voltage detection module, and a temperature sensor, the three-phase current, power factor, operating frequency, shell temperature, and ambient temperature of the water pump body are collected. A soft measurement algorithm for winding temperature based on the fusion of thermodynamic model and neural network is constructed. The algorithm outputs the estimated value of the hottest spot temperature of the winding in real time (error ≤ ±3℃) and performs dynamic correction with the built-in thermocouple reference point. When the estimated temperature reaches the set threshold, the protection action is triggered immediately, and the response time is shortened to less than 5 seconds. This fast response mechanism effectively avoids local overheating or even inter-turn short circuit.

[0017] 3. In this invention, a non-volatile memory is set on one side of the casing to record the output temperature-time curve, shutdown reasons (normal shutdown / high temperature protection / overcurrent protection) and subsequent maintenance feedback in the past 100 operating cycles. Through online clustering algorithm, the "healthy temperature envelope" of the water pump body is automatically identified. This analysis of the historical temperature change curve of abnormal records allows for the setting of the optimal threshold for each water pump body, improving the adaptability to different water pumps. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the front and rear covers of the present invention when they are closed; Figure 2 This is a schematic diagram of the overall structure of the front and rear covers of the present invention after they are opened; Figure 3 This is a schematic diagram of the evaluation institution for this invention; Figure 4 For the present invention Figure 3 Enlarged view of the A-section structure; Figure 5 This is a schematic diagram of the load-lowering mechanism of the present invention; Figure 6 This is a perspective view of the box sleeve of the present invention.

[0019] Figure label: 100. Evaluation agency; 110. Pump body; 120. Box sleeve; 121. Box body; 122. Z-shaped board; 130. PCB; 140. MCU; 150. Three-phase power cord; 160. Current transformer; 170. Circuit detection module; 180. Temperature sensor one; 190. Temperature sensor two; 191. Thermocouple; 200. Load lowering mechanism; 210. PWM drive module; 220. Front cover; 230. Human-machine interface; 240. Non-volatile memory; 250. Real-time clock module; 260. Audible and visual alarm; 300, back cover; 400. Leather case. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0021] It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the invention.

[0022] The following describes, with reference to the accompanying drawings, some embodiments of a water pump controller with high-temperature protection provided by the present invention. Example

[0023] Combination Figures 1-6 As shown, the present invention provides a water pump controller with high-temperature protection, including an evaluation mechanism 100 and a load-reducing mechanism 200. The evaluation mechanism 100 includes a water pump body 110, a housing 120 disposed on one side of the water pump body 110, a PCB 130 fixedly connected to the inner bottom surface of the housing 120, an MCU 140 fixedly connected to the top center of the PCB 130, a three-phase power line 150 fixedly connected between the water pump body 110 and the PCB 130, and a movably sleeved outside the three-phase power line 150 and connected to... The current transformer 160 fixed to the housing 120, the circuit detection module 170 and temperature sensor 180 located outside the PCB 130 and fixed to the inner bottom surface of the housing 120, the temperature sensor 190 fixed to the outside of the housing 120, and the thermocouple 191 inserted into the top of the water pump body 110 are all electrically connected to the MCU 140. The unloading mechanism 200 includes a PWM drive module 210 fixed to the top of the PCB 130, a front cover 220 fixed to the top of the housing 120, a human-machine interface 230 embedded in the top of the front cover 220, a non-volatile memory 240 inserted into one side of the housing 120, a real-time clock module 250 embedded in one side wall inside the housing 120, and an audible and visual alarm 260 fixed to one end of the housing 120. The PWM drive module 210, the human-machine interface 230, the non-volatile memory 240, the real-time clock module 250, and the audible and visual alarm 260 are all electrically connected to the MCU 140.

[0024] Furthermore, the housing 120 is composed of a housing 121 and a Z-shaped plate 122. The Z-shaped plate 122 extends through one end of the housing 121. The current transformer 160 is located outside the housing 121 and is fixedly connected to the top of the Z-shaped plate 122. This structural design provides conditions for firmly fixing the current transformer 160 to the outside of the housing 120.

[0025] Furthermore, one end of the Z-shaped plate 122 is bent, and the second temperature sensor 190 is snapped into the inside of the bent position. The shape design of the Z-shaped plate 122 can improve the installation firmness of the second temperature sensor 190.

[0026] Furthermore, the three-phase power lines 150 and current transformers 160 are each set to three, with the three current transformers 160 arranged in a row at equal intervals. This number design allows for more accurate sampling of the signal conditioning circuit (operational amplifier, filter) connected from the three-phase power lines 150 to the PCB 130.

[0027] Furthermore, the sound and light alarm 260 has three built-in lights, which are set to green, yellow and red respectively, providing a means to distinguish three levels of warning. Example

[0028] Combination Figure 2 and Figure 5 As shown, based on Embodiment 1, a rear cover 300 is snapped onto the top of the box sleeve 120. The rear cover 300 fits snugly against the front cover 220. The rear cover 300 provides conditions for flexible maintenance of the internal structure of the box sleeve 120.

[0029] Furthermore, the rear cover 300 is composed of a plastic plate and multiple buckles, all of which are fixed to the bottom of the plastic plate. The top of the box sleeve 120 is provided with multiple buckle slots suitable for buckle engagement. The structural design of the rear cover 300 allows it to be flexibly disassembled and assembled with the box sleeve 120, facilitating subsequent maintenance of the internal structure of the box sleeve 120.

[0030] Furthermore, the top of the back cover 300 is provided with two recessed areas, which are vertically symmetrical about the vertical center plane of the back cover 300. The recessed areas further improve the ease of removing the back cover 300. Example

[0031] Combination Figure 5 As shown, in the above embodiment, multiple sheaths 400 are sleeved between the three three-phase power lines 150. The sheaths 400 are made of elastic material. The purpose of setting the sheaths 400 is to reinforce the three three-phase power lines 150 and avoid the situation of the circuit being messy.

[0032] Working principle and usage process of this invention: A. Hardware Installation and Connection Three current transformers 160 are respectively threaded onto three three-phase power lines 150 (in the same direction, with arrows pointing to the load side). Then, the secondary signal lines of the current transformers 160 are connected to the "current sampling" terminal of the PCB 130. During this period, the integrated circuit detection module 170, temperature sensor 180, temperature sensor 190, and thermocouple 191 are plugged into the top of the water pump body 110 inside the housing 120. The circuit detection module 170 is connected in parallel to the three-phase voltage (U, V, W) and the neutral line (N) to the corresponding terminals. B. Pre-operation checks Confirm that the human-machine interface 230 and the audible and visual alarm 260 are securely installed, then power on the device and confirm that the real-time clock module 250, the audible and visual alarm 260, and the MCU140 are successfully connected. C. Input the basic parameters of the water pump body 110 The rated power (kW), rated current (A), and rated frequency (Hz) of the water pump body 110 can be set through the human-machine interface 230. D. Setting static calibration Then, when the water pump body 110 is set to stop and reach equilibrium with the ambient temperature (stop time > 2 hours), the MCU 140 records all sensor zero points to the non-volatile memory 240; E. Set tiered early warning parameters As required on site, the three-level early warning parameters were set via the human-machine interface 230: Level 1 Warning: Temperature change rate > 0.5℃ / s and temperature < 85℃ Level 2 warning: Current harmonic distortion rate > 15% and temperature > 95℃ Level 3 protection: Temperature > 110℃ (This value can be automatically adjusted by Innovation Point 3 later). Soft deload step: Reduce output frequency by 5% every 10 seconds PWM frequency reduction target value: Reduce to 4kHz during Level 1 warning. F. Set adaptive threshold learning parameters Historical data record length: up to 100 running cycles (cyclic overwrite). Threshold adjustment mode: Automatic (analyzes after each shutdown) or Manual (requires user confirmation). Short-term over-temperature test enabled: On (Recommended) Temperature margin ΔT for healthy individuals: 5~10℃ (default 8℃) G. Set the Real-Time Clock (RTC) Enter the current date and time (year-month-day, hour:minute:second) to timestamp the temperature trajectory; H. Normal Startup The water pump body 110 is started, and the current, voltage, shell temperature and ambient temperature are collected every second. The estimated hottest temperature of the winding is output through the fusion algorithm (error ±3℃), and is dynamically corrected in real time with the thermocouple 191 reference point. Then, the temperature change rate (dT / dt) and current harmonic distortion rate (THD) are continuously calculated. New operating cycle records are created, and the temperature, timestamp and operating condition are written to the non-volatile memory 240 every second. I. Graded Early Warning and Active Load Reduction When the temperature reaches the first-level warning level, the MCU140 reduces the carrier frequency of the PWM drive module 210 (e.g., 8kHz → 4kHz), and then the audible and visual alarm 260 emits a green light. When the temperature reaches the level 2 warning, soft load reduction is implemented—the output frequency is reduced by 5% every 10 seconds, the audible and visual alarm 260 emits a yellow light and is accompanied by a short, high-frequency buzzer, while the human-machine interface 230 displays "Overload load reduction in progress"; When the temperature reaches the level 3 warning, the MCU140 immediately blocks the output of the PWM drive module 210, and the water pump 110 stops freely; the audible and visual alarm 260 emits a red light and a long-lasting buzzer; then the non-volatile memory 240 records the shutdown reason as "high temperature protection".

[0033] J. Intelligent Cooling and Restart After the three-level protection shutdown, the MCU140 automatically enters the cooling mode and runs the water pump body 110 at 10%~20% of the rated speed to force convection heat dissipation. At this time, the temperature sensor 180 monitors the temperature of each area inside the casing 120 in real time. When the temperature difference between the highest and lowest points is less than 5℃ and the highest temperature is less than 60℃, the human-machine interface 230 displays the "can be restarted" command.

[0034] K. Normal shutdown and data storage During the shutdown of the water pump body 110, the MCU140 stores the complete temperature trajectory, average load, and shutdown reason (normal) of this operating cycle into the non-volatile memory 240 and closes the log file.

[0035] Although embodiments of the invention have been shown and described, those skilled in the art will understand 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 claims and their equivalents.

Claims

1. A water pump controller with high-temperature protection, characterized in that, include: Evaluation agency (100), the evaluation agency (100) includes a water pump body (110), a housing (120) disposed on one side of the water pump body (110), a PCB (130) fixed to the inner bottom surface of the housing (120), an MCU (140) fixed to the top center of the PCB (130), a three-phase power line (150) fixed between the water pump body (110) and the PCB (130), and a current transformer (16) movably sleeved on the outside of the three-phase power line (150) and fixed to the housing (120). 0) A circuit detection module (170) and a temperature sensor one (180) are located on the outside of the PCB (130) and fixed to the bottom surface of the inner box (120), a temperature sensor two (190) is fixed to the outside of the box (120), and a thermocouple (191) is inserted into the top of the water pump body (110). The current transformer (160), circuit detection module (170), temperature sensor one (180), temperature sensor two (190) and thermocouple (191) are all electrically connected to the MCU (140). The unloading mechanism (200) includes a PWM drive module (210) fixed to the top of the PCB (130), a front cover (220) fixed to the top of the housing (120), a human-machine interface (230) embedded in the top of the front cover (220), a non-volatile memory (240) inserted into one side of the housing (120), a real-time clock module (250) embedded in one side wall inside the housing (120), and an audible and visual alarm (260) fixed to one end of the housing (120). The PWM drive module (210), human-machine interface (230), non-volatile memory (240), real-time clock module (250), and audible and visual alarm (260) are all electrically connected to the MCU (140).

2. A water pump controller with high-temperature protection according to claim 1, characterized in that, The box sleeve (120) is composed of a box body (121) and a Z-shaped plate (122). The Z-shaped plate (122) passes through one end of the box body (121). The current transformer (160) is located outside the box body (121) and is fixedly connected to the top of the Z-shaped plate (122).

3. A water pump controller with high-temperature protection according to claim 2, characterized in that, One end of the Z-shaped plate (122) is bent, and the second temperature sensor (190) is snapped into the inside of the bent position.

4. A water pump controller with high-temperature protection according to claim 1, characterized in that, The three-phase power lines (150) and current transformers (160) are each set to three, with the three current transformers (160) arranged in a row at equal intervals.

5. A water pump controller with high-temperature protection according to claim 1, characterized in that, The sound and light alarm (260) has three built-in lights, which are set to green, yellow and red respectively.

6. A water pump controller with high-temperature protection according to claim 1, characterized in that, The top of the box sleeve (120) is snapped with a back cover (300), and the back cover (300) and the front cover (220) fit together.

7. A water pump controller with high-temperature protection according to claim 6, characterized in that, The back cover (300) is composed of a plastic plate and multiple buckles, all of which are fixed to the bottom of the plastic plate. The top of the box sleeve (120) has multiple buckle grooves suitable for buckle engagement.

8. A water pump controller with high-temperature protection according to claim 6, characterized in that, The top of the rear cover (300) is provided with two recessed areas, which are vertically symmetrical about the vertical center plane of the rear cover (300).

9. A water pump controller with high-temperature protection according to claim 1, characterized in that, Multiple sheaths (400) are sleeved between the three three-phase power lines (150), the sheaths (400) being made of elastic material.

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