Intelligent operation and monitoring device and method for sewage pump station

Abstract

The application discloses a sewage pump station intelligent operation and monitoring device and method, which comprises an automatic control system and a field intelligent acquisition system; the field intelligent acquisition system comprises a data acquisition module and a first data transmission radio station, and the data acquisition module is used for acquiring liquid level signals and voltage state signals; the automatic control system comprises a PLC system, a host computer, an Internet of Things module and a second data transmission radio station; the second data transmission radio station is used for receiving the liquid level signals and the voltage state signals and sending them to the PLC system; the PLC system is used for generating alarm signals according to the liquid level signals and the voltage state signals; the host computer is connected with the PLC system and is used for displaying local data; and the Internet of Things module is used for being connected with an upper node to send data and alarm signals to a monitoring platform. The data acquisition module can detect the liquid level and power-off signals, the data transmission radio station is used for ensuring stable signal transmission, and the whole pump station operation is stable.

Description

Technical Field

[0001] This invention relates to the operation and monitoring of railway sewage pumping stations, specifically to an intelligent operation and monitoring device and method for sewage pumping stations. Background Technology

[0002] Railway sump pits are used to collect railway sewage. They are usually equipped with level gauges to detect the sewage level. Railway sump pits are generally scattered, located in remote areas, with unstable public network coverage and harsh environmental conditions. The level gauges are usually directly connected to the PLC. If the control cabinet or PLC fails, data collection and control will be impossible, and the entire station will need to be shut down for maintenance. In addition, the remote location may block signals, resulting in lagging and unstable data transmission, making it impossible to monitor the pump station in real time. Summary of the Invention

[0003] To address the shortcomings of the existing technology, this invention provides an intelligent operation and monitoring device and method for sewage pumping stations. This invention includes a data acquisition module that can detect liquid level and power failure signals, and a data transmission radio that ensures stable signal transmission and stable operation of the entire pumping station.

[0004] To achieve the above technical objectives, the present invention adopts the following technical solution: an intelligent operation and monitoring device for sewage pumping stations, comprising an automatic control system and an on-site intelligent data acquisition system; The on-site intelligent acquisition system includes a data acquisition module and a first data transmission radio. The data acquisition module is used to acquire the liquid level signal and voltage status signal of the railway sump, and transmit the liquid level signal to the second data transmission radio through the first data transmission radio. The automatic control system includes a PLC system, a host computer, an IoT module, and a second data transmission radio. The second data transmission radio is used to receive liquid level signals and voltage status signals and send them to the PLC system. The PLC system is used to generate alarm signals based on the liquid level signals and voltage status signals. The host computer is connected to the PLC system to display local data. The IoT module is used to connect to the host node to send data and alarm signals to the monitoring platform.

[0005] The on-site intelligent data acquisition system also includes a reed switch level gauge for acquiring the level signal of the railway sump. The output of the reed switch level gauge is connected to the data acquisition module.

[0006] The on-site intelligent data acquisition system also includes a UPS system and a data acquisition box, wherein the UPS system, the data acquisition module, and the first data transmission radio are all located inside the data acquisition box.

[0007] The automatic control system also includes a control cabinet, in which the PLC system, the Internet of Things module, and the second data transmission radio are all housed.

[0008] A method for intelligent operation and monitoring of sewage pumping stations, comprising: The liquid level signal and voltage status signal of the railway sump are collected, and the liquid level signal is transmitted to the second data transmission radio through the first data transmission radio. Receive liquid level signals and voltage status signals and send them to the PLC system; An alarm signal is generated based on the liquid level signal and voltage status signal; Send data and alarm signals to the monitoring platform.

[0009] Calculate the actual liquid level H in the sump, and set the warning liquid level P1 and the danger liquid level P2; When the actual liquid level H is greater than the warning liquid level P1 but less than the danger liquid level P2, a level one alarm is triggered. The IoT module sends the alarm event to the monitoring platform, and the monitoring platform provides a notification via SMS or a dialog box on the display interface. The alarm event includes the actual liquid level H, the current time, and the sump number. When the actual liquid level H is greater than the danger level P2, a level 2 alarm is triggered. The IoT module sends the alarm event to the monitoring platform, which then provides a notification via SMS, a dialog box on the display interface, and a buzzer. The alarm event includes the actual liquid level H, the current time, and the sump number. When the buzzer button is pressed, the buzzer stops sounding.

[0010] When the liquid level signal detected by the reed switch level gauge lasts for t seconds, the current liquid level is taken as the actual liquid level H, where t is greater than or equal to 3 seconds.

[0011] When the number of pump start-stop cycles changes within time period T but the liquid level signal detected by the reed switch level gauge remains unchanged, the float is determined to be stuck, triggering a level one alarm. The IoT module sends this alarm event to the monitoring platform, which then provides a notification via SMS or a dialog box on the display interface. The alarm event includes the change in the number of pump start-stop cycles, the current time, the sump number, the current liquid level, and the reed switch level gauge number.

[0012] In summary, the present invention has achieved the following technical effects: This invention uses a reed switch level gauge, which is effectively corrosion-resistant and provides more stable and reliable detection. This invention features a data acquisition module that works in conjunction with an uninterruptible DC power supply to ensure stable output transmission even during power outages, while simultaneously issuing a power outage alarm signal to facilitate timely maintenance by operators. The present invention sets up a data transmission radio that can stably transmit signals to prevent the pump station from going offline and can reliably transmit the pump station's operating status information in real time. Attached Figure Description

[0013] Figure 1 This is a flowchart of a method for intelligent operation and monitoring of a sewage pumping station according to this application. Detailed Implementation

[0014] The present invention will be further described in detail below with reference to the accompanying drawings.

[0015] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

[0016] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0017] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0018] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0019] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0020] Example: A smart operation and monitoring device for a sewage pumping station includes an automatic control system and a field intelligent data acquisition system; The on-site intelligent acquisition system includes a data acquisition module and a first data transmission radio. The data acquisition module is used to acquire the liquid level signal and voltage status signal of the railway sump, and transmit the liquid level signal to the second data transmission radio through the first data transmission radio. The on-site intelligent data acquisition system also includes a reed switch level gauge for collecting the level signal of the railway sump. The output of the reed switch level gauge is connected to the data acquisition module.

[0021] Water sump gauges typically use floats as level sensors. However, because the sump is relatively shallow, changes in the float's weight, entanglement with other floats, or pipe entanglement can cause malfunctions, making it impossible to effectively collect water level data. Therefore, intelligent data acquisition systems use reed switch level gauges made of 304 stainless steel, which is corrosion-resistant. Furthermore, the reed switch's float provides more stable and reliable vertical movement.

[0022] The data acquisition module is an I / O acquisition module that collects liquid level and voltage status signals from the site. In the event of a high liquid level or power failure, the data acquisition module can still transmit data to the data transmission radio thanks to the continuous power supply from the uninterruptible DC power supply, and will also issue a power failure alarm message.

[0023] The on-site intelligent data acquisition system also includes a UPS system and a data acquisition box, wherein the UPS system, the data acquisition module, and the first data transmission radio are all located inside the data acquisition box.

[0024] Since many sewage pumping stations are installed in basements or concealed locations, users are unaware of the equipment status on-site in the event of a power outage. Therefore, this application includes the installation of an uninterruptible DC power supply (UPS system) to ensure effective system monitoring even during a power outage.

[0025] Due to the dispersed and concealed nature of sewage pumping stations, some locations lack mobile phone signal. Therefore, traditional solutions using network cables or 4G-DTUs to transmit data to the central control center are impractical. This application therefore adopts LoRa for data transmission. The radio supports line-of-sight transmission up to 25 kilometers, meeting the needs of most usage scenarios.

[0026] The automatic control system includes a PLC system, a host computer, an IoT module, and a second data transmission radio. The second data transmission radio is used to receive liquid level signals and voltage status signals and send them to the PLC system. The PLC system is used to generate alarm signals based on the liquid level signals and voltage status signals. The host computer is connected to the PLC system to display local data. The IoT module is used to connect to the host node to send data and alarm signals to the monitoring platform.

[0027] The automatic control system also includes a control cabinet, in which the PLC system, the Internet of Things module, and the second data transmission radio are all housed.

[0028] The PLC used in this application is Siemens S7-1200, which has the advantages of stable performance, fast operation and processing, high integration, powerful communication functions, and good data security.

[0029] The host computer is equipped with an HMI (Human Machine Interface) to allow users to fully understand the operating status of the equipment on-site. The configuration can be either a touch screen or a host computer, depending on the selected model.

[0030] The IoT module acts as a communication processor connecting the field PLC system, monitoring system, host computer system, and mobile terminal. Therefore, adhering to four principles—advanced maturity, security, compatibility with a large number of integrable devices, and practicality—and combining cutting-edge IoT, cloud computing, sensor, and automatic control technologies, it enables real-time display of the operational status of all connected devices on a web browser or mobile WeChat and APP client. Simultaneously, through big data analysis and statistical analysis, it provides strong data support for equipment operation and maintenance, after-sales service, equipment upgrades, fault alarms, and fault diagnosis. This allows for more refined and dynamic management of the entire operation, management, and service process of the equipment system, thereby improving management efficiency, reducing operation and maintenance costs, and ultimately achieving a highly efficient, high-energy, and intelligent state.

[0031] Given that traditional methods of transmitting data to the central control center via network cabling or 4G-DTU are impractical, this application employs a second data radio in conjunction with LoRa for data transmission. The radio supports line-of-sight transmission up to 25 kilometers, meeting the needs of most application scenarios.

[0032] like Figure 1As shown, a method for intelligent operation and monitoring of a sewage pumping station includes, The liquid level signal and voltage status signal of the railway sump are collected, and the liquid level signal is transmitted to the second data transmission radio through the first data transmission radio. Receive liquid level signals and voltage status signals and send them to the PLC system; An alarm signal is generated based on the liquid level signal and voltage status signal; Send data and alarm signals to the monitoring platform.

[0033] Furthermore, the spacing between reed switch level gauges is generally 50mm, 100mm, or 200mm. The level is flat between the two levels. Therefore, the formula for calculating the level is H=H0+N×Δh, where H0 is the vertical distance from the zero point of the reed switch level gauge to the bottom of the pool, N is the number of levels currently triggered by the float magnet, and Δh is the installation spacing between adjacent reed switches.

[0034] Therefore, the alarm signal generated based on the liquid level signal in this application is specifically as follows: Calculate the actual liquid level H in the sump, and set the warning liquid level P1 and the danger liquid level P2; When the actual liquid level H is greater than the warning liquid level P1 but less than the danger liquid level P2, a level one alarm is triggered. The IoT module sends the alarm event to the monitoring platform, and the monitoring platform provides a notification via SMS or a dialog box on the display interface. The alarm event includes the actual liquid level H, the current time, and the sump number. In this situation, it indicates that the liquid level has risen and drainage is needed, prompting operators to drain the liquid promptly. Further steps include: activating the water pump based on the alarm signal, continuing until the actual liquid level H is less than or equal to the warning level P1, and then shutting off the water pump.

[0035] This application can simultaneously send a message to the on-duty personnel and automatically trigger the water pump to drain water when the actual liquid level exceeds the warning level. This eliminates the need for on-duty personnel to manually operate the water pump, allowing for a fully automated drainage process and reducing their workload.

[0036] When the actual liquid level H is greater than the danger level P2, a level 2 alarm is triggered. The IoT module sends the alarm event to the monitoring platform, which then provides a notification via SMS, a dialog box on the display interface, and a buzzer. The alarm event includes the actual liquid level H, the current time, and the sump number. When the buzzer button is pressed, the buzzer stops sounding.

[0037] In this situation, the sudden increase in surface sewage may be caused by rain / flood backflow: at low-lying stations along the railway line, the pipeline may overflow during heavy rain, causing backflow into the sump, with the inflow volume far exceeding the design capacity. Even with all pumps running, the flow cannot keep up after reaching the warning level P1; centralized discharge of passenger train water supply / train washing wastewater: during peak train arrivals and departures, leaking water hydrants or accidental opening of the train washing tank bypass may cause a large flow into the tank in a short period; all pumps may fail: the pumps may experience a power phase loss, a stuck float causing the pump to burn out due to prolonged dry running, or the pump body may be blocked by tangled fibers; the outlet pipe may be blocked / the check valve may fail: sewage along the railway line contains silt and coal dust, causing the check valve to be stuck and unable to open, or the outlet pipe may be blocked by debris, causing the pump to run but the water to not drain. At this time, the existing pumps cannot drain the water in time, requiring repair or additional pumps to be added. Further, this may include: starting the backup pumps based on the alarm signal until the actual liquid level H is less than or equal to the warning level P1, and then shutting down all pumps.

[0038] This application can simultaneously send a message to the on-duty personnel, sound a buzzer, and automatically trigger the water pump to drain water when the actual liquid level exceeds the danger level. This reminds the on-duty personnel of the sudden increase in the liquid level in the sump and the need to prevent malfunctions or sudden increases in external water. At the same time, it realizes the drainage process without human intervention, reducing the workload of the on-duty personnel.

[0039] Because the float of the reed switch vibrates within the sump, causing sudden changes in the liquid level signal followed by a reset, this application further includes: after the liquid level signal detected by the reed switch level gauge lasts for t seconds, the current liquid level is taken as the actual liquid level H, where t is greater than or equal to 3 seconds. This application can solve the problem of false alarms caused by float vibration; only when the liquid level signal lasts for t seconds is it taken as the true liquid level, otherwise it is discarded, so as not to affect the true data.

[0040] Since the sewage in the sump may contain fibers or other objects that can entangle the float, and once the float is entangled, the true liquid level cannot be measured, this application also includes: detecting the float status: when the number of pump start-stop cycles changes within time period T but the liquid level signal detected by the reed switch level gauge does not change, it is determined that the float is stuck, triggering a level one alarm. The IoT module sends the alarm event to the monitoring platform, and the monitoring platform provides a notification via SMS or a dialog box on the display interface; the alarm event includes the change in the number of pump start-stop cycles, the current time, the sump number, the current liquid level, and the reed switch level gauge number.

[0041] This application can detect whether the float is malfunctioning. Once a float malfunction is detected, it will immediately prompt the operator to handle the situation to ensure the smooth operation of the sewage pumping station.

[0042] This application also includes fault detection and handling steps: (1) The system does not display or alarm after the float floats up: After lifting the float, use a multimeter to measure the continuity: If it is continuous, the float is normal. Check the cable or I0 module input point; if it is not continuous, replace the float. (2) The intelligent acquisition unit does not work after power failure: check whether the working indicator light of the DC uninterruptible power supply is normal and whether there is DC12V power output; (3) Prompt for the intelligent data acquisition terminal to disconnect: Check whether the 220V input line of the intelligent data acquisition terminal is normal; whether the working indicator light of the DC uninterruptible power supply is normal and whether there is DC12V power output; whether the power indicator light of the data transmission radio is normal and whether the communication indicator light is flashing. (4) Touch screen does not display: Is the touch screen power supply voltage DC24V? If the voltage is normal, the touch screen is damaged. (5) Touch screen displays "Communication not connected": Check if the PLC is working properly; check if the PLC power indicator is working properly and if the communication indicator is flashing.

[0043] In addition, this application also provides routine maintenance logic: A. Hardware section 1. Water pump unit: Daily inspection, listen to whether the water pump is running smoothly and evenly, and whether there is any abnormal vibration or harsh noise.

[0044] 2. Intelligent control cabinet / electrical control section: (1) Cleaning and dust removal: Clean with dry compressed air or a soft brush every week or half month (depending on the cleanliness of the environment). Clean the dust inside the cabinet, and remove dust accumulation on the PLC and contactors to prevent short circuits and poor heat dissipation.

[0045] (2) Check for tightness: Periodically (e.g., monthly) check the wiring terminals of the main circuit and control circuit for looseness and tighten them when the power is off.

[0046] (3) Observe the status: check whether the indicator lights and display instruments are normal, whether the soft starter has any fault codes, and whether the circuit breaker and contactor have any abnormal sounds (such as buzzing or squeaking).

[0047] (4) Check the cooling fan: Ensure that the cooling fan of the control cabinet and the frequency converter is operating normally and that the ventilation is smooth.

[0048] (5) Sensors and instruments: Pressure / level / flow sensor: Check for blockages in the pressure tap and for leaks in the interface. Regularly (e.g., quarterly) compare the readings with the field mechanical gauges to verify their accuracy.

[0049] (6) Temperature sensor: Check whether the installation is secure and whether the wiring is intact.

[0050] (7) Cleaning: Keep the sensor probe clean and free of debris and scale.

[0051] B. Software and Monitoring Systems 1. Data monitoring and recording: (1) Regularly check: Check the main interface of the monitoring system to confirm whether the status of all water pumps (running / stopping / faulting) and key parameters (pressure, flow rate, liquid level, current, frequency) are within the normal range.

[0052] (2) Analyze trends: Regularly review historical trend curves and analyze changes in equipment performance (e.g., a slow increase in current may indicate pump wear; abnormal energy consumption may indicate a decrease in efficiency).

[0053] (3) Confirm alarm records: Check the system alarm / event records daily, and investigate the cause and record the processing results for any historical alarms (even if they have been automatically recovered).

[0054] 2. System Functionality Test: (1) Regularly test the alarm function: Simulate a common fault once a month (such as manually triggering a high liquid level alarm) to confirm that the on-site audible and visual alarm, monitoring screen alarm, SMS / App push and other functions are normal. Test the system redundancy function (such as whether the standby pump can be automatically put into operation when the main pump fails; whether the redundant system can seamlessly switch when the main PLC fails).

[0055] (2) Test control logic: On a regular basis (e.g., quarterly), test whether the control logic such as automatic switching and rotation operation is executed correctly, ensuring safety.

[0056] 3. Data Backup and Security: (1) Regular backup: Regularly back up the configuration, programs, parameter settings and historical database of the monitoring system.

[0057] (2) System security: Regularly update the security patches for the operating system and monitoring software, and manage user accounts and passwords properly.

[0058] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall fall within the scope of the technical solution of the present invention.

Claims

1. A smart operation and monitoring device for a sewage pumping station, characterized in that: This includes automatic control systems and on-site intelligent data acquisition systems; The on-site intelligent acquisition system includes a data acquisition module and a first data transmission radio. The data acquisition module is used to acquire the liquid level signal and voltage status signal of the railway sump, and transmit the liquid level signal to the second data transmission radio through the first data transmission radio. The automatic control system includes a PLC system, a host computer, an IoT module, and a second data transmission radio. The second data transmission radio is used to receive liquid level signals and voltage status signals and send them to the PLC system. The PLC system is used to generate alarm signals based on the liquid level signals and voltage status signals. The host computer is connected to the PLC system to display local data. The IoT module is used to connect to the host node to send data and alarm signals to the monitoring platform.

2. The intelligent operation and monitoring device for a sewage pumping station according to claim 1, characterized in that: The on-site intelligent data acquisition system also includes a reed switch level gauge for acquiring the level signal of the railway sump. The output of the reed switch level gauge is connected to the data acquisition module.

3. The intelligent operation and monitoring device for a sewage pumping station according to claim 1, characterized in that: The on-site intelligent data acquisition system also includes a UPS system and a data acquisition box, wherein the UPS system, the data acquisition module, and the first data transmission radio are all located inside the data acquisition box.

4. The intelligent operation and monitoring device for a sewage pumping station according to claim 1, characterized in that: The automatic control system also includes a control cabinet, in which the PLC system, the Internet of Things module, and the second data transmission radio are all housed.

5. A method for intelligent operation and monitoring of a sewage pumping station, characterized in that: An intelligent operation and monitoring device for a sewage pumping station as described in any one of claims 1-4, comprising: The liquid level signal and voltage status signal of the railway sump are collected, and the liquid level signal is transmitted to the second data transmission radio through the first data transmission radio. Receive liquid level signals and voltage status signals and send them to the PLC system; An alarm signal is generated based on the liquid level signal and voltage status signal; Send data and alarm signals to the monitoring platform.

6. The intelligent operation and monitoring method for a sewage pumping station according to claim 5, characterized in that: Calculate the actual liquid level H in the sump, and set the warning liquid level P1 and the danger liquid level P2; When the actual liquid level H is greater than the warning liquid level P1 but less than the danger liquid level P2, a level one alarm is triggered. The IoT module sends the alarm event to the monitoring platform, and the monitoring platform provides a notification via SMS or a dialog box on the display interface. The alarm event includes the actual liquid level H, the current time, and the sump number. When the actual liquid level H is greater than the danger level P2, a level 2 alarm is triggered. The IoT module sends the alarm event to the monitoring platform, which then provides a notification via SMS, a dialog box on the display interface, and a buzzer. The alarm event includes the actual liquid level H, the current time, and the sump number. When the buzzer button is pressed, the buzzer stops sounding.

7. The intelligent operation and monitoring method for a sewage pumping station according to claim 5, characterized in that: When the liquid level signal detected by the reed switch level gauge lasts for t seconds, the current liquid level is taken as the actual liquid level H, where t is greater than or equal to 3 seconds.

8. The intelligent operation and monitoring method for a sewage pumping station according to claim 5, characterized in that: When the number of pump start-stop cycles changes within time period T but the liquid level signal detected by the reed switch level gauge remains unchanged, the float is determined to be stuck, triggering a level one alarm. The IoT module sends this alarm event to the monitoring platform, which then provides a notification via SMS or a dialog box on the display interface. The alarm event includes the change in the number of pump start-stop cycles, the current time, the sump number, the current liquid level, and the reed switch level gauge number.

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