Water pump fault monitoring system

Abstract

The utility model relates to the technical field of mechanical fault monitoring, in particular to a water pump fault monitoring system which comprises a LoRa network module, a remote service terminal and a plurality of acquisition and control units, and each acquisition and control unit comprises a power box, an acquisition and control integrated terminal, a frequency converter and a temperature vibration sensing unit arranged on a slurry pump. The power box is electrically connected with the acquisition and control integrated terminal, the temperature vibration sensing unit is connected to the acquisition and control integrated terminal, the acquisition and control integrated terminal is in communication connection with the remote service terminal through the LoRa network module, and the frequency converter is in communication connection with the acquisition and control integrated terminal and is electrically connected with the slurry pump. According to the technical scheme, all the slurry pumps are connected to the remote service terminal through the Internet of Things, the operation state of equipment can be remotely monitored, the equipment can be controlled in the direction, the operation state of the slurry pumps can be analyzed in real time, linkage adjustment of all the slurry pumps in a plant area is achieved, energy consumption of the whole production line is optimized, and therefore electricity is saved.

Description

Technical Field

[0001] The utility model relates to the technical field of mechanical failure monitoring, in particular to a water pump failure monitoring system. Background Art

[0002] At present, some factories use manual inspection to conduct regular inspections of slurry pump (water pump) equipment and record various working parameters of slurry pump. However, manual inspection has information lag, and due to the complex working environment of the equipment, there will be certain safety hazards. Due to the different working environments of slurry pumps, sometimes slurry pump equipment will have failures such as ropes, bags and other foreign objects entangled in the equipment or other failures. When the equipment fails, it is difficult to eliminate it in time, which will affect normal production. Therefore, it is necessary to monitor the operating status of the equipment and diagnose it in real time, so that potential problems can be discovered in advance, the number of equipment failures and unexpected shutdowns during work can be reduced, and early fault prediction, early cause judgment, and early problem solving can be achieved to avoid or reduce the occurrence of accidents. By analyzing the fault, it is also convenient to take appropriate solutions in time.

[0003] The Chinese invention patent document with the prior art publication number CN116292334A discloses a method for diagnosing faults of slurry pumps, which uses sensors installed on the slurry pumps to collect data on the normal operation and failure of the slurry pumps, and then performs noise reduction and analysis on the data to determine the specific location of the failure; for other faults, the fault sample data set is trained, tested and optimized to complete the equipment fault diagnosis. This technical solution can diagnose and predict equipment faults, and take appropriate solutions in a timely manner through fault analysis. However, this technical solution is mainly for equipment fault diagnosis, focusing on the processing and application of collected data, and cannot achieve the operation control of multiple devices. For factories with multiple devices, the practicality of this technical solution is not strong. Utility Model Content

[0004] The purpose of the utility model is to propose a water pump fault monitoring system in response to the deficiencies of the above-mentioned prior art. Through the Internet of Things, all slurry pumps are connected to the network access control center, so as to realize both remote monitoring of the equipment operation status and direction control of the equipment, and to analyze the slurry pump operation status in real time, to achieve linkage adjustment of all slurry pumps in the factory, to optimize the energy consumption of the entire production line, and thus save electricity.

[0005] The utility model is realized by adopting the following technical solutions:

[0006] A water pump fault monitoring system, comprising a LoRa network module, a remote service terminal and several acquisition and control units, wherein the acquisition and control units include a power box, an integrated acquisition and control terminal, a frequency converter and a temperature and vibration sensor unit arranged on a slurry pump;

[0007] The power supply box is electrically connected to the integrated acquisition and control terminal and is used to provide the integrated acquisition and control terminal with a working power supply;

[0008] The temperature and vibration sensing unit is connected to the integrated acquisition and control terminal to collect and transmit the temperature signal and vibration signal of the slurry pump to the integrated acquisition and control terminal;

[0009] The integrated acquisition and control terminals of all acquisition and control units are connected to the remote service terminal through the LoRa network module to analyze the collected signals including temperature and vibration, obtain monitoring data and upload it to the remote service system, and receive the slurry pump operation status control commands from the remote service system;

[0010] The frequency converter is communicatively connected to the integrated acquisition and control terminal and electrically connected to the slurry pump, and is used to execute the control of the integrated acquisition and control terminal on the operating state of the slurry pump.

[0011] Preferably, the temperature vibration sensing unit includes temperature vibration sensor I and temperature vibration sensor II, the axial directions of temperature vibration sensor I and temperature vibration sensor II coincide with the radial direction of the slurry pump, and temperature vibration sensor I and temperature vibration sensor II are orthogonally distributed at 90° in the radial direction of the slurry pump.

[0012] Preferably, it also includes an electrical signal acquisition unit communicatively connected to the integrated acquisition and control terminal; the electrical signal acquisition unit includes three voltage transformers for acquiring the working voltage of the slurry pump and three current transformers for acquiring the working current of the slurry pump.

[0013] Preferably, the integrated acquisition and control terminal includes a signal processing unit and a micro-control unit; the signal processing unit includes a current signal processing circuit, a voltage signal processing circuit and a temperature vibration signal acquisition circuit; the voltage transformer is connected to the micro-control unit through the voltage signal processing circuit, the current transformer is connected to the micro-control unit through the current signal processing circuit, and the temperature vibration sensing unit is connected to the micro-control unit through the temperature vibration signal acquisition circuit.

[0014] Preferably, the integrated acquisition and control terminal also includes an audible and visual alarm, and the audible and visual alarm is electrically connected to the micro-control unit.

[0015] Preferably, the integrated acquisition and control terminal also includes a digital display unit, and the digital display unit is electrically connected to the micro-control unit.

[0016] Preferably, the integrated acquisition and control terminal is connected to the frequency converter via an RS485 communication unit.

[0017] Preferably, it also includes a signal box, and the integrated acquisition and control terminal is installed in the signal box.

[0018] Beneficial technical effects brought by the utility model:

[0019] 1) This technical solution proposes a water pump fault monitoring system. Through the construction of the Internet of Things, it supports connecting multiple slurry pumps to the network and accessing the remote service terminal, which can not only remotely monitor the operating status of the equipment but also reversely control the equipment.

[0020] 2) This technical solution proposes a water pump fault monitoring system. For the operation of the slurry pump, the front-end integrated acquisition and control terminal and the back-end remote service terminal can analyze the operation status of the slurry pump in real time. Once a failure risk occurs, the emergency plan can be activated. For example, the personnel can be notified to prepare spare parts to inspect and repair the risk pump body, and the workload of the associated pumps on the production line can be reduced or shut down through various linkage mechanisms to minimize losses.

[0021] 3) According to the operation of the production line, the workload of each pump can be adjusted in a coordinated manner to optimize the energy consumption of the entire production line and save electricity. Specifically, the data obtained by the sensor reaches the integrated acquisition and control terminal, which performs preliminary conversion of the numerical value and then transmits it to the remote service terminal for comparison of real-time data with reference data, and then dynamically adjusts the inverter to control the motor power, thereby saving electricity. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is the structural principle diagram of the slurry pump fault monitoring system;

[0023] Figure 2 This is the working principle diagram of the integrated acquisition and control terminal.

[0024] In the figure:

[0025] 1. LoRa antenna; 2. LoRa gateway; 3. Remote service terminal; 4. Power box; 5. Integrated acquisition and control terminal; 6. Frequency converter; 7. Slurry pump; 8. Temperature and vibration sensor I; 9. Temperature and vibration sensor II; 10. Voltage transformer; 11. Current transformer; 12. Signal box. DETAILED DESCRIPTION

[0026] In order to make the purpose, technical solution and advantages of the utility model clearer, the technical solution of the utility model will be clearly and completely described below in conjunction with the drawings in the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, rather than all of the embodiments.

[0027] Therefore, the following detailed description of the present invention provided in the accompanying drawings is not intended to limit the scope of the present invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0028] Example 1

[0029] This embodiment discloses a water pump fault monitoring system, as a basic implementation scheme of the utility model, including a LoRa network module, a remote service terminal 3 and several acquisition and control units, the acquisition and control units including a power box 4, an integrated acquisition and control terminal 5, a frequency converter 6 and a temperature and vibration sensor unit arranged on a slurry pump 7. Figure 1 As shown, the LoRa network module is formed by the cooperation of the LoRa antenna 1 and the LoRa gateway 2. Furthermore, when there are multiple acquisition and control units, the LoRa network module can be composed of a LoRa gateway 2 and multiple LoRa antennas 1 corresponding to the acquisition and control units. The power box 4 is electrically connected to the acquisition and control integrated terminal 5, and is used to equip the acquisition and control integrated terminal 5 with a working power supply; the temperature and vibration sensor unit is connected to the acquisition and control integrated terminal 5, and is used to collect and transmit the temperature signal and vibration signal of the slurry pump 7 to the acquisition and control integrated terminal 5; the acquisition and control integrated terminal 5 of all acquisition and control units is connected to the remote service terminal 3 through the LoRa network module, and is used to perform data analysis on the collected signals including temperature and vibration, obtain monitoring data and upload them to the remote service system, and receive the remote service system's slurry pump 7 operation status control command; the frequency converter 6 is connected to the acquisition and control integrated terminal 5, and is electrically connected to the slurry pump 7, and is used to execute the acquisition and control integrated terminal 5 to control the operation status of the slurry pump 7.

[0030] In this technical solution, one acquisition and control unit corresponds to one slurry pump 7. Based on this, data is wirelessly transmitted to the remote service terminal 3 through the acquisition and control integrated terminal 5, so that multi-linking can be achieved. Among them, the acquisition and control integrated terminal 5 has the ability to perform preliminary signal processing locally and has the ability to analyze fault characteristics. It can not only obtain the status signal of the slurry pump 7 motor, but also reversely control the slurry pump 7 motor through the slurry pump 7 motor inverter 6. Specifically, when a more serious fault occurs in the motor, the motor shutdown command sent by the remote service system can be sent to the inverter 6 through data communication to quickly shut down the slurry pump 7 motor, so as to avoid greater losses caused by the slurry pump 7 motor failure.

[0031] Example 2

[0032] The present embodiment discloses a water pump fault monitoring system, which is a preferred implementation scheme of the utility model, including a LoRa network module, a remote service terminal 3 and several acquisition and control units, wherein the acquisition and control unit includes a power box 4, an integrated acquisition and control terminal 5, a frequency converter 6 and a temperature and vibration sensor unit arranged on a slurry pump 7; the power box 4 is electrically connected to the integrated acquisition and control terminal 5, and is used to equip the integrated acquisition and control terminal 5 with a working power supply; the temperature and vibration sensor unit is connected to the integrated acquisition and control terminal 5, and is used to collect and transmit the temperature signal and vibration signal of the slurry pump 7 to the integrated acquisition and control terminal 5; the integrated acquisition and control terminals 5 of all acquisition and control units are communicatively connected to the remote service terminal 3 through the LoRa network module, and are used to perform data analysis on the collected signals including temperature and vibration, obtain monitoring data and upload them to the remote service system, and receive the remote service system's slurry pump 7 operating status control command; the frequency converter 6 is communicatively connected to the integrated acquisition and control terminal 5, and is electrically connected to the slurry pump 7, and is used to execute the control of the operating status of the slurry pump 7 by the integrated acquisition and control terminal 5.

[0033] Furthermore, the temperature vibration sensing unit includes a temperature vibration sensor I8 and a temperature vibration sensor II9, the axial directions of the temperature vibration sensor I8 and the temperature vibration sensor II9 are coincident with the radial direction of the slurry pump 7, and the temperature vibration sensor I8 and the temperature vibration sensor II9 are orthogonally distributed at 90° in the radial direction of the slurry pump 7. Specifically, Figure 1 As shown, the temperature vibration sensor II 9 is installed close to the motor housing of the slurry pump 7 , and the temperature vibration sensor I 8 is installed close to the pump body housing of the slurry pump 7 .

[0034] Based on the layout structure of the above-mentioned temperature vibration sensing unit, this technical solution accurately obtains the vibration amount of the slurry pump 7x in the horizontal direction and y in the vertical direction, and can obtain the radial centrifugal vibration by calculating the vibration of x\y to determine the bearing failure problem.

[0035] Example 3

[0036] The present embodiment discloses a water pump fault monitoring system, which is a preferred implementation scheme of the utility model, including a LoRa network module, a remote service terminal 3 and several acquisition and control units, wherein the acquisition and control unit includes a power box 4, an integrated acquisition and control terminal 5, a frequency converter 6 and a temperature and vibration sensor unit arranged on a slurry pump 7; the power box 4 is electrically connected to the integrated acquisition and control terminal 5, and is used to equip the integrated acquisition and control terminal 5 with a working power supply; the temperature and vibration sensor unit is connected to the integrated acquisition and control terminal 5, and is used to collect and transmit the temperature signal and vibration signal of the slurry pump 7 to the integrated acquisition and control terminal 5; the integrated acquisition and control terminals 5 of all acquisition and control units are communicatively connected to the remote service terminal 3 through the LoRa network module, and are used to perform data analysis on the collected signals including temperature and vibration, obtain monitoring data and upload them to the remote service system, and receive the remote service system's slurry pump 7 operating status control command; the frequency converter 6 is communicatively connected to the integrated acquisition and control terminal 5, and is electrically connected to the slurry pump 7, and is used to execute the control of the operating status of the slurry pump 7 by the integrated acquisition and control terminal 5.

[0037] Furthermore, the temperature vibration sensing unit includes temperature vibration sensor I8 and temperature vibration sensor II9, the axial directions of temperature vibration sensor I8 and temperature vibration sensor II9 coincide with the radial direction of the slurry pump 7, and temperature vibration sensor I8 and temperature vibration sensor II9 are distributed orthogonally at 90° in the radial direction of the slurry pump 7.

[0038] Furthermore, it also includes an electrical signal acquisition unit that is communicatively connected to the integrated acquisition and control terminal 5; the electrical signal acquisition unit includes a voltage transformer 10 for obtaining the working voltage of the slurry pump 7 and a current transformer 11 for obtaining the working current of the slurry pump 7. Since the slurry pump 7 is connected to a three-phase power supply, three voltage transformers 10 and three current transformers 11 are respectively provided.

[0039] Example 4

[0040] The present embodiment discloses a water pump fault monitoring system, which is a preferred implementation scheme of the utility model, including a LoRa network module, a remote service terminal 3 and several acquisition and control units, wherein the acquisition and control unit includes a power box 4, an integrated acquisition and control terminal 5, a frequency converter 6 and a temperature and vibration sensor unit arranged on a slurry pump 7; the power box 4 is electrically connected to the integrated acquisition and control terminal 5, and is used to equip the integrated acquisition and control terminal 5 with a working power supply; the temperature and vibration sensor unit is connected to the integrated acquisition and control terminal 5, and is used to collect and transmit the temperature signal and vibration signal of the slurry pump 7 to the integrated acquisition and control terminal 5; the integrated acquisition and control terminals 5 of all acquisition and control units are communicatively connected to the remote service terminal 3 through the LoRa network module, and are used to perform data analysis on the collected signals including temperature and vibration, obtain monitoring data and upload them to the remote service system, and receive the remote service system's slurry pump 7 operating status control command; the frequency converter 6 is communicatively connected to the integrated acquisition and control terminal 5, and is electrically connected to the slurry pump 7, and is used to execute the control of the operating status of the slurry pump 7 by the integrated acquisition and control terminal 5.

[0041] Furthermore, the temperature vibration sensing unit includes temperature vibration sensor I8 and temperature vibration sensor II9, the axial directions of temperature vibration sensor I8 and temperature vibration sensor II9 coincide with the radial direction of the slurry pump 7, and temperature vibration sensor I8 and temperature vibration sensor II9 are distributed orthogonally at 90° in the radial direction of the slurry pump 7.

[0042] Furthermore, it also includes an electrical signal acquisition unit that is communicatively connected to the integrated acquisition and control terminal 5; the electrical signal acquisition unit includes three voltage transformers 10 for obtaining the working voltage of the slurry pump 7 and three current transformers 11 for obtaining the working current of the slurry pump 7.

[0043] Furthermore, the integrated acquisition and control terminal 5 includes a signal processing unit and a micro-control unit; the signal processing unit includes a current signal processing circuit, a voltage signal processing circuit and a temperature vibration signal acquisition circuit; the voltage transformer 10 is connected to the micro-control unit through the voltage signal processing circuit, the current transformer 11 is connected to the micro-control unit through the current signal processing circuit, and the temperature vibration sensing unit is connected to the micro-control unit through the temperature vibration signal acquisition circuit. Figure 2 As shown, the micro-control unit adopts an MCU (DSP) module which integrates an ADC sampling unit and a fast Fourier transform (FFT) unit.

[0044] Based on the above-mentioned integrated acquisition and control terminal 5, the technical solution can calculate the three-phase balance and phase error through the collected current to obtain the error value to determine the motor coil fault; calculate the supply voltage and back electromotive force voltage by collecting the voltage to determine whether the motor coil and the rotor are abnormal; when the temperature exceeds the rated temperature, the motor is overloaded, and the cause of the motor overload is usually excessive load and mechanical damage; when the vibration in the x and y directions is too large, it is determined that the motor bearing or fixed seat is abnormal.

[0045] Example 5

[0046] The present embodiment discloses a water pump fault monitoring system, which is a preferred implementation scheme of the utility model, including a LoRa network module, a remote service terminal 3 and several acquisition and control units, wherein the acquisition and control unit includes a power box 4, an integrated acquisition and control terminal 5, a frequency converter 6 and a temperature and vibration sensor unit arranged on a slurry pump 7; the power box 4 is electrically connected to the integrated acquisition and control terminal 5, and is used to equip the integrated acquisition and control terminal 5 with a working power supply; the temperature and vibration sensor unit is connected to the integrated acquisition and control terminal 5, and is used to collect and transmit the temperature signal and vibration signal of the slurry pump 7 to the integrated acquisition and control terminal 5; the integrated acquisition and control terminals 5 of all acquisition and control units are communicatively connected to the remote service terminal 3 through the LoRa network module, and are used to perform data analysis on the collected signals including temperature and vibration, obtain monitoring data and upload them to the remote service system, and receive the remote service system's slurry pump 7 operating status control command; the frequency converter 6 is communicatively connected to the integrated acquisition and control terminal 5, and is electrically connected to the slurry pump 7, and is used to execute the control of the operating status of the slurry pump 7 by the integrated acquisition and control terminal 5.

[0047] Furthermore, the temperature vibration sensing unit includes temperature vibration sensor I8 and temperature vibration sensor II9, the axial directions of temperature vibration sensor I8 and temperature vibration sensor II9 coincide with the radial direction of the slurry pump 7, and temperature vibration sensor I8 and temperature vibration sensor II9 are distributed orthogonally at 90° in the radial direction of the slurry pump 7.

[0048] Furthermore, it also includes an electrical signal acquisition unit that is communicatively connected to the integrated acquisition and control terminal 5; the electrical signal acquisition unit includes three voltage transformers 10 for obtaining the working voltage of the slurry pump 7 and three current transformers 11 for obtaining the working current of the slurry pump 7.

[0049] Furthermore, the integrated acquisition and control terminal 5 includes a signal processing unit and a micro-control unit; the signal processing unit includes a current signal processing circuit, a voltage signal processing circuit and a temperature vibration signal acquisition circuit; the voltage transformer 10 is connected to the micro-control unit through the voltage signal processing circuit, the current transformer 11 is connected to the micro-control unit through the current signal processing circuit, and the temperature vibration sensing unit is connected to the micro-control unit through the temperature vibration signal acquisition circuit. Figure 2 As shown, the integrated acquisition and control terminal 5 is also provided with a LoRa wireless communication unit for interacting with the antenna module (LoRa antenna 1).

[0050] Furthermore, the integrated acquisition and control terminal 5 also includes an audible and visual alarm, and the audible and visual alarm is electrically connected to the micro-control unit. When a device fails, an audible and visual alarm is issued, so that the staff can know and quickly find the fault location in time.

[0051] Furthermore, the integrated acquisition and control terminal 5 further includes a digital display unit, and the digital display unit is electrically connected to the micro-control unit. The digital display unit can display the numerical value of the signal collected by the technical solution.

[0052] Furthermore, the integrated acquisition and control terminal 5 is connected to the frequency converter 6 via an RS485 communication unit.

[0053] Furthermore, it also includes a signal box 12, and the integrated acquisition and control terminal 5 is installed in the signal box 12, which protects the integrated acquisition and control terminal 5 while regulating electricity safety.

Claims

1. A water pump fault monitoring system, characterized in that: It comprises a LoRa network module, a remote service terminal (3) and a plurality of acquisition and control units, wherein the acquisition and control units comprise a power supply box (4), an integrated acquisition and control terminal (5), a frequency converter (6) and a temperature and vibration sensor unit arranged on a slurry pump (7); The power supply box (4) is electrically connected to the integrated acquisition and control terminal (5) and is used to provide the integrated acquisition and control terminal (5) with a working power supply; The temperature vibration sensing unit is connected to the integrated acquisition and control terminal (5) and is used to collect and transmit the temperature signal and vibration signal of the slurry pump (7) to the integrated acquisition and control terminal (5); the temperature vibration sensing unit comprises a temperature vibration sensor I (8) and a temperature vibration sensor II (9); the axial directions of the temperature vibration sensor I (8) and the temperature vibration sensor II (9) both coincide with the radial direction of the slurry pump (7), and the temperature vibration sensor I (8) and the temperature vibration sensor II (9) are orthogonally distributed at 90 degrees in the radial direction of the slurry pump (7); The integrated acquisition and control terminals (5) of all acquisition and control units are connected to the remote service terminal (3) through the LoRa network module, and are used to perform data analysis on the acquisition signals including temperature and vibration, obtain monitoring data and upload it to the remote service system, and receive the operation status control command of the slurry pump (7) from the remote service system; The frequency converter (6) is communicatively connected to the integrated acquisition and control terminal (5) and electrically connected to the slurry pump (7), and is used to execute control of the operating state of the slurry pump (7) by the integrated acquisition and control terminal (5).

2. A water pump fault monitoring system as claimed in claim 1, characterized in that: It also includes an electric signal acquisition unit that is communicatively connected to the integrated acquisition and control terminal (5); the electric signal acquisition unit includes three voltage transformers (10) for acquiring the working voltage of the slurry pump (7) and three current transformers (11) for acquiring the working current of the slurry pump (7).

3. A water pump fault monitoring system as claimed in claim 2, characterized in that: The integrated acquisition and control terminal (5) comprises a signal processing unit and a micro-control unit; the signal processing unit comprises a current signal processing circuit, a voltage signal processing circuit and a temperature vibration signal acquisition circuit; the voltage transformer (10) is connected to the micro-control unit via the voltage signal processing circuit, the current transformer (11) is connected to the micro-control unit via the current signal processing circuit, and the temperature vibration sensing unit is connected to the micro-control unit via the temperature vibration signal acquisition circuit.

4. A water pump fault monitoring system as claimed in claim 3, characterized in that: The integrated acquisition and control terminal (5) also includes an audible and visual alarm, and the audible and visual alarm is electrically connected to the micro-control unit.

5. A water pump fault monitoring system as claimed in claim 3, characterized in that: The integrated acquisition and control terminal (5) further comprises a digital display unit, and the digital display unit is electrically connected to the micro-control unit.

6. A water pump fault monitoring system as claimed in claim 1, characterized in that: The integrated acquisition and control terminal (5) is connected to the frequency converter (6) via an RS485 communication unit.

7. A water pump fault monitoring system as claimed in claim 1, characterized in that: It also includes a signal box (12), wherein the integrated acquisition and control terminal (5) is installed in the signal box (12).

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