Structure fault diagnosis system of pump station unit

Abstract

The utility model provides a structure fault diagnosis system of a pump station unit, which comprises an upper semi-circular shell and a lower semi-circular shell, the rear parts of the two semi-circular shells are hinged together, the front parts of the two semi-circular shells are fixed together through a locking mechanism, an air bag assembly is sleeved in the semi-circular shells, the air bag assembly comprises a semi-circular air bag body, an air tap and a communicating pipe, and an inflating mechanism is configured. A semicircular air bag body is respectively sleeved in each semicircular shell, the upper semicircular air bag body and the lower semicircular air bag body are communicated through a communicating pipe, the semicircular air bag body on the upper side is provided with an air nozzle so as to facilitate inflation and deflation operation, sensor modules are uniformly distributed on the inner surface of each semicircular air bag body, and each sensor is respectively connected with a signal input end of a controller. The device can meet the detection requirements of different pipe diameters, is high in flexibility, is convenient to use in various occasions, achieves the quick and convenient installation and disassembly through the design of the semicircular housing and the locking mechanism, and improves the work efficiency.

Description

Technical Field

[0001] The utility model belongs to the technical field of pump station fault detection, and in particular relates to a structural fault diagnosis system for a pump station unit. Background Art

[0002] A pump station unit is a kind of equipment system used to lift and transport liquids, which is widely used in municipal water supply and drainage, industrial production, agricultural irrigation and other fields. It is mainly composed of pumps, drive devices, pipeline systems and control systems, etc., and lifts liquids from low places to high places, or transports them from one place to another by electric or mechanical drive. Pump station units may have various faults during operation, including but not limited to: wear and damage of the pump body, failure of the drive device, leakage or blockage of the pipeline, insufficient or abnormal flow, abnormal temperature and pressure, and vibration and noise problems.

[0003] In order to ensure the normal operation of the pump station unit, the following diagnostic methods and equipment are usually used: Vibration sensor: used to detect vibration during equipment operation and identify mechanical failures. Flow meter: used to monitor liquid flow and determine the working efficiency and performance of the pump station. Infrared thermal imager: used to monitor the temperature distribution of the equipment and detect overheating or uneven cooling. Strain sensor: used to detect pipeline stress and deformation to prevent pipeline rupture and leakage. The purpose of diagnosing the pump station unit is to promptly detect and handle abnormalities in equipment operation, prevent the expansion of faults, reduce equipment downtime and maintenance costs, and ensure the safe and efficient operation of the system.

[0004] However, in the prior art, the fault diagnosis of pump station units usually relies on a single or a few sensor devices, such as vibration sensors and flow meters, to monitor local or single parameters. These devices usually transmit data to the local control center by wire for preliminary analysis and processing. After a fault occurs, it is handled by manual inspection and maintenance. The prior art has the following problems and shortcomings in the fault diagnosis of pump station units. Limited monitoring range: Existing diagnostic equipment can usually only monitor a single parameter (such as vibration or flow), and cannot fully grasp the operating status of the equipment. Poor real-time performance: Due to reliance on manual detection and analysis, the real-time performance of fault diagnosis and processing is poor, and it is difficult to detect and respond to equipment failures in a timely manner. Single data transmission method: Most existing systems rely on wired transmission, which has poor flexibility and is greatly affected by the environment. Inconvenient installation and maintenance: Existing equipment is complicated to install and maintain, affecting normal production operations. High cost: A large amount of manpower and equipment investment is required, which increases operating costs.

[0005] These deficiencies in the existing technology lead to low fault diagnosis efficiency and high maintenance costs for pump station units. Therefore, there is an urgent need for an efficient system that can monitor and diagnose pump station unit faults in real time and comprehensively to improve management efficiency and reduce maintenance costs. Utility Model Content

[0006] In view of the defects and problems existing in the prior art, the utility model aims to provide a comprehensive monitoring system suitable for different pipe diameters, easy to install and disassemble, and capable of real-time monitoring and diagnosis of pipeline faults of pump station units, thereby improving management efficiency and reducing maintenance costs.

[0007] The utility model solves the technical problem by adopting a structural fault diagnosis system of a pump station unit, comprising an upper and lower semicircular ring shell, the rear parts of the two are hinged together by a hinge, the front parts of the two are fixed together by a locking mechanism, and after the two are buckled, a combined cylindrical structure can be formed; an airbag assembly is installed in the semicircular ring shell, the airbag assembly includes a semicircular airbag body, an air nozzle and a connecting pipe, and an inflation mechanism is configured, each semicircular ring shell is respectively installed with a semicircular airbag body, the upper and lower semicircular airbag bodies are connected by a connecting pipe, the upper semicircular airbag body is equipped with an air nozzle to facilitate inflation and deflation operations, and sensor modules are evenly distributed on the inner surface of each semicircular airbag body, and each sensor is respectively connected to the signal input of the controller.

[0008] Preferably, the semicircular ring shell includes a shell body, a partition, a connection end and an airbag area. The partitions are respectively arranged at both ends of the shell body near the port position, the area outside the partitions at both ends is the connection end, the connection end is filled with a filling layer, the area between the partitions at both ends is the airbag area, and the airbag assembly is installed in the airbag area.

[0009] Preferably, the sensor module includes a vibration sensor, an ultrasonic flowmeter or an electromagnetic flowmeter, an infrared thermal imager and a strain sensor.

[0010] Preferably, a human-machine interface is fixedly installed on the outer side of the semicircular ring housing, and the signal output end of the controller is connected to the human-machine interface.

[0011] Preferably, the locking mechanism includes a clearance groove, a through hole and a fixing bolt. The clearance grooves are respectively arranged at the butt edges of the upper and lower semicircular ring shells, and a through hole is respectively arranged at the bottom of each clearance groove. A fixing bolt is installed through the upper and lower through holes.

[0012] Preferably, handles are provided at the front of the upper and lower semicircular ring shells, respectively, to facilitate opening and closing operations.

[0013] The beneficial effects of the utility model are as follows: Based on the above scheme, the system can be applied to the detection needs of different pipe diameters, has high flexibility, and is easy to use in a variety of occasions. The design of the semi-circular ring shell and the locking mechanism enables fast and convenient installation and disassembly, thereby improving work efficiency. The integration of multiple sensor modules can collect pipeline vibration, flow, temperature and stress data in real time to ensure comprehensive monitoring and rapid diagnosis of pipeline operation status. The airbag assembly is used to achieve reliable fitting of the sensor and the pipeline, and a non-invasive method is used for signal acquisition to avoid interference with the normal operation of the pipeline. By displaying real-time data and alarm information through the human-machine interface, managers can promptly grasp the equipment status, quickly respond to and handle abnormal situations, and improve management efficiency. Real-time monitoring and diagnosis of faults reduce equipment downtime and reduce maintenance and overhaul costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a schematic diagram of the appearance structure of the utility model;

[0015] Figure 2 yes Figure 1 Schematic diagram of the longitudinal section structure;

[0016] Figure 3 yes Figure 1 Schematic diagram of the structure of the lower and middle semicircular ring shell;

[0017] Figure 4 yes Figure 1 Schematic diagram of the structure of the upper and middle semicircular ring shell.

[0018] Figure 5 It is a system block diagram of the utility model.

[0019] Numbers in the figure: Numbers in the figure: semicircular ring shell 1; hinge 2; locking mechanism 3; handle 4; airbag assembly 5; sensor module 6; filling layer 7; human-machine interface 8; shell body 11; partition 12; connecting end 13; airbag area 14; clearance groove 31; through hole 32; fixing bolt 33; semicircular airbag body 51; air nozzle 52; connecting pipe 53. DETAILED DESCRIPTION

[0020] The utility model is further described below in conjunction with the accompanying drawings and embodiments. Example

[0021] A structural fault diagnosis system for pump station units, such as Figure 1-Figure 4 As shown, the system mainly includes two upper and lower semicircular housings 1, the rear parts of which are hinged together by a hinge 2, and the front parts of which are fixed together by a locking mechanism 3. After the two are buckled, a combined cylindrical structure can be formed, which is fixed on the outside of the pipe to be tested when in use. The front parts of the upper and lower semicircular housings 1 are also provided with handles 4 respectively to facilitate opening and closing operations.

[0022] like Figure 3 As shown, the semicircular ring housing 1 comprises a housing body 11, a partition 12, a connection end 13 and an airbag area 14. The partitions 12 are respectively arranged at both ends of the housing body 11 near the port positions, the area outside the partitions 12 at both ends is the connection end 13, the connection end 13 is filled with a filling layer 7, the area between the partitions 12 at both ends is the airbag area 14, and the airbag assembly 5 is mounted in the airbag area 14.

[0023] like Figure 2 and Figure 3 As shown, the airbag assembly 5 includes a semicircular airbag body 51, an air nozzle 52 and a connecting tube 53. A semicircular airbag body 51 is respectively installed in each semicircular ring shell 1, and the upper and lower semicircular airbag bodies 51 are connected by a connecting tube 53. The upper semicircular airbag body 51 is installed with an air nozzle 52 to facilitate the inflation and deflation operation. Sensor modules 6 are evenly distributed on the inner surface of each semicircular airbag body 51. The sensor module 6 includes a vibration sensor, an ultrasonic flowmeter or an electromagnetic flowmeter, an infrared thermal imager and a strain sensor (for detecting pipeline stress and deformation), etc. Each sensor is connected to the signal input of the controller. A human-machine interface 8 is fixedly installed on the outer side of the semicircular ring shell 1. The signal output end of the controller is connected to the human-machine interface 8, which is used to display the detection signal through the human-machine interface 8.

[0024] like Figure 2 and Figure 4 As shown, the locking mechanism 3 includes a clearance groove 31, a through hole 32 and a fixing bolt 33. The clearance grooves 31 are respectively arranged at the butt edges of the upper and lower semicircular ring shells 1, and a through hole 32 is respectively arranged at the bottom of each clearance groove 31, and a fixing bolt 33 is installed between the upper and lower through holes 32.

[0025] Vibration sensor: installed on the pad on the inner wall of the airbag to detect the vibration of the pipeline. Ultrasonic flow meter or electromagnetic flow meter: used to detect the flow rate of liquid in the pipeline. Infrared thermal imager: used to monitor the temperature distribution on the surface of the pipeline and detect overheating or uneven cooling.

[0026] Strain sensor: installed on the pad to detect the stress and deformation of the pipeline.

[0027] Data acquisition module: The sensor module collects the vibration, flow, temperature and stress data of the pipeline in real time and transmits them to the data acquisition module through the airbag.

[0028] Communication module: Use wireless transmission technology (such as WiFi, LoRa, etc.) or wired transmission technology (such as Ethernet) to achieve remote data transmission. Ensure that data is transmitted to the remote monitoring center in real time, so that managers can grasp the status of equipment in a timely manner.

[0029] Human-machine interface (HMI): The display is used to display real-time data, historical data, alarm information, etc. The operation panel is used for parameter setting and data query.

[0030] Fault detection and alarm: The data processing module detects abnormalities in the sensor data according to the set threshold. Once an abnormality is found, the system sends an alarm message through the communication module and displays it on the HMI interface.

[0031] Remote monitoring and maintenance: The system supports remote monitoring via wireless or wired networks, and managers can view the status of equipment remotely. The remote monitoring center can arrange maintenance and repairs in a timely manner based on alarm information.

[0032] Based on the above scheme, after the upper and lower semicircular ring shells 1 are assembled and mounted on the outside of the detected pipeline, the inner wall of the semicircular airbag 51 can be pressed against the outer wall of the pipeline by inflating the air nozzle 52, so that the sensor module 6 can reliably fit the outer wall of the pipeline, and the corresponding signal is collected through the outer wall of the pipeline in a non-invasive manner. This scheme is suitable for the detection needs of different pipe diameters, and is flexible and convenient to install and remove. This scheme can be connected to an external power supply, or a battery and a wireless transceiver module can be configured to transmit detection signals to the background server. The fault diagnosis system can comprehensively monitor the operating status of the pipeline of the pump station unit, collect data through a variety of sensors, analyze and detect faults in real time, and ensure the safe and efficient operation of the system. Remote monitoring is achieved through wireless or wired networks, which improves management efficiency and reduces maintenance costs.

[0033] Based on the above scheme, the specific steps of using the pump station unit structural fault diagnosis system are as follows:

[0034] (1) Prepare the equipment: Confirm that all equipment components (semi-circular housing 1, hinge 2, locking mechanism 3, handle 4, airbag assembly 5, sensor module 6, human-machine interface 8, etc.) are intact and functioning properly.

[0035] (2) Install the housing: connect the upper and lower semicircular housings 1 to the outside of the pipe to be tested, hinge the rear parts of the two together through the hinge 2, and fix the front parts together through the locking mechanism 3 to form a combined cylindrical structure. Use the handle 4 to open and close the housing to ensure that the housing is stable.

[0036] (3) Installing the airbag assembly: a partition 12 is provided at both ends of the housing body 11 near the port positions, and the airbag assembly 5 is mounted in the airbag area 14 .

[0037] (4) Inflation and fixation: Inflate the airbag assembly 5 through the air nozzle 52 so that the inner wall of the semicircular airbag body 51 presses against the outer wall of the pipe, ensuring that the sensor module 6 can reliably fit the outer wall of the pipe and complete the signal acquisition in a non-invasive manner.

[0038] (5) Connect the sensor module: Ensure that each sensor (vibration sensor, ultrasonic flowmeter or electromagnetic flowmeter, infrared thermal imager and strain sensor) in the sensor module 6 is correctly connected to the signal input terminal of the controller. A human-machine interface 8 is fixedly installed on the outer side of the semicircular ring housing 1, and the signal output terminal of the controller is connected to the human-machine interface 8 to display the detection signal through the human-machine interface 8.

[0039] (6) Data acquisition: The sensor module 6 collects the vibration, flow, temperature and stress data of the pipeline in real time and transmits them to the data acquisition module through the airbag component 5.

[0040] (7) Fault detection and alarm: The data processing module detects abnormal conditions in the sensor data according to the set threshold. Once an abnormality is found, the system sends an alarm message through the communication module and displays it on the HMI interface. Managers can view real-time data, historical data and alarm information through the HMI interface.

[0041] (8) Remote monitoring and maintenance: The system supports remote monitoring via wireless or wired networks, and managers can view the status of equipment remotely. The remote monitoring center arranges maintenance and repairs in a timely manner based on alarm information to ensure the safe and efficient operation of the system.

[0042] (9) Maintenance and disassembly: After maintenance and overhaul, the installation steps are reversed to easily disassemble the system, making it easier to move and reinstall the equipment.

[0043] Through the above specific implementation steps, the system can comprehensively and real-time monitor and diagnose the operating status of the pump station unit pipeline, improve management efficiency, reduce maintenance costs, and ensure the safe and efficient operation of the system.

[0044] The above specific implementations of the present invention are only used to illustrate or explain the principles of the present invention, and do not constitute a limitation of the present invention. Therefore, any modification, equivalent replacement, improvement, etc. made without departing from the spirit and scope of the present invention should be included in the protection scope of the present invention.

Claims

1. A structural fault diagnosis system for a pump station unit, characterized in that: The invention comprises two upper and lower semicircular ring shells (1), the rear parts of which are hinged together by a hinge (2), and the front parts of which are fixed together by a locking mechanism (3). When the two are buckled, they can form a combined cylindrical structure. An airbag assembly (5) is mounted inside the semicircular ring shell (1), and the airbag assembly (5) comprises a semicircular airbag body (51), an air nozzle (52) and a connecting pipe (53). An inflation mechanism is provided. A semicircular airbag body (51) is mounted inside each semicircular ring shell (1). The upper and lower semicircular airbag bodies (51) are connected by a connecting pipe (53). The upper semicircular airbag body (51) is equipped with an air nozzle (52) to facilitate inflation and deflation operations. Sensor modules (6) are evenly distributed on the inner surface of each semicircular airbag body (51), and each sensor is connected to a signal input of a controller.

2. The structural fault diagnosis system of the pump station unit according to claim 1 is characterized in that: The semicircular ring housing (1) comprises a housing body (11), a partition (12), a connection end (13) and an airbag area (14). The partitions (12) are respectively arranged at both ends of the housing body (11) near the ports. The areas outside the partitions (12) at both ends are the connection ends (13). The connection ends (13) are filled with a filling layer (7). The area between the partitions (12) at both ends is the airbag area (14). The airbag assembly (5) is mounted in the airbag area (14).

3. The structural fault diagnosis system of a pump station unit according to claim 1, characterized in that: The sensor module (6) comprises a vibration sensor, an ultrasonic flow meter or an electromagnetic flow meter, an infrared thermal imager and a strain sensor.

4. The structural fault diagnosis system of a pump station unit according to claim 1, characterized in that: A human-machine interface (8) is fixedly mounted on the outer side of the semicircular ring housing (1), and a signal output end of the controller is connected to the human-machine interface (8).

5. The structural fault diagnosis system of a pump station unit according to claim 1, characterized in that: The locking mechanism (3) comprises a clearance groove (31), a through hole (32) and a fixing bolt (33). The clearance grooves (31) are respectively arranged at the butt edges of the upper and lower semicircular ring shells (1). A through hole (32) is respectively arranged at the bottom of each clearance groove (31). A fixing bolt (33) is installed between the upper and lower through holes (32).

6. The structural fault diagnosis system of a pump station unit according to claim 1, characterized in that: The front parts of the upper and lower semicircular ring shells (1) are also respectively provided with handles (4) to facilitate opening and closing operations.

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