Sewage pump service life wireless monitoring system

Abstract

The utility model relates to the technical field of water pump monitoring, in particular to a sewage pump service life wireless monitoring system, which comprises a programmable logic controller (PLC) control system, an electric actuating mechanism, a frequency converter, an internet of things subscriber identity module (SIM) card, a lightning protection control cabinet, an ultrasonic cleaning driving circuit and a data acquisition unit, the internet-of-things SIM card is arranged in an SIM card slot of the PLC control system, the input end of the PLC control system is connected with the data acquisition unit, the output end of the PLC control system is connected with the ultrasonic cleaning driving circuit, the electric actuating mechanism and the frequency converter, the output end of the frequency converter is connected to the water pump, and the water pump is connected with the PLC control system. The PLC control system is in wireless communication with a mobile terminal through an Internet of Things SIM card. According to the utility model, multi-dimensional sensing detection can be carried out on industrial sewage and the water pump, so that the service life of the sewage pump can be monitored more comprehensively, the judgment is more accurate, and wireless data transmission of the system is realized by the PLC control system through the Internet of Things SIM card.

Description

TECHNICAL FIELD

[0001] The utility model relates to water pump monitoring technical field especially relates to a sewage water pump life wireless monitoring system. BACKGROUND

[0002] Industrial sewage water pump is the key power equipment in metallurgy, chemical industry, pharmacy, printing and dyeing and other various industrial production processes and end treatment facilities, and bears the heavy responsibility of conveying industrial wastewater with high corrosion, high abrasion, complex composition and possibly containing solid particles and fiber winding objects. Compared with domestic sewage, industrial sewage is more severe and complex in water quality and working condition, and its damage to the water pump is also more severe and rapid. The traditional water pump life monitoring only monitors the current voltage and vibration of the water pump, and judges the abnormal condition and service life of the water pump according to the current voltage or vibration, but because the industrial sewage is complex, it is also necessary to detect the water quality in multiple dimensions to match the detection of the sewage water pump to realize the comprehensive monitoring of the service life of the sewage water pump. And because the detection sensor in the sewage is easy to produce dirt, which causes the detection sensor to be inaccurate, affecting the judgment of the service life of the water pump. The sludge and sundries in the sewage also need to be handled by the actuator to prolong the service life of the sewage water pump. UTILITY MODEL CONTENTS

[0003] The utility model provides a kind of sewage water pump life wireless monitoring system, and the service life of sewage water pump is monitored more comprehensively and judged more accurately by carrying out multi-dimensional sensing detection to industrial sewage and water pump, carrying out ultrasonic cleaning to the sensor used for detection, treating sludge and other impurities in sewage using electric actuator, and realizing the wireless data transmission of the system by the PLC control system through Internet of Things SIM card.

[0004] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0005] A kind of sewage water pump life wireless monitoring system, including PLC control system, electric actuator, frequency converter, Internet of Things SIM card, lightning protection control cabinet, ultrasonic cleaning drive circuit, data acquisition unit, the PLC control system and frequency converter are arranged in lightning protection control cabinet, the Internet of Things SIM card is arranged in the SIM card slot of PLC control system, the input end of the PLC control system is connected with data acquisition unit, the output end of the PLC control system is connected with ultrasonic cleaning drive circuit, electric actuator and frequency converter, the output end of the frequency converter is connected to water pump, the PLC control system is communicated with mobile terminal wireless by Internet of Things SIM card;

[0006] The data acquisition unit comprises a water quality monitoring sensor, a water pump flow sensor, a liquid level sensor, a pressure sensor, a sewage temperature sensor, a sludge interface instrument, a water pump current sensor, a water pump voltage sensor, a water pump vibration sensor and a water pump temperature sensor;

[0007] The water quality monitoring sensor comprises a pH sensor, a dissolved oxygen sensor, a turbidity sensor, a biological oxygen demand online analyzer, an ammonia nitrogen online analyzer, a redox potential sensor and a conductivity sensor;

[0008] The ultrasonic cleaning driving circuit is arranged at a position capable of cleaning the data acquisition unit, the ultrasonic cleaning driving circuit comprises a shell, an ultrasonic generating circuit and a control circuit, the ultrasonic circuit and the control circuit are arranged in the shell, the ultrasonic generating circuit emits ultrasonic waves in a transmission channel of the shell towards the data acquisition unit, a signal input end of the ultrasonic generating circuit is connected to a signal output end of the control circuit, and a signal input end of the control circuit is connected to a signal output end of the PLC control system.

[0009] Further, the PLC control system comprises a master station PLC system and a slave station PLC system, the master station PLC system and the slave station PLC system each comprise a power module, a CPU, a digital quantity input and output module, an analog quantity input and output module and a communication module, a signal line of the data acquisition unit is connected to a signal input end of the slave station PLC system, the slave station PLC system is electrically connected to the master station PLC system, and the master station PLC system adopts a redundant PLC.

[0010] Further, the electric actuator comprises an electric regulating valve, an electric butterfly valve, an electric gate valve, a mechanical grid cleaner, a submersible agitator, an air volume regulating valve and a mud scraper, and signal lines of the electric regulating valve, the electric butterfly valve, the electric gate valve, the mechanical grid cleaner, the submersible agitator, the air volume regulating valve and the mud scraper are connected to an output end of the slave station PLC system.

[0011] Further, the control circuit comprises a control chip, a capacitor and a resistor R1, the control chip adopts an AT89C51 chip, two ends of the capacitor are respectively connected to an RST pin and an EA pin of the control chip, the EA pin of the control chip is in communication with a VCC pin, the RST pin of the control chip is further connected to one end of a common connection of the resistor R1 and the capacitor, XTAL2 and XTAL3 pins of the control chip are connected to input and output ends of a crystal oscillator circuit, a grounding end of the crystal oscillator circuit is connected to the other end of the resistor R1, P1.0 and P1.1 pins of the control chip are connected to signal output ends of the PLC control system.

[0012] Further, the ultrasonic wave generating circuit comprises an ultrasonic transducer and a resistor R2, one end of the ultrasonic transducer is connected to a P0.0 pin of the control chip and a common terminal of the resistor R2, the other end of the resistor R2 is connected to a VCC terminal of the control chip, and the other end of the ultrasonic transducer is grounded.

[0013] Further, the lightning protection control cabinet is provided with a connecting pipe fixedly installed at each top end of the two sides, the lightning rod is fixedly connected with the connecting pipe, and the connecting pipe is welded with a down lead, and the bottom of the down lead is connected with the metal grounding body.

[0014] Further, the lightning rod is located at the top of the control cabinet, the length of the lightning rod is one third of the length of the control cabinet main body, and the diameter of the lightning rod is greater than 8 mm.

[0015] Compared with the prior art, the utility model has the advantages that:

[0016] 1) the overall detection of industrial sewage and the water pump is realized by using each detection sensor in the data acquisition unit, so that the life monitoring of the water pump is more comprehensive and accurate;

[0017] 2) each electric control in the electric actuator is controlled to move by the PLC control system, the sludge, water pump flow and large particles and other sundries in the sewage are treated, so that the operation of the sewage water pump is more smooth and safe, and the service life of the sewage water pump is increased;

[0018] 3) the real-time or periodic ultrasonic cleaning of each detection sensor in the data acquisition unit is realized by the ultrasonic cleaning driving circuit, the influence of repeated maintenance of the sensor on production and monitoring is avoided, the detection of each detection sensor in the data acquisition unit is more accurate and has a longer service life by the ultrasonic cleaning, and the accuracy of the life judgment of the sewage water pump is further ensured;

[0019] 4) the system realizes real-time wireless transmission and remote monitoring of monitoring data by the Internet of Things SIM card, and cable wiring is reduced;

[0020] 5) the main station PLC system adopts redundant PLC, so that the stability of the system is ensured;

[0021] 6) the lightning protection control cabinet is adopted, so that the PLC control system and the frequency converter in the control cabinet are prevented from being damaged due to lightning high voltage, and the equipment failure rate is reduced. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 is a structural diagram of the utility model.

[0023] Figure 2 is a wiring schematic diagram of the frequency converter and the water pump.

[0024] Figure 3 is the control circuit structure schematic view of the utility model.

[0025] Figure 4 is the ultrasonic wave generating circuit structure schematic view of the utility model. DETAILED DESCRIPTION

[0026] The specific embodiments of the utility model will be further described in combination with the drawings:

[0027] See Figure 1 , the structure block diagram of the utility model. The utility model discloses a sewage pump life wireless monitoring system, including PLC control system, electric actuator, frequency converter, internet of things SIM card, lightning protection control cabinet, ultrasonic cleaning drive circuit, data acquisition unit, the PLC control system and frequency converter set up in lightning protection control cabinet.

[0028] The PLC control system includes master station PLC system and slave station PLC system, and the master station PLC system and the slave station PLC system all include power module, CPU, digital quantity input and output module, analog quantity input and output module and communication module, the master station PLC system adopts redundant PLC, the signal line of data acquisition unit is connected to the signal input end of slave station PLC system, the slave station PLC system is electrically connected master station PLC system, and the output end of the slave station PLC system is connected to ultrasonic cleaning drive circuit, electric actuator and frequency converter, and the PLC control system is wirelessly communicated with mobile terminal through internet of things SIM card, the internet of things SIM card is arranged in the SIM card slot of PLC control system CPU, and the PLC control system selects Siemens series PLC.

[0029] The frequency converter is multiple, and corresponds to multiple water pumps. Figure 2 The frequency converter selects GD350 series, and three-phase power supply is connected to the power terminal R, S, T of frequency converter through switch Q1, fuse FU1 and three-phase reactor, the frequency converter is also connected to the indicator light HL1 and HL2 of two 24V power supplies, and is respectively used for fault display and operation display, the digital quantity input terminal DI of the frequency converter is electrically connected to the digital quantity output terminal of the digital quantity input and output module of slave station PLC through relay, and is used for controlling frequency converter to adjust water pump low-speed, medium-speed and high-speed operation, the output end U, V, W of the frequency converter is connected to the input end of three-phase output reactor, the output end of three-phase output reactor is connected to the input end of three-phase contactor KM11 contact, and the output end of three-phase contactor KM11 contact is connected to water pump M.

[0030] The electric actuator includes an electric regulating valve, an electric butterfly valve, an electric gate valve, a mechanical grid cleaner, a submersible agitator, an air volume regulating valve and a mud scraper, wherein the digital signal line of the electric regulating valve, the electric butterfly valve, the electric gate valve, the mechanical grid cleaner, the submersible agitator, the air volume regulating valve and the mud scraper is connected to the digital output end of the slave PLC system, and the analog signal line is connected to the analog output end of the slave PLC system.

[0031] The data acquisition unit includes a water quality monitoring sensor, a water pump flow sensor, a liquid level sensor, a pressure sensor, a sewage temperature sensor and a sludge interface instrument, a water pump current sensor, a water pump voltage sensor, a water pump vibration sensor and a water pump temperature sensor.

[0032] The water quality monitoring sensor includes a pH sensor, a dissolved oxygen sensor, a turbidity sensor, a biological oxygen demand online analyzer, an ammonia nitrogen online analyzer, a redox potential sensor and a conductivity sensor, wherein the detection sensor in the data acquisition unit is connected to the digital input end of the slave PLC system if the signal is digital, and is connected to the analog input end of the slave PLC system if the signal is analog.

[0033] The ultrasonic cleaning driving circuit is arranged at a position capable of cleaning the data acquisition unit, and includes a shell, an ultrasonic generating circuit and a control circuit, wherein the ultrasonic circuit and the control circuit are arranged in the shell, the ultrasonic waves emitted by the ultrasonic generating circuit are distributed in the emission channel of the shell towards the data acquisition unit, the signal input end of the ultrasonic generating circuit is connected to the signal output end of the control circuit, and the signal input end of the control circuit is connected to the signal output end of the PLC control system.

[0034] See Figure 3 The control circuit includes an AT89C51 chip, a capacitor C1, a crystal oscillator circuit and a resistor R1, wherein the control chip adopts the AT89C51 chip, the two ends of the capacitor C1 are respectively connected to the RST pin and the EA pin of the AT89C51 chip, the EA pin of the AT89C51 chip is in communication with the VCC pin, the RST pin of the AT89C51 chip is further connected to one end of the common connection of the resistor R1 and the capacitor C1, the XTAL2 and XTAL3 pins of the AT89C51 chip are connected to the input and output ends of the crystal oscillator circuit, the ground end of the crystal oscillator circuit is connected to the other end of the resistor R1, and the P1.0 and P1.1 pins of the AT89C51 chip are connected to the digital output end of the digital input and output module of the master PLC system.

[0035] See Figure 4The ultrasonic wave generating circuit comprises an ultrasonic transducer T and a resistor R2, one end of the ultrasonic transducer is connected to the P0.0 pin of the AT89C51 chip and the common terminal of the resistor R2, the other end of the resistor R2 is connected to the VCC terminal of the AT89C51 chip, and the other end of the ultrasonic transducer is grounded.

[0036] The lightning protection control cabinet is provided with a connecting pipe fixedly installed at the top of each side, a lightning rod is fixedly connected with the connecting pipe, a down lead is welded and installed on the connecting pipe, the bottom of the down lead is connected with the metal grounding body, the lightning rod is located at the top of the control cabinet, the length of the lightning rod is one third of the length of the main body of the control cabinet, and the diameter of the lightning rod is greater than 8 mm.

[0037] Working principle: the data acquisition unit is arranged at a position capable of detecting required data, for example, a liquid level sensor is arranged in a water pump housing to detect the corrosion condition of the water pump housing and the height of water entering the housing; a pressure sensor is arranged at the outlet of a water pump pipeline to detect the output pressure of the water pump, thereby detecting the change of the outlet water pressure under the condition that the frequency of the water pump is the same; when the control frequency of the water pump is the same, the fluid pressure detected by the pressure sensor becomes smaller, proving that the water outlet pipeline of the water pump is blocked; the flow, current, voltage, vibration and temperature changes of the water pump are detected in real time by the water pump flow sensor, water pump current sensor, water pump voltage sensor, water pump vibration sensor and water pump temperature sensor, thereby the running state of the sewage water pump is perceived in multiple dimensions.

[0038] The water quality condition in the industrial sewage is comprehensively detected by a pH sensor, a dissolved oxygen sensor, a turbidity sensor, a biological oxygen demand online analyzer, an ammonia nitrogen online analyzer, a redox potential sensor, a conductivity sensor, a sewage temperature sensor and a sludge interface instrument; whether the electrically operated regulating valve, the electrically operated butterfly valve, the electrically operated gate valve, the mechanical grid cleaner, the submersible agitator, the air volume regulating valve and the mud scraper in the electrically operated actuating mechanism act or not is judged by the mobile terminal by using data coupling whether the control command is sent by the PLC control system, for example, when the sludge height distance sensor height monitored by the sludge interface instrument becomes smaller and smaller, it proves that the sludge accumulation becomes more and more, which seriously affects the running condition of the water pump, therefore, the mechanical grid cleaner, the submersible agitator and the mud scraper cooperate with the water pump to handle the sludge; when the pH value detected by the pH sensor is too large, the electrically operated regulating valve is started to adjust the amount of added reagent to adjust the pH value of the sewage; that is, by the cooperation of the data acquisition unit and the PLC control system, the water quality and the running condition of the water pump are improved, thereby the service life of the water pump is increased, and the water pump whose running state temperature rise, energy consumption, vibration and the like are obviously different from normal values is subjected to alarm processing, reminding personnel to go to the site for investigation and treatment.

[0039] The slave PLC system controls the control circuit in the ultrasonic cleaning driving circuit through a signal, the control circuit controls the ultrasonic generating circuit to emit ultrasonic waves, and the ultrasonic waves are periodically or real-timely emitted to each detection sensor in the data acquisition unit according to needs, so that the service life of the data acquisition unit is prolonged.

[0040] All data are wirelessly transmitted to a mobile terminal through an Internet of Things SIM card for data processing and analysis, and are saved, so that wireless monitoring of the service life of the sewage pump is comprehensively realized.

[0041] The above examples are implemented on the premise of the technical scheme of the utility model, detailed implementation modes and specific operation processes are given, but the protection scope of the utility model is not limited to the above examples. The methods used in the above examples are all conventional methods unless otherwise specified.

Claims

1. A sewage water pump life wireless monitoring system, characterized in that, The system includes a PLC control system, an electric actuator, a frequency converter, an IoT SIM card, a surge protection control cabinet, an ultrasonic cleaning drive circuit, and a data acquisition unit. The PLC control system and the frequency converter are housed in the surge protection control cabinet. The IoT SIM card is located in the SIM card slot of the PLC control system. The input terminal of the PLC control system is connected to the data acquisition unit, and the output terminal of the PLC control system is connected to the ultrasonic cleaning drive circuit, the electric actuator, and the frequency converter. The output terminal of the frequency converter is connected to a water pump. The PLC control system communicates wirelessly with a mobile terminal via the IoT SIM card. The data acquisition unit includes a water quality monitoring sensor, a water pump flow sensor, a liquid level sensor, a pressure sensor, a wastewater temperature sensor, a sludge interface meter, a water pump current sensor, a water pump voltage sensor, a water pump vibration sensor, and a water pump temperature sensor. The water quality monitoring sensors include a pH sensor, a dissolved oxygen sensor, a turbidity sensor, an online biological oxygen demand analyzer, an online ammonia nitrogen analyzer, a redox potential sensor, and a conductivity sensor. The ultrasonic cleaning drive circuit is located at a position capable of cleaning the data acquisition unit. The ultrasonic cleaning drive circuit includes a housing, an ultrasonic generating circuit, and a control circuit. The ultrasonic circuit and the control circuit are located inside the housing. The ultrasonic waves emitted by the ultrasonic generating circuit are distributed in the emission channel of the housing facing the data acquisition unit. The signal input terminal of the ultrasonic generating circuit is connected to the signal output terminal of the control circuit, and the signal input terminal of the control circuit is connected to the signal output terminal of the PLC control system.

2. A sewage pump life wireless monitoring system according to claim 1, characterized in that, The PLC control system includes a master PLC system and a slave PLC system. Both the master PLC system and the slave PLC system include a power supply module, a CPU, a digital input / output module, an analog input / output module, and a communication module. The signal line of the data acquisition unit is connected to the signal input terminal of the slave PLC system. The slave PLC system is electrically connected to the master PLC system. The master PLC system uses redundant PLCs.

3. A sewage pump life wireless monitoring system according to claim 2, wherein, The electric actuators include an electric regulating valve, an electric butterfly valve, an electric gate valve, a mechanical bar screen cleaner, a submersible mixer, an air volume regulating valve, and a sludge scraper. The signal lines of the electric regulating valve, electric butterfly valve, electric gate valve, mechanical bar screen cleaner, submersible mixer, air volume regulating valve, and sludge scraper are all connected to the output terminal of the slave PLC system.

4. The system of claim 1, wherein, The control circuit includes a control chip, a capacitor, and a resistor R1. The control chip is an AT89C51 chip. The two ends of the capacitor are connected to the RST and EA pins of the control chip, respectively. The EA pin of the control chip is connected to the VCC pin. The RST pin of the control chip is also connected to one end of the common connection of the resistor R1 and the capacitor. The XTAL2 and XTAL3 pins of the control chip are connected to the input and output terminals of the crystal oscillator circuit. The ground terminal of the crystal oscillator circuit is connected to the other end of the resistor R1. The P1.0 and P1.1 pins of the control chip are connected to the signal output terminals of the PLC control system.

5. A sewage pump life wireless monitoring system according to claim 4, wherein, The ultrasonic wave generating circuit comprises an ultrasonic transducer and a resistor R2, one end of the ultrasonic transducer is connected to a P0.0 pin of the control chip and a common terminal of the resistor R2, the other end of the resistor R2 is connected to a VCC terminal of the control chip, and the other end of the ultrasonic transducer is grounded.

6. The system of claim 1, wherein, The lightning protection control cabinet is provided with a connecting pipe fixedly installed at the top of each side, a lightning rod is fixedly connected with the connecting pipe, and a down conductor is welded and installed on the connecting pipe.

7. A sewage pump life wireless monitoring system according to claim 6, wherein, The lightning rod is located at the top of the control cabinet, the length of the lightning rod is one third of the length of the main body of the control cabinet, and the diameter of the lightning rod is greater than 8 mm.

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