Pump unit state monitoring and electric energy optimizing controller
By designing a pump unit status monitoring and power optimization controller that integrates multiple modules and sensors, the problem of monitoring old pump units has been solved, achieving power optimization and loss reduction, and supporting real-time monitoring and prediction of equipment status.
Patent Information
- Application Number
- CN202520069373.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-13
- Publication Date
- 2025-12-12
- Estimated Expiration
- 2035-01-13
AI Technical Summary
The existing old pump units in the factory area cannot centrally monitor information such as power quality, temperature, and vibration. They have low power factors and serious line losses, which affect production.
Design a pump unit condition monitoring and power optimization controller that integrates a control module, a quadrant power measurement module, a compensation control module, an RTD acquisition module, and multiple sensors to achieve centralized monitoring of power quality, temperature, vibration, and other information, and optimize power consumption and reduce line losses through compensation capacitors.
It enables centralized monitoring of information such as power quality, temperature, and vibration of pump units, reduces line losses, optimizes power consumption, and supports the prediction of energy consumption levels and the formulation of maintenance plans.
Smart Images
Figure CN223662049U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model belongs to the pump unit state monitoring and electric energy optimization controller belongs to pump machine controller technical field, specifically related to a kind of pump unit state monitoring and electric energy optimization controller. BACKGROUND
[0002] Pump is the mechanical of conveying fluid or making fluid pressure increase. It transmits the mechanical energy of prime mover or other external energy to liquid, so that liquid energy increases. Pump is mainly used to transport water, oil, acid and alkali liquid, emulsion, suspension emulsion and liquid metal and other liquids, and can also transport liquid, gas mixture and liquid containing suspended solid. Involve multiple fields, many factory areas are provided with pump in use process, but the state of many existing factory areas old pump and other key equipment cannot be monitored, including the electric energy quality, temperature, vibration of pump unit, the temperature, pressure, flow information of fluid;Old equipment power factor is low, line loss is serious, which affects related production work;Therefore, the utility model provides a kind of pump unit state monitoring and electric energy optimization controller to solve the above problems. UTILITY MODEL CONTENTS
[0003] In order to overcome the problems mentioned in the background art, the utility model provides a kind of pump unit state monitoring and electric energy optimization controller. The controller of the utility model can monitor the electric energy quality, temperature, vibration information of pump unit and the temperature, pressure, flow information of fluid, and through the monitoring of electric energy quality, the controller can control the compensation capacitor reasonably, compensate the circuit, thereby reduce the reactive power in line, reduce the loss in line, and optimize the electric energy.
[0004] In order to achieve the above purpose, the utility model is realized by the following technical scheme: a kind of pump unit state monitoring and electric energy optimization controller includes control module 1, quadrant electric energy measuring module 2 for collecting three-phase voltage and current, compensation control module 3 for controlling compensation output, optimization feedback module 4 for feeding back the state of compensation control module 3 access, RTD acquisition module 5 for collecting the temperature of compensation control module 3, analog input module 6 for collecting fluid data and first serial communication module 7 for monitoring the state of pump unit, quadrant electric energy measuring module 2 is connected with three-phase power supply, three-phase power supply is connected with current transformer, quadrant electric energy measuring module 2 is also connected with current transformer, the input end of control module 1 is connected with quadrant electric energy measuring module 2, optimization feedback module 4, RTD acquisition module 5, analog input module 6 and first serial communication module 7, the output end of control module 1 is connected with compensation control module 3.
[0005] Further, the compensation control module 3 includes a capacitor compensator and a contactor, the capacitor compensator and the contactor are connected in series, the series-connected capacitor compensator and contactor are connected in parallel to the three-phase power supply circuit of the pump unit, and the contactor is connected with the output end of the control module 1.
[0006] Furthermore, the controller also includes a light-emitting diode 8 connected to the output terminal of the control module 1.
[0007] Furthermore, the controller also includes a second serial communication module 9 connected to the output of the control module 1.
[0008] Furthermore, the controller also includes an IoT module 10 connected to the output of the control module 1.
[0009] Furthermore, the controller also includes a third serial communication module 11 connected to the output of the control module 1.
[0010] Furthermore, the controller also includes a voltage conversion module 12, a DC-DC step-down module 13, and a power isolation module 14. The input terminal of the voltage conversion module 12 is connected to the three-phase power supply, and the output terminal of the voltage conversion module 12 is connected to the DC-DC step-down module 13, the second serial communication module 9, and the analog input module 6. The output terminal 13 of the DC-DC step-down module is connected to the power isolation module 14 and the IoT module 10. The output terminal of the power isolation module 14 is connected to the control module 1.
[0011] Furthermore, the control module 1 is an ARM microprocessor.
[0012] The beneficial effects of this utility model are:
[0013] This invention enables centralized monitoring of the power quality, temperature, and vibration information of the pump unit, as well as the temperature, pressure, and flow rate information of the fluid. By monitoring the power quality, the controller can rationally control the compensation capacitor, perform circuit compensation, optimize power consumption, thereby reducing reactive power and losses in the circuit and saving energy. During equipment operation, the pump unit's equipment status information can be continuously transmitted to the control module for data analysis. This allows for the prediction of the overall energy consumption level and failure potential of the pump unit, facilitating the early formulation of maintenance plans. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the controller of this utility model.
[0015] Figure reference numerals: 1. Control module; 2. Quadrant energy measurement module; 3. Compensation control module; 4. Optimization feedback module; 5. RTD acquisition module; 6. Analog input module; 7. First serial communication module; 8. Light-emitting diode; 9. Second serial communication module; 10. IoT module; 11. Third serial communication module; 12. Voltage conversion module; 13. DC-DC step-down module; 14. Power isolation module. Detailed Implementation
[0016] To make the objectives, technical solutions, and beneficial effects of this utility model clearer, the preferred embodiments of this utility model will be described in detail below with reference to the accompanying drawings, so as to facilitate the understanding of those skilled in the art.
[0017] like Figure 1This utility model discloses a pump unit status monitoring and power optimization controller. The controller includes a control module 1 (ARM microprocessor), a quadrant power measurement module 2 for acquiring three-phase voltage and current, a compensation control module 3 for controlling the compensation output, an optimization feedback module 4 for feedback on the connection status of the compensation control module 3, an RTD acquisition module 5 for acquiring the temperature of the compensation control module 3, an analog input module 6 for acquiring fluid data, and a first serial communication module 7 for monitoring the pump unit status. The analog input module 6 is externally connected to multiple transmitters for acquiring fluid data. Sensors, including pressure sensors, flow sensors, and fluid temperature sensors, are used to collect pressure, flow, and temperature data of the fluid within the pump unit. The analog input module 6 converts the monitoring data from analog to digital and sends it to the control module 1 via the IIC protocol for data processing. The first serial communication module 7 is externally connected to multiple sensors monitoring the pump unit's status, including a pump temperature sensor and a vibration sensor, which monitor the pump unit's operating temperature and vibration status, respectively. The monitoring data is sent to the control module 1 via the UART protocol. The quadrant energy measurement module 2 is connected to a three-phase power supply, which is connected to a current transformer for quadrant energy measurement. Module 2 is also connected to a current transformer. The input terminal of control module 1 is connected to quadrant energy measurement module 2, optimization feedback module 4, RTD acquisition module 5, analog input module 6, and first serial communication module 7. The output terminal of control module 1 is connected to compensation control module 3. The compensation control module 3 includes a capacitor compensator and a contactor, which are connected in series and then in parallel to the power supply circuit of the pump unit. The contactor is connected to the output terminal of control module 1. The RTD acquisition module 5 acquires the temperature of the capacitor compensator in compensation control module 3 and sends the acquired temperature to the control module via the SPI protocol. The module monitors the temperature of the capacitor compensator. The quadrant energy measurement module collects three-phase voltage and current, and obtains parameters such as reactive power, voltage, and harmonics of the pump unit. This data is transmitted to the control module via UART protocol. The control module, based on the monitoring data from the quadrant energy measurement module, controls the compensation control module to perform compensation, controlling the contactor to engage and conduct, allowing the capacitor compensator to be connected in parallel to the circuit. Connecting the capacitor compensator absorbs and eliminates harmonic currents, reduces harmonic content in the power supply circuit, and maintains circuit purity and stability. It can also perform power factor correction and voltage regulation, reducing line losses, improving transmission capacity, and suppressing harmonics. The optimization feedback module 4 monitors the status of the contactor, specifically whether the auxiliary normally open contacts are engaged, and uses the contactor status to monitor whether the compensation capacitor is connected to the circuit. Through this controller, the power quality, temperature, vibration information of the pump unit, and the temperature, pressure, and flow rate information of the fluid can be centrally monitored and alarmed.By monitoring power quality, the controller can rationally control the compensation capacitors to optimize power consumption, thereby reducing reactive power and losses in the lines. During equipment operation, the status information of the pump unit can be continuously transmitted to the control module. Data analysis allows for the prediction of the overall energy consumption level and potential failures of the pump unit, facilitating the early development of maintenance plans.
[0018] The controller also includes a light-emitting diode 8 connected to the output terminal of the control module 1; when the fluid data, pump unit temperature or vibration data, or capacitor compensator temperature data exceed the limit, an alarm is triggered, i.e., the light-emitting diode lights up red to provide an alarm reminder; when the control module controls the contactor of the compensation control module 3 to engage and conduct for capacitor compensation, but the optimization feedback module 4 does not detect the engagement of the auxiliary normally open contact of the contactor, the control module performs a shutdown operation to protect the equipment.
[0019] The controller also includes a second serial communication module 9 connected to the output of the control module 1. The second serial communication module 9 is externally connected to an HMI monitoring module to facilitate monitoring and data display and to realize data exchange.
[0020] The controller also includes an IoT module 10 connected to the output of the control module 1; the IoT module can upload data to a cloud server for easy data storage or analysis.
[0021] The controller also includes a third serial communication module 11 connected to the output of the control module 1; the third serial communication module facilitates connection to third-party devices and allows third-party devices to read the operating status of the pump unit through the third serial communication module.
[0022] The controller also includes a voltage conversion module 12, a DC-DC step-down module 13, and a power isolation module 14. The input of the voltage conversion module 12 is connected to a three-phase power supply, and the output of the voltage conversion module 12 is connected to the DC-DC step-down module 13, the second serial communication module 9, and the analog input module 6. The output of the DC-DC step-down module 13 is connected to the power isolation module 14 and the IoT module 10. The output of the power isolation module 14 is connected to the control module 1. The voltage conversion module converts AC220V to DC24V to power the second serial communication module and the analog input module. The DC-DC step-down module converts DC24V to DC5V to power the IoT module. The power isolation module converts DC5V to 3.3V to power the control module, i.e., the ARM microprocessor.
[0023] Work process:
[0024] The working principle of this utility model is as follows: Quadrant energy measurement module 2 is connected to a three-phase power supply, which is connected to a current transformer. Quadrant energy measurement module 2 is also connected to the current transformer. Quadrant energy measurement module 2 can collect three-phase voltage and current, and obtain parameters such as reactive power, voltage, and harmonics of the pump unit. Quadrant energy measurement module 2 transmits data to control module 1 via UART protocol. Control module 1 controls compensation control module 3 to perform compensation based on the monitoring data of quadrant energy measurement module 2, controlling the contactor to engage and conduct, so that the capacitor compensator is connected in parallel in the circuit. By connecting the capacitor compensator, harmonic current can be absorbed and eliminated, the harmonic content in the power supply circuit can be reduced, and the purity and stability of the circuit can be maintained. Optimization feedback module 4 monitors the state of the contactor, monitoring whether the auxiliary normally open contact of the contactor is engaged, and monitors the compensation capacitor through the state of the contactor. Whether it is connected to the circuit; the analog input module 6 is externally connected to multiple sensors for collecting fluid data, including a pressure sensor, a flow sensor, and a fluid temperature sensor, which are used to collect the pressure, flow rate, and temperature data of the fluid in the pump unit, respectively. After analog-to-digital conversion, the monitoring data is sent to the control module 1 via the IIC protocol for data processing; the first serial communication module 7 is externally connected to multiple sensors for monitoring the status of the pump unit, including a pump temperature sensor and a vibration sensor, which monitor the operating temperature and vibration status of the pump unit, respectively, and send the monitoring data to the control module 1 via the UART protocol; through this controller, the power quality, temperature, vibration information of the pump unit and the temperature, pressure, and flow information of the fluid can be centrally monitored and alarmed; and by monitoring the power quality, the controller can reasonably control the compensation capacitor to optimize power.
[0025] Finally, it should be noted that the above preferred embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although the utility model has been described in detail through the above preferred embodiments, those skilled in the art should understand that various changes can be made to it in form and detail without departing from the scope defined by the claims of this utility model.
Claims
1. A pump unit status monitoring and power optimization controller, characterized in that: The pump unit status monitoring and power optimization controller includes a control module (1), a quadrant power measurement module (2) for collecting three-phase voltage and current, a compensation control module (3) for controlling the compensation output, an optimization feedback module (4) for feeding back the access status of the compensation control module (3), an RTD acquisition module (5) for collecting the temperature of the compensation control module (3), an analog input module (6) for collecting fluid data, and a first serial communication module (7) for monitoring the pump unit status. The quadrant power measurement module (2) is connected to a three-phase power supply, and the three-phase power supply is connected to a current transformer. The quadrant power measurement module (2) is also connected to the current transformer. The input terminal of the control module (1) is connected to the quadrant power measurement module (2), the optimization feedback module (4), the RTD acquisition module (5), the analog input module (6), and the first serial communication module (7). The output terminal of the control module (1) is connected to the compensation control module (3).
2. The pump unit status monitoring and power optimization controller according to claim 1, characterized in that: The compensation control module (3) includes a capacitor compensator and a contactor. The capacitor compensator and the contactor are connected in series, and the series-connected capacitor compensator and the contactor are connected in parallel to the three-phase power supply circuit of the pump unit. The contactor is connected to the output terminal of the control module (1).
3. The pump unit status monitoring and power optimization controller according to claim 1, characterized in that: The controller also includes a light-emitting diode (8) connected to the output terminal of the control module (1).
4. The pump unit status monitoring and power optimization controller according to claim 1, characterized in that: The controller also includes a second serial communication module (9) connected to the output of the control module (1).
5. A pump unit status monitoring and power optimization controller according to claim 4, characterized in that: The controller also includes an IoT module (10) connected to the output of the control module (1).
6. The pump unit status monitoring and power optimization controller according to claim 1, characterized in that: The controller also includes a third serial communication module (11) connected to the output of the control module (1).
7. A pump unit status monitoring and power optimization controller according to claim 5, characterized in that: The controller also includes a voltage conversion module (12), a DC step-down module (13), and a power isolation module (14). The input terminal of the voltage conversion module (12) is connected to a three-phase power supply. The output terminal of the voltage conversion module (12) is connected to the DC step-down module (13), the second serial communication module (9), and the analog input module (6). The output terminal of the DC step-down module is connected to the power isolation module (14) and the IoT module (10). The output terminal of the power isolation module (14) is connected to the control module (1).
8. The pump unit status monitoring and power optimization controller according to claim 1, characterized in that: The control module (1) is an ARM microprocessor.