Intelligent inspection system for water supply plant water pump unit

Abstract

The intelligent inspection system comprises an acceleration vibration sensor, a liquid sensor, a temperature sensor, a lubricating oil turbidity sensor, a video collector, a thermal imaging instrument, an audible and visual alarm, an edge processor, a pressure sensor, a flow sensor, a water pump motor controller and an inspection terminal. Sensing equipment arranged at each key node of water pump unit equipment can realize in-situ monitoring and control of the water pump unit, and real-time video recording and thermal imaging of abnormal node equipment can be completed through a video collector or a thermal imaging instrument arranged at the corresponding key node when the related key node is monitored to have an abnormal state; the device working state of the abnormal node can be visually checked by the background, manual inspection in the water pump machine room is not needed, meanwhile, the audible and visual alarm at the abnormal node can give an alarm prompt, an operator going to the machine room for maintenance can conveniently and rapidly lock the fault position, and the inspection labor cost of the water pump unit is reduced.

Description

Technical Field

[0001] This utility model relates to the field of automatic monitoring technology for water pump units in waterworks, and specifically to an intelligent inspection system for water pump units in waterworks. Background Technology

[0002] Waterworks are institutions or facilities responsible for treating and supplying tap water to urban or rural residents for domestic, industrial, and other purposes. They need to continuously manage water usage throughout the city, delivering water to various locations to ensure the normal water needs of residents and industrial production. Therefore, waterworks must constantly monitor the daily inflow and storage volume to ensure the normal daily supply of tap water. Water pump units are key equipment for maintaining the stable operation of waterworks; therefore, waterworks need to conduct regular or irregular inspections of the relevant water pump units to ensure a stable supply of domestic water.

[0003] Currently, waterworks inspections typically involve manual checks of all water treatment equipment to identify potential hazards and address them. This method, relying on manual inspection, lacks intelligence and is prone to oversight, leading to missed problems and errors in water treatment operations. With societal development, automated monitoring devices have replaced traditional manual methods. However, these devices are often rigid, offering only passive, fixed-point monitoring and lacking intelligent inspection capabilities. In waterworks inspections, the inspection of pump units is particularly crucial. Real-time online monitoring of pump unit operation is essential for understanding their status and providing timely alarms to prevent major accidents. However, daily pump unit monitoring is complex, requiring numerous personnel with high workloads. This large workforce inevitably leads to more monitoring errors, increasing safety risks. Furthermore, traditional pump unit monitoring systems involve numerous, geographically dispersed devices, resulting in low system reliability and time-consuming, labor-intensive troubleshooting. Summary of the Invention

[0004] To solve the above-mentioned technical problems, this utility model provides an intelligent inspection system for water pump units in waterworks.

[0005] The technical solution adopted by this utility model to achieve the above-mentioned technical effects is:

[0006] A smart inspection system for water pump units in a waterworks includes:

[0007] Accelerometer vibration sensors are installed on motors, water pumps, and bearing housings to detect vibration status data on these components.

[0008] Liquid sensors are placed at the inlet and outlet connections of the water pump and at the oil seal position of the bearing housing to detect the leakage status data of lubricating oil at the inlet and outlet connections of the water pump and in the bearing housing.

[0009] A temperature sensor is placed on the motor to obtain the motor's temperature status data;

[0010] A lubricating oil turbidity sensor is installed inside the lubricating oil tank to acquire turbidity status data of the lubricating oil in the tank.

[0011] Video capture devices are deployed at the motor, water pump, and bearing housing to record video footage in real time at the corresponding locations when abnormal vibration of the motor, water pump, or bearing housing is detected, or when liquid leakage is detected in the water pump or bearing housing.

[0012] A thermal imaging instrument is placed at the motor to perform thermal imaging when an abnormal motor temperature is detected.

[0013] Audible and visual alarms are deployed at each node detection location to issue audible and visual alarm signals when an anomaly is detected.

[0014] The edge processor has its data input terminal connected to the acceleration vibration sensor, liquid sensor, temperature sensor, and lubricating oil turbidity sensor, and its signal output terminal connected to the video acquisition unit, thermal imager, and audible and visual alarm.

[0015] A pressure sensor, installed in the water pump outlet pipe and connected to the edge processor, is used to detect the water pump outlet pressure.

[0016] A flow sensor is installed in the water pump outlet pipe and connected to the edge processor to detect the water pump outlet flow rate;

[0017] A water pump motor controller, connected to the edge processor, is used to control the operating status of the water pump motor;

[0018] The inspection terminal is remotely bidirectionally connected to the edge processor, and connected to the video acquisition device and the thermal imaging instrument, for remote inspection and control of the water pump unit.

[0019] Preferably, in the above-mentioned intelligent inspection system for water pump units in waterworks, the inspection terminal includes a back-end control host and a monitoring display screen connected to the back-end control host. The back-end control host is bidirectionally connected to the edge processor, and the video acquisition device and the thermal imaging instrument are connected to the back-end control host.

[0020] Preferably, the above-mentioned intelligent inspection system for water pump units in waterworks further includes a wireless communication module and a wired communication module. The wireless communication module is deployed at the edge, and the wired communication module is deployed at the terminal. The wireless communication module is bidirectionally connected to the edge processor. The signal output terminals of the acceleration vibration sensor, liquid sensor, temperature sensor, and lubricating oil turbidity sensor are connected to the signal input terminals of the edge processor through the wireless communication module. The signal control output terminal of the edge processor is connected to the video acquisition device and the thermal imaging instrument through the wireless communication module. The data output terminals of the video acquisition device and the thermal imaging instrument are connected to the back-end control host through the wired communication module.

[0021] Preferably, in the above-mentioned intelligent inspection system for water pump units in waterworks, the temperature sensor includes a motor winding temperature sensor, which is used to obtain the stator winding temperature of the water pump motor.

[0022] Preferably, the above-mentioned intelligent inspection system for water pump units in waterworks also includes an abnormal noise sensor arranged in the impeller housing of the water pump, and the abnormal noise sensor is connected to the edge processor.

[0023] Preferably, in the above-mentioned intelligent inspection system for water pump units in waterworks, four acceleration vibration sensors are provided, which are respectively arranged at the free end of the motor, the drive end of the motor, the free end of the water pump, and the drive end of the water pump.

[0024] Preferably, in the above-mentioned intelligent inspection system for water pump units in a waterworks, the water pump motor controller includes a motor current acquisition circuit, a phase loss protection circuit, an overvoltage protection circuit, an undervoltage protection circuit, and a frequency converter. The edge processor is connected to the water pump motor through the frequency converter. The motor current acquisition circuit, the phase loss protection circuit, the overvoltage protection circuit, and the undervoltage protection circuit are respectively connected between the edge processor and the water pump motor.

[0025] The beneficial effects of this utility model are as follows: The intelligent inspection system for water pump units in waterworks can achieve on-site monitoring and control of water pump units through sensors deployed at key nodes of the equipment. When an abnormal state is detected at a relevant key node, real-time video recording and thermal imaging of the abnormal node can be completed by video acquisition devices or thermal imaging instruments deployed at the corresponding key nodes, and the images can be transmitted back in real time. This allows the backend to intuitively view the working status of the abnormal node without the need for manual inspection in the pump room, and the monitoring location is unrestricted. At the same time, the audible and visual alarms at the abnormal nodes will issue alarm prompts, making it convenient for maintenance personnel to quickly locate the fault and troubleshoot quickly and accurately. Moreover, the system collects comprehensive data on the working status of the water pump units, with higher system integration, reliability, and intelligence, making it more real-time and convenient, reducing the labor costs of water pump unit inspection, and improving the overall operational efficiency of the waterworks. Attached Figure Description

[0026] Figure 1 This is a modular structure diagram of the intelligent inspection system according to an embodiment of the present invention.

[0027] Figure 2 This is an overall module structure diagram of the intelligent inspection system according to an embodiment of the present invention.

[0028] Figure 3 This is an overall module structure diagram of the intelligent inspection system according to an embodiment of the present invention.

[0029] Figure 4 This is a module structure diagram of the water pump motor controller described in this utility model.

[0030] Figure 5 This is the circuit diagram for motor current acquisition of this utility model.

[0031] Figure 6 This is the circuit diagram for the phase failure protection of this utility model. Detailed Implementation

[0032] To further understand this utility model, the following description, with reference to the accompanying drawings and specific embodiments, further illustrates the present utility model: In the description of this utility model, it should be noted that the terms "vertical," "upper," "lower," "horizontal," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the utility model. Furthermore, "first," "second," "third," and "fourth" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or a connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0034] Please see Figure 1As shown in the figure, this utility model proposes an intelligent inspection system for water pump units in a waterworks, including: an acceleration vibration sensor, a liquid sensor, a temperature sensor, a lubricating oil turbidity sensor, a video acquisition unit, a thermal imaging instrument, an audible and visual alarm, an edge processor, a pressure sensor, a flow sensor, a water pump motor controller, and an inspection terminal. Specifically, in this utility model embodiment, the acceleration vibration sensor is arranged on the motor, water pump, and bearing housing to detect vibration status data on the motor, water pump, and bearing housing, respectively. The acceleration vibration sensor transmits the vibration status data of the corresponding node location to the edge processor, where the vibration status data of the motor, water pump, and bearing housing are processed and analyzed. When abnormal vibration status data is detected, the corresponding abnormal vibration status data and signal are uploaded to the inspection terminal so that the inspection terminal can promptly obtain the abnormal vibration dynamics at the corresponding node. The liquid sensor is arranged at the inlet and outlet connection ends of the water pump and at the oil seal position of the bearing housing to detect the leakage status data of lubricating oil at the inlet and outlet connection ends of the water pump and in the bearing housing, respectively. The liquid sensor transmits leakage status data at corresponding node locations to the edge processor. At the edge processor, the leakage status data at the inlet and outlet connections of the water pump and the bearing housing oil seal are processed and analyzed. When abnormal leakage status data is detected, the corresponding abnormal leakage status data and signal are uploaded to the inspection terminal, allowing the inspection terminal to promptly obtain leakage dynamics at the corresponding node. This enables leakage detection at the inlet and outlet connections of the water pump and the bearing housing oil seal. The temperature sensor is installed on the motor to acquire its temperature status data. It transmits this temperature status data from the motor, a critical heat-generating node, to the edge processor. At the edge processor, the temperature status data is processed and analyzed. When abnormal temperature status data is detected, the corresponding abnormal temperature status data and signal are uploaded to the inspection terminal, allowing the inspection terminal to promptly obtain abnormal high-temperature dynamics at the motor node. This enables high-temperature heat detection at the motor node. The lubricating oil turbidity sensor is installed inside the lubricating oil tank to acquire the turbidity status data of the lubricating oil within the tank. The lubricating oil turbidity sensor transmits the lubricating oil turbidity status data of the lubricating oil tank node to the edge processor. The edge processor performs calculations and analysis on the lubricating oil turbidity status data of the lubricating oil tank node. When abnormal lubricating oil turbidity status data is detected, the corresponding abnormal turbidity status data and signal are uploaded to the inspection terminal so that the inspection terminal can obtain the turbidity dynamics at the lubricating oil tank node in a timely manner. This enables the detection of the lubricating oil turbidity status of the lubricating oil tank node.

[0035] To enable the backend to intuitively view the operational status of abnormal nodes in the pump room and achieve unmanned on-site inspection of the pump room, such as... Figure 1As shown, video capture devices are also installed at the motor, water pump, and bearing housing. Each device at each node is used to record the real-time operating status of that node's equipment. Specifically, when abnormal vibration of the motor, water pump, or bearing housing is detected, or when liquid leakage is detected in the water pump or bearing housing, video footage of the corresponding location is recorded in real time. When any node equipment is operating normally, the video capture devices do not record. When a node malfunctions, such as abnormal motor vibration, the corresponding video capture device at that motor is activated, recording real-time video footage of the motor exhibiting abnormal vibration. This footage is then transmitted back to the inspection terminal in real time, allowing inspection terminal managers to visually inspect abnormal node equipment without physically visiting the pump room. Furthermore, as... Figure 1 As shown, a thermal imaging instrument is also installed at the motor node. This thermal imaging instrument is used to perform thermal imaging when an abnormal motor temperature is detected. The thermal imaging image is transmitted back to the inspection terminal in real time, so that the management personnel of the inspection terminal can intuitively see the high temperature heating status of the motor.

[0036] After the inspection terminal detects a node device with abnormal operating status, it dispatches maintenance personnel to the pump room for on-site inspection and repair. To facilitate the rapid location of the faulty equipment after entering the pump room, audible and visual alarms are installed at various node detection locations, including the motor, pump, bearing housing, and lubricating oil tank. The audible and visual alarm signals guide the maintenance personnel to quickly locate the faulty equipment, greatly improving maintenance efficiency.

[0037] Specifically, in the embodiments of this utility model, such as Figure 1 As shown, the edge processor's data input is connected to an acceleration vibration sensor, a liquid sensor, a temperature sensor, and a lubricating oil turbidity sensor, while its signal output is connected to a video acquisition unit, a thermal imager, and an audible and visual alarm. When a fault is detected in a corresponding node device, i.e., its operating status data is abnormal, the edge processor sends response commands to the video acquisition unit, thermal imager, and audible and visual alarm at the node device with the abnormal status data. This causes the video acquisition unit, thermal imager, and audible and visual alarm to start working, thereby completing real-time recording of video footage, real-time generation of thermal images, and issuance of alarm signals.

[0038] Furthermore, such as Figure 1As shown, a pressure sensor is installed in the water pump outlet pipe, which is connected to the edge processor to detect the water pump outlet pressure. A flow sensor is also installed in the water pump outlet pipe, which is connected to the edge processor to detect the water pump outlet flow rate. The water pump motor controller is connected to the edge processor to control the operating status of the water pump motor. The inspection terminal is remotely bidirectionally connected to the edge processor and to a video acquisition device and thermal imaging instrument for remote inspection and control of the water pump unit. When the pressure sensor detects insufficient or excessive water pressure in the water pump outlet pipe, the edge processor sends a control command to the water pump motor controller, which then adjusts the operating parameters of the water pump motor in real time to regulate the water pump outlet pressure to the set range. Similarly, the control of the water pump outlet flow rate is the same as the control of the outlet pressure, and will not be described again here.

[0039] Furthermore, in a preferred embodiment of this utility model, such as Figure 2 As shown, the inspection terminal includes a back-end control host and a large monitoring display screen connected to the back-end control host. The back-end control host has a bidirectional communication connection with the edge processor, and the video acquisition device and thermal imaging instrument are connected to the back-end control host. The real-time images and thermal images recorded by the video acquisition device and thermal imaging instrument are played and displayed on the large monitoring display screen in the back-end control room, allowing back-end management personnel to intuitively view the real-time images of node equipment with abnormal working status in the pump room.

[0040] Furthermore, in a preferred embodiment of this utility model, such as Figure 3As shown, the system also includes a wireless communication module and a wired communication module. The wireless communication module is deployed at the edge, and the wired communication module is deployed at the terminal. Specifically, in a preferred embodiment of this invention, the wireless communication module is bidirectionally connected to the edge processor. The signal output terminals of the acceleration vibration sensor, liquid sensor, temperature sensor, and lubricating oil turbidity sensor are connected to the signal input terminals of the edge processor through the wireless communication module. The signal control output terminal of the edge processor is connected to the video acquisition unit and thermal imaging instrument through the wireless communication module, and the data output terminals of the video acquisition unit and thermal imaging instrument are connected to the back-end control host through the wired communication module. By deploying the wireless communication module at the edge, the sensing devices at each node can be quickly deployed and connected to the edge processor, reducing the wiring difficulty of the sensing devices. At the same time, the edge processor can perform calculations and processing on the data collected by the edge sensing devices nearby, and then upload the abnormal status data to the inspection terminal, avoiding the need to send a large amount of raw data collected by the edge sensing devices to the inspection terminal, which can reduce the computing load of the inspection terminal. The wired communication module can send the dynamic images recorded in real time by the video acquisition unit and the thermal imaging images generated in real time by the thermal imaging instrument to the inspection terminal in high definition and without loss, improving the data transmission speed and reducing latency.

[0041] Furthermore, in a preferred embodiment of this utility model, the temperature sensor includes a motor winding temperature sensor, which is used to obtain the stator winding temperature of the water pump motor.

[0042] In some embodiments of this utility model, such as Figure 3 As shown, it also includes a noise sensor arranged in the impeller housing of the water pump, which is connected to the edge processor. The noise sensor can detect abnormal noises in the impeller housing of the water pump, such as impeller malfunctions.

[0043] In some embodiments of this utility model, four acceleration vibration sensors are provided, which are respectively arranged at the free end of the motor, the driving end of the motor, the free end of the water pump, and the driving end of the water pump.

[0044] Furthermore, in a preferred embodiment of this utility model, such as Figure 4 As shown, the water pump motor controller includes a motor current acquisition circuit, a phase loss protection circuit, an overvoltage protection circuit, an undervoltage protection circuit, and a frequency converter. The edge processor is connected to the water pump motor via the frequency converter, and the motor current acquisition circuit, phase loss protection circuit, overvoltage protection circuit, and undervoltage protection circuit are respectively connected between the edge processor and the water pump motor.

[0045] Specifically, such as Figure 5As shown, the motor current acquisition circuit includes an overcurrent protection circuit and an undercurrent protection circuit. The current flowing into the motor coil winding is acquired through a current transformer L6, then converted into a voltage value by an operational amplifier D4 after a second transformation. After rectification, filtering, and sampling, the voltage is sent to an AD conversion circuit. The resulting digital value is converted back into a voltage value according to a proportional relationship. The system's overcurrent and undercurrent protection values ​​are used to determine if the motor is experiencing overcurrent or undercurrent. In case of overcurrent or undercurrent, the edge processor controls the motor to stop, thus protecting the motor. It should be noted that in this embodiment, the overcurrent protection circuit and undercurrent protection circuit are mature circuit protection circuits already in use in the prior art. This embodiment only provides one optional circuit protection structure. Similarly, the overvoltage protection circuit and undervoltage protection circuit also use mature circuit protection circuits already in use in the prior art, and their working principle is the same as the overcurrent protection circuit and undercurrent protection circuit described above, which will not be repeated here. Figure 6 The diagram shown is a circuit diagram of a phase-loss protection circuit. Phase-loss protection protects the three phase lines of a three-phase power grid. If one phase line breaks, the current flowing through that phase line is zero, the system activates the phase-loss protection, and the motor is stopped via an edge processor. Specifically, as shown... Figure 6 As shown, optocoupler U19 isolates high-voltage and low-voltage circuits. If the three-phase power is operating normally, current flows through the input terminal of optocoupler U19, and its output terminal is conductive. At this time, the phase loss protection circuit does not operate. If any phase of the three-phase power is disconnected, no current flows through the input terminal of optocoupler U19, and its output terminal will be disconnected. At this time, the phase loss protection circuit will immediately operate, achieving the function of phase loss protection.

[0046] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope. All such changes and modifications fall within the scope of protection claimed by this utility model, which is defined by the appended claims and their equivalents.

Claims

1. An intelligent inspection system for water pump units in a waterworks, characterized in that, include: Accelerometer vibration sensors are installed on motors, water pumps, and bearing housings to detect vibration status data on these components. Liquid sensors are placed at the inlet and outlet connections of the water pump and at the oil seal position of the bearing housing to detect the leakage status data of lubricating oil at the inlet and outlet connections of the water pump and in the bearing housing. A temperature sensor is placed on the motor to obtain the motor's temperature status data; A lubricating oil turbidity sensor is installed inside the lubricating oil tank to acquire turbidity status data of the lubricating oil in the tank. Video capture devices are deployed at the motor, water pump, and bearing housing to record video footage in real time at the corresponding locations when abnormal vibration of the motor, water pump, or bearing housing is detected, or when liquid leakage is detected in the water pump or bearing housing. A thermal imaging instrument is placed at the motor to perform thermal imaging when an abnormal motor temperature is detected. Audible and visual alarms are deployed at each node detection location to issue audible and visual alarm signals when an anomaly is detected. The edge processor has its data input terminal connected to the acceleration vibration sensor, liquid sensor, temperature sensor, and lubricating oil turbidity sensor, and its signal output terminal connected to the video acquisition unit, thermal imager, and audible and visual alarm. A pressure sensor, installed in the water pump outlet pipe and connected to the edge processor, is used to detect the water pump outlet pressure. A flow sensor is installed in the water pump outlet pipe and connected to the edge processor to detect the water pump outlet flow rate; A water pump motor controller, connected to the edge processor, is used to control the operating status of the water pump motor; The inspection terminal is remotely bidirectionally connected to the edge processor, and connected to the video acquisition device and the thermal imaging instrument, for remote inspection and control of the water pump unit.

2. The intelligent inspection system for water pump units in a waterworks according to claim 1, characterized in that, The inspection terminal includes a back-end control host and a large monitoring display screen connected to the back-end control host. The back-end control host is bidirectionally connected to the edge processor. The video acquisition device and the thermal imaging instrument are connected to the back-end control host.

3. The intelligent inspection system for water pump units in a waterworks according to claim 2, characterized in that, It also includes a wireless communication module and a wired communication module. The wireless communication module is deployed at the edge, and the wired communication module is deployed at the terminal. The wireless communication module is bidirectionally connected to the edge processor. The signal output terminals of the acceleration vibration sensor, liquid sensor, temperature sensor, and lubricating oil turbidity sensor are connected to the signal input terminals of the edge processor through the wireless communication module. The signal control output terminal of the edge processor is connected to the video acquisition device and the thermal imaging instrument through the wireless communication module. The data output terminals of the video acquisition device and the thermal imaging instrument are connected to the back-end control host through the wired communication module.

4. The intelligent inspection system for water pump units in a waterworks according to claim 1, characterized in that, The temperature sensor includes a motor winding temperature sensor, which is used to obtain the stator winding temperature of the water pump motor.

5. The intelligent inspection system for water pump units in a waterworks according to claim 1, characterized in that, It also includes a noise sensor arranged in the impeller housing of the water pump, the noise sensor being connected to the edge processor.

6. The intelligent inspection system for water pump units in a waterworks according to claim 1, characterized in that, Four acceleration vibration sensors are provided, which are respectively arranged at the free end of the motor, the drive end of the motor, the free end of the water pump, and the drive end of the water pump.

7. The intelligent inspection system for water pump units in a waterworks according to claim 1, characterized in that, The water pump motor controller includes a motor current acquisition circuit, a phase loss protection circuit, an overvoltage protection circuit, an undervoltage protection circuit, and a frequency converter. The edge processor is connected to the water pump motor through the frequency converter. The motor current acquisition circuit, the phase loss protection circuit, the overvoltage protection circuit, and the undervoltage protection circuit are respectively connected between the edge processor and the water pump motor.

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