Filter press monitoring process system

Abstract

The utility model relates to a filter monitoring process system, including many for the filter body of medicinal liquor filtration, monitoring module, integrated display device and alarm device, the quantity of monitoring module is consistent with the quantity of filter, and every monitoring module corresponds to install on a filter, monitoring module includes motor speed sensor part, filter pressure sensor part and working current sensor part, and the quantity of alarm device corresponds with filter body, including alarm lamp one, alarm lamp two and alarm lamp three connected with integrated display device, the utility model discloses through many parameters real -time monitoring, wireless transmission to integrated display device, and effective reduction of fault discovery lag time, avoid medicinal liquor filtration interruption or impurity overproof, and production continuity promotes.

Description

Technical Field

[0001] This utility model relates to the field of monitoring technology for pharmaceutical filtration equipment, and in particular to a process monitoring system for a filter machine. Background Technology

[0002] In the production processes of industries such as chemicals, pharmaceuticals, and electronics, multiple filters are often used to filter chemicals to remove impurities, ensure the purity of the chemicals, and meet the requirements of subsequent production processes. Currently, multiple filters typically operate simultaneously on-site, and because the filters themselves generate noise during operation, coupled with the operating noise of other equipment on-site, the overall environmental noise level is quite high.

[0003] In actual production, filtration machines may experience malfunctions such as shutdowns, filter clogging, and chemical leaks. However, due to the high noise levels on-site, it is difficult for staff to detect abnormalities in the filtration machines in a timely manner by sound. Furthermore, with multiple filtration machines scattered across the site, staff cannot closely monitor each machine in real time. This means that when a filtration machine shuts down or malfunctions, staff cannot promptly identify and address the problem, leading to interruptions in chemical filtration or reduced filtration efficiency, thus impacting production progress and product quality. Utility Model Content

[0004] This utility model addresses the shortcomings of existing technologies by providing a filter monitoring process system, the specific technical solution of which is as follows: A filter monitoring system includes multiple filter bodies for chemical filtration, monitoring modules, an integrated display device, and an alarm device. The number of monitoring modules is the same as the number of filter bodies, and each monitoring module is installed on one filter body. The monitoring module includes a motor speed sensor, a filter pressure sensor, and a working current sensor. The motor speed sensor includes a Hall effect speed sensor and a magnetic induction sheet mounted on the motor shaft of the filter body. The integrated display device is located at the entrance of the inlet circuit and is connected to the monitoring module in communication. The number of alarm devices corresponds to the filter body, including alarm light one, alarm light two, and alarm light three connected to the integrated display device. When the filter body motor speed sensor detects that the preset fault threshold has been reached, alarm light one flashes; when the filter pressure sensor detects that the preset fault threshold has been reached, alarm light two flashes; and when the working current sensor detects that the preset fault threshold has been reached, alarm light three flashes.

[0005] Preferably, the monitoring module further includes a data processing unit and a wireless communication unit. The data processing unit is connected to the motor speed sensor, the filter pressure sensor, and the operating current sensor, respectively, and is used to generate standardized operating status information and fault information. The data processing unit includes an STM32 microcontroller. The wireless communication unit is connected to the data processing unit and is used to send the standardized operating status information and fault information to the integrated display device. The wireless communication unit includes a WiFi module.

[0006] Preferably, the sensing probe of the Hall effect speed sensor is aligned with the magnetic induction sheet to receive the magnetic field change signal generated by the rotation of the filter body motor shaft. The working current sensing unit converts the magnetic signal into a pulse electrical signal, and then the data processing unit calculates the pulse frequency, which is finally converted into the speed of the filter body motor.

[0007] Preferably, the working current sensor is an openable sensor, which wraps around the motor power supply wire of the filter body, and the filter pressure sensor is a diffused silicon pressure sensor, with the probe of the diffused silicon pressure sensor in contact with the fluid at the inlet and outlet of the filter.

[0008] Preferably, the integrated display device includes a display and a controller, the controller is communicatively connected to a wireless communication unit, and the alarm light one, alarm light two, and alarm light three are electrically connected to the controller.

[0009] Preferably, the alarm device further includes a buzzer electrically connected to the controller, which emits an alarm sound when any of the alarm lights one, two, or three flashes.

[0010] Preferably, the first alarm light is a red LED, the second alarm light is a yellow LED, and the third alarm light is a green LED.

[0011] The beneficial effects of this utility model are: 1. Real-time anomaly detection: Through real-time monitoring of multiple parameters and wireless transmission to the integrated display device, the delay time for fault detection is effectively shortened, avoiding interruption of chemical filtration or excessive impurities, and improving production continuity.

[0012] 2. Comprehensive monitoring dimensions: Covering three core parameters: motor speed, filter pressure, and operating current, it can identify various faults such as shutdown, filter blockage, motor overload / phase loss, etc., thus improving the fault identification coverage.

[0013] 3. More precise fault location: "Equipment number + color alarm light" correspond one-to-one, shortening the time for locating faulty equipment and the time for judging the fault type, thus improving maintenance efficiency.

[0014] 4. Convenient operation: The integrated display device is installed at the workshop entrance, and the touch screen provides visual operation, eliminating the need for manual inspection of each machine, reducing the number of dedicated inspection personnel by 1-2, and saving annual labor costs; the alarm sound + light dual reminders are not affected by workshop noise (a 90dB buzzer can cover 80dB of on-site noise). Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0016] Reference numerals: 1. Filter body; 2. Monitoring components; 21. Motor speed sensor; 22. Filter pressure sensor; 23. Working current sensor; 30. Controller; 3. Integrated display device; 31. Buzzer; 32. Display; 33. Alarm light one; 34. Alarm light two; 35. Alarm light three. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0018] Example A filter monitoring process system, please refer to Figure 1 It includes a filter unit cluster 1, a monitoring module, an integrated display device 3, and an alarm device. Each component is linked to the electronic control logic via wireless communication. The filter unit cluster 1 consists of multiple chemical filter units with identical structures, providing monitoring targets for the monitoring system. Specific structure: A single filter unit 1 can be a horizontal cartridge filter (model GLQ-50, processing capacity 5m³). 3 / h, filtration accuracy 1-10μm), including a polypropylene pleated filter element installed inside the filter cartridge to intercept solid impurities in the solution; inlet and outlet: both are stainless steel flange interfaces, the inlet is located at the top of one end of the filter cartridge (connected to the solution delivery pipe), and the outlet is located at the bottom of the other end (connected to the clean solution storage tank); drive motor: model Y132M-4 connected to the stirring impeller inside the filter cartridge via a coupling (to promote solution flow and improve filtration efficiency); the motor is equipped with an independent power supply circuit (380V / 50Hz), and the circuit is equipped with a circuit breaker (model DZ47-63, rated current 20A).

[0019] Multiple filter units 1 (5-20 units) are evenly arranged along the workshop assembly line. Each unit is numbered (e.g., #1-#20) and corresponds to the monitoring module and alarm device number for easy and accurate positioning.

[0020] Each monitoring module corresponds one-to-one with the filter body 1 (one set per filter body). Installed on the filter body 1, it collects three core parameters in real time: motor speed, filtration pressure, and operating current. This includes a motor speed sensor 21: monitoring the motor's operating status and determining if it has stopped or is experiencing abnormal speed. The magnetic induction sheet uses a neodymium iron boron permanent magnet (15mm diameter, 3mm thickness, 12000Gs magnetic strength), fixed to the end of the motor shaft in the filter body 1 (10mm from the shaft end, coaxial with the shaft), rotating synchronously with it. A Hall effect speed sensor (model A3144) is installed on the outside of the motor end cover (fixed by an L-shaped bracket, with a 5-8mm gap between the sensor probe and the magnetic induction sheet, aligned with the center of the induction sheet). The sensor converts the magnetic field changes generated by the shaft rotation into pulse electrical signals (one pulse per revolution). The signal output is connected to the data processing unit via a shielded wire. The measurement range is 0-3000r / min, with an accuracy of ±1r / min, suitable for monitoring all operating conditions from motor start-up to stable operation.

[0021] The filtration pressure sensing unit 22 monitors the pressure difference between the inlet and outlet of the filter cartridge to determine the degree of filter clogging. It includes diffused silicon pressure sensors: model MPX5700, two sensors per group, installed on the flange sides of the inlet and outlet of the filter body 1 (connected via threaded interfaces, with the probe in direct contact with the solution). The sensors have a full stainless steel housing (resistant to acid and alkali corrosion, suitable for solutions with pH 2-12), a measurement range of 0-1.6 MPa, and an accuracy of ±0.25%FS. The inlet sensor monitors the pressure before filtration (P1), and the outlet sensor monitors the pressure after filtration (P2). The difference between the two (ΔP=P1-P2) reflects the degree of filter clogging (ΔP>0.3 MPa indicates clogging). The signal output is connected to the data processing unit via a shielded cable.

[0022] The working current sensing unit 23 monitors the motor's working current to determine whether there is overload or phase loss. It includes an openable current sensor: model SCT-013-050, which adopts a snap-fit ​​structure and is wrapped around the outside of the motor power supply wire (live wire) of the filter body 1 (no need to cut the wire, easy to install); the sensor converts AC current into a 0-5V DC signal based on the Hall effect, with a measurement range of 0-50A and an accuracy of ±1%FS; it can monitor the motor's operating current in real time (normal operating current is about 15A), and it is judged to be abnormal when the current exceeds 20A (overload) or fluctuates more than ±5A (phase loss); the signal output terminal is connected to the data processing unit through a shielded cable.

[0023] The data processing and communication unit performs parameter conversion, data standardization, and wireless transmission. It includes a data processing unit with an STM32F103C8T6 microcontroller (32-bit ARM core, 72MHz clock speed) at its core. This unit receives analog / digital signals from the speed sensor, pressure sensor, and current sensor via an ADC interface (12-bit resolution). It converts the speed pulse signal into the actual speed (speed = pulse frequency × 60, unit r / min), calculates the pressure difference (ΔP = P1 - P2), and determines if the current is within the normal range. Simultaneously, it assigns a unique ID to each device (consistent with the filter body number 1) and generates a standardized data frame in the format "Device ID - Parameter Type - Value - Timestamp" (e.g., #1 - Speed ​​- 1438 r / min - 202406011000). Wireless communication unit: adopts ESP8266 WiFi module (supports 802.11b / g / n protocol, transmission rate 150Mbps, communication distance ≤100m), and connects to the data processing unit through UART interface; wirelessly sends standardized data frames to integrated display device 3, with a transmission cycle of 1 second (to ensure real-time performance); the module supports AP / STA dual mode and can be connected to the workshop local area network to avoid signal interference.

[0024] The integrated display device 3 is installed at the entrance of the workshop (for easy observation by staff) to centrally display and monitor the operating data of multiple filters. It includes a controller 30: an STM32F407ZGT6 microcontroller (with enhanced performance and support for parallel data processing from multiple devices), which receives data from all monitoring modules via a WiFi module (paired with the ESP8266 monitoring module); a built-in data storage unit (SD card, 16GB capacity) capable of storing 3 months of historical operating data (at 1 second / record), and supporting export of data to Excel format via USB interface; the controller 30 also has pre-stored fault thresholds for various parameters (modifiable via touchscreen). Speed ​​fault threshold: <1000r / min (judged as shutdown or too low speed); Pressure failure threshold: ΔP > 0.3MPa (indicated as filter blockage); Current fault threshold: >20A or <10A (judged as overload or phase loss).

[0025] The monitor 32 features a 10.1-inch TFT LCD touchscreen (resolution 1280×800, brightness 500 cd / m²). 2 (Adaptable to strong light environments in workshops), connected to controller 30 via HDMI interface; the display interface is divided into three main areas: Equipment Status Overview: Displays the number, current speed, pressure differential, and operating current of all filter units 1 in a list format. Normal parameters are displayed in green, and parameters exceeding thresholds are displayed in red (e.g., #1 filter speed 1438 r / min (green), ΔP = 0.25 MPa (green), current 14.8 A (green); #5 filter speed 0 r / min (red), ΔP = 0 MPa (red), current 0 A (red)). Single device details area: Click on the device number in the overview area to display the real-time operating curve of the device (the trend of speed, pressure difference, and current changes in the past 10 minutes), which is convenient for analyzing the parameter change patterns (such as a gradual increase in ΔP indicating that the filter is gradually becoming clogged). Historical data query area: Supports querying historical data by device number and time range, allowing you to view parameter changes before and after a fault occurs, and assisting in the analysis of the cause of the fault.

[0026] Each alarm device corresponds to one of the filter units 1 and is installed on the panel of the integrated display device 3 (arranged according to device number), including: Each device is equipped with three LEDs of different colors for categorized alarm lights, which are electrically connected to the controller 30 (controlled by the GPIO interface for switching): Alarm light 33: Red LED light (wavelength 620-660nm, power 1W, brightness 2000mcd), corresponding to motor speed fault; when the monitoring module detects a speed <1000r / min, the controller 30 triggers alarm light 33 to flash (frequency 1Hz). Alarm light 2 34: Yellow LED light (wavelength 580-595nm, same power brightness), corresponding to filter pressure failure; when ΔP>0.3MPa, controller 30 triggers alarm light 2 34 to flash (frequency 1Hz). Alarm light three: Green LED light (wavelength 520-570nm, same power brightness), corresponding to working current fault; when the current is >20A or <10A, the controller 30 triggers alarm light three to flash (frequency 1Hz). The device number (e.g., #1-Red / Yellow / Green) is marked next to the alarm light, allowing staff to quickly locate the faulty device and the type of fault by the color and number of the light.

[0027] Buzzer 31: Model TMB12A05 (DC 5V, volume 90dB), electrically connected to controller 30 through a transistor drive circuit; when any alarm light flashes, controller 30 triggers buzzer 31 to emit a continuous alarm sound (frequency 2kHz); after the staff confirms the fault, the alarm can be paused by the "mute" button on the integrated display device 3 (if the fault is not resolved, the alarm will automatically restart after 30 seconds).

[0028] System Workflow (1) Normal operation phase 1. Real-time Data Acquisition and Transmission: After all filter units 1 are started, the monitoring module corresponding to each filter unit 1 enters a continuous working state—the Hall effect speed sensor of the motor speed sensing unit 21 captures the changes in the magnetic field generated by the rotation of the magnetic induction plate in real time, and outputs a set of pulse signals every 1 second; the two diffused silicon pressure sensors of the filter pressure sensing unit 22 synchronously collect the pressure data of the inlet (P1) and outlet (P2); the opening and closing current sensor of the working current sensing unit 23 monitors the current changes of the motor power supply wire in real time. These raw signals are all transmitted to the data processing unit (STM32F103C8T6 microcontroller) through shielded wires.

[0029] 2. Data Processing and Standardization: The data processing unit converts and integrates the received signals—converting the rotational speed pulse signal into the actual rotational speed value (rotational speed = pulse frequency × 60, unit r / min), calculating the pressure difference between the inlet and outlet (ΔP = P1 - P2), and restoring the 0-5V DC signal output by the current sensor into the actual current value (A). Subsequently, the unit adds a "Device ID-Parameter Type-Timestamp" tag to the data (e.g., #8-Rotational Speed-1435r / min-20240610142501), generates a standardized data frame, and sends it to the integrated display device 3 at a frequency of 1 second / time via the wireless communication unit (ESP8266 WiFi module).

[0030] 3. Data Visualization and Storage: After receiving data from all monitoring modules, the controller 30 (STM32F407ZGT6 microcontroller) of the integrated display device 3 displays the number, speed, ΔP, and current of each filter unit 1 in a list format in the "Equipment Status Overview Area" of the display 32 (10.1-inch touchscreen). Parameters within the normal range (speed 1000-1500 r / min, ΔP ≤ 0.3 MPa, current 10-20 A) are displayed in green. Simultaneously, the data is written to an SD card (16GB) in real time, categorized and stored in folders created by "Equipment Number - Date," supporting historical data traceability within 3 months. Staff can click on any equipment number in the "Single Equipment Details Area" to view the parameter change curve of that equipment over the past 10 minutes (e.g., ΔP stable at 0.2-0.25 MPa indicates the filter is not clogged). Data can be exported in Excel format from the "Historical Data Query Area" by time range for analyzing equipment operating patterns (e.g., the filter needs to be replaced on average every 3 days).

[0031] (2) Fault warning and response stage 1. Fault Identification and Alarm Triggering: When a filter unit 1 malfunctions, the controller 30 triggers the corresponding alarm mechanism by comparing real-time data with a pre-stored fault threshold. Motor speed failure: If the #5 filter motor stops due to power failure and the speed drops to 0 r / min (<1000 r / min threshold), the controller 30 immediately sends a flashing command (frequency 1Hz) to the alarm light 33 (red LED light) corresponding to the #5 equipment, and at the same time triggers the buzzer 31 (90dB) to emit a 2kHz continuous alarm sound; Filtration pressure failure: If the filter screen of #12 causes ΔP to rise to 0.35MPa (>0.3MPa threshold) due to the accumulation of impurities, the controller 30 will trigger the alarm light 34 (yellow LED light) of #12 to flash, and the buzzer 31 will sound an alarm simultaneously; Operating current fault: If the #3 filter motor is overloaded due to bearing wear, and the current rises to 22A (>20A threshold), or the current drops to 8A (<10A threshold) due to phase loss, the controller 30 will trigger the #3 alarm light three (green LED light) to flash, and the buzzer 31 will sound an alarm.

[0032] All alarm information is simultaneously marked in the "Equipment Status Overview Area" of display 32 (corresponding parameters are displayed in red), and a fault prompt window pops up (such as "#5 filter motor stops, please check power supply").

[0033] 2. Fault Confirmation and Handling: At the workshop entrance, staff can quickly locate the faulty equipment and its type using the integrated display device 3, based on the "equipment number + alarm light color" (e.g., flashing red light → #5 motor stops), eliminating the need for individual inspections. Upon arrival at the site, staff can view the parameter changes before and after the fault using the "Fault Details" button on the touchscreen (e.g., the current of the #5 filter suddenly drops to 0 before stopping, indicating a power outage), and then take targeted action (e.g., checking if the circuit breaker for the #5 motor has tripped and resetting it). During the troubleshooting process, the "Mute" button can be pressed to pause the buzzer 31 alarm (it will automatically restart after 30 seconds if the fault is not resolved, to prevent omissions).

[0034] 3. Troubleshooting and System Recovery: After the fault is resolved (e.g., power is restored to motor #5, and the speed returns to 1440 r / min; filter screen replaced in filter #12, ΔP drops to 0.2 MPa), the parameters collected by the monitoring module return to the normal range, and the data processing unit sends a "parameter normal" data frame to controller 30. Upon receiving this data, controller 30 automatically stops the corresponding alarm light from flashing, restores the parameter color on display 32 from red to green, stops the buzzer 31 from blaring, and the system returns to normal operation. Controller 30 simultaneously records the fault handling time and recovery status on the SD card (e.g., "#5 filter - motor stopped - 202406101430 processing - 1432 restored to normal"), facilitating subsequent tracking of fault handling efficiency.

[0035] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A filter monitoring process system, characterized in that, It includes multiple filter bodies for filtering medicine, monitoring modules, integrated display devices and alarm devices. The number of monitoring modules is the same as the number of filter bodies, and each monitoring module is installed on one filter body. The monitoring module includes a motor speed sensor, a filter pressure sensor, and a working current sensor. The motor speed sensor includes a Hall effect speed sensor and a magnetic induction sheet mounted on the motor shaft of the filter body. The integrated display device is located at the entrance of the inlet circuit and is connected to the monitoring module in communication. The number of alarm devices corresponds to the filter body, including alarm light one, alarm light two, and alarm light three connected to the integrated display device. When the filter body motor speed sensor detects that the preset fault threshold has been reached, alarm light one flashes; when the filter pressure sensor detects that the preset fault threshold has been reached, alarm light two flashes; and when the working current sensor detects that the preset fault threshold has been reached, alarm light three flashes.

2. The filter monitoring process system according to claim 1, characterized in that: The monitoring module further includes a data processing unit and a wireless communication unit. The data processing unit is connected to the motor speed sensor, the filter pressure sensor, and the operating current sensor, respectively, and is used to generate standardized operating status information and fault information. The data processing unit includes an STM32 microcontroller. The wireless communication unit is connected to the data processing unit and is used to send the standardized operating status information and fault information to the integrated display device. The wireless communication unit includes a WiFi module.

3. The filter monitoring process system according to claim 2, characterized in that: The Hall effect speed sensor's sensing probe is aligned with the magnetic induction plate to receive the magnetic field change signal generated by the rotation of the filter body motor shaft. The working current sensing unit converts the magnetic signal into a pulse electrical signal, and then the data processing unit calculates the pulse frequency, which is finally converted into the speed of the filter body motor.

4. The filter monitoring process system according to claim 3, characterized in that: The working current sensor is an openable sensor, which wraps around the motor power supply wire of the filter body. The filter pressure sensor is a diffused silicon pressure sensor, and the probe of the diffused silicon pressure sensor is in contact with the fluid at the inlet and outlet of the filter.

5. The filter monitoring process system according to claim 4, characterized in that: The integrated display device includes a display and a controller. The controller is communicatively connected to a wireless communication unit, and the alarm lights one, two, and three are electrically connected to the controller.

6. The filter monitoring process system according to claim 5, characterized in that: The alarm device also includes a buzzer electrically connected to the controller. When any one of the alarm lights, alarm light one and alarm light three, flashes, the buzzer emits an alarm sound.

7. The filter monitoring process system according to claim 1, characterized in that: The first alarm light uses a red LED, the second alarm light uses a yellow LED, and the third alarm light uses a green LED.

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