Communication device

Abstract

We propose a communication device that can be retrofitted to existing pump systems and transmit the status of the pump system to an external source. [Solution] A communication device is proposed that can be attached separately from the pump controller to a pump system comprising a pump and a pump controller for controlling the pump, and comprises: an input unit that receives a detection signal from a sensor that detects operation-related information, which is a physical quantity related to the operation of the pump; a determination unit that determines the pump system state, including an operation stop state, indicating whether the pump is in operation or stopped, based on the detection signal from the sensor; and a transmission unit that transmits output information to the outside based on the pump system state determined by the determination unit.

Description

Technical Field

[0005]

[0001] The present invention relates to a communication device, and more particularly, to a communication device that can be separately attached to a pump device including a pump and a pump controller for controlling the pump, separately from the pump controller.

Background Art

[0002] Conventionally, pump devices equipped with a pump for transferring a fluid such as air or water, such as a blower or a water supply device, have been widely used. Generally, a pump device includes a pump, a motor for driving the pump, and a controller for controlling the operation of the pump. In such a pump device, the controller controls the operation and stop of the pump so that a fluid such as air or water is sent according to the user's request.

[0003] As an example of a pump device, a water supply device in which the presence or absence of a pump failure is monitored by a remote monitoring device is known (see, for example, Patent Document 1). For example, when a decrease in the discharge pressure of the pump or a failure of an inverter that controls the rotation speed of the pump occurs, an abnormal signal is transmitted from the pump device to the remote monitoring device, and the remote monitoring device grasps the failure of the pump.

[0004] Also, conventionally, a communication device that is connected to the output terminal of a pump device and is configured to be able to transmit signals for each event of the pump to a management device has been proposed (see, for example, Patent Document 2). In Patent Document 2, it is stated that by retrofitting a communication device to a pump device that does not have a long-distance communication function, events of the pump device can be managed by a remote monitoring device.

Prior Art Documents

Patent Documents

[0006] As described above, it is sometimes desirable for pump systems to be manageable from a remote location, such as by a remote monitoring device. In Patent Document 2, a communication device is attached to an output terminal that can output a signal for each event in the pump system. However, pump systems may not have an output terminal that can output information suitable for remote monitoring. For example, when a remote monitoring device determines whether or not a pump is malfunctioning, the cumulative operating time of the pump can be an important determining factor. However, if the controller of the pump system does not measure the cumulative operating time, neither the pump system nor the remote monitoring device can determine the cumulative operating time.

[0007] The present invention was made to solve at least some of the above-mentioned problems, and one of its objectives is to propose a communication device that can be retrofitted to an existing pump system and transmit the status of the pump system to an external source. [Means for solving the problem]

[0008] According to one embodiment of the present invention, a communication device that can be attached separately from the pump controller to a pump system comprising a pump and a pump controller for controlling the pump, wherein the device is equipped with a sensor that detects operation-related information, which is a physical quantity related to the operation of the pump. A communication device is proposed that includes an input unit to which a detection signal is input, a determination unit that determines whether the pump is operating or stopped based on the detection signal from the sensor, and a transmission unit that transmits output information to the outside based on the operation stop state determined by the determination unit. [Brief explanation of the drawing]

[0009] [Figure 1] This diagram schematically shows the configuration of a water supply device and a communication device according to one embodiment of a pump system. [Figure 2] This flowchart shows an example of a pump system status determination process performed by a communication device. [Figure 3] This diagram schematically illustrates an example of how the calculation unit calculates the average current value when the pump is in operation. [Figure 4] This diagram schematically shows the configuration of the water supply device and communication device according to the second embodiment. [Figure 5] This diagram schematically shows the configuration of the water supply device and communication device according to the third embodiment. [Figure 6] This flowchart shows an example of the verification process for pump controller signals performed by a communication device. [Modes for carrying out the invention]

[0010] Embodiments of the present invention will be described below with reference to the drawings. In the drawings, identical or corresponding components are denoted by the same reference numerals, and redundant descriptions are omitted.

[0011] <First Embodiment> Figure 1 is a schematic diagram showing the configuration of a water supply device and a communication device according to one embodiment of a pump device. This water supply device is mainly used to supply tap water, which is an example of a transported liquid, to buildings (targets of water supply) such as condominiums, office buildings, commercial facilities, or schools. In Figure 1, the water supply device 100 is used in a direct water supply system, and the suction port of the water supply device 100 is connected to the water pipe (main water pipe) 104 via the introduction pipe 105. However, the water supply device 100 may also be used in a water tank system where the suction port is connected to a water tank. A water supply pipe 107 is connected to the discharge port of the water supply device 100, and this water supply pipe 107 is in communication with the water taps (e.g., faucets) 110 of each building. The water supply device 100 increases the pressure of the water from the water pipe 104 and supplies water to each water tap 110 of the building.

[0012] The water supply device 100 includes a pump 12, a motor 13 as a drive unit for driving the pump 12, an inverter 20 as a frequency converter for variable speed driving of the motor 13, and a controller 40.

[0013] A backflow prevention device 25 is provided on the suction side (upstream side) of the pump 12. The backflow prevention device 25 is installed in the inlet pipe 105 connected to the suction port of the water supply device 100, and prevents backflow of water from the water supply device 100 to the water pipe 104. A pressure sensor 21 is provided upstream of the backflow prevention device 25. The pressure sensor 21 is a pressure measuring instrument for measuring the suction side pressure of the pump 12.

[0014] On the discharge side (downstream side) of the pump 12, a check valve 22, a flow switch 24, a pressure sensor 26, and a pressure tank 28 are provided. In the example shown in Figure 1, two sets of pumps 12, motors 13, check valves 22, and flow switches 24 are provided, and these are installed in parallel. Alternatively, one or more sets of pumps 12, motors 13, check valves 22, and flow switches 24 may be provided. By providing multiple pumps 12, if some pumps 12 become inoperable, the water supply can be continued using the other operational pumps 12 to avoid water outages as much as possible.

[0015] A check valve 22 is installed in the discharge pipe connected to the discharge port of the pump 12 to prevent backflow of water when the pump 12 stops. A flow switch 24 is installed downstream (secondary) of the check valve 22. The flow switch 24 is a flow sensor that detects when the flow rate of water flowing through the discharge pipe drops to a predetermined value, i.e., an insufficient water flow (low water flow). Further downstream of the flow switch 24 in the discharge pipe, a pressure sensor 26 and a pressure tank 28 are installed. The pressure sensor 26 is a pressure measuring instrument for measuring the discharge side pressure of the pump 12 (hereinafter, discharge side pressure refers to the pressure value measured by the pressure sensor 26). The pressure tank 28 is a pressure retainer for maintaining the discharge side pressure while the pump 12 is stopped.

[0016] The inverter 20 controls the current flowing through the motor 13 based on the control command from the controller 40. As an example, the inverter 20 calculates a command frequency (e.g., PID control, etc.) based on the target rotational speed of the pump 12, and generates a PWM signal to minimize the difference between this command frequency and the actual frequency of the motor 13. The inverter 20 is connected to the commercial power supply 90 via the earth leakage circuit breaker 91. Note that the water supply device 100 may not include the inverter 20.

[0017] The water supply device 100 includes a controller 40 that controls the water supply operation. The controller 40 of the present embodiment includes a storage unit 47, an arithmetic unit 48, an I / O unit 50, a setting unit 46, and a display unit 49. The setting unit 46 and the display unit 49 are provided on the operation panel 51 of the water supply device 100. The controller 40 controls the drive of the pump 12 via the inverter 20. In the example shown in FIG. 1, the inverter 20 and the controller 40 are configured separately, but the inverter 20 and the controller 40 may be integrated.

[0018] The setting unit 46 is used to set various set values used for water supply by external operation. The various set values set in the setting unit 46 are input as signals to the I / O unit 50 and stored in the storage unit 47. As an example, the user can input, via the setting unit 46, the stop pressure, start pressure, discharge side pressure PA at maximum flow rate, discharge side pressure PB during cut-off operation, and other information used for control.

[0019] The display unit 49 functions as a user interface, and displays various data such as set values stored in the storage unit 47, the current operation status (operation state) of the pump 12, the operation or stop of the pump 12, the operation frequency (rotation speed), current, suction side pressure, discharge side pressure, and water supply pressure, etc., via the I / O unit 50. Further, when an abnormality occurs in the water supply device 100 such as the inverter 20, the display unit 49 notifies the user of the abnormality by lighting an alarm lamp and sounding a buzzer.

[0020] As the storage unit 47, memories such as RAM and ROM are used. The storage unit 47 stores various data, for example, data of calculation results in the calculation unit 48, pressure values (suction side pressure, discharge side pressure), data input through the setting unit 46, and data input or output through the I / O unit 50.

[0021] As the I / O unit 50, ports or the like are used. The I / O unit 50 has a circuit for acquiring signals such as signals from the pressure sensors 21 and 26 and the signal of the flow switch 24, and sends the acquired signal information to the calculation unit 48.

[0022] As the calculation unit 48, for example, a CPU is used. The calculation unit 48 performs setting, timing, calculation, etc. of various data for operating the pump 12 based on the program and various data stored in the storage unit 47 and the signals input from the I / O unit 50. The output from the calculation unit 48 is input to the I / O unit 50.

[0023] Also, the I / O unit 50 and the inverter 20 are connected to each other by communication means such as RS422, RS232C, RS485, etc. Control signals such as various setting values, frequency command values, start / stop signals (operation / stop signals) are sent from the I / O unit 50 to the inverter 20, and operation status (operation state) such as actual frequency values, current values, inverter trip signals, etc. are sequentially sent from the inverter 20 to the I / O unit 50. However, as the control signals transmitted and received between the I / O unit 50 and the inverter 20, analog signals and / or digital signals can be used instead of or in addition to the above-described communication means.

[0024] Next, the control of the water supply device 100 by the controller 40 will be explained. When the discharge pressure drops to a predetermined starting pressure while the pump 12 is stopped, the controller 40 starts the pump 12. Specifically, the controller 40 commands the inverter 20 to start driving the motor 13. While the pump 12 is operating, control such as constant estimated terminal pressure control or constant target pressure control is performed based on the set pressure (set pressure). Specifically, in the case of constant estimated terminal pressure control, the target pressure (SV) is set using the rotational speed of the pump 12 and the target pressure control curve, and in the case of constant target pressure control, the set pressure is used as the target pressure (SV). The discharge pressure is used as the current pressure (PV). Based on the difference between SV and PV, a PI calculation using proportional gain Gp and integral gain Gi, or a PID calculation using proportional gain Gp, integral gain Gi, and differential gain Gd is performed to set the commanded rotational speed of the pump 12. Furthermore, if there are multiple pumps as in this embodiment, the controller 40 also controls the number of pumps according to the water volume, based on the number of pumps that can be started simultaneously (number of pumps operating in parallel).

[0025] When water usage in the building decreases while pump 12 is operating, the flow switch 24 detects the low water volume and sends a detection signal to the controller 40 (low water volume state). The controller 40 receives this detection signal and commands pump 12 to increase its rotation speed until the discharge pressure reaches a predetermined stop pressure Pf, then stores pressure in the pressure tank 28 and stops pump 12 (low water volume stop). After pump 12 has stopped at a low water volume, when water is used again in the building, the discharge pressure drops to below the starting pressure Ps and pump 12 starts. In the case of multiple pumps as in this embodiment, it is preferable to rotate which pump 12 is started to prevent water from accumulating inside pump 12. In addition, as a method for detecting low water volume, other means such as low load based on the current value of motor 13 or shut-off pressure may be used instead of using the flow switch 24.

[0026] The communication device 200 is configured to be retrofitted to an existing water supply device 100. The communication device 200 in this embodiment includes an input unit 202, a storage unit 204, an arithmetic unit 206, and a communication unit 210. The communication device 200 may include a casing (not shown) to house these components, or it may consist of, for example, one or more control boards and be mounted inside a casing (not shown) of the water supply device 100.

[0027] The input unit 202 is composed of a port, for example. The I / O unit 50 has a circuit that acquires detection signals from a current sensor 60 installed on a power line connected to the commercial power supply 90 and the inverter 20 of the water supply device 100, and sends the acquired signal information to the calculation unit 206. Although not limited, in this embodiment the current sensor 60 is not a sensor mounted on the water supply device 100, and the detected value from the current sensor 60 is not input to the controller 40 of the water supply device 100 and is not used by the controller 40 to control the pump 12. The current sensor 60 may be mounted on the communication device 200, or it may be provided separately from the communication device 200. In addition, multiple sensors may be provided to detect the current flowing for each of the multiple inverters 20, or the current sensor 60 may be provided on a power line that integrates the power lines connected to each inverter 20. Furthermore, the current sensor 60 is connected to the controller 4 It may be provided on the main power line of the water supply device 100, including the power supply to 0. In addition, the input unit 202 only needs to receive detection signals from sensors that detect operation-related information, which is a physical quantity related to the operation of the pump. Instead of or in addition to the detection signal from the current sensor 60, detection signals from pressure sensors 21, 26 or flow switch 24 may be input.

[0028] Memory such as RAM or ROM is used as the storage unit 204. The storage unit 204 stores various types of data, such as data input through the input unit 202, calculation result data from the calculation unit 206, and data input or output through the communication unit 210.

[0029] For example, a CPU is used as the arithmetic unit 206. Based on the program and various data stored in the memory unit 204, as well as signals input from the I / O unit 50, the arithmetic unit 206 sets, measures, and performs calculations for determining the status of the water supply device 100.

[0030] The communication unit 210 is configured to communicate with the external device 300 via wired or wireless communication. Any wireless communication method can be used, such as Bluetooth® and Wi-Fi. For wired communication, the communication unit 210 may be provided with an external connection terminal such as USB (Universal Serial Bus), to which an external terminal is connected for communication, or serial communication such as RS422, RS232C, or RS485 may be used. The external device 300 may be a general-purpose terminal device such as a smartphone, mobile phone, personal computer, or tablet, or a dedicated terminal device such as a remote monitoring device. Furthermore, the external device 300 may be composed of multiple devices spaced apart from each other. Additionally, the external device 300 may be built as an edge server or a cloud server, or as a combination of an edge server and a cloud server.

[0031] The communication device 200 is configured to determine the state of the water supply device 100 (hereinafter referred to as the pump device state) and transmit it to the outside. Figure 2 is a flowchart showing an example of the pump device state determination process performed by the communication device 200. This process is repeatedly executed at predetermined intervals (for example, a few milliseconds, tens of milliseconds, or hundreds of milliseconds) while the communication device 200 is started up and operating. Furthermore, the determination of the pump device state in the communication device 200 is mainly performed by the calculation unit 206 and the storage unit 204, and in this embodiment, the calculation unit 206 and the storage unit 204 constitute an example of a "determination unit".

[0032] The arithmetic unit 206 of the communication device 200 first reads the detected value that has been input from the sensor to the input unit 202 and stored in the storage unit 204 (step S102). In this embodiment, an example of reading the current value detected by the current sensor 60 will be described. However, the example is not limited to this example, and any sensor can be used as the sensor, as long as it is a sensor that detects operation-related information, which is a physical quantity related to the operation of the pump.

[0033] Next, the calculation unit 206 determines the state of the water supply device 100 (hereinafter referred to as the "pump device state") based on the read detection values ​​(step S103). Here, the pump device state may include an operation stop state indicating whether the pump 12 is operating or stopped. In this embodiment, the calculation unit 206 determines the operation stop state based on the current value flowing through the inverter 20 detected by the current sensor 60. Since the detection signals of sensors, including the current sensor 60, may contain noise, the calculation unit 206 may acquire detection values ​​multiple times (e.g., 5 times, 10 times) at predetermined time intervals (e.g., tens of msec, hundreds of msec) and use their average value for determination. In addition, the input unit 202 may be provided with a filter circuit to remove noise contained in the detection signal.

[0034] The calculation unit 206 determines the pump system status by, for example, comparing the detected value from a sensor with a threshold value. In this embodiment, the calculation unit 206 determines that the pump 12 is operating when the detected current value from the current sensor 60 is equal to or greater than the threshold value, and determines that the pump 12 is stopped when the detected current value is less than the threshold value. Furthermore, if a current sensor 60 is provided for each of the multiple inverters 20, the calculation unit 206 may determine the operating or stopped state for each of the multiple pumps 12. Here, the threshold value for determining the pump system status may be set in the storage unit 204 when the communication device 200 is manufactured, or it may be set based on a predetermined external input to the communication device 200 via the input unit 202 or the communication unit 210. By making it possible to set a threshold value for determining the pump system status based on an external input, the pump system status can be properly determined regardless of the model of the water supply device 100. In addition, the communication device 200 may receive device information of the water supply device 100 as a predetermined external input. The device information may include, for example, information indicating the model (or model number) of the water supply device 100, the model of the pump 12, or information indicating ratings such as voltage or current. The calculation unit 206 may then set thresholds for determining the pump device status based on the input device information of the water supply device. For example, the calculation unit 206 can set thresholds by applying the externally input device information to a map in which the relationship between pre-stored device information and thresholds is defined. Alternatively, the calculation unit 206 may set thresholds by multiplying the rated value based on the input device information by a predetermined coefficient (e.g., 10%, 5%, etc.).

[0035] Furthermore, in this embodiment, the calculation unit 206 determines (calculates) the average current value when the pump 12 is operating, based on the current value detected by the current sensor 60, as the pump device state. Figure 3 is a schematic diagram showing an example of how the calculation unit 206 calculates the average current value when the pump 12 is operating. As described above, the calculation unit 206 acquires multiple detection values ​​at predetermined time intervals and calculates the average value (see upper section in Figure 3). The calculation unit 206 also determines the operation stop state based on the calculated average value (see middle section in Figure 3). Then, the calculation unit 206 calculates the average current value when it determines that the pump 12 is operating, excluding the current value when it determines that the pump 12 is stopped (see lower section in Figure 3). In this way, the communication device 200 of this embodiment can determine (calculate) the average current value when the pump 12 is operating, as the pump device state. Furthermore, the communication device 200 does not need to calculate the average current value when the pump 12 is operating, or it may calculate the average current value when the pump 12 is stopped or when it is not operating.

[0036] Furthermore, the calculation unit 206 may perform an abnormality determination of the sensor or water supply device 100 based on the value detected by the sensor. The abnormality determination can be performed by a known method depending on the type of sensor connected to the input unit 202. For example, the calculation unit 206 determines that an abnormality has occurred in the sensor 60 or water supply device 100 when the detected current by the current sensor 60 is greater than an abnormality threshold. In this case, the communication device 200 may notify the abnormality using a lamp or buzzer (not shown) or notify the external device 300 of the abnormality. Alternatively, the communication device 200 may not notify the abnormality until it has determined that an abnormality has occurred in the sensor or water supply device 100 after a predetermined number of filtering cycles (e.g., several cycles), and only notify the abnormality when it has determined that an abnormality has occurred after more than the number of filtering cycles. This can prevent false alarms by the communication device 200.

[0037] Next, based on the determined pump device status, the calculation unit 206 measures the cumulative operating time of the pump 12 if the pump 12 is operating (step S104: Yes) (step S106). If the water supply device 100 is equipped with multiple pumps 12, it is preferable for the calculation unit 206 to measure the cumulative operating time for each pump 12. Here, the communication device 200 communicates to the water supply device 100 via the input unit 202 or the communication unit 210. It is preferable that the system be configured to allow setting the cumulative operating time of the pump 12 before installation. This way, when the communication device 200 is retrofitted to the water supply device 100, the cumulative operating time can be measured taking into account the operating time of the pump before the installation of the communication device 200. The communication device 200 may also be configured to allow resetting of the cumulative operating time via the input unit 202 or the communication unit 210 when the pump 12 is replaced, etc. In this embodiment, the cumulative operating time of the pump 12 is measured as the pump device state, but such measurement of cumulative operating time is not required.

[0038] Then, the calculation unit 206 updates the pump device status stored in the storage unit 204 based on the determined pump device status (step S108), and terminates this process. The pump device status stored in the storage unit 204 is transmitted from the communication unit 210 to the external device 300 each time the pump device status is updated, at predetermined intervals (e.g., several hundred seconds, several seconds), or in response to a request from the external device 300.

[0039] According to the communication device 200 described above, the pump device status, including an operation stop state indicating whether the pump 12 is operating or stopped, is determined based on detection signals from the sensor and transmitted from the communication unit 210 to the external device 300. By attaching such a communication device 200 to an existing water supply system 100, the status of the water supply system 100 can be transmitted externally. Moreover, in this embodiment, the cumulative operating time of the pump 12 and the average current value during operation of the pump 12 are calculated as the pump device status, and parameters suitable for managing the water supply system 100 can be transmitted to the external device 300. Furthermore, in this embodiment, the communication device 200 determines the pump device status based on detection signals from sensors that are not input to the controller 40 of the water supply system 100. This allows the external device 300 to manage the pump device status based on sensors not mounted on the water supply system 100.

[0040] <Second Embodiment> Figure 4 is a schematic diagram showing the configuration of the water supply system and communication device according to the second embodiment. In the second embodiment, the water supply system 100 is used in an elevated water tank system, and the water supply pipe 107 of the water supply system 100 is connected to the elevated water tank 120 of the building. The water supply system 100 in the second embodiment is identical to the water supply system 100 in the first embodiment, so redundant explanations are omitted.

[0041] The elevated water tank 120 is installed at a height such as the rooftop of a building, where sufficient water pressure can be obtained to supply water to the water taps (e.g., faucets) 110 on the top floor. The water supply system 100 pressurizes water from the main water pipe 104 or a receiving tank, stores it in the elevated water tank 120, and then supplies water to the water taps 110 on each floor by releasing water from the elevated water tank 120. The elevated water tank 120 is equipped with a float switch 140, which is a water level sensor that detects the water level inside the elevated water tank 120. The float switch 140 detects the starting water level at which the water supply system 100 begins supplying water and the stopping water level at which the water supply system 100 stops supplying water. In addition to or instead of the float switch 140, the elevated water tank 120 may also be equipped with a water level sensor having a water level rod. In this embodiment, the detection signal from the float switch 140 is transmitted to both the controller 40 of the water supply device 100 and the input unit 202 of the communication device 200.

[0042] In the water supply device 100 of the second embodiment, when the controller 40 determines, based on the detection signal from the float switch 140, that the water level in the elevated water tank 120 is below the starting water level, it starts the pump 12 to transfer water from the water supply device 100 to the elevated water tank 120. Also, when the controller 40 determines, based on the detection signal from the float switch 140, that the water level in the elevated water tank 120 is above the stop water level, it stops the operation of the pump 12 and stops the transfer of water from the water supply device 100 to the elevated water tank 120. Through this control, water can be transferred from the water supply device 100 to the elevated water tank 120 and supplied to the target.

[0043] The communication device 200 of the second embodiment is identical to the communication device 200 of the first embodiment, except that it receives the detected water level from the float switch 140, and redundant explanations will be omitted. In other words, in the first embodiment described above, the communication device 200 receives detection signals from sensors that are not input to the water supply device 100 and are not used in the controller 40 to control the pump 12. Instead, in the second embodiment, the communication device 200 receives detection signals from sensors used in the controller 40 of the water supply device 100 to control the pump 12. However, in addition to detection signals from sensors used in the controller 40 to control the pump 12, the input section 202 of the communication device 200 may also receive detection signals from sensors not used in the control of the pump 12, similar to the first embodiment. Furthermore, the input section 202 of the communication device 200 may receive detection signals from pressure sensors 21, 26 or the flow switch 24, etc., instead of or in addition to the detection signals from the float switch 140.

[0044] The communication device 200 of the second embodiment can determine the pump device status by executing the process shown in Figure 2, similar to the communication device 200 of the first embodiment. Note that the explanation of the pump device status determination process that overlaps with that of the first embodiment will be omitted. The communication device 200 of the second embodiment receives the detected water level from the float switch 140, and the calculation unit 206 can determine the operation stop state of the pump 12 based on the detected water level of the float switch 140 (step S103 in Figure 2). For example, the calculation unit 206 determines that the pump 12 is stopped when the float switch 140 detects a water level of or above the stop water level. Furthermore, the calculation unit 206 determines that the pump 12 is stopped until the float switch 140 detects a water level below the start water level while the pump 12 is stopped. In addition, the calculation unit 206 determines that the pump 12 is operating when the float switch 140 detects a water level below the start water level. The calculation unit 206 then determines that the pump 12 is operating until the float switch 140 detects a water level above the stop level while the pump 12 is running.

[0045] The determination of the operation stop state by such communication device 200 may be based on detection signals from pressure sensors 21, 26 or flow switch 24. For example, the calculation unit 206 may determine, based on the detection signal from flow switch 24, that the pump 12 is stopped when a low water volume is detected, and that the pump 12 is operating when a low water volume is not detected. Alternatively, the calculation unit 206 may determine the pump system state, including the operation stop state, based on signals from multiple sensors.

[0046] In the communication device 200 of the second embodiment described above, similar to the communication device 200 of the first embodiment, the pump device status can be determined based on the detection signal from the sensor and transmitted from the communication unit 210 to the external device 300. In the second embodiment, the communication device 200 determines the pump device status based on the detection signal from the sensor input to the controller 40 of the water supply device 100. Such a communication device 200 can be retrofitted to, for example, a water supply device 100 that does not have an external communication function or a water supply device 100 that does not have an output unit suitable for outputting the pump device status to the outside, and the external device 300 can appropriately manage the pump device status.

[0047] <Third Embodiment> Figure 5 is a schematic diagram showing the configuration of the water supply device and communication device according to the third embodiment. The water supply device 100 and communication device 200 of the third embodiment are identical to those of the first embodiment, except that the output signal from the controller 40 of the water supply device 100 is input to the input unit 202 of the communication device 200, and redundant explanations will be omitted.

[0048] In the third embodiment, an output signal is transmitted from the I / O unit 50 of the controller 40 to the input unit 202 of the communication device 200. The connection between the controller 40 and the communication device 200 can be wired or wireless. For example, an output terminal (not shown) provided on the I / O unit 50 of the controller 40 may be electrically connected to an input terminal (not shown) provided on the input unit 202 of the communication device 200. Alternatively, the controller 40 and the communication device 200 may be connected by serial communication such as RS422, RS232C, or RS485.

[0049] The signals transmitted from the controller 40 of the water supply system 100 to the communication device 200 may, for example, be event-specific signals for the water supply system 100. Event-specific signals may include signals indicating the operation stop status of the pump 12, signals corresponding to events related to malfunctions of the water supply system 100, and signals corresponding to events related to the water level of the receiving tank or elevated water tank connected to the water supply system 100. Furthermore, the signals transmitted from the controller 40 of the water supply system 100 to the communication device 200 may, for example, be control command values ​​from the controller 40. These control command values ​​may include, for example, the target pressure or target rotational speed of the pump 12. Additionally, the signals transmitted from the controller 40 of the water supply system 100 to the communication device 200 may be parameters of the inverter 20. Finally, the signals transmitted from the controller 40 of the water supply system 100 to the communication device 200 may be detected values ​​from sensors (pressure sensors 21, 26 or flow switch 24) installed in the water supply system 100. Furthermore, the signals transmitted from the controller 40 of the water supply device 100 to the communication device 200 may include setting value information related to the operation of the pump 12 (such as stop pressure, starting pressure, discharge side pressure PA at maximum flow rate, discharge side pressure PB during shut-off operation, etc.), or other information used for control.

[0050] Furthermore, in the third embodiment, the communication device 200 receives a detection signal from the current sensor 60, similar to the first embodiment. As described in the first and second embodiments, the communication device 200 only needs to receive a detection signal from a sensor that detects operation-related information, which is a physical quantity related to the operation of the pump. In addition to or instead of the current sensor 60, detection signals from other sensors may also be received.

[0051] The communication device 200 of this third embodiment can determine the pump device status by performing the processing shown in Figure 2, similar to the communication devices 200 of the first and second embodiments. Here, the determination of the pump device status by the calculation unit 206 may be performed based on the signal from the controller 40. In addition to or instead of determining the pump device status, the communication device 200 of the third embodiment can determine whether the signal from the controller 40 is appropriate based on the detection signal from the sensor.

[0052] Figure 6 is a flowchart showing an example of the signal verification process from the controller 40 of the water supply device 100, which is performed by the communication device. This process is repeatedly executed at predetermined intervals (for example, a few milliseconds, tens of milliseconds, or hundreds of milliseconds) while the communication device 200 is started up and operating.

[0053] The calculation unit 206 of the communication device 200 first reads the signal from the controller (pump controller) 40 of the water supply device 100 (hereinafter referred to as the "controller signal") and the detection signal from the sensor connected to the input unit 202 (step S202). As an example, the calculation unit 206 reads the detected current from the current sensor 60 connected to the input unit 202.

[0054] Next, the calculation unit 206 determines (verifies) whether the controller signal is correct based on the detected value read from the sensor (step S204). In this process, as an example, if the controller signal and the detected value from the sensor are inconsistent, the calculation unit 206 may determine that the controller signal is abnormal. As a specific example, even if the controller 40 has input a signal indicating that the pump 12 is operating, If the current detected by the current sensor 60 is zero or very small and it is determined that the pump 12 has stopped, the calculation unit 206 determines that the controller signal is abnormal. The consistency and inconsistency between such controller signals and detected values ​​from sensors may be determined based on a relationship that is stored in the storage unit 204 beforehand. In addition, although the current detected by the current sensor 60 has been described as an example of a sensor, if detection signals from pressure sensors 21, 26, flow switch 24, or float switch 140 are input to the input unit 202, the controller signal may be verified based on these detection signals.

[0055] Then, if the calculation unit 206 determines that the controller signal is correct based on the detection signal from the sensor (step S206: Yes), it terminates the process. On the other hand, if the calculation unit 206 determines that the controller signal is abnormal based on the detection signal from the sensor (step S206: No), it notifies the external device 300 of this information via the communication unit 210 (step S208) and terminates the process.

[0056] According to the communication device 200 of the third embodiment described above, the signal from the controller 40 of the water supply device 100 and the detection signal from the sensor are input to the input unit 202. The calculation unit 206 of the communication device 200 then determines whether the controller signal is correct based on the detection signal from the sensor. As a result, an abnormality in the water supply device 100 can be determined by the add-on communication device 200.

[0057] <Variation> In the first to third embodiments, a water supply device for supplying water to a target was described as an example of a pump device. However, the pump device only needs to include a pump and a controller for controlling the pump, and can be various types of pump devices, such as a vacuum pump device, a blower device, a sewage pump, or a fluid transport device in a plant. Furthermore, in the embodiments described above, the pump device was assumed not to include a communication unit. However, the pump device may include a communication unit configured to communicate with an external terminal by wired or wireless communication.

[0058] The embodiment described above can also be described in the following form. [Embodiment 1] According to Embodiment 1, a communication device is proposed that can be attached separately from the pump controller to a pump system comprising a pump and a pump controller for controlling the pump, and comprises an input unit to which a detection signal is input from a sensor that detects operation-related information, which is a physical quantity related to the operation of the pump; a determination unit that determines the pump system state, including an operation stop state, indicating whether the pump is in operation or stopped, based on the detection signal from the sensor; and a transmission unit that transmits output information to the outside based on the pump system state determined by the determination unit. According to Embodiment 1, a communication device can be retrofitted to an existing pump system and capable of transmitting the status of the pump system to the outside.

[0059] [Form 2] According to Form 2, in Form 1, the determination unit measures the cumulative operating time of the pump based on the determined operating stop state, and the transmission unit transmits the cumulative operating time of the pump as output information. According to Form 2, the cumulative operating time of the pump can be transmitted to an external device from a communication device.

[0060] In another embodiment, in embodiment 1 or 2, the communication device includes the sensor, and the detection signal from the sensor is not used by the pump controller to control the pump. In this embodiment, the state of the pump device determined based on the detection value not used by the pump controller to control the pump can be transmitted to an external source.

[0061] [Form 4] According to Form 4, in Forms 1 to 3, the sensor is a current sensor that detects the current flowing through the pump device, and the determination unit determines the operation stop state based on the detection signal from the current sensor.

[0062] [Embodiment 5] According to Embodiment 5, in Embodiments 1 to 4, the sensor is at least one of the following: a pressure sensor that detects the suction-side pressure or discharge-side pressure of the pump, a rotation speed sensor that detects the rotation speed of the pump, a flow rate sensor that detects the transfer flow rate by the pump, or a water level sensor that detects the water level of a water tank connected to the pump device, and the detection signal from the sensor is also input to the pump controller. According to Embodiment 5, the status of the pump device determined based on the detected value input to the pump controller can be transmitted to the outside.

[0063] [Embodiment 6] According to Embodiment 6, in Embodiments 1 to 5, the communication device is configured to set a threshold based on an external input, and the determination unit determines the pump device status by comparing the value detected by the sensor with the threshold. According to Embodiment 6, a threshold for determining the pump device status can be set based on an external input.

[0064] [Embodiment 7] According to Embodiment 7, in Embodiment 6, the external input is an input indicating the device information of the pump device, and the communication device sets the threshold based on the device information. According to Embodiment 7, the threshold can be set in the communication device based on the device information of the pump device.

[0065] [Embodiment 8] According to Embodiment 8, in Embodiment 2, the communication device can be set to a pre-installation operating time indicating the cumulative operating time of the pump before the installation of the communication device, and the determination unit measures the cumulative operating time of the pump by adding the pre-installation operating time. According to Embodiment 8, the cumulative operating time of the pump can be measured taking into account the operating time of the pump before the installation of the communication device.

[0066] [Embodiment 9] According to embodiment 9, in embodiments 1 to 8, when an abnormality is determined in the sensor or the pump device based on the detection signal from the sensor, the system is configured to notify the external party of the abnormality. According to embodiment 9, when an abnormality is determined in the sensor or the pump device, the communication device can notify the external party.

[0067] [Form 10] In Form 10, in Forms 1 to 9, the input unit receives a signal from the pump controller, and the determination unit determines whether the signal from the pump controller is appropriate based on the detection signal from the sensor. In Form 10, the communication device can determine whether the output signal from the pump controller is appropriate.

[0068] While embodiments of the present invention have been described above, the embodiments of the invention described above are for the purpose of facilitating understanding of the present invention and do not limit it. The present invention can be modified and improved without departing from its spirit, and of course, the present invention includes equivalents thereof. Furthermore, any combination of embodiments and modifications is possible to the extent that at least some of the above-mentioned problems can be solved or at least some of the effects can be achieved, and any combination or omission of each component described in the claims and specification is possible. [Explanation of Symbols]

[0069] 12... Pump 13…motor 20…Inverter 21…Pressure sensor 24... Flow switch 26…Pressure sensor 28... Pressure tank 40…Controller 46...Settings section 47...Storage section 48...Arithmetic section 49…Display section 50…I / O Department 51…Driver's panel 60...Current sensor 60... Power sensor 90…Commercial power supply 100…Water supply device 120... Elevated water tank 140... Float switch 200...Communication equipment 202...Input section 204...Storage section 206...Arithmetic section 210... Communications Department 300...External device

Claims

1. A communication device that can be attached separately from the pump controller to a pump system comprising a pump and a pump controller for controlling the pump, An input unit to which a detection signal is input from a sensor that detects operation-related information, which is a physical quantity related to the operation of the pump, A determination unit that determines the pump device status, including an operation stop state, which indicates whether the pump is operating or stopped, based on the detection signal from the sensor, A transmission unit that transmits output information based on the pump device status determined by the determination unit to an external source, A communication device equipped with the following features.

2. The determination unit measures the cumulative operating time of the pump based on the determined operating stop state, The transmitting unit transmits the cumulative operating time of the pump as output information. The communication device according to claim 1.

3. The aforementioned sensor is a current sensor that detects the current flowing through the pump device, The determination unit determines the operation stop state based on the detection signal from the current sensor. The communication device according to claim 1 or 2.

4. The sensor is at least one of the following: a pressure sensor for detecting the suction or discharge pressure of the pump; a rotation speed sensor for detecting the rotation speed of the pump; a flow rate sensor for detecting the flow rate transferred by the pump; or a water level sensor for detecting the water level in a tank connected to the pump device. The detection signal from the aforementioned sensor is also input to the pump controller. The communication device according to claim 1 or 2.

5. The communication device is configured to be able to set a threshold based on an external input, The determination unit determines the state of the pump device by comparing the value detected by the sensor with the threshold value. The communication device according to claim 1 or 2.

6. The aforementioned external input is an input indicating the device information of the pump device, The communication device sets the threshold based on the device information. The communication device according to claim 5.

7. The communication device can be configured to show a pre-installation operating time, which indicates the cumulative operating time of the pump before the installation of the communication device. The determination unit measures the cumulative operating time of the pump by adding the pre-installation operating time. The communication device according to claim 2.

8. The communication device according to claim 1 or 2, which is configured to notify an external party of an abnormality in the sensor or the pump device when an abnormality is determined based on a detection signal from the sensor.

9. The input unit receives a signal from the pump controller. The determination unit determines whether the signal from the pump controller is appropriate based on the detection signal from the sensor. The communication device according to claim 1 or 2.

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