Failure detection for a pump system

Abstract

Disclosed herein are a pump system and a method for controlling the pump system for detecting a failure of the pump system. The pump system may include a pump comprising a motor configured to drive an impeller to discharge fluid, a basin accommodating the pump, a discharge pipe connected to the pump and being pathway of the fluid, a check valve provided on the discharge pipe and configured to prevent backflow of the fluid,. The pump system may also include sensor configured to detect environmental data of at least one of the pump, the basin, the discharge pipe, and the check valve. The pump system may further include a processor configured to, based on the environmental data, determine whether the failure of the pump system is likely to occur, and when the failure is determined to be likely, send a notification.

Description

FAILURE DETECTION FOR A PUMP SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Patent Application No. 63 / 557,790, filed Feb. 26, 2024.BACKGROUND

[0002] A pump is a device that uses mechanical, hydraulic, pneumatic, or electrical energy to move fluids from one place to another, often against a pressure difference or a gravitational force. Pumps are used to provide adequate drainage for both commercial and residential uses. Examples of different types of pumps include sump, sewage, and drainage pumps.

[0003] A sump pump is a pump installed in a basin or pit below the ground level, usually in basements, crawl spaces, or other low-lying areas, to collect and remove excess water that may accumulate from rain, groundwater, or flooding. Sump pumps can be placed inside or above a sump basin. Sump pumps prevent water damage, mold growth, and structural problems in buildings and foundations.

[0004] A sewage pump is a pump typically used to transport wastewater or sewage from a building to a septic tank, a sewer system, or a treatment plant. Sewage pumps can handle solid waste, organic matter, and other contaminants that may clog or damage other types of pumps. Some sewage pumps are equipped with a grinder, that is, a cutting mechanism to reduce the size of the solids suspended in the fluid. Sewage pumps prevent sanitary and health hazards, odors, and backups in plumbing systems.

[0005] A drainage pump is a pump used to remove water from surfaces or subsurfaces, such as fields, gardens, roads, roofs, or mines. Drainage pumps can be portable (moved from one location to another) or fixed (installed permanently in a specific location). Drainage pumps prevent flooding, erosion, and waterlogging in various settings

[0006] Pumps can have various designs, sizes, and applications depending on the type and properties of the fluid, the flow rate and pressure required, and the environmental and operational conditions. To ensure proper drainage, pumps should be installed with the appropriate performance for the location where they are installed. Frequent maintenancemay also be required to maintain pump performance. However, pumps may suddenly fail due to a variety of factors. When a pump suddenly fails, emergency repair or replacement may be required. Systems and methods are needed to proactively detect a failure of a pump system.SUMMARY

[0007] According to an embodiment, a pump system is provided. The pump system may include a pump comprising a motor configured to drive an impeller to discharge fluid. The pump system may include a basin accommodating the pump. The pump system may include a discharge pipe connected to the pump and being pathway of the fluid. The pump system may include a check valve provided on the discharge pipe and configured to prevent backflow of the fluid. The pump system may also include sensor configured to detect environmental data of at least one of the pump, the basin, the discharge pipe, and the check valve. The pump system may further include a processor configured to, based on the environmental data, determine whether a failure of the pump system is likely to occur, and when the failure is determined to be likely, send a notification.

[0008] System, device, and computer program product aspects are also disclosed.

[0009] Further features and advantages, as well as the structure and operation of various aspects, are described in detail below with reference to the accompanying drawings. It is noted that the specific aspects described herein are not intended to be limiting. Such aspects are presented herein for illustrative purposes only. Additional aspects will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The accompanying drawings are incorporated herein and form a part of the specification.

[0011] FIG. l is a block diagram of a pump system, according to some embodiments.

[0012] FIG. 2 is a block diagram of a check valve, according to some embodiments.

[0013] FIG. 3 is a block diagram of a discharge pipe, according to some embodiments.

[0014] FIG. 4 is a block diagram of a basin, according to some embodiments.

[0015] FIG. 5 is a block diagram of an input / output (I / O) package, according to some embodiments.

[0016] FIG. 6 is a chart explaining a duty point, according to some embodiments.

[0017] In the drawings, like reference numbers generally indicate identical or similar elements. Additionally, generally, the left-most digit(s) of a reference number identifies the drawing in which the reference number first appears.DETAILED DESCRIPTION

[0018] FIG. 1 is a block diagram of pump system 100, according to some embodiments. Pump system 100 may include pump 102, discharge pipe 104, check valve 106, power line 108, basin 130, controller 120, control module 122, user app 128, sensor package(s) 200, 300, 400 and I / O package 500.

[0019] Pump 102 may be a sewage pump. Pump 102 may discharge the water from basin 130 to the outside through discharge pipe 104. Power to pump 102 may be supplied via power line 108. Pump 102 may include I / O package 500. Pump 102 may exchange sensing data and control data to controller 120 via I / O package 500. Details of I / O package 500 are described below. Pump 102 may include a motor and an impeller rotated by the motor.

[0020] Discharge pipe 104 may be connected to pump 102 and be a pathway of the water discharged by pump 102. Discharge pipe 104 may include discharge pipe sensor package 300 for sensing the environment inside or outside discharge pipe 104. The data sensed by discharge pipe sensor package 300 may be transmitted to controller 120. Details of discharge pipe sensor package 300 are described below. Discharge pipe 104 may include check valve 106 to prevent backflow of the water. Discharge pipe 104 may be located both upstream and downstream of check valve 106.

[0021] Check valve 106 may be provided on discharge pipe 104. Check valve 106 may prevent backflow of the water. Discharge pipe 104 may include check valve sensor package 200 for sensing the environment inside or outside check valve 106. The data sensed by check valve sensor package 200 may be transmitted to controller 120. Details of check valve sensor package 200 are provided below.

[0022] Basin 130 may accommodate pump 102. Basin 130 may enclose pump 102 within basin wall 132 and basin bottom 134. Basin wall 132 may be an inner wall of basin 130. Basin bottom 134 may be a bottom wall of basin 130. Basin wall 132 and basin bottom 134 wall may form a tube shaped form into which pump 102 is placed such that the bottom portion of pump 102 rests on basin bottom 134. Basin 130 may include basin sensorpackage 400 for sensing the environment inside or outside basin 130. The data sensed by basin sensor package 400 may be transmitted to controller 120. Details of basin sensor package 400 are described below.

[0023] Controller 120 may transmit the received sensing data to control module 122. Controller 120 may transmit the control data generated by control module 122 to pump 102 to control pump 102.

[0024] Control module 122 may include WiFi / data connection module 124 and capture / processing module 126. Capture / processing module 126 may process data received from controller 120, via WiFi / data connection module 124 or from user app 128, and transmit the processing results to controller 120 or user app 128. Capture / processing module 126 may be a processor. WiFi / data connection module 124 may receive data from a network or other connected devices. WiFi / data connection module 124 may transmit data to the network or other connected devices. WiFi / data connection module 124 may be equipped with a 5G modem in case of WiFi outages in a facility. User app 128 may be an application installed in a device of a user or an administrator of pump system 100. User app 128 may monitor the status of pump system 100 and control functions of pump system 100. Control module 122 may be connected to an auxiliary power supply so that it can operate even if the power supply to pump system 100 is cut off.

[0025] FIG. 2 is a block diagram of check valve 106, according to some embodiments. Checkvalve 106 may include check valve sensor package 200 and flapper 212. Check valve sensor package 200 may include temperature sensor 202, pressure sensor 204, flow sensor 206, water level sensor 208, or mechanical sensor 210.

[0026] Temperature sensor 202 may detect a temperature of the outflow water temperature. In an example, temperature sensor 202 may be a thermocouple. Pressure sensor 204 may detect the pressure (e.g., pressure per square inch (PSI)) of the outflow water. In an example, pressure sensor 204 may be a transducer or diaphragm type sensor. Flow sensor 206 may detect the flow rate of the outflow water. In an example, flow sensor 206 may be for a mechanical flow rate detector (e.g., a pinwheel sensor). Water level sensor 208 may detect a water level of check valve 106. In an example, water level sensor 208 may be a capacitive-based detector or a hall detector.

[0027] Mechanical sensor 210 may detect the open / close status or angle of flapper 212. Mechanical sensor 210 may be a potentiometer provided to a hinge to secure one end of flapper 212. Mechanical sensor 210 may be a magnetic sensor provided to a free end offlapper 212. Mechanical sensor 210 may detect magnetism, such as a magnet at the free end of flapper 212. Mechanical sensor 210 may measure the acceleration with respect to the opening and closing of flapper 212. Mechanical sensor 210 may monitor the displacement of an elastic part, such as a spring, securing flapper 212. Flapper 212 is arranged to selectively open and close the drainage path of check valve 106. Flapper 212 may be secured to check valve 106 at one end. Mechanical sensor 210 may also detect the opening and closing state of flapper 212, which is formed to open and close inside check valve 106 around a pivot axis, by detecting the rotation of the pivot axis formed on the outside of check valve 106.

[0028] The arrangement of temperature sensor 202, pressure sensor 204, flow sensor 206, water level sensor 208, or mechanical sensor 210 shown in FIG. 2 is an example, and may be changed as appropriate depending on the types of sensors and the shape of check valve 106. For example, each of the sensors may be provided on or in the wall of check valve 106, or within the flow path within check valve 106. Temperature sensor 202, pressure sensor 204, flow sensor 206, water level sensor 208, or mechanical sensor 210 may not be located in pump system 100 and may be replaced by other components that can detect similar phenomena. Multiple temperature sensors 202, pressure sensors 204, flow sensors 206, water level sensors 208, or mechanical sensors 210 may be located in check valve 106.

[0029] FIG. 3 is a block diagram of discharge pipe 104, according to some embodiments. Discharge pipe 104 may include discharge pipe sensor package 300. Discharge pipe sensor package 300 may include temperature sensor 302, pressure sensor 304, flow sensor 306, and water level sensor 308.

[0030] Temperature sensor 302 may detect a temperature of the outflow water temperature.In an example, temperature sensor 302 may be a thermocouple. Pressure sensor 304 may detect the pressure of the outflow water. In an example, pressure sensor 304 may be a transducer or diaphragm type sensor. Flow sensor 306 may detect the flow rate of the outflow water. In an example, flow sensor 306 may be for a mechanical flow rate detector. Water level sensor 308 may detect a water level of discharge pipe 104. In an example, water level sensor 308 may be a capacitive-based detector or a hall detector.

[0031] The arrangement of temperature sensor 302, pressure sensor 304, flow sensor 306, or water level sensor 308 shown in FIG. 3 is an example, and may be changed as appropriate depending on the types of sensors and the shape of discharge pipe 104. For example, each of the sensors may be provided on or in the wall of discharge pipe 104, or within the flowpath within discharge pipe 104. The temperature sensor 302, pressure sensor 304, flow sensor 306, and water level sensor 308 may not be located in pump system 100 and may be replaced by other components that can detect similar phenomena. Multiple temperature sensors 302, pressure sensors 304, flow sensors 306, and water level sensors 308 may be located in discharge pipe 104.

[0032] FIG. 4 is a block diagram of basin 130, according to some embodiments. Basin 130 may include basin sensor package 400. Basin sensor package 400 may include temperature sensor 402, flow sensor 406, and water level sensor 408.

[0033] Temperature sensor 402 may detect a temperature of the water temperature. In an example, temperature sensor 402 may be a thermocouple. Flow sensor 406 may detect the flow rate of the water. In an example, flow sensor 406 may be for a mechanical flow rate detector. Water level sensor 408 may detect a water level of basin 130. In an example, water level sensor 408 may be a capacitive-based detector or a hall detector.

[0034] The arrangement of temperature sensor 402, flow sensor 406, or water level sensor408 shown in FIG. 4 is an example, and may be changed as appropriate depending on the types of sensors and the shape of basin 130. For example, each of the sensors may be provided on an interior portion of basin wall 132, where the sensor is placed between basin wall 132 and pump 102. The temperature sensor 402, flow sensor 406, and water level sensor 408 may not be located in pump system 100 and may be replaced by other components that can detect similar phenomena. Multiple temperature sensors 402, flow sensors 406, and water level sensors 408 may be located in basin 130.

[0035] FIG. 5 is a block diagram of I / O package 500, according to some embodiments. I / O package 500 may include memory 502 and pump sensor package 510. Memory 502 may record the value detected by pump sensor package 510. Pump sensor package 510 may include temperature sensor 512, amperage sensor 514, or voltage sensor 516. Pump sensor package 510 may include a wattage sensor instead of or in addition to amperage sensor 514, or voltage sensor 516.

[0036] Temperature sensor 512 may detect a temperature of pump 102. In an example, temperature sensor 512 may be a thermocouple. Temperature sensor 512 may be located on the capacitor, which regulates the power supply of pump 102. Temperature sensor 512 may be located inside a cap of pump 102 to avoid contamination by motor oil, etc. Temperature sensor 512 may be located inside a motor housing of pump 102 to detect thetemperature of motor oil. Amperage sensor 514, and / or voltage sensor 516 may detect a current value, a voltage value, or a watt value of the power supplied via power line 108.

[0037] Check valve sensor package 200, discharge pipe sensor package 300, basin sensor package 400 or pump sensor package 510 may be located where data for each component can be detected. In other words, Check valve sensor package 200, discharge pipe sensor package 300, basin sensor package 400 or pump sensor package 510 may not be located within each component. Data sensed by check valve sensor package 200, discharge pipe sensor package 300, basin sensor package 400 or pump sensor package 510 may be collectively referred to as environmental data.

[0038] The hardware configuration of pump system 100 described above is an example and can be modified in various ways. For example, the hardware for fault detection described below may be added to pump system 100 as appropriate. For example, a memory to record sensing data, a timer to measure a predetermined time, etc. may be added to any part of pump system 100 as needed.EXEMPLARY FAILURE DETECTION METHODS OF PUMP SYSTEM

[0039] The following are examples of how pump system 100 can predict and notify pump 102 of faulty operation using the hardware configuration described above.

[0040] Pump system 100 can detect a failure when the temperature at a specific location in pump system 100 exceeds the rated temperature specified for each location. For example, if capture / processing module 126 detects that the temperature detected by temperature sensor 202 exceeds the rated temperature of check valve 106 (e.g., 130 °F), capture / processing module 126 may notify the failure of pump system 100. Similarly, if capture / processing module 126 detects that the temperature detected by temperature sensor 302 or 402 exceeds the rated temperature of discharge pipe 104 or basin 130, controller 120 may notify the failure of pump system 100. Likewise, if capture / processing module 126 detects that the temperature of electric parts (e.g., capacitors) or motor oil detected by temperature sensor 512 exceeds the rated temperature, controller 120 may notify the failure of pump system 100. How controller 120 notifies pump system 100 of a failure is described below.

[0041] Detection of the temperature rise is not limited to the above methods. For example, capture / processing module 126 may detect the temperature rise when the temperature rise at a predetermined location exceeds a predetermined temperature for a predetermined timeor longer. In another example, capture / processing module 126 may detect the temperature rise in which the temperature at a predetermined location exceeds a predetermined temperature for a predetermined number of times or more.

[0042] Pump system 100 can detect a failure when the flow rate at a specific location in pump system 100 exceeds the predetermined value for each location. For example, if capture / processing module 126 detects that the flow rate detected by flow sensor 206 exceeds the predetermined value, capture / processing module 126 may notify the failure of pump system 100. Similarly, if capture / processing module 126 detects that the flow rate detected by flow sensor 306 or 406 exceeds the predetermined value of discharge pipe 104 or basin 130, controller 120 may notify the failure of pump system 100.

[0043] Detection of the flow rate is not limited to the above methods. For example, capture / processing module 126 may detect the flow rate based on the cross sectional area of the specific locations and the temperature detected at multiple locations of the specific locations. For instance, capture / processing module 126 may calculate the flow rate by calculating the flow velocity from the time at which the first temperature sensor of temperature sensors 202, 302, or 402 detects a temperature change and the time at which the second temperature sensor of temperature sensors 202, 302, or 402, located a predetermined distance away from the first temperature sensor, detects a temperature change and multiplying by the cross-sectional area at the locations of check valve 106, discharge pipe 104, or basin 130 where the first and second temperature sensors are located. As such, the flow rate can be estimated by detecting the movement of fluid in pump system 100 based on temperature changes.

[0044] Pump system 100 can detect a failure when the pressure at a specific location in pump system 100 exceeds the predetermined pressure specified for each location. For example, if capture / processing module 126 detects that the pressure detected by pressure sensor 204 exceeds the predetermined pressure of check valve 106, controller 120 may notify the failure of pump system 100. Similarly, if capture / processing module 126 detects that the pressure detected by pressure sensor 304 exceeds the predetermined pressure of discharge pipe 104, controller 120 may notify the failure of pump system 100. The predetermined value of the specific location may be set to a value that makes the notification if the pressure is above or below a predetermined percentage compared to the normal pressure, in each case during operation or non-operation of pump 102.

[0045] Pump system 100 can detect a failure of check valve 106 based on changes in pressure in check valve 106 over time. For example, if capture / processing module 126 detects a gradual decrease in pressure based on pressure sensor 204 at check valve 106 when flapper 212 is closed, it may determine that there is a failure in check valve 106. Capture / processing module 126 may detect the open / closed state of the flapper based on a sensing result of mechanical sensor 210.

[0046] Methods for detecting a failure of check valve 106 are not limited to those described above. For example, when flapper 212 is closed, capture / processing module 126 may determine that a fault exists in check valve 106 if flow sensor 206 detects a minute flow or if water level sensor 208 detects a drop in water level.

[0047] Failure of check valve 106 based on the phenomena described above is most likely based on a defective gasket in check valve 106. Therefore, capture / processing module 126 may transmit information indicating a defective gasket in check valve 106 to user app 128 or externally via WiFi / data connection module 124.

[0048] Pump system 100 may predict the failure of check valve 106 by detecting the number of water hammer occurrences. When flapper 212 of check valve 106 opens and pump 102 stops operating while water is being discharged to the outside, the water that was discharged to the outside falls by gravity and hits flapper 212, which is called the water hammer. The water hammer may gradually degrade the components of check valve 106. Therefore, capture / processing module 126 may notify the deterioration of check valve 106 based on the number of water hammering. Capture / processing module 126 may also notify that maintenance of check valve 106 is required at a particular time depending on the average number of water hammers within a given period of time.

[0049] Capture / processing module 126 may use various methods to detect water hammer. For example, capture / processing module 126 may detect that the water hammer is occurring when the pressure detected by pressure sensor 204 is turbulent, e.g., the pressure alternates up and down between a first and second value within a predetermined time period multiple times. Capture / processing module 126 may detect the occurrence of a water hammer if the open / close status or acceleration of flapper 212 sensed by mechanical sensor 210 shows that the flapper opens and closes more than a predetermined number of times within a predetermined period.

[0050] Pump system 100 can detect an airlock of pump 102. The airlock is a phenomenon in which air sucked into pump 102 stays at the impeller inlet and prevents water from beingpumped. Thus, capture / processing module 126 may notify the occurrence of the airlock as a failure. For example, capture / processing module 126 may detect that the airlock is occurring if pressure sensor 204, or 304 does not detect pressure due to water even though pump 102 is running. Capture / processing module 126 may refer to the sensing result of amperage sensor 514 of pump 102 to distinguish between the airlock and other failure causes, e.g., a rotor of the motor of pump 102 is locked. For example, if pump 102 is in operation, the sensing result of amperage sensor 514 is normal and the sensing result of pressure sensor 204, or 304 is abnormal as described above, capture / processing module 126 may determine that the airlock is occurring.

[0051] Pump system 100 can detect a failure when the flow rate at a specific location in pump system 100 lowers the specified value for each location. For example, if capture / processing module 126 detects that the flow rate detected by flow sensor 206 lowers the predetermined value, controller 120 may notify the failure of pump system 100. Similarly, if capture / processing module 126 detects that the flow rate detected by flow sensor 306 or 406 lowers the predetermined value of discharge pipe 104 or basin 130, capture / processing module 126 may notify the failure of pump system 100.

[0052] Pump system 100 may detect that clogging is likely to occur at a specific location if the flow rate at the specific location within pump system 100 is detected to decrease by more than a predetermined percentage over time. For example, if a liquid mixed with oil or grease is passing through discharge pipe 104, impurities may accumulate on the wall surface, causing the inner diameter of discharge pipe 104 to become smaller and smaller. Also, if pump system 100 is operated in a cold climate, ice may accumulate in discharge pipe 104. Thus, capture / processing module 126 may notify of a possible pipe blockage if, during the operation of pump 102, the flow rate detected by flow sensor 206, 306, or 406 decreases by more than a predetermined percentage within a predetermined time period.

[0053] Pump system 100 may detect and notify whether pump 102 has been abnormally flooded. Under normal circumstances, the water around pump 102 should drain away, but depending on the weather and the condition of pump 102, pump 102 may be abnormally flooded and the water level may be abnormally high. To detect this issue, capture / processing module 126 may detect whether pump 102 has been abnormally flooded based on water level sensor 208. The water level that water level sensor 208 can detect includes not only the water level inside discharge pipe 104, but also the water level below the outside of check valve 106. It is not unusual for water level sensor 208 to detect thewater level inside check valve 106 above flapper 212, since water stays inside check valve 106 during normal operation. However, detecting a water level outside check valve 106 and near the bottom below flapper 212 indicates that pump 102 is flooded by an abnormal water level. Thus, if capture / processing module 126 detects the water level outside check valve 106 and near the bottom below flapper 212, capture / processing module 126 may notify that an abnormal water level has been detected. Similarly, if capture / processing module 126 detects that the water level sensor 308 detects the water level outside discharge pipe 104, capture / processing module 126 may notify that an abnormal water level has been detected. Capture / processing module 126 may also notify of the user that the pipe may be clogged with ice if, during the operation of pump 102, the flow rate detected by flow sensor 206, 306, or 406 decreases by more than a predetermined percentage within a predetermined time period, and weather data indicates that the temperature at the location where pump 102 is located is below freezing.

[0054] Pump system 100 may detect a failure of flapper 212. For example, capture / processing module 126 may notify that there is a fault in flapper 212 if mechanical sensor 210 does not indicate that flapper 212 is open even though pump 102 is running and at least one of the sensors of discharge pipe sensor package 300 detects water in discharge pipe 104.

[0055] Pump system 100 can detect that solids are mixed in the water and may cause a failure of the pump system 100. If the water contains solids, such as stones for example, it may lead to failure of pump system 100. The solids may abruptly push flapper 212 up or down. Therefore, capture / processing module 126 may monitor the acceleration related to the opening and closing of flapper 212, and if it opens or closes with abnormal acceleration, it may notify that solids are mixed in the water.

[0056] Pump system 100 can detect cavitation. Cavitation is the formation of bubbles in the pump system 100, which can cause drainage problems. Capture / processing module 126 may monitor mechanical sensor 210 to detect the acceleration related to the opening and closing of flapper 212, and if flapper 212 opens and closes in a cavitation-specific pattern, it may notify the occurrence of the cavitation. Capture / processing module 126 may also detect a drop in fluid pressure from the sensing result of pressure sensor 204 or 304 to detect the cavitation.

[0057] Pump system 100 may monitor whether water is properly discharged in discharge pipe 104, which is provided downstream of check valve 106 (in the direction from whichthe water is discharged). Discharge pipe 104 may slope at an angle close to parallel to the ground as it goes to the end. When pump system 100 is installed, it should be designed to provide adequate drainage according to the angle of discharge pipe 104. However, factors such as deterioration and changes in the angle of discharge pipe 104 may prevent proper drainage. To detect this issue, for example, capture / processing module 126 can detect whether water is being discharged properly based on the sensing results from two water level sensors 308 located in the upstream portion of discharge pipe 104. Specifically, for example, if water level sensor 308 closer to check valve 106 detects the water level but water level sensor 308 farther from check valve 106 does not even after a predetermined period of time, capture / processing module 126 may determine that water is stagnant in discharge pipe 104 and notify it. Similarly, if water level sensor 308 farther from check valve 106 detects the water level but water level sensor 308 closer from check valve 106 does not, capture / processing module 126 may determine that water is stagnant in discharge pipe 104 and notify it. Further, if water level sensor 308 closer to check valve 106 stops detecting the water level after water level sensor 308 farther from check valve 106 stops detecting the water level, capture / processing module 126 can determine that water is flowing back into discharge pipe 104 and notify the user.

[0058] Pump system 100 may detect and notify the user that the water level in basin 130 is not dropping despite pump 102 operating. For example, capture / processing module 126 may operate pump 102 depending on when the water level is detected by the multiple water level sensors 408 located at different heights in basin 130. For example, if low-level, midlevel, and high-level water level sensors 408 are located, capture / processing module 126 may start pump 102 after the low-level water level sensor 408 detects water and the midlevel water level sensor 408 detects water subsequently. Capturing / processing module 126 may also terminate the operation of pump 102 if the low-level water level sensor 408 no longer detects water after the mid-level water level sensor 408 no longer detects water. In a similar case, if the high level water level sensor 408 detects a water level, capturing / processing module 126 may notify that pump 102 is not draining well. Ifabackup pump (e.g., a DC pump driven by a lithium iron phosphate battery) is installed in basin 130 the capturing / processing module 126 may drive the backup pump. Capture / processing module 126 may also check the battery health of the backup pump and notify if the battery needs to be replaced. Battery health can be detected, for example, by measuring changes in the amount of discharge or the time required for a full charge. Capture / processing module126 can also inform the user of the duration of operation from that point after switching to the backup pump based on the battery level.

[0059] Pump system 100 may detect and notify that the rotor of pump 102 is locked. For example, capture / processing module 126 may notify that the rotor is locked if it detects from the sensing result of amperage sensor 514 (or current value calculated based on the volt value sensed by voltage sensor 516 and the watt value sensed by the wattage sensor) that the current value flowing in pump 102 exceeds a predetermined value. Similarly, capture / processing module 126 may notify that the rotor is locked if it detects from the sensing result of temperature sensor 512 that the temperature of the electronic parts of pump 102 (e.g., capacitor) exceeds a predetermined value.

[0060] Pump system 100 may detect dirty power and notify that the dirty power is supplied to pump system 100. Dirty power means that the supplied power is unstable for some reason and the supplied power becomes larger or smaller than the rated value in the short or long term. For example, capture / processing module 126 records the current and voltage values detected by amperage sensor 514 or voltage sensor 516 located at the electronic parts of pump 102 (e.g., capacitor) during the initial setup of pump 102. If subsequent current or voltage values is detected that deviate significantly from the current and voltage values recorded in memory 502, (e.g., current or voltage value is greater than a predetermined value) capture / processing module 126 may determine that dirty power is being supplied.

[0061] Pump system 100 may detect that an actual duty point is outside the normal range determined based on a reference duty point and notify or calibrate the issue. FIG. 6 is a chart explaining a duty point, according to some embodiments. FIG. 6 shows that the intersection of system curve 610 and pump curve 620 is duty point 630. System curve 610 is a curve determined by the entire path and shape of pump system 100 and represents the relationship of flow rate to head (the height at which pump 102 can raise water.) Pump curve 620 is a curve determined by the characteristics of pump 102 and represents the relationship of flow rate to head. In other words, ideally, pump system 100 may operate at the flow rate and head represented by duty point 630. However, various factors can cause the actual duty point to differ from duty point 630. The factors can include dirty power and other conditions that can cause the failures described above. The fact that pump system 100 is operating at a duty point different from duty point 630 indicates that each element of pump system 100 has failed or is predictive of possible failure. To address these issues, capture / processing module 126 may perform a calibration to bring the duty point back tothe normal range. The normal range may, for example, be the area bounded by the 3 -sigma range of system curve 610 (indicated by system curves 612, 614) and the 3 -sigma range of pump curve 620 (indicated by pump curves 622, 624). Methods of calibrating the duty point may include, for example, changing the operating parameters of pump 102 (e.g., rotational speed) or the path parameters of pump system 100 (e.g., pipe diameter). Pump system 100 may determine the actual duty point from the sensing result of flow sensor 206, 306 or 406. Pump system 100 may predetermine duty point 630 or the range of duty point 630 to be referenced based on an input from an installer or from the sensing result of flow sensor 206, 306 or 406. The input from the installer may include 1) an actual head of pump system 100 at an initial operation of pump system 100 or system curve 610 and 2) an actual flow of pump 102 at the initial operation of pump system 100 or pump curve 620 of pump 102.

[0062] Pump system 100 may signal the failure or anticipated failure of a component of pump 102 (e.g., a switch terminal) based on the number or frequency of duty cycles. The duty cycle is the cycle in which pump 102 operates. With each duty cycle, the components within pump 102 can deteriorate. For example, the contacts used in the switch may become welded, especially if many duty cycles occur in a short period of time. To address these issues, capture / processing module 126 may monitor duty cycles from the sensing result of amperage sensor 514, or voltage sensor 516, and provide notification if it detects more than a predetermined number of duty cycles within a predetermined period. Capture / processing module 126 may also compare the number of duty cycles with the predetermined number of cycles defined for pump 102 to notify that pump 102 needs maintenance or replacement.

[0063] Pump system 100 may evaluate whether a failure is imminent for pump system 100 depending on the season or weather conditions and notify the results of the evaluation. Extreme weather conditions may adversely affect pump system 100. For example, hurricanes or unusual rainfall can cause pump system 100 to fail. Extremely low temperatures can also cause pump system 100 to fail as a result of water freezing inside pump system 100. Extreme high temperatures can cause pump system 100 to overheat. To address such issues capture / processing module 126 may obtain seasonal or weather data via, for example, WiFi / data connection module 124. Capture / processing module 126 may notify when the temperature or rainfall indicated in the weather data is above or below a predetermined threshold. Capture / processing module 126 may also use seasonal data to evaluate whether pump system 100 is operating properly. For example, if pump system 100 is operating more frequently than usual, it may not notify the user if it is the wet season,but capture / processing module 126 may notify the user of a problem if it is the dry season. Capture / processing module 126 may also run pump 102 longer than usual during seasonal periods when algae are likely to grow.

[0064] The above described methods of failure detection / prediction are just examples, and specific failure prediction methods are not limited to the specific methods described above. For example, the operation to check the deviation from the threshold value or normal value in the above failure predictions may be performed based on a model created by machine learning. In other words, failure prediction may be performed after setting appropriate threshold values and reference values based on time-series data prepared in advance or obtained through the actual operation of pump system 100.

[0065] Also, the above described methods of failure detection / prediction may be described as being done primarily by capture / processing module 126, but may also be done by other components. For example, capture / processing module 126 may send sensing data to an external server via WiFi / data connection module 124, which may perform failure prediction and return the failure prediction results to pump system 100.EXEMPLARY METHODS FOR NOTIFYING FAILURE DETECTION

[0066] In the above mentioned failure prediction, it was mentioned that pump system 100 may send notifications as needed. The following are examples of ways in which pump system 100 may notify the user.

[0067] Pump system 100 may notify the user via user app 128. For example, capture / processing module 126 may notify the user via user app 128 of a notification containing specific detection details (e.g., "motor oil is overheated"). Capture / processing module 126 may also notify the user via user app 128 with a notification including the probable cause of the failure (e.g., "abnormal current value detected, the rotor may be locked"). Capture / processing module 126 may also notify the user via user app 128 with a notification including recommended remedies (e.g., "melt ice in discharge pipe"). Capture / processing module 126 may also notify the user via user app 128 of contact information for the customer center. The above notifications may be sent to the e-mail address registered with user app 128 or the distributor. The above notifications may be notified not only to the user, but also to the distributor or repairer via WiFi / data connection module 124.

[0068] Pump system 100 may notify the user by sounding an alarm. For example, capture / processing module 126 may provide notification by driving an alarm connected to controller 120. Capture / processing module 126 may also sound the terminal on which user app 128 is installed.

[0069] Pump system 100 may stop driving pump 102 when making the above notification and start operating the backup pump (e.g., DC pump driven by a lithium iron phosphate battery) installed in basin 130.

[0070] While the above describes how pump system 100 can predict and notify the user of a failure, the occurrence of a failure can also be prevented by taking appropriate measures when installing pump system 100. For example, user app 128 or a dedicated application may be used to properly install pump system 100 by displaying the steps to be followed during installation to the installer of pump system 100. The installer of pump system 100 may enter the checklist displayed in the application to certify that he / she has followed the instructions displayed in the application. The installer of pump system 100 may also send data (e.g., video data, sensing data) indicating that the installed pump system 100 is operating properly to the user or distributor via the application in order to prove that the instructions displayed in the application have been followed. The sensing data sent via the application may be used as a threshold, reference value or parameter for machine learning for the failure prediction.

[0071] User app 128 may also display a maintenance tip to the user to prevent failures. For example, user app 128 may display a maintenance checklist for the user. User app 128 may also display a video explaining the tasks shown in the checklist. An example of a task included in the checklist would be checking to see if a weep hole of pump system 100 is clogged. User app 128 may also notify the user to have pump system 100 professionally maintained after a predetermined period of time (e.g., five years) has elapsed since installation.

[0072] It is to be appreciated that the Detailed Description section, and not any other section, is intended to be used to interpret the claims. Other sections can set forth one or more but not all exemplary embodiments as contemplated by the inventor(s), and thus, are not intended to limit this disclosure or the appended claims in any way.

[0073] While this disclosure describes exemplary embodiments for exemplary fields and applications, it should be understood that the disclosure is not limited thereto. Other embodiments and modifications thereto are possible, and are within the scope and spirit ofthis disclosure. For example, and without limiting the generality of this paragraph, embodiments are not limited to the software, hardware, firmware, and / or entities illustrated in the figures and / or described herein. Further, embodiments (whether or not explicitly described herein) have significant utility to fields and applications beyond the examples described herein.

[0074] Embodiments have been described herein with the aid of functional building blocks illustrating the implementation of specified functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined as long as the specified functions and relationships (or equivalents thereof) are appropriately performed. Also, alternative embodiments can perform functional blocks, steps, operations, methods, etc. using orderings different than those described herein.

[0075] References herein to “one embodiment,” “an embodiment,” “an example embodiment,” or similar phrases, indicate that the embodiment described can include a particular feature, structure, or characteristic, but every embodiment can not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it would be within the knowledge of persons skilled in the relevant art(s) to incorporate such feature, structure, or characteristic into other embodiments whether or not explicitly mentioned or described herein. Additionally, some embodiments can be described using the expression “coupled” and “connected” along with their derivatives. These terms are not necessarily intended as synonyms for each other. For example, some embodiments can be described using the terms “connected” and / or “coupled” to indicate that two or more elements are in direct physical or electrical contact with each other. The term “coupled,” however, can also mean that two or more elements are not in direct contact with each other, but yet still co-operate or interact with each other.

[0076] The breadth and scope of this disclosure should not be limited by any of the abovedescribed exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

Claims

WHAT IS CLAIMED IS:

1. A pump system, comprising: a pump comprising a motor configured to drive an impeller to discharge fluid; a basin accommodating the pump; a discharge pipe connected to the pump and being pathway of the fluid; a check valve provided on the discharge pipe and configured to prevent backflow of the fluid; a sensor configured to detect environmental data of at least one of the pump, the basin, the discharge pipe, and the check valve; and a processor configured to: based on the environmental data, determine whether a failure of the pump system is likely to occur; and when the failure is determined to be likely, send a notification.

2. The pump system of claim 1, wherein the environmental data includes pressure data inside the check valve, the processor is configured to determine that the failure of the pump system is likely to occur if the pressure data shows that a pressure alternates up and down between a first and second value within a predetermined time period multiple times, and the notification indicates that a water hammer is occurring inside the check valve.

3. The pump system of claim 1, wherein the environmental data includes pressure data inside the check valve, the processor is configured to determine that the failure of the pump system is likely to occur if the pressure data shows that a pressure inside the check valve is lower than a predetermined value while the motor is driving, and the notification indicates that an airlock is occurring inside the check valve.

4. The pump system of claim 1, wherein the environmental data includes flow rate data inside the check valve, the processor is configured to determine that the failure of the pump system is likely to occur if the flow rate data shows that a flow rate decreases over time, and the notification indicates that a clogging is occurring inside the check valve.

5. The pump system of claim 1, wherein the sensor is a water level sensor provided on an inner wall of the basin.

6. The pump system of claim 1, wherein the environmental data includes an open / close status of a flapper in the check valve, the processor is configured to determine that the failure of the pump system is likely to occur if the open / close status shows that the flapper opens and closes more than a predetermined number of times within a predetermined period, and the notification indicates that a water hammer is occurring inside the check valve.

7. The pump system of claim 1, wherein the environmental data includes an open / close status of a flapper in the check valve, the processor is configured to determine that the failure of the pump system is likely to occur if the open / close status shows that the flapper is closed while the motor is driving.

8. The pump system of claim 1, wherein the environmental data includes power data of a power supplied to the pump, the processor is configured to determine that the failure of the pump system is likely to occur if the power data shows that a difference between the power data of the currently supplied power and the power data obtained during an initial setup of pump is greater than a predetermined value.

9. The pump system of claim 1, wherein the environmental data includes current value of a power supplied to the pump and a pressure data inside the check valve, the processor is configured to determine that the failure of the pump system is likely to occur if the current value exceeds a first predetermined value and the pressure data shows that a pressure inside the check valve is lower than a second predetermined value while the motor is driving.

10. The pump system of claim 1 , wherein the processor is further configured to obtain a weather data and determine that the failure of the pump system is likely to occur based on the weather data.

11. The pump system of claim 1, wherein the environmental data includes flow rate data of at least one of the basin, the discharge pipe, and check valve, the processor is configured todetermine that the failure of the pump system is likely to occur if a duty point determined based on the flow rate is out of a range determined based on a reference duty point.

12. The pump system of claim 1, wherein the environmental data includes power data of a power supplied to the pump, the processor is configured to determine that the failure of the pump system is likely to occur if the power data shows that a number of duty cycles of the pump exceeds a predetermined number within a predetermined period.

13. A method for controlling a pump system, the method comprising: driving a pump accommodated in a basin, wherein the pump comprises a motor configured to drive an impeller to discharge fluid through a discharge pipe connected to the pump, and a check valve is provided on the discharge pipe and configured to prevent backflow of the fluid; based on a sensing result of a sensor, detecting an environmental data of at least one of the pump, the basin, the discharge pipe, and the check valve; based on the environmental data, determining whether a failure of the pump system is likely to occur; and when the failure is determined to be likely, sending a notification.

14. The method of claim 13, wherein the environmental data includes pressure data inside the check valve, the notification indicates that a water hammer is occurring inside the check valve, and the determining whether the failure of the pump system is likely to occur comprises: determining that the failure of the pump system is likely to occur if the pressure data shows that a pressure alternates up and down between a first and second value within a predetermined time period multiple times.

15. The method of claim 13, wherein the environmental data includes pressure data inside the check valve, the notification indicates that an airlock is occurring inside the check valve, and the determining whether the failure of the pump system is likely to occur comprises:determining that the failure of the pump system is likely to occur if the pressure data shows that a pressure inside the check valve is lower than a predetermined value while the motor is driving.

16. The method of claim 13, wherein the environmental data includes flow rate data inside the check valve, the notification indicates that a clogging is occurring inside the check valve, and the determining whether the failure of the pump system is likely to occur comprises: determining that the failure of the pump system is likely to occur if the flow rate data shows that a flow rate decreases over time.

17. The method of claim 13, wherein the environmental data includes an open / close status of a flapper in the check valve, the notification indicates that a water hammer is occurring inside the check valve, and the determining whether the failure of the pump system is likely to occur comprises: determining that the failure of the pump system is likely to occur if the open / close status shows that the flapper opens and closes more than a predetermined number of times within a predetermined period.

18. The method of claim 13, wherein the environmental data includes an open / close status of a flapper in the check valve, the determining whether the failure of the pump system is likely to occur comprises: determining that the failure of the pump system is likely to occur if the open / close status shows that the flapper is closed while the motor is driving.

19. The method of claim 13, wherein the environmental data includes flow rate data of at least one of the basin, the discharge pipe, and the check valve, and the determining whether the failure of the pump system is likely to occur comprises: determining that the failure of the pump system is likely to occur if a duty point determined based on the flow rate data is out of a range determined based on a reference duty point.

20. The method of claim 13, wherein the environmental data includes power data of a power supplied to the pump, and the determining whether the failure of the pump system is likely to occur comprises: determining that the failure of the pump system is likely to occur if the power data shows that a number of duty cycles of the pump exceeds a predetermined number within a predetermined period.

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