Method for monitoring an industrial plant by means of a mobile monitoring unit

Abstract

The present invention relates to a method for monitoring an industrial plant comprising a plurality of pumps and / or hydraulic fittings, using a mobile monitoring unit which has: - a sensor system for sensing the environment of the mobile monitoring unit; - communication means for communicating with a pump and / or a hydraulic fitting of the industrial plant; and a drive for moving the mobile monitoring unit within the industrial plant, wherein the mobile monitoring unit evaluates acquired sensor data and, taking into account data regarding the industrial plant which are stored in a storage unit, controls movement of the mobile unit in order to move the mobile monitoring unit autonomously to at least one pump and / or hydraulic fitting, and wherein, after reaching the navigated-to pump and / or hydraulic fitting, the mobile monitoring unit establishes a communication connection in order to exchange data between the mobile unit and the pump and / or the fitting using the communication means.

Description

[0001] 30287F

[0002] KSB SE & Co. KGaA 67227 Frankenthal

[0003] Description

[0004] Method for monitoring an industrial plant using a mobile monitoring unit

[0005] The invention relates to a method for monitoring an industrial plant comprising several pump units and / or hydraulic fittings.

[0006] In practice, large industrial plants often contain a large number of different pumps and hydraulic valves. These devices require periodic monitoring, maintenance, or control system adjustments. Currently, this is done by an internal or external service technician who visits the pumps and valves on-site and performs the necessary work locally. This approach can be very time-consuming and costly, especially in large industrial plants. This is not only due to the sheer number of devices, but also because some are not readily accessible. Often, access to the pumps and valves requiring inspection necessitates shutting down entire systems, or at least sections of them, and in the worst-case scenario, even partially dismantling them.

[0007] For the future, it is therefore desirable that corresponding tasks, i.e. the maintenance, inspection or configuration of existing pumps and valves in large industrial plants, can be carried out more easily.

[0008] This problem is solved by a method according to the features of claim 1. Advantageous embodiments of the method are the subject of the dependent claims. 2 30287F

[0009] According to the invention, it is proposed that the monitoring of an industrial plant with multiple pumps or hydraulic valves be carried out using a mobile monitoring unit. The monitoring unit comprises sensors for detecting its surroundings, as well as communication means for communicating with a pump and / or a hydraulic valve for data exchange. Furthermore, the monitoring unit includes a drive mechanism for moving the unit within the industrial plant. An internal control unit of the monitoring unit manages the drive control. During operation of the mobile monitoring unit, particularly during its movement, received sensor data is continuously evaluated, and the control unit, taking into account the data on the industrial plant stored in a memory unit of the monitoring unit, controls the movement of the mobile monitoring unit.This allows the mobile monitoring unit to move independently and autonomously within the industrial plant to reach the reception range of at least one pump or valve for data exchange. Therefore, physical or visual contact between the monitoring unit and the pump / valve is not necessary; it is sufficient for the monitoring unit to approach the pump / valve closely enough to enable unambiguous identification and data exchange.

[0010] After the monitoring unit approaches the pump / valve and it has been identified, a communication link can be established with the pump / valve via the communication device to exchange the desired data between the communication partners. The communication link is preferably bidirectional; however, a unidirectional communication link can also be sufficient to implement the invention.

[0011] According to the preferred embodiment, operating data from the pump or valve is transmitted to the mobile monitoring unit 3 30287F via the established communication link. Possible operating parameters include current configuration parameters of the integrated control system of the pump / valve, sensor values ​​acquired by the pump / valve, or specific operating variables such as the data from an operating hours counter, etc.

[0012] The mobile monitoring unit can, for example, transmit one or more operating or configuration parameters to the pump or valve, enabling adjustments to the internal control system of the pump or valve. This could include, for instance, transmitting setpoint values ​​for pump or valve operation, or other alternative configuration parameters that influence the operation of the pump or valve. In other words, the mobile monitoring unit not only allows for reading data from the existing pumps or valves in the industrial plant, but also enables the configuration, adjustment, and adaptation of the devices' control routines.

[0013] Ideally, the mobile monitoring unit analyzes the operating data received from the pump / valve to determine its current operating mode. Based on this analysis, one or more operating and / or configuration parameters can then be adjusted. These adjusted parameters can subsequently be transmitted from the monitoring unit to the pump or valve via the communication link. It is conceivable that the mobile monitoring unit performs the analysis on-site within the communication range of the pump or valve. After reading the data, the analysis is performed, and one or more operating or configuration parameters are adjusted and then transmitted directly to the pump / valve. Only after these steps are completed is the monitoring unit moved.

[0014] However, it is also possible for the monitoring unit to forward the pump's operating data to a higher-level control unit. The evaluation then takes place in the higher-level control unit. In this context, the higher-level control unit can also provide operating or configuration parameters to the mobile monitoring unit. Upon receipt, the monitoring unit forwards these parameters to the addressed pump / valve. In the simplest case, the monitoring unit thus only functions as a communication interface to enable data exchange between a higher-level control unit and a pump / valve.

[0015] The same or an additional communication method of the monitoring unit can be used for communication with the higher-level control unit. Communication between the monitoring unit and the higher-level control unit can take place either locally near the pump / valve, or the monitoring unit can first be moved to a different location to establish communication with the higher-level control unit.

[0016] For example, the industrial plant could have a base station for the mobile monitoring unit. Such a base station would serve as a kind of home base for the monitoring unit. The base station could include a power source to supply the monitoring unit. An internal battery for the monitoring unit could then be recharged within the base station. The base station could also store all other necessary operating supplies for the monitoring unit. It is also conceivable that the base station represents or incorporates the higher-level control unit. It is equally possible that the base station serves as a communication gateway for the monitoring unit to communicate with a higher-level control unit. In this case, the base station would include primary communication channels for communication with the monitoring unit and secondary communication channels for communication with a higher-level control unit.

[0017] It is also possible that the mobile monitoring unit or the base station has access to a cloud-based application via a communication link. For example, the higher-level control unit can be cloud-based. 5 30287F

[0018] A storage unit can be integrated within the mobile monitoring unit, containing position data for one or more pumps or valves within the industrial plant. This stored position data corresponds to the pumps / valves being monitored. The position data can include GPS coordinates, allowing the monitoring unit with its internal GPS receiver to locate the pumps / valves. Alternatively, the position data can include coordinates for a map stored within the monitoring unit, such as a 2D or 3D map of the industrial plant. Using this map and the stored coordinates of the pumps / valves, the mobile monitoring unit can then navigate within the industrial plant via its internal control system.In this context, it is also conceivable that the internal map is constantly updated by the monitoring unit, especially with the help of the data collected by the monitoring unit's sensors.

[0019] Furthermore, it is conceivable that one or more motion trajectories are stored within a memory unit of the mobile monitoring unit, along which one or more of the pumps or valves of the industrial plant to be monitored are located. The mobile monitoring unit is then moved autonomously along one of these motion trajectories by its internal control system. In this case, it is conceivable that the pumps or valves to be monitored periodically emit specific signals, which can be received by the communication device of the mobile monitoring unit while traversing the motion trajectory. If such a signal is received, the mobile monitoring unit can use it to directly move the transmitting pump or hydraulic valve until a communication link to the pump / valve can be established.

[0020] A ground vehicle, such as a robot equipped with a suitable drive system, can be used as a mobile monitoring unit. No guidance devices, such as rails, are required; the ground vehicle can move freely within area 6 30287F of the industrial plant. The use of a drone as a mobile monitoring unit is particularly preferred, as this simplifies navigation within the industrial plant. Due to the typically wireless communication with the pumps or valves, a drone can easily and relatively quickly establish a reception area for communication.

[0021] The sensors of the mobile monitoring unit can operate using ultrasound, radar, or laser measurement methods. It is also conceivable to use a camera to capture images of the surroundings, which are then analyzed using image analysis techniques and processed for navigation and interpretation of the environment. Captured camera images can also be used to map the industrial plant, thus improving the navigation of the monitoring unit.

[0022] Communication between the at least one pump or fitting and the mobile monitoring unit can be based on a known, in particular wireless, transmission standard. Suitable standards include, for example, WLAN standards such as IEEE 802.11, the Bluetooth standard, or the ZigBee standard. However, the method according to the invention is not limited to the aforementioned transmission standards.

[0023] In addition to the aforementioned sensors, which are primarily used for the navigation and autonomous operation of the mobile monitoring unit within the industrial plant, the unit can also be equipped with one or more sensors for inspecting the pumps or valves being monitored. For this purpose, the mobile monitoring unit must first enter the working area, specifically the line of sight, of the pumps or valves. The sensors then record the condition, particularly the health status, of the pumps or valves, and the sensor data is analyzed. Based on this analysis, a condition diagnosis of the inspected pump or valve is performed. It is conceivable that such an analysis could be carried out directly on-site by the mobile monitoring unit.Alternatively, it can of course also be provided that the monitoring unit, after recording the sensor data, is first moved back to 7 30287F of a base station, where the evaluation is then carried out externally, i.e. a transmission of the recorded sensor data to a higher-level control unit takes place.

[0024] It is also conceivable that, in addition to the measurement data from its own sensors, the monitoring unit could also use and retrieve sensor data from existing sensors on the pump and valve. It is equally possible that the mobile monitoring unit has no internal sensors for condition diagnosis, but instead relies exclusively on the sensors already installed on the pump or valve.

[0025] Suitable sensors for the monitoring unit, pump, or valve can include cameras, especially thermal imaging cameras, optical and acoustic sensors, vibration sensors, or odor sensors. Using a laser measuring device to create a 3D laser scan of the valve or pump is also conceivable.

[0026] It is particularly advantageous if the mobile monitoring unit uses AI-based methods to optimize its operation through self-learning algorithms. For example, AI-based methods could be used to continuously optimize the mapping and navigation of the monitoring unit. It is also conceivable that the aforementioned evaluation of operational data, as well as the procedures for condition diagnosis based on sensor data, could be continuously optimized. For this purpose, the monitoring unit can be fed suitable training data via the higher-level control unit.

[0027] In addition to the method according to the invention, the present invention also relates to a mobile monitoring unit, in particular a mobile robot or a flying drone, with integrated sensors, communication means, and an integrated control system configured to execute the method according to the invention. Accordingly, the mobile monitoring unit offers the same advantages and properties as already explained above with reference to the method according to the invention (8 30287F). A repetitive description is therefore omitted in this context.

[0028] Further advantages and features of the invention will be explained in more detail below with reference to a specific embodiment shown in the figure.

[0029] In critical applications, it is often necessary to monitor pumps and / or valves. In large industrial plants, these pumps and / or valves are distributed throughout the entire facility. They may also be installed in hard-to-reach locations. Furthermore, adjustments to pumps and / or valves, such as their speed, may be required. These tasks are frequently performed manually on-site, which can be time-consuming, dangerous, and / or prone to errors. The aim of the invention is to automate these tasks.

[0030] A schematic representation of such an industrial plant can be found in the figure. The industrial plant comprises several pumps 30 and hydraulic valves 40. During operation, the pumps 30 and valves record operating parameters that can be read out via a communication interface 31, e.g., IEEE 802.11, Bluetooth, ZigBee. Furthermore, one or more operating parameters or configuration parameters can be transmitted via this interface to the internal control system of the pump 30 or valve 40.

[0031] For monitoring the pumps 30 and valves 40, one or more mobile and self-contained monitoring units 10 are used, specifically a drone 10. However, ground vehicles similar to robotic lawnmowers and vacuum cleaners can also be used. The monitoring unit 10 is self-contained because it has its own power supply and sensors for locating and activating the pumps and valves, as well as its own communication devices (WLAN, Bluetooth, ZigBee, etc.) for interacting with the pumps 30 and / or valves 40. 9 30287F

[0032] The locations of pumps 30 and / or valves 40 are stored in monitoring unit 10 using GPS data. However, it is also conceivable that a monitoring unit 10 flies / walks a predefined route and, upon detecting a signal, e.g., one sent by pump / valve 30 or 40, directly approaches / locates it.

[0033] On-site at the pump / valve 30, the monitoring unit 10 can then interact directly with it via the communication link 31. This allows for both data acquisition, e.g., of operating data, and data transmission (e.g., from the monitoring unit 10 to the pump / valve 30 or 40 for adjusting / changing pump parameters such as speed). Furthermore, the monitoring unit 10 can perform data analysis of the operating data previously received from the pump 30 or valve 40 in order to transmit operating parameters to the pump 30 or valve 40 for adjusting / changing the pump / valve parameters. The data analysis by the monitoring unit 10 can be performed directly on-site at the pump 30 or valve 40, thus enabling corresponding adjustments / changes to the internal control of the pump 30 or valve 40 to be initiated directly on-site.Alternatively, the monitoring unit 10 can first return to its home base 20 and make the collected operating data from the pumps 30 and / or valves 40 available there. This allows, for example, an employee to read a large number of operating data / key parameters from the various pumps 30 and / or valves 40 directly from a single location. It is also conceivable that the home base 20 of the monitoring unit 10 has its own communication module to communicate both with the monitoring unit 10 and with other external communication partners. For example, the data collected by the mobile monitoring unit 10 can be transmitted via the communication link 25 from the home base 20 directly to the control room and / or a cloud 50.

[0034] It is also conceivable that data from the control center or from the cloud 50 can be transmitted directly via connection 25 to the home base 20 and / or the mobile monitoring unit 10 30287F

[0035] 10 are sent and the monitoring unit 10 then starts with a corresponding order (monitoring / adjustment) and directly controls the affected pumps / valves 30, 40.

[0036] To minimize disruption to ongoing operations, corresponding monitoring and adjustment tasks can be scheduled accordingly (e.g., at night, on public holidays, ... ).

[0037] It is also conceivable that the mobile monitoring unit 10 is equipped with an artificial intelligence that continuously learns, which offers a multitude of advantages. For example, routes can be optimized and accidents minimized, while "critical" pumps / fittings 30, 40 can be identified, as the frequency with which they are visited is documented and stored. It is also conceivable that a pump / fitting 30, 40 emits a specific signal that prompts the artificial intelligence to initiate / execute a specific action (e.g., immediate notification to the control center before returning to home base 20).

[0038] An important feature of the invention is that the mobile and self-contained monitoring unit 10 can be equipped with additional onboard equipment. This includes, among other things, a (thermal imaging) camera, optical and / or acoustic and / or olfactory sensors, laser measuring devices, etc. This makes it possible to perform a diagnosis directly on-site at the pump / fitting 30, 40. Often, corresponding monitoring solutions are installed on the pumps / fittings 30, 40. Within the scope of the invention, relevant data can be transmitted to the mobile monitoring unit 10 (provided that a corresponding process has been initiated by it, for example). The mobile monitoring unit 10 is also capable of performing a corresponding check or of verifying / validating values ​​received from the pump / fitting 30, 40.

Claims

11 30287F Patent claims Method for monitoring an industrial plant using a mobile monitoring unit 1. A method for monitoring an industrial plant comprising several pumps (30) and / or hydraulic valves (40), using a mobile monitoring unit (10) which has sensors for detecting the environment of the mobile monitoring unit (10), communication means for communicating with a pump (30) and / or a hydraulic valve (40) of the industrial plant and a drive for moving the mobile monitoring unit (10) within the industrial plant, wherein the mobile monitoring unit (10) evaluates detected sensor data and, taking into account data on the industrial plant stored in a memory unit, controls a movement of the mobile monitoring unit (10) in order to move the mobile monitoring unit (10) autonomously to at least one pump (30) and / or hydraulic valve (40),wherein the mobile monitoring unit (10) establishes a communication link after reaching the controlled pump (30) and / or hydraulic valve (40) in order to exchange data between the mobile monitoring unit (10) and the pump (30) and / or the valve (40) using the communication means.

2. Method according to claim 1, characterized in that operating data from the pump (30) or the valve (40) to the mobile monitoring unit (10) and / or operating parameters from the mobile monitoring unit (10) to the pump (30) or valve (40) are transmitted via the established communication link (31), wherein the operating parameters or configuration parameters include, for example, setpoint values. 12 30287F 3. Method according to claim 2, characterized in that the mobile monitoring unit (10) performs an evaluation of the received operating data and optionally transmits one or more operating or configuration parameters to the pump (30) or fitting (40) based on the evaluation, or changes these parameters in the pump (30) or fitting (40).

4. Method according to claim 2, characterized in that the mobile monitoring unit forwards the received operating data to a higher-level control unit (20, 50), in particular for the purpose of evaluation, and / or receives operating and / or configuration parameters from the higher-level control unit (20, 50) and forwards these to the corresponding pump (30) and / or fitting (40).

5. Method according to one of the preceding claims, characterized in that position data of one or more pumps (30) and / or valves (40) to be monitored are stored within a storage unit of the mobile monitoring unit (10), in particular in the form of GPS data, and the mobile monitoring unit (10) is moved autonomously to the at least one pump (30) and / or valve (40) using the stored position data.

6. Method according to any one of the preceding claims 1 to 4, characterized in that one or more motion trajectories are stored within a storage unit of the mobile monitoring unit (10), along which one or more of the pumps (30) and / or hydraulic valves (40) of the industrial plant are located, and the mobile monitoring unit (10) is moved autonomously along these motion trajectories, wherein the communication means and / or the sensor technology monitors the reception of signals from the pumps (30) and / or valves (40) during movement along the motion trajectory and, upon receiving a signal, selectively controls the sending pump (30) or valve (40). 13 30287F 7. Method according to one of the preceding claims, characterized in that the mobile monitoring unit (10) is a flying drone or a ground vehicle.

8. Method according to one of the preceding claims, characterized in that the sensors of the mobile monitoring unit (10) use ultrasound and / or radar and / or lidar and / or a camera.

9. Method according to one of the preceding claims, characterized in that communication between at least one pump (30) and / or at least one fitting (40) takes place using a WLAN standard and / or Bluetooth standard and / or ZigBee standard.

10. Method according to one of the preceding claims, characterized in that a base station (20) for the mobile monitoring unit (10) is provided within the industrial plant, wherein the base station (20) serves to supply power to the mobile monitoring unit (10) and / or to program the mobile monitoring unit (10) and / or to receive and evaluate provided operating data of at least one pump (30) or valve (40) and / or to transmit operating parameters for at least one pump (30) or valve (40) to the monitoring unit (10).

11. Method according to one of the preceding claims, characterized in that the mobile monitoring unit (10) comprises one or more sensors for inspecting a pump (30) or fitting (40), wherein the mobile monitoring unit (10) evaluates measured values ​​of at least one of these sensors after reaching a pump (30) or fitting (40) and creates a condition diagnosis for the inspected pump (30) or fitting (40).

12. Method according to claim 11, characterized in that the sensors for inspection comprise a camera, in particular a thermal imaging camera, and / or at least one optical and / or acoustic sensor and / or at least 14 30287F include an odor sensor and / or at least a laser scanner, in particular a 3D laser scanner.

13. Method according to claim 11 or 12, characterized in that the monitoring unit (10) retrieves and evaluates sensor data from an integrated sensor system of the pump (30) or fitting (40) for the purpose of creating the condition diagnosis.

14. Method according to one of the preceding claims, characterized in that the mobile monitoring unit (10) optimizes stored trajectories and / or autonomous motion control by means of self-learning algorithms.

15. Mobile monitoring unit (10), in particular a mobile robot or a drone, with integrated sensors, communication means and an integrated control system configured to perform the method according to one of the preceding claims.

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