Cellular Pump Monitoring for Timely Failure Detection
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Solution Overview
Problem
Conventional pump monitoring methods are either cost-ineffective and impractical for many installations or require periodic manual monitoring, which may not detect initial degradation or failure in a timely manner, especially for portable pumps without SCADA systems.
Innovation Solution
A remote monitoring system with a single, mechanically attached device that detects vibration, temperature, and location, using internal batteries with the option for continuous external power, enabling frequent data sampling and uploads via cellular networks, and communicating threshold alerts through various wireless means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If SCADA systems with pressure sensors, temperature sensors, and vibration sensors are used for pump monitoring, then monitoring capability is improved, but system cost and complexity increase making it impractical for many pump installations and portable pumps
Solution Approach 1:
The monitoring system is segmented into a portable monitoring device that can be detached and transported between different pump locations. This allows comprehensive monitoring capabilities to be distributed rather than requiring a centralized SCADA system at each location, reducing overall system complexity while maintaining monitoring reliability.
Solution Approach 2:
A cellular communication module serves as an intermediary between the portable monitoring device and remote users. This mediator enables data transmission without requiring direct physical connection or complex wiring infrastructure, simplifying the system while maintaining reliable monitoring capability.
2Ease of manufacture
If periodic manual monitoring with handheld devices is used for portable pumps, then system cost is reduced, but detection timeliness deteriorates as monitoring may not coincide with initial pump degradation or failure
Solution Approach 1:
The monitoring device continuously samples pump data at predetermined intervals and automatically uploads data samples via cellular connection. This continuous monitoring approach eliminates the time loss associated with periodic manual checks while maintaining cost-effectiveness for portable pump applications.
Solution Approach 2:
The monitoring device autonomously performs data collection, processing, and transmission without requiring manual intervention. The device self-manages battery power, data sampling, and cellular communication, enabling timely detection of pump degradation while keeping operational costs low.
3Loss of time
If frequent data sampling and uploads are implemented for continuous monitoring, then detection timeliness is improved, but energy consumption increases reducing battery life
Solution Approach 1:
The system implements periodic data sampling at predetermined intervals rather than continuous monitoring. Data is uploaded to the cellular network at scheduled intervals, balancing timely detection of pump issues with responsible battery power consumption for portable operation.
Solution Approach 2:
The monitoring device dynamically adjusts its operation based on available battery power and monitoring priorities. The system can modify sampling frequency and upload intervals to optimize between detection timeliness and energy conservation, extending battery life while maintaining effective monitoring.
Data Source
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AI summary
A device, system, and methods are provided for remotely monitoring pump equipment. A monitoring device is mechanically mounted to a pump. The monitoring device includes internal vibration, temperature, and location sensors to periodically monitor a pump and upload data samples via cellular connection to a provider network. The monitoring device additionally includes connections to external sensors that can be sampled and uploaded with the other data samples, when the monitoring device is connected to external power. Authenticated users access the pump data though a user device that connects to the provider network.