Cloud-Connected Pump Control With Integrated Sensing and VFD Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pumping systems face inaccuracies due to sensor placement and calibration issues, leading to improper operation and lack of real-time monitoring, especially when using variable frequency drives (VFD/VSDs), which do not account for component degradation or system faults.
Innovation Solution
Integration of sensors within a pumping system to create a controlled, closed loop system that exports performance data to the cloud for remote monitoring, providing predictive and prescriptive maintenance alerts, and includes a programmable logic controller (PLC) for accurate VFD/VSD control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external sensors are installed in the piping system to monitor pumping system parameters, then real-time monitoring capability is improved, but sensor placement and calibration issues lead to measurement inaccuracies
Solution Approach 1:
The patent integrates the data acquisition system and sensors directly into the pump assembly, merging previously separate components (pump, sensors, data acquisition system) into a single integrated unit. This eliminates the need for separate sensor installation in the piping system, avoiding placement and calibration issues while maintaining measurement capability.
2Use of energy by moving object
If VFD/VSD is used to reduce electrical frequency for energy savings, then energy consumption is reduced, but the system becomes blind to component degradation and system faults
Solution Approach 1:
The patent implements a data acquisition system with sensors that continuously monitor pump parameters and provide feedback to the control system. This feedback mechanism enables real-time detection of component degradation and system faults while the VFD/VSD operates to reduce energy consumption, resolving the contradiction between energy savings and fault detection capability.
3Productivity
If pump shaft force is applied to pump the liquid, then pumping function is achieved, but component degradation occurs over time affecting system performance
Solution Approach 1:
The patent employs predictive analytics and condition monitoring to detect early signs of component degradation before they affect pumping performance. By taking preliminary action to identify and address potential issues, the system maintains optimal productivity while extending component life through proactive maintenance.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A pumping system featuring a pump, motor, a bearing assembly, integrated data acquisition system and combined programmable logic controller (PLC), data acquisition and modem. The pump couples to a pump shaft that responds to a pump shaft force to pump a liquid. The motor couples to the pump shaft, responds to VFD/VSD control signaling and provides the pump shaft force to drive the pump shaft. The bearing assembly includes a bearing with the pump shaft arranged therein and couples the pump and the motor. The variable frequency/speed drive (VFD/VSD) receives PLC control signaling and provides the VFD/VSD control signaling to drive the motor. The integrated data acquisition system responds to PLC data acquisition signaling, and provides integrated data acquisition system signaling containing information about an integrated set of pumping system parameters related to the pump, the bearing assembly, the motor and the VFD/VSD in the pump system. The combined programmable logic controller (PLC), data acquisition and modem provides the PLC data acquisition signaling and receive the integrated data acquisition signaling, provides PLC data acquisition modem signaling that exports performance data to the Internet to allow remote manual monitoring of the pump system, and provides the PLC control signaling to control the VFD/VSD and operate the pumping system as a controlled, closed loop system.