Electric Pump Mechanical Fault Detection via Electrical Impedance
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Solution Overview
Problem
Current methods for detecting mechanical faults in electric pumps are costly, complex, and difficult to implement, especially in submerged or hard-to-access environments, often requiring pump shutdown and causing production line disruptions.
Innovation Solution
A method involving the acquisition and filtering of three-phase voltages and currents, transformation into a two-phase reference, estimation of electrical impedance phase, calculation of impedance evolution, and comparison with predetermined reference values to detect mechanical faults in electric pumps, allowing for rapid and reliable fault detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fault detection methods are used, then mechanical faults can be detected, but the pump must be shut down causing production disruptions and the implementation becomes complex
Solution Approach 1:
The patent replaces mechanical fault detection methods with electrical impedance analysis. By monitoring changes in the electrical impedance of the motor driving the pump, the system can detect mechanical faults (such as bearing wear, misalignment, or cavitation) without requiring physical access to the pump or shutting it down. This substitution of mechanical inspection with electrical measurement resolves the contradiction by enabling continuous operation while maintaining fault detection capability
Solution Approach 2:
The patent introduces electrical impedance as an intermediary parameter that reflects the mechanical state of the pump. Instead of directly measuring mechanical conditions (which would require shutdown and complex instrumentation), the system measures electrical impedance changes that are caused by mechanical faults. This intermediary measurement approach allows for non-intrusive, continuous monitoring that maintains production continuity while detecting faults
2Reliability
If traditional fault detection methods are used, then mechanical faults can be detected, but the implementation becomes costly and complex especially in submerged environments
Solution Approach 1:
The patent replaces complex mechanical inspection systems with simple electrical impedance measurement circuits. The implementation requires only standard electrical measurement equipment that can be integrated into the existing motor control system, avoiding the need for complex mechanical sensors or inspection mechanisms that would be particularly difficult to implement in submerged or hard-to-access environments
Solution Approach 2:
The patent uses the existing electrical power system of the motor to perform both power delivery and fault detection functions. The same electrical connections and measurement circuits used for motor control are also used to monitor impedance changes, eliminating the need for separate dedicated fault detection hardware. This multi-functionality reduces implementation complexity and cost, especially in challenging environments where additional hardware would be difficult to install and maintain
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables simple, cost-effective, and rapid detection of mechanical faults in electric pumps, including issues like incorrect orientation, dry running, cavitation, and misalignment, without the need for pump shutdown, thereby minimizing production disruptions and maintenance complexity.
Implementation Method 1
an electric pump driven by an electric machine powered by a three-phase electrical network
Implementation Method 2
A step of estimating the phase of the electrical impedance of said rotating electrical machine as a function of said transformed voltages and currents
Data Source
Figure 1~3
Figure 2~4
AI summary
The invention relates to a method for detecting a mechanical fault in an electric pump driven by an electric machine powered by a three-phase electrical network, said method comprising: - A step of acquiring (10, 11) the three-phase voltages and three-phase currents at the input of the electric machine; - A step of filtering the acquired three-phase voltages and currents; - A step of transforming (12, 13) the acquired voltages and currents into a two-phase reference frame; - A step of estimating (14) the phase of the electrical impedance of said rotating electric machine as a function of said transformed voltages and currents;- A calculation step (15) of at least one representative value of the time evolution of the electrical impedance as a function of said calculated electrical impedance phase, and - A detection step (16) of a fault of the mechanical pump comprising comparing said at least one representative value of the time evolution of the calculated electrical impedance with at least one predetermined reference value.