Centrifugal Pump Rotor Modeling for Reliable Blockage Detection

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Solution Overview

Problem

Existing methods for detecting anomalies in centrifugal pumps, particularly blockages, are not reliable and timely, leading to potential damage and inefficiency.

Innovation Solution

A computer-implemented method that accelerates and decelerates the rotor of a centrifugal pump to quantify a dynamic rotor model, identifies fault parameters by solving an inverse problem, and classifies anomalies using a digital twin, enabling rapid unblocking routines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional anomaly detection methods are used in centrifugal pumps, then the detection process is simple, but the reliability and timeliness of anomaly detection is insufficient

Engineering Contradiction:

Improveanomaly detection reliabilityVSAvoiddetection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-accelerating the rotor to a target rotational speed before the actual measurement process. This allows the system to quantify the dynamic rotor model and establish a baseline for normal operation in advance, enabling more reliable anomaly detection during actual pumping operations without repeatedly subjecting the rotor to high-speed acceleration.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional mechanical anomaly detection methods with a computational approach. By using a dynamic rotor model and solving inverse problems based on measured acceleration and torque data, the system substitutes physical inspection and simple mechanical tests with mathematical modeling and data analysis, significantly improving detection reliability and timeliness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If the rotor is accelerated to quantify the dynamic rotor model in normal state, then the model accuracy is improved, but the time required for detection increases

Engineering Contradiction:

Improvedynamic rotor model accuracyVSAvoiddetection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by performing the time-consuming rotor acceleration and dynamic model quantification during a preliminary phase when the pump is known to be in normal condition. This establishes the dynamic rotor model in advance, so that during actual operation, only brief measurements of acceleration and torque are needed to detect anomalies by comparing against the pre-established model, significantly reducing detection time while maintaining high accuracy.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If fault parameters are detected by accelerating the rotor in fault state, then the anomaly classification accuracy is improved, but the productivity of the pump decreases

Engineering Contradiction:

Improveanomaly classification accuracyVSAvoidpump operational efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent applies the skipping principle by rapidly accelerating the rotor to the target speed and immediately performing measurements, rather than allowing the system to reach steady state. This rushed-through approach captures the dynamic characteristics during the acceleration phase itself, enabling fast anomaly detection and classification without prolonged interruption to pump productivity, while still achieving high classification accuracy through the dynamic rotor model.

Inventive Principle:

Principle #21Skipping (Rushing through)

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

Enhances the detection and classification of anomalies, particularly blockages, allowing for faster and more efficient unblocking of centrifugal pumps, reducing downtime and damage.

Implementation Method 1

accelerating and/or decelerating a rotor of the centrifugal pump for quantifying at least one term of a dynamic rotor model

Methodology Applied

Scientific EffectInertia: Inertia

Implementation Method 2

accelerating and/or decelerating the rotor of the centrifugal pump for detecting at least one fault parameter

Methodology Applied

Scientific EffectTorque: Torque

Data Source

PatentUS20250341214A1Computer-implemented method for detecting and/or determining an anomaly in a centrifugal pump

Publication Date: 2025.11.06 WILO SE

AI summary

A computer-implemented method for detecting and/or determining an anomaly in a centrifugal pump includes the steps: in a normal state, accelerating and/or decelerating a rotor of the centrifugal pump for quantifying at least one term of a dynamic rotor model of the centrifugal pump, in a fault state differing from the normal state, accelerating and/or decelerating the rotor of the centrifugal pump for detecting at least one fault parameter, and solving an inverse problem of the dynamic rotor model for identifying the at least one fault parameter for detecting and/or determining the anomaly.