Sensor Assembly for Pump Fault Detection
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Solution Overview
Problem
Current methods require separate sensors for detecting motor bearing faults and cavitation in pumps, making it difficult to use a single sensor assembly for both detections effectively.
Innovation Solution
A sensor assembly with a housing configured to attach to a pump, featuring one or more vibration sensing elements and a calculation unit that processes signals to detect both motor bearing faults and cavitation simultaneously or independently, using a single vibration sensing element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate sensors are used for motor bearing fault detection and cavitation detection, then detection reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines motor bearing fault detection and cavitation detection into a single sensor assembly. The sensor assembly includes a vibration sensor and a hydrophone that can detect both types of faults simultaneously, eliminating the need for separate sensor arrangements and reducing system complexity while maintaining detection reliability.
Solution Approach 2:
The sensor assembly is designed with multi-functional capability to detect both motor bearing faults and cavitation. By integrating multiple detection functions into one assembly with a unified positioning structure, the system achieves versatility without requiring multiple specialized sensors, thereby reducing device complexity.
2Measurement precision
If multiple sensors are arranged in various separate positions, then detection precision is improved, but ease of operation deteriorates
Solution Approach 1:
Multiple sensing functions are merged into a single sensor assembly that can be installed at one location. The assembly includes both vibration sensing and acoustic sensing capabilities, allowing precise detection of different fault types from a unified installation point, thereby improving ease of operation while maintaining detection precision.
Solution Approach 2:
The sensor assembly internally segments different detection functions (vibration sensing, acoustic sensing) into separate sensing elements while maintaining a unified external interface. This allows each function to operate optimally while simplifying the overall installation process, as the entire multi-functional assembly is installed as a single unit rather than multiple separate sensors.
3Device complexity
If a single sensor assembly is used for both detections, then device complexity is reduced, but measurement precision may deteriorate
Solution Approach 1:
The sensor assembly internally segments different detection functions into separate sensing elements (vibration sensor, hydrophone). Each sensing element is optimized for its specific detection function, maintaining high measurement precision for both motor bearing faults and cavitation, while the unified assembly structure reduces overall device complexity.
Solution Approach 2:
Different parts of the sensor assembly have specialized properties optimized for their specific detection functions. The vibration sensor is positioned and configured for optimal mechanical vibration detection, while the hydrophone is configured for acoustic signal detection. This local optimization ensures high measurement precision for each fault type despite the unified assembly structure.
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 the detection of motor bearing faults and cavitation using a single sensor assembly, improving fault detection efficiency and reducing the complexity and cost of sensor arrangements in pump systems.
Implementation Method 1
one or more vibration sensing element(s) are arranged in the housing and that the sensor assembly comprises a calculation unit, wherein the calculation unit is configured to receive sensor signals from the vibration sensing element(s)
Data Source
Figure 1A~1C
Figure 2A~2D
Figure 3
AI summary
A sensor assembly (2) configured to perform fault detection in a pump assembly comprising an electric motor (70) and a fluid pump (30) is disclosed. The sensor assembly (2) comprises a housing (4) configured to be mechanically attached to the pump (30) and configured to be attached into a bore provided in the pump (30). One or more vibration sensing element(s) (16) is/are arranged in the housing (4). The sensor assembly (2) comprises a calculation unit (84) configured to receive sensor signals (V1, V2, V3) from the vibration sensing element(s) (16) and perform calculations and hereby detect motor bearing faults and cavitation.