Pump Status Detection via Tempering Element Energy
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Solution Overview
Problem
Existing pump monitoring methods in high-capacity printing apparatuses often lead to delayed detection of pump failures, resulting in significant economic losses due to unnecessary downtimes and costs, as traditional methods require regular servicing and additional sensors for predictive maintenance.
Innovation Solution
A method that predicts pump malfunctions by analyzing the temperature change of a tempering element within the pump's fluid circuit, using existing measurement data to determine the status point, which indicates the pump's performance, without requiring additional sensors, by associating the tempering energy and element temperature with a normal or hazard range, and employing an OC-SVM model for anomaly detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional regular servicing intervals are used for pump monitoring, then the pump can be serviced at scheduled times, but the actual pump status remains unknown until servicing, leading to delayed failure detection and unnecessary pump exchanges
Solution Approach 1:
The system continuously monitors pump status parameters (power consumption, temperature, vibration) and provides real-time feedback about pump health. This feedback loop enables early detection of degradation trends, allowing maintenance to be scheduled based on actual pump condition rather than fixed intervals, thus reducing both false replacements and unexpected failures.
Solution Approach 2:
The monitoring system detects pump degradation trends before actual failure occurs by analyzing parameter changes over time. This preliminary detection allows maintenance actions to be taken in advance, preventing complete pump failure and extending the useful life of the pump beyond traditional servicing intervals.
2Reliability
If additional sensors are installed for predictive maintenance, then pump failure can be predicted in advance, but the system complexity and costs increase
Solution Approach 1:
The system uses existing multi-functional components in the pump assembly (motor windings, housing, bearings) that serve both their primary functions and act as sensors for condition monitoring. For example, the motor windings' electrical properties provide information about pump load and friction, eliminating the need for separate sensors.
Solution Approach 2:
The pump system monitors its own status using its inherent components without requiring external sensing equipment. The pump's electrical motor provides self-diagnostic information through its power consumption and electrical characteristics, allowing the system to self-assess its health status.
3Measurement precision
If detailed pump models with precise fluid properties are used for monitoring, then accurate status detection is achieved, but the complexity of implementation increases significantly
Solution Approach 1:
The system monitors changes in electrical parameters (power consumption, current, impedance) of the pump motor as indicators of pump health. Instead of using complex hydraulic models, the system tracks parameter deviations from baseline values, which correlate with pump degradation without requiring detailed fluid property data.
Solution Approach 2:
The system replaces complex mechanical and hydraulic modeling with electrical measurement and analysis. By substituting mechanical status assessment with electrical parameter monitoring, the system achieves accurate pump status detection while avoiding the complexity of detailed mechanical models and fluid property measurements.
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
This method allows for early detection of pump failures, reducing downtime and costs by predicting pump failures with a high probability, even in existing printing apparatuses, without the need for additional sensors, and can be retrofitted into existing systems, effectively minimizing production disruptions.
Implementation Method 1
at least one status point is detected, wherein the temperature of a fluid is regulated by a tempering element during the operation of the pump
Data Source
AI summary
In a method for monitoring a pump arranged in a flow path to pump a fluid, the temperature of a fluid is regulated by a tempering element during the operation of the pump. The regulation of the temperature may include detecting at least one status point which is formed from an energy supplied to the tempering element and a temperature slope of the tempering element. The status point may be determined in a hazard range by checking whether the status point is located outside of a normal status range, which means that the lifespan of the pump is limited.