CN111365223B - Intelligent water pump fault early warning system - Google Patents
Intelligent water pump fault early warning system Download PDFInfo
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- CN111365223B CN111365223B CN202010255068.XA CN202010255068A CN111365223B CN 111365223 B CN111365223 B CN 111365223B CN 202010255068 A CN202010255068 A CN 202010255068A CN 111365223 B CN111365223 B CN 111365223B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B51/00—Testing machines, pumps, or pumping installations
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/06—Control using electricity
- F04B49/065—Control using electricity and making use of computers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/10—Other safety measures
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Computer Hardware Design (AREA)
- Control Of Non-Positive-Displacement Pumps (AREA)
- Control Of Positive-Displacement Pumps (AREA)
Abstract
The invention relates to an intelligent water pump fault early warning system which comprises a sensor group and a water pump control center which are connected with each other, wherein the sensor group comprises a current measuring module, a motor bearing temperature sensor, a motor stator temperature sensor, an IGBT built-in temperature sensor, a pressure sensor and a flow sensor; the current measuring module is used for detecting the running current of the motor; the motor bearing temperature sensor is used for detecting the temperature of a motor bearing; the motor stator temperature sensor is used for detecting the temperature of the motor stator; the IGBT built-in temperature sensor is used for detecting the temperature of the IGBT of the frequency converter; the pressure sensor is used for detecting the input pressure of the water pump; the flow sensor is used for detecting the flow of the water pump; and the water pump control center compares and analyzes the data acquired by the sensor group with the stored water pump data model, and judges whether the water pump has failure foreboding. The invention can effectively avoid the expansion of water pump faults.
Description
Technical Field
The invention relates to the technical field of water pump fault diagnosis, in particular to an intelligent water pump fault early warning system.
Background
Along with intelligent water pump's popularity, traditional water pump control system only just sends alarm information when the trouble takes place, often needs longer time to maintain after the trouble takes place, and the district of serious influence supplies water, and the requirement of the fast rhythm life in modern city can more and more not be satisfied to this kind of trouble treatment mode, so need an intelligent water pump early warning system urgently.
Disclosure of Invention
The invention aims to solve the technical problem of providing an intelligent water pump fault early warning system which can effectively avoid the expansion of water pump faults.
The technical scheme adopted by the invention for solving the technical problems is as follows: the intelligent water pump fault early warning system comprises a sensor group and a water pump control center which are connected with each other, wherein the sensor group comprises a current measuring module, a motor bearing temperature sensor, a motor stator temperature sensor, an IGBT built-in temperature sensor, a pressure sensor and a flow sensor; the current measuring module is used for detecting the running current of the motor; the motor bearing temperature sensor is used for detecting the temperature of a motor bearing; the motor stator temperature sensor is used for detecting the temperature of the motor stator; the IGBT built-in temperature sensor is used for detecting the temperature of the IGBT of the frequency converter; the pressure sensor is used for detecting the input pressure of the water pump; the flow sensor is used for detecting the flow of the water pump; and the water pump control center compares and analyzes the data acquired by the sensor group with the stored water pump data model, and judges whether the water pump has failure foreboding.
The water pump control center calculates the load rate of the current water pump according to the data detected by the pressure sensor and the flow sensor, and when the load factor of the water pump is 50%, 80% and 100%, acquiring detection data of the current measuring module, the motor bearing temperature sensor, the motor stator temperature sensor and the IGBT built-in temperature sensor, comparing the detected temperature maximum values of the motor bearing temperature sensor, the motor stator temperature sensor and the IGBT built-in temperature sensor with the temperature stable value in the water pump data model, when the detected temperature maximum value exceeds the temperature stable value, comparing the current data detected by the current measuring module with the current stable value in the water pump data model, when the detected current data is higher than the current stable value and has periodic jumping or shows an ascending trend, the water pump control center judges that the water pump has failure foreboding.
Under the normal condition of the water pump, the corresponding relation curve of the motor stator temperature, the motor bearing temperature, the IGBT built-in temperature, the motor running current and the time is obtained under different load rates.
The water pump data model is adaptively adjusted by collecting the motor running current value, the motor stator highest temperature, the motor bearing highest temperature and the frequency converter IGBT highest temperature when the water pump load rate is 50%, 80% and 100%.
The sensor group further comprises an ambient temperature sensor, the ambient temperature sensor is used for detecting ambient temperature, and the water pump control center carries out temperature compensation on received data detected by the motor bearing temperature sensor, the motor stator temperature sensor and the IGBT built-in temperature sensor through detected ambient temperature.
The water pump control center is further connected with a display module, and when the water pump control center judges that a failure precursor exists in the water pump, the display module displays a current curve change diagram, a motor stator temperature curve change diagram, a frequency converter IGBT temperature curve change diagram and a motor bearing temperature curve change diagram under the same load.
The water pump control center is further connected with a terminal system through a communication module, and when the water pump control center judges that the water pump has failure foreboding, the failure foreboding information is transmitted to the terminal system through the communication module.
Advantageous effects
Due to the adoption of the technical scheme, compared with the prior art, the invention has the following advantages and positive effects: the intelligent water pump early warning system realizes early warning and alarming of the intelligent water pump, finds and processes the water pump in time, effectively avoids expansion of water pump faults, and greatly improves maintenance efficiency. And simple structure, simple to operate, cost are lower, but wide application in water pump intelligence on-line monitoring.
Drawings
FIG. 1 is a system composition topology of the present invention;
FIG. 2 is a flow chart of the present invention;
FIG. 3 is a graph of the trend of current change in an embodiment of the present invention;
fig. 4 is a temperature change trend graph in the embodiment of the present invention.
Detailed Description
The invention will be further illustrated with reference to the following specific examples. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the present invention. Further, it should be understood that various changes or modifications of the present invention may be made by those skilled in the art after reading the teaching of the present invention, and such equivalents may fall within the scope of the present invention as defined in the appended claims.
The embodiment of the invention relates to an intelligent water pump fault early warning system, which comprises a sensor group and a water pump control center which are connected with each other, wherein the sensor group comprises a current measuring module, a motor bearing temperature sensor, a motor stator temperature sensor, an IGBT built-in temperature sensor, a pressure sensor and a flow sensor; the current measuring module is used for detecting the running current of the motor; the motor bearing temperature sensor is used for detecting the temperature of a motor bearing; the motor stator temperature sensor is used for detecting the temperature of the motor stator; the IGBT built-in temperature sensor is used for detecting the temperature of the IGBT of the frequency converter; the pressure sensor is used for detecting the input pressure of the water pump; the flow sensor is used for detecting the flow of the water pump; and the water pump control center compares and analyzes the data acquired by the sensor group with the stored water pump data model, and judges whether the water pump has failure foreboding.
In the embodiment, the water pump control center is further connected with a display module, and when the water pump control center judges that the water pump has a failure precursor, the display module displays a current curve change diagram, a motor stator temperature curve change diagram, a frequency converter IGBT temperature curve change diagram and a motor bearing temperature curve change diagram under the same load. The display module can enable field personnel to know the current running state of the water pump immediately. The water pump control center is further connected with a terminal system through a communication module, and when the water pump control center judges that the water pump has failure foreboding, the failure foreboding information is transmitted to the terminal system through the communication module. The communication module can transmit failure foreboding information to a terminal system in an Ethernet, GPRS or Bluetooth mode, and can immediately notify pump station maintenance personnel by utilizing the communication module so that the maintenance personnel can timely maintain and clear away potential failures, and the service life of the water pump is prolonged.
The working flow of the intelligent water pump fault early warning system of the embodiment is shown in fig. 2, the water pump control center firstly collects data detected by the pressure sensor and the flow sensor, calculates the load factor of the current water pump according to the data detected by the pressure sensor and the flow sensor, and when the load factor of the water pump is 50%, 80% or 100%, the water pump control center collects the detection data of the current measuring module, the motor bearing temperature sensor, the motor stator temperature sensor and the IGBT built-in temperature sensor, and compares the maximum detected temperature values of the motor bearing temperature sensor, the motor stator temperature sensor and the IGBT built-in temperature sensor with the temperature stability value in the water pump data model. When the water pump is output under the same load during normal operation, the temperature of a motor stator, the temperature of a motor bearing and the temperature of an IGBT (insulated gate bipolar transistor) of the frequency converter respectively have fixed temperature rise rising trends, and the temperature rise can rise to a stable value during operation (the temperature rise rising trend is a water pump data model stored in a water pump control center, namely a corresponding relation curve of the temperature of the motor stator, the temperature of the motor bearing and the built-in temperature of the IGBT under different load rates under normal conditions of the water pump), once the water pump has a fault, the temperature change trend can obviously change abnormally, and the temperature rise can exceed the stable value under normal conditions. When the detected maximum temperature value exceeds the temperature stability value, the water pump control center needs to collect the running current data of the motor under the same load rate, and the judgment is carried out by combining a relation curve of the running current of the motor and the time in the water pump data model. The water pump control center compares the current data detected by the current measuring module with the current stable value in the water pump data model, and as the current of the water pump is constant or slightly fluctuated when the water pump normally operates, when foreign matters exist in the water pump, water conservancy components are loosened or bearing rolling bodies are cracked, the current can show periodic rapid jump, and the current value can also obviously increase or slowly rise. Therefore, when the detected current data is higher than the current stable value and has periodic jumping or shows an ascending trend, the water pump control center judges that the water pump has a failure precursor, when the water pump is judged to have the failure precursor, the display module displays the graphs shown in figures 3 and 4, and the communication module sends the failure precursor information and the graphs shown in figures 3 and 4 to the terminal system.
It is worth mentioning that in order to ensure the accuracy of data, the water pump data model is adaptively adjusted by collecting the motor running current value, the motor stator highest temperature, the motor bearing highest temperature and the frequency converter IGBT highest temperature when the water pump load rate is 50%, 80% and 100%. Specifically, when the water pump control center judges that no failure precursor exists in the water pump, current values of the water pump at the load rates of 100%, 80% and 50% and the highest working temperature value detected by each temperature sensor are collected, a database is respectively established, the database needs 1000 pieces of basic data at minimum, the basic data are increased to 5000 pieces of basic data along with the increase of the running time of the water pump, and the data are updated and filed in a water pump data model. In addition, in order to reduce the influence of external environmental factors, the sensor group further comprises an environmental temperature sensor, the environmental temperature sensor is used for detecting the environmental temperature, the water pump control center carries out temperature compensation on the received data detected by the motor bearing temperature sensor, the motor stator temperature sensor and the IGBT built-in temperature sensor through the detected environmental temperature, and therefore the incremental value temperature rise is adopted for all the data to carry out comparison calculation through the system configuration of the environmental temperature sensor.
Claims (6)
1. An intelligent water pump fault early warning system comprises a sensor group and a water pump control center which are connected with each other, and is characterized in that the sensor group comprises a current measuring module, a motor bearing temperature sensor, a motor stator temperature sensor, an IGBT built-in temperature sensor, a pressure sensor and a flow sensor; the current measuring module is used for detecting the running current of the motor; the motor bearing temperature sensor is used for detecting the temperature of a motor bearing; the motor stator temperature sensor is used for detecting the temperature of the motor stator; the IGBT built-in temperature sensor is used for detecting the temperature of the IGBT of the frequency converter; the pressure sensor is used for detecting the input pressure of the water pump; the flow sensor is used for detecting the flow of the water pump; the water pump control center compares and analyzes the data collected by the sensor group with a stored water pump data model, and judges whether a failure precursor exists in the water pump; the water pump control center calculates the load rate of the current water pump according to the data detected by the pressure sensor and the flow sensor, and when the load factor of the water pump is 50%, 80% and 100%, acquiring detection data of the current measuring module, the motor bearing temperature sensor, the motor stator temperature sensor and the IGBT built-in temperature sensor, comparing the detected temperature maximum values of the motor bearing temperature sensor, the motor stator temperature sensor and the IGBT built-in temperature sensor with the temperature stable value in the water pump data model, when the detected temperature maximum value exceeds the temperature stable value, comparing the current data detected by the current measuring module with the current stable value in the water pump data model, when the detected current data is higher than the current stable value and has periodic jumping or shows an ascending trend, the water pump control center judges that the water pump has failure foreboding.
2. The intelligent water pump fault early warning system of claim 1, wherein the water pump data model comprises a corresponding relationship curve of motor stator temperature, motor bearing temperature, IGBT built-in temperature, and motor running current and time under different load rates under normal conditions of the water pump.
3. The intelligent water pump fault early warning system of claim 1, wherein the water pump data model is adaptively adjusted by collecting motor running current values, motor stator maximum temperature, motor bearing maximum temperature and frequency converter IGBT maximum temperature when water pump load rates are 50%, 80% and 100%.
4. The intelligent water pump fault early warning system according to claim 1, wherein the sensor group further comprises an ambient temperature sensor, the ambient temperature sensor is used for detecting ambient temperature, and the water pump control center performs temperature compensation on received data detected by the motor bearing temperature sensor, the motor stator temperature sensor and the IGBT built-in temperature sensor through the detected ambient temperature.
5. The intelligent water pump fault early warning system according to claim 1, wherein the water pump control center is further connected with a display module, and when the water pump control center determines that a fault precursor exists in the water pump, the display module displays a current curve change diagram, a motor stator temperature curve change diagram, a frequency converter IGBT temperature curve change diagram and a motor bearing temperature curve change diagram under the same load.
6. The intelligent water pump fault early warning system according to claim 1, wherein the water pump control center is further connected with a terminal system through a communication module, and when the water pump control center determines that a fault precursor exists in the water pump, the fault precursor information is transmitted to the terminal system through the communication module.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010255068.XA CN111365223B (en) | 2020-04-02 | 2020-04-02 | Intelligent water pump fault early warning system |
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| CN202010255068.XA CN111365223B (en) | 2020-04-02 | 2020-04-02 | Intelligent water pump fault early warning system |
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| CN111365223A CN111365223A (en) | 2020-07-03 |
| CN111365223B true CN111365223B (en) | 2021-03-19 |
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Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112983844B (en) * | 2021-03-01 | 2021-10-08 | 合肥恒大江海泵业股份有限公司 | Submersible electric pump monitoring control system |
| GB2611362A (en) * | 2021-10-04 | 2023-04-05 | Aspen Pumps Ltd | Condensate pump assembly & control methods |
| CN114427970B (en) * | 2021-11-29 | 2024-01-30 | 中国航发沈阳发动机研究所 | Bearing monitoring method for aeroengine main bearing test |
| CN114738295A (en) * | 2022-04-22 | 2022-07-12 | 奇力士（武汉）智慧水务科技有限公司 | Vexed turn protection detection early warning method and system of intelligent flood-proof silent pump |
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