JP2020090935A - Failure detection system and failure detection method - Google Patents

Abstract

To provide a failure detection system capable of more satisfactorily detecting occurrence of a failure in an air pump.SOLUTION: A failure detection system 1 comprises an air pump, a current sensor for detecting a current value to be supplied to the air pump, a transmitter 3 connected to the current sensor, and a management server 4 communicable with the transmitter 3. The transmitter 3 transmits the current value detected by the current sensor to the management server 4. In a case that the current value is zero, the management server 4 notifies a worker of a first failure. In a case that the current value is not zero, if the current value is lower than a first current value, the worker is notified of the first failure but if the current value is higher than a second current value, the worker is notified of a second failure. The first current value is lower than the second current value.SELECTED DRAWING: Figure 1

Description

The present invention relates to an air pump failure detection system and failure detection method.

As a septic tank installed in a general household or the like, a septic tank equipped with a diaphragm type air pump for sending air to a tank containing aerobic microorganisms has been put into practical use. Such an air pump usually has a function of automatically stopping when the diaphragm is damaged.As a method of automatically stopping the diaphragm, when the amplitude of the vibrator for amplitude operation of the diaphragm reaches the specified amplitude, it is sent to the control unit. Has been proposed (for example, refer to Patent Document 1).

Stopping (faulting) the air pump in the septic tank does not perform good sewage treatment by aerobic microorganisms and causes bad odors. Conventionally, such troubles of the air pump are discovered and dealt with by workers during regular inspections. However, there is a problem that it takes time to find a failure. Further, even if a failure is found during the periodic inspection, if a replacement part is not present, the replacement part must be picked up, which imposes a heavy burden on the worker.

Therefore, an abnormality detection method has been proposed that detects the occurrence of an abnormality in the air pump based on the current value and reports the abnormality (for example, see Patent Document 2).

Japanese Patent Laid-Open No. 2009-57941 Unexamined-Japanese-Patent No. 2001-322968

If the abnormality detection method disclosed in Patent Document 2 is used, the occurrence of an abnormality in the air pump can be known at a remote location, but the type of abnormality cannot be known.

An object of the present invention is to provide a detection system capable of better detecting the occurrence of a defect in an air pump.

A malfunction detection system according to the present invention includes an air pump, a current sensor for detecting a current value supplied to the air pump, a transmitter connected to the current sensor, and a management server capable of communicating with the transmitter. Comprising, the transmitter transmits the current value detected by the current sensor to the management server, the management server, if the current value is zero, notifies the worker of a failure of the air pump, When the current value is not zero, the management server notifies the worker of the first failure if the current value is lower than the first current value, and if the current value is higher than the second current value, the management server notifies the worker of the first defect. A second defect different from the first defect is notified to the worker, and the first current value is lower than the second current value.

A malfunction detection system according to the present invention includes an air pump, a sensor unit for detecting a current value and an electric power value supplied to the air pump, a transmitter connected to the sensor unit, and a management server capable of communicating with the transmitter. And the transmitter transmits the current value and the power value detected by the sensor means to the management server, and the management server operates the air pump when the power value is zero. If the current value is lower than the first current value, the management server notifies the worker of the first failure and the current value is the second current value. If it is higher than the above, a second defect different from the first defect is notified to the worker, and the first current value is lower than the second current value.

Further, the failure detection method according to the present invention, a step of receiving a current value supplied to the air pump through a network, and a step of notifying a worker of a failure of the air pump when the current value is zero, When the current value is not zero, if the current value is lower than the first current value, the worker is notified of the first failure, and if the current value is higher than the second current value, the first failure is detected. And a step of notifying the worker of a different second defect, wherein the first current value is lower than the second current value.

A malfunction detecting method according to the present invention includes a step of receiving a current value and a power value supplied to an air pump via a network, and a step of notifying a worker of a failure of the air pump when the power value is zero. , When the electric power value is not zero, if the current value is lower than the first current value, notify the worker of the first failure, and if the current value is higher than the second current value, the first failure And a step of notifying the worker of a second malfunction different from the above, wherein the first current value is lower than the second current value.

According to the failure detection system and the failure detection method of the present invention, when the current value or the power value supplied to the air pump is zero, the operator is notified of the failure of the air pump, and when the current value or the power value is not zero, the current value is concerned. Is lower than the first current value, the worker is notified of the first failure, and if higher than the second current value, the worker is notified of a second failure different from the first failure. It is possible to promptly respond to the type of defect.

1 is a schematic diagram showing a defect detection system according to a first embodiment of the present invention. Sectional drawing of the air pump used in the malfunction detection system of FIG. FIG. 2 is a schematic block diagram showing the configuration of the defect detection system of FIG. 1. The figure which shows the structure of the septic tank data table memorize|stored in the management server shown in FIG. The figure which shows the structure of the worker data table memorize|stored in the management server shown in FIG. 4 is a flowchart showing a first determination process executed by the management server shown in FIG. 3. 7 is a flowchart showing a default value determination process executed in S13 of FIG. FIG. 4 is a diagram showing the configuration of a detection value data table stored in the management server shown in FIG. 3. 4 is a flowchart showing a second determination process executed by the management server shown in FIG. 3. The schematic block diagram which shows the structure of the malfunction detection system which concerns on 2nd Embodiment of this invention.

[First Embodiment]
Hereinafter, a defect detection system and a defect detection method according to a first embodiment of the present invention will be described with reference to the accompanying drawings. With reference to FIG. 1, the malfunction detection system 1 of the present embodiment manages a plurality of septic tanks 2, a transmitter 3 connected to each septic tank 2, and a communication capable of communicating with each transmitter 3 via a network N. And a server 4.

Each septic tank 2 is, for example, a septic tank of an anaerobic filter floor contact aeration system, which purifies treated water such as sewage in a toilet or domestic wastewater, and air is supplied to the contact aeration tank (not shown). It has an air pump 5 (FIG. 2) for feeding.

Referring to FIG. 2, the air pump 5 is a diaphragm type air pump, and includes a drive unit 50 including a vibrator 51, a pair of diaphragms 52 fixed to both sides of the vibrator 51, and a current supplied to the drive unit 50. And a power cable (not shown). The volume of the pump chamber 54 is changed by the oscillator 51 being reciprocally driven in the left-right direction, and the air sucked into the pump chamber 54 through the suction port 55 is discharged to the merging chamber 57 through the discharge port 56 and the merging chamber 57. Is supplied to the contact aeration tank (not shown) through the connecting pipe 58.

Further, the air pump 5 has an automatic stop function, and when the diaphragm 52 is damaged, the power supply to the control unit (not shown) is stopped. Since the configuration related to the automatic stop function is known, detailed description thereof will be omitted.

Here, when the inventor of the present application damaged the diaphragm 52, the air pump 5 continued to be driven for several days and then automatically stopped. At this time, when the current value flowing through the power cable and the vibration value of the air pump 5 were measured, both the current value and the vibration value rose beyond the normal range, and at the same time the air pump 5 automatically stopped, it became 0 (zero). Became.

When the connection pipe 58 of the air pump 5 was closed, the air pump 5 continued to be driven without being automatically stopped, but the current value flowing through the power cable was below the normal range. Similarly, when both the suction ports 55, 55 were closed, the air pump 5 continued to be driven without being automatically stopped, but the current value flowing through the power cable was below the normal range.

Therefore, in the present embodiment, the current sensor 91 (FIG. 3) is connected to the power cable of each septic tank 2, and the vibration sensor 92 (FIG. 3) is attached to the air pump 5, and the current sensor 91 or the vibration sensor 92 detects the vibration. A warning sign of failure is detected based on the current value and the vibration value, and is notified before the air pump 5 automatically stops.

More specifically, since the current supplied from the commercial power source is an alternating current, the working current of the air pump 5 fluctuates within a slight range from a predetermined current value (specified current value). Therefore, the range is defined as the predetermined current value range of the air pump 5, and when the current value is lower than the first current value which is lower than the lower limit value of the predetermined current value range, it is determined as a sign of failure due to clogging of the air pump 5. However, when the current value exceeds the lower second current value which is higher than the upper limit value of the predetermined current value range, it is determined as a sign of a failure due to damage of the diaphragm 52. The first current value is preferably 2% to 50% lower than the specified current value, and more preferably 2% to 40% lower. The second current value is preferably 2% to 50% higher than the specified current value, and more preferably 2% to 40% higher. If the first current value is too high or the second current value is too low, there is a high possibility of false alarms. If the first current value is too low or the second current value is too high, the notification will be delayed and it will not be possible to respond before the automatic stop. This is because there is a higher risk. Further, the specified current value is an average value of the current values actually detected within a predetermined time after the use of the air pump 5 is started.

Similarly, when the vibration value exceeds the vibration value (normal vibration value) higher than the normal vibration value (average vibration value) by a predetermined ratio, it is determined as a sign of a failure due to the damage of the diaphragm 52. The predetermined ratio is preferably 2% to 50%.

The transmitter 3 periodically (for example, every 30 minutes) notifies the management server 4 of the current value detected by the current sensor 91 and the vibration value detected by the vibration sensor 92. The input unit 31 to which the current value and the vibration value from the vibration sensor 92 are input, the memory 32 that stores the terminal ID and the like assigned to each oscillator 3, and the current value and the vibration value input to the input unit 31 An output unit 33 that outputs (notifies) to the management server 4 via the network N as detection information together with the terminal ID stored in the memory 32.

The management server 4 determines whether or not there is a defect in each septic tank 2 (air pump 5) based on the detection information from each transmitter 3, and when it determines that a defect has occurred, notifies the worker in charge of this by e-mail. Notice. More specifically, the management server 4 includes a reception unit 41, a memory 42, a control unit 43, and a transmission unit 44. The receiver 41 receives the detection information from the transmitter 3. The memory 42 stores various control programs for operation control, setting data, a data table, and the like. The control program in this embodiment includes a first determination program P1 and a second determination program P2, and the data tables include a septic tank data table T1, a worker data table T2, and a detection value data table T3. The control unit 43 executes various processes according to the control program stored in the memory 42. The transmission unit 44 transmits an e-mail to the mobile terminal M1 carried by the worker via the network N.

FIG. 4 shows a specific example of the septic tank data table T1. In this septic tank data table T1, the individual ID of each septic tank 2, the location, the user name, the contact telephone number, the model number of the air pump 5, the ID of the worker in charge (the worker ID), the first, the second, and the third. The notified flag is stored in advance, and the determination process described below is executed to store the last reception time of the detection information, the specified current value, the first current value, the second current value, and the specified vibration value. It The first to third notified flags are initially set to off.
FIG. 5 shows a specific example of the worker data table T2. This worker data table T2 stores the worker ID, name, mail address, etc. of each worker.

Next, the first determination processing executed by the control unit 43 of the management server 4 based on the first determination program P1 will be described with reference to the flowchart of FIG. In the first determination process, first, it is determined whether or not the detection information is received from any of the transmitters 3 (S1). If the detection information is not received (S1: NO), the process of S1 is repeated until the detection information is received. On the other hand, when the detection information is received (S1: YES), the individual ID is extracted from the detection information to identify the target septic tank 2 (S3), and the final reception time of the septic tank data table T1 is overwritten with the current time (S5). ).

Next, it is determined whether or not the second notified flag of the septic tank data table T1 is on (S7). If it is not on (S7: NO), the current value is extracted from the detection information and it is determined whether the current value is zero (S9). If it is not zero (S9: NO), it is determined whether the specified current value is stored in the septic tank data table T1 (S11). If not stored (S11: NO), a default value determination process is executed (S13), and the process returns to S1.

On the other hand, if the specified current value is stored (S11: YES), it is determined whether the first notified flag is on (S15). If it is not on (S15: NO), it is determined whether the current value is lower than the first current value (S17). If the current value is not lower than the first current value (S17: NO), it is determined whether the current value is higher than the second current value (S19). If it is not higher than the second current value (S19: NO), the vibration value is extracted from the detection information, and it is determined whether or not the vibration value is higher than the specified current value (S21). If it is not higher than the specified current value (S21: NO), the process returns to S1.

On the other hand, if it is determined in S17 that the current value is lower than the first current value (S17: YES), it is determined as a sign of a failure due to the clogging of the air pump 5, and the mobile terminal M1 carried by the worker in charge makes the first A notification mail is sent (S23). This first notification mail notifies the worker in charge that the air pump 5 may be clogged (first malfunction), and the worker in charge is identified by referring to the septic tank data table T1. Done. The first notification mail also includes septic tank information regarding the septic tank 2 (for example, the location of the septic tank 2, the user name, the telephone number, the model number of the air pump 5, etc.). After that, the first notified flag of the septic tank data table T1 is turned on (S25), and the process returns to S1.

Further, when it is determined that the current value is higher than the second current value in S19 (S19: YES), it is presumed that the diaphragm 52 has a problem, and the mobile terminal M1 carried by the worker in charge has the second value. 2 Send a notification mail (S27). The second notification mail notifies the worker in charge of the possibility that the diaphragm 52 has been damaged (second malfunction), and the above-mentioned septic tank information is also added to this second notification mail. Then, it transfers to S25. If the vibration value is higher than the specified vibration value in S21 (S21: YES), the process proceeds to S27.

Further, when it is determined in S9 that the current value is zero (S9: YES), it is determined that the air pump 5 has stopped, and the third notification mail is transmitted to the mobile terminal M1 of the worker in charge (S29). ). This third notification mail notifies the worker in charge of the stop (failure) of the air pump 5, and the above-mentioned septic tank information is also added to this third notification mail. After that, the second notified flag is turned on (S31), and the process returns to S1. If the second notified flag is turned on in S7 (S7: YES), the process directly returns to S1.

As described above, according to the malfunction detection system 1 of the present embodiment, the operator is notified of the failure sign of the air pump 5 based on the current value and the vibration value and notifies the operator, so that the operator automatically stops the air pump 5. The repair can be performed at an earlier stage, and it is possible to prevent the generation of a bad odor due to the stop of the air pump 5. Further, since the type of failure is reported to the worker, the worker can easily take measures according to the type of failure, and the burden on the worker can be reduced.

Next, the default value determination process executed in S13 of FIG. 6 will be described with reference to the flowchart of FIG. In this default value determination processing, first, the current value included in the detection information received in S1 of FIG. 6 is stored in the detection value data table T3 shown in FIG. 8 in association with the individual ID of the septic tank 2 (S41), and the same. Then, the vibration value included in the detection information is stored in the detection value data table T3 (S43). Next, it is determined whether or not the current value for a predetermined number of times (for a predetermined time (for example, two days)) is stored in the detection value data table T3 (S45). If the number of times is less than the predetermined number (S45: NO), the process directly returns to S1 of FIG.

On the other hand, when the current value for the predetermined number of times is stored (S45: YES), the average value of the current values for the predetermined number of times stored in the detection value data table T3 is obtained, and this is set as the specified current value. It is stored in the septic tank data table T1 (S47). Next, the first and second current values are calculated based on the specified current values calculated in the process of S47, and these are stored in the septic tank data table T1 (S48).

Then, the average value of the vibration values for the predetermined number of times stored in the detected value data table T3 is obtained, the specified current value is calculated based on the average value, and this is stored in the septic tank data table T1 (S49). , And returns to S1 in FIG.

Next, the second determination processing executed by the control unit 43 based on the second determination program P2 will be described based on the flowchart of FIG. In the second determination process, when the notification information is not received from any one of the communication devices 3 for a predetermined time (for example, 24 hours), the notification information is notified to the worker in charge by the email. The cause of not receiving is the failure of the transmitter 3 or the like.

In the second determination process, first, the counter value n is initialized to 0 (S51), and it is determined whether or not the third notified flag is turned on for the nth septic tank 2 in the septic tank data table T1 (S53). .. If it is not turned on (S33: NO), it is determined whether a predetermined time has elapsed from the last reception time (S55). If the predetermined time has not elapsed (S55: NO), the process proceeds to S61.

On the other hand, if the predetermined time has elapsed (S55: YES), the fourth notification mail is transmitted to the worker in charge (S57). The fourth notification mail informs that there is a possibility that some trouble has occurred in the transmitter 3 without receiving the detection information (fourth failure), and the fourth notification mail also includes the above-mentioned septic tank. Information is included. After that, the third notified flag is turned on (S59), and the process proceeds to S61.

In S61, it is determined whether or not the processes of S53 to S59 described above have been completed for all the septic tanks. If not completed (S61: NO), 1 is added to the counter value n (S63) and S53. Return to. On the other hand, if it is determined in S61 that the processing has been completed for all septic tanks 2 (S61: YES), the process returns to S51.

In this way, when the predetermined time elapses with the detection information from any one of the transmitters 3 being interrupted, this is notified to the worker in charge, so that the transmitter 3 itself should be promptly dealt with in case of failure or the like. You can

The first to third notified flags which are turned on in S25 and S31 of FIG. 6 and S59 of FIG. 9 are turned off by the worker himself or the administrator after the work by the worker is completed. Further, the notification to the worker is not limited to the one by e-mail, and any means can be used as long as it can notify the worker of necessary information such as a notification by telephone using voice guidance.

[Second Embodiment]
Next, a defect detection system and a defect detection method according to the second embodiment of the present invention will be described. The malfunction detection system and the malfunction detection method according to the present embodiment are substantially the same as those of the above-described first embodiment, but the malfunction detection system of this embodiment includes a power consumption sensor (power sensor) 93 shown in FIG. It is different from that of the first embodiment in that the air pump 5 is determined based on the electric power value detected by the power consumption sensor 93. Hereinafter, only parts different from those in the first embodiment will be described, and description of other parts will be omitted.

The power consumption sensor 93 is connected to a power cable (not shown) of the air pump 5, detects a power value supplied to the air pump 5 via the power cable (power value consumed by the air pump 5), and inputs the detected value. Enter in 31. The detection information output (notified) from the output unit 33 to the management server 4 includes the electric power value input to the input unit 31 in addition to the current value, the vibration value, and the terminal ID described above.

The first determination process executed by the management server 4 in this embodiment is substantially the same as that shown in FIG. 6, but in S9, instead of determining whether or not the current value is zero, the power value is zero. If the power value is zero (S9: YES), the process proceeds to S29. If the power value is not zero (S9: NO), the process proceeds to S11.

Even in this configuration, the same effect as that of the first embodiment can be obtained. In the present embodiment, the current sensor 91 and the power consumption sensor 93 function as the sensor means, but the sensor means does not necessarily have to include the power sensor 91 and the power consumption sensor 93, and the current value and the power value can be detected. It may be composed of a single sensor.

Although the defect detection system and the defect detection method according to the embodiments of the present invention have been described above with reference to the accompanying drawings, the present invention is not limited to the embodiments and various modifications can be made without departing from the scope of the present invention. It can be transformed and modified.

For example, in the above-described embodiment, the sign of the failure caused by the diaphragm 52 is determined using the current value and the vibration value, but it may be determined based on only the current value. In this case, the vibration sensor 92 is unnecessary, and the detection information does not include the vibration value.

Further, in the above embodiment, the first, second or third notification mail is immediately transmitted when the abnormality of the current value or the vibration value is detected. However, for example, the abnormality of the current value or the vibration value is transmitted a plurality of times. It may be transmitted only when it is detected or when it is continuously detected a plurality of times.

Further, in the above embodiment, the air pump 5 is used for the septic tank 2, but the fault notification system 1 of the present invention can also be applied to an air pump used for equipment other than the septic tank.

Further, although the air pump 5 in the above embodiment has the automatic stop function, the air pump 5 may not have the automatic stop function.

1 Failure Notification System 2 Septic Tank 3 Transmitter 4 Management Server 5 Air Pump 52 Diaphragm 91 Current Sensor 92 Vibration Sensor 93 Power Consumption Sensor

Claims (7)

An air pump,
A current sensor for detecting a current value supplied to the air pump,
An oscillator connected to the current sensor,
A management server capable of communicating with the transmitter,
The transmitter transmits the current value detected by the current sensor to the management server,
The management server notifies a worker of a failure of the air pump when the current value is zero,
If the current value is not zero, the management server notifies the worker of the first failure if the current value is lower than the first current value, and if the current value is higher than the second current value, the management server notifies the worker. Notifying the worker of a second defect different from the first defect,
The defect detection system, wherein the first current value is lower than the second current value. An air pump,
Sensor means for detecting a current value and an electric power value supplied to the air pump,
An oscillator connected to the sensor means,
A management server capable of communicating with the transmitter,
The transmitter transmits a current value and a power value detected by the sensor means to the management server,
The management server notifies the worker of a failure of the air pump when the power value is zero,
If the power value is not zero, the management server notifies the worker of the first failure if the current value is lower than the first current value, and if the current value is higher than the second current value, the management server notifies the worker. Notifying the worker of a second defect different from the first defect,
The defect detection system, wherein the first current value is lower than the second current value. Further comprising a vibration sensor for detecting vibration of the air pump,
The transmitter transmits the vibration value detected by the vibration sensor to the management server,
The said management server notifies the said 2nd malfunction to the said worker, when the said vibration value exceeds a regulation vibration value, The malfunction detection system of Claim 1 or 2 characterized by the above-mentioned. The first current value is 2% to 50% lower than the specified current value of the air pump, and the second current value is 2% to 50% higher than the specified current value,
The defect detection system according to claim 1, wherein the specified current value is an average value of current values of the air pump detected within a predetermined period. The air pump is a diaphragm type air pump including a diaphragm,
The first problem is a sign of clogging in the air pump,
The defect detection system according to any one of claims 1 to 4, wherein the second defect is a sign of breakage of the diaphragm. Receiving a current value supplied to the air pump via a network,
Notifying a worker of the failure of the air pump when the current value is zero,
If the current value is not zero, if the current value is lower than the first current value, the worker is notified of the first failure, and if the current value is higher than the second current value, the first failure is detected. Informing the worker of a different second defect,
The first current value is lower than the second current value. Receiving a current value and a power value supplied to the air pump through a network,
Notifying a worker of a failure of the air pump when the power value is zero,
If the current value is lower than the first current value when the power value is not zero, the worker is notified of the first failure, and if the current value is higher than the second current value, the first failure is detected. Informing the worker of a different second defect,
The first current value is lower than the second current value.

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