JP7462955B2 - Communication device - Google Patents

Description

The present invention relates to a communication device that can be attached to a pump device.

In recent years, with the aging of maintenance workers and a lack of successors, there is a demand for products that can be monitored from remote locations using long-distance communication for pump equipment. For example, there is a demand for information on pump equipment failures and operating conditions to be obtained through long-distance communication. However, pump equipment generally has a long product life of about 10 years, making it difficult to replace existing equipment with new models that have long-distance communication capabilities.

Patent No. 5007411

The present invention aims to provide a communication device that can be retrofitted to an existing pump device.

A communication device according to one aspect of the present invention is a device that can be attached to a pump device having a plurality of output terminals that can output a signal for each pump event. The communication device includes a plurality of input terminals, a detection unit, and a communication unit. The plurality of input terminals are electrically and individually connected to each of the plurality of output terminals, so that the signal is input from each of the plurality of output terminals individually. The detection unit individually detects the signal input from each of the plurality of input terminals. Based on the detection result of the detection unit, the communication unit transmits output information corresponding to the event, the output information including the terminal number of the input terminal to which the signal was input, to a management device. The management device previously associates and sets each terminal number of the plurality of input terminals with an event indicated by a signal input to the input terminal, and manages the event based on the transmitted output information.

The present invention provides a communication device that can be retrofitted to an existing pump device.

FIG. 1 is a block diagram illustrating a management system for managing a pump device to which a communication device is attached according to one embodiment. FIG. 2 is a block diagram illustrating the communication device and the pump device of FIG. 1 . FIG. 3 is a schematic diagram illustrating the communication device of FIG. 2 and its peripheral configuration; 4 is a schematic diagram illustrating a board layout of the communication device of FIG. 3; FIG. 4 is a block diagram illustrating an example of the input unit and its peripheral configuration in FIG. 3 . 6 is a schematic diagram illustrating an equivalent circuit formed by the input unit of FIG. 5 . 6 is a schematic diagram illustrating an equivalent circuit formed by the input unit of FIG. 5 . FIG. 2 is a block diagram illustrating a configuration of the user terminal of FIG. 1 . FIG. 2 is a block diagram illustrating a configuration of a management server of FIG. 1 . 10 is a schematic diagram illustrating a setting table stored in the management server of FIG. 9 . 2 is a sequence diagram illustrating an example of an operation in the management system of FIG. 1 .

Below, the embodiments will be described with reference to the drawings. In the following, elements that are the same or similar to elements already described will be given the same or similar reference numerals, and duplicate descriptions will generally be omitted. For example, when there are multiple identical or similar elements, a common reference numeral may be used to describe each element without distinguishing between them, and a subnumber and/or lowercase English letter may be used in addition to the common reference numeral to describe each element with distinction between them.

<One embodiment>
Fig. 1 is a block diagram illustrating a management system that manages pump devices to which a communication device according to one embodiment is attached, and Fig. 2 is a block diagram illustrating the communication device and the pump devices, etc. This management system includes pump devices 10-1, 10-2, 10-3, ... to be managed, communication devices 30-1, 30-2, ... that can be retrofitted, user terminals 50-1, 50-2, ..., a management server 60 as an in-house server, and a management server 70 as a cloud server.

Note that the number of devices in FIG. 1 is merely an example. For example, the management server 60 may be made redundant as multiple servers. The number of pump devices 10 is optional and may be more or less than three. The number of communication devices 40 and user terminals 50 is also optional.

On the other hand, the pump device 10 is a device that supplies water to a building, for example, and has multiple output terminals that can output signals for each pump event, such as a fault condition or operating condition. The pump device 10 may be, for example, a so-called direct-connected booster water supply device that is directly connected to a water main pipe, directly boosts the pressure of the water flowing through the water main pipe, and supplies water to a supply destination such as a faucet or shower head installed in a building, or an elevated water tank or water tank. Note that the pump device 10 of this embodiment is a device that does not have a communication function with external devices such as the management server 70 or user terminal 50.

As shown in FIG. 2, the pump device 10 includes a pump unit 20, a control device 30, and suction and discharge piping (not shown). The pump device 10 uses the pump unit 20 to take in water on the primary side via the suction piping and supplies water to the secondary side via the discharge piping. The suction piping connects, for example, a water distribution pipe branched off from a water main pipe and the pump unit 20. The discharge piping connects the pump unit 20 to the water supply destination on the secondary side.

The control device 30 is electrically connected to the pump unit 20 (the motor thereof) and controls the pump unit 20. Specifically, the control device 30 controls the driving of the motor of the pump unit 20 via the inverter 31 based on sensing signals from various sensors 21.

For example, the control device 30 can perform constant target pressure control, such as constant estimated terminal pressure control, during pump operation based on sensing signals from pressure sensors that are attached to the suction piping and discharge piping of the pump device 10 and can detect the suction pressure and discharge pressure of the pump. The control device 30 can also control the motor to operate at a desired rotation speed during pump operation, increasing or decreasing the motor rotation speed as necessary.

Furthermore, the control device 30 can stop the pump when it detects that the flow rate is a small amount of water based on a sensing signal from a flow sensor that is attached to the secondary piping of the pump included in the pump section 20 and is capable of detecting the flow rate of water flowing through the piping. Then, when the control device 30 detects that the pressure on the secondary side of the pump has dropped below a predetermined starting pressure based on a sensing signal from the pressure sensor, it restarts the pump. The control device 30 may also be called a control panel.

As shown in FIG. 2, the control device 30 includes an inverter 31, a power supply unit 32, an operation display unit 33, and a control input/output board 34.

Here, the inverter 31 is controlled by the control unit 346 of the control input/output board 34 to drive the pump unit 20. Specifically, the inverter 31 receives an inverter control signal from the control unit 346. The inverter 31 operates in response to this inverter control signal. For example, the inverter 31 may stop or start the operation of the pump unit 20 in response to an inverter control signal equivalent to an operation stop signal or an operation start signal. The inverter 31 may also control the rotation speed of the motor of the pump unit 20 in response to an inverter control signal equivalent to a rotation speed control signal. The inverter 31 may be separate from the control panel constituting the control device 30, or may be incorporated in the control panel. When the inverter 31 is separate from the control panel, the inverter 31 is mounted on, for example, the pump unit 20. When the inverter 31 is incorporated in the control panel, the control device 30 may be called a control panel.

The power supply unit 32 supplies power to the inverter 31 and the control input/output board 34 via the noise filter 321. The power supply unit 32 also supplies power to the operation display unit 33 via the noise filter 321 and the control input/output board 34.

The operation display unit 33 may include, for example, a device for accepting user input, such as an operation panel or a touch panel, and a display device, typically a liquid crystal display or an organic EL display. The operation display unit 33 may also include a speaker, an LED (Light Emitting Diode) lighting unit, etc., instead of or in addition to the display device.

The control input/output board 34 includes a control power supply unit 341, a switch 342, a terminal block 343, an input unit 344, a memory 345, a control unit 346, and an output unit 347.

The control power supply unit 341 adjusts the voltage of the power supply supplied from the power supply unit 32 through the noise filter 321 and supplies it to the memory 345 and control unit 346 in the control input/output board 34 and to the operation display unit 33 outside the control input/output board 34.

The switch 342 switches the electrical connection between the power supplied from the power supply unit 32 through the noise filter 321 and the terminal block 343 having a power terminal between the on state and the off state in response to the operation of the operator.

The terminal block 343 has one or more power terminals for externally outputting the power supplied from the power supply unit 32 via the noise filter 321 and the switch 342. The power terminal of the terminal block 343 is a terminal that can be electrically connected via a wiring cable or the like to an external device such as an inflow valve for allowing water to flow into the water tank or a communication device 40 that can be installed later, and is used to supply power to the external device.

The input unit 344 inputs signals input from various sensors 21 to the control unit 346. For example, a connector or an A/D converter can be used as the input unit 344 as appropriate. When the input unit 344 includes an A/D converter, the input unit 344 operates by receiving power supply from the control power supply unit 341.

Memory 345 stores programs executed by control unit 346 to realize each process and data used by control unit 346. Programs stored include, for example, firmware, an OS, a display control program, a pump control program, and the like, as appropriate. Data stored include, for example, pump control parameters, thresholds, tables, and the like, as appropriate. Memory 345 may include a RAM having a work area in which such programs/data are expanded. Memory 345 is an example of a storage unit.

The control unit 346 is typically a microcomputer, but may also be a CPU, GPU, FPGA, DSP, or other general-purpose or dedicated processor. The control unit 346 performs any process, such as communication control, display control, and pump control.

The control unit 346 executes the program stored in the memory 345 to control the inverter 31, the operation display unit 33, the output unit 347, and the like. For example, the control unit 346 generates an inverter control signal in response to sensing signals from various sensors 21 according to a control policy determined by the program in the memory 345, and sends the inverter control signal to the inverter 31. For example, the control unit 346 acquires operation data indicating the operation state of the pump device 10 based on the sensing signals from the various sensors 21, and outputs the operation data to the operation display unit 33 and the memory 345. The control unit 346 may also calculate the cumulative operation time and/or the cumulative number of operations according to the actual operation state of the pump device 10 and write the calculated value to the memory 345. The control unit 346 also outputs a signal to the output unit 347 for each event of the pump device 10. As the signal for each event, for example, a signal corresponding to an event related to the operation of the pump device 10, a signal corresponding to an event related to a failure of the pump device 10, a signal corresponding to an event related to the water level of the water tank connected to the pump device 10, etc. can be used as appropriate. The signal corresponding to an event related to operation is, for example, a signal indicating the operation content of the switch of the operation display unit 33, such as Unit 1 operation/stop, Unit 2 operation/stop, and Units 1 and 2 operation/stop. The signal corresponding to an event related to a failure is, for example, a signal indicating the failure content based on the sensing signal of the various sensors 21. The signal corresponding to an event related to the water level of the water tank is a signal indicating full water or low water in the sensing signal of the sensor that detects the water level of the water tank among the various sensors 21. Note that the signal corresponding to an event related to the water level of the water tank is not limited to this, and may include a signal indicating the on state (open) or off state (closed) of the inflow valve.

2 and 3, the output unit 347 includes a plurality of relays Ry2, Ry3, Ry5 to Ry10 whose contacts are opened and closed in response to a signal from the control unit 346, and a terminal block 34A having a plurality of output terminals electrically connected to the contacts of any of the relays Ry2, 3, .... In the example of FIG. 3, the output terminal A1 is connected to the output terminal A2 via the relay Ry2 and is connected to the output terminal A3 via the relay Ry3. That is, when the relays Ry2 and Ry3 are in the on state, the output terminals A2 and A3 are conductive to the output terminal A1. Similarly, the output terminal A4 is connected to the output terminal A5 via the relay Ry5 and is connected to the output terminal A6 via the relay Ry6. The output terminal A4 is also connected to the output terminal A7 via the relay Ry7 and is connected to the output terminal A8 via the relay Ry8. The output terminal A4 is also connected to the output terminal A9 via the relay Ry9 and is connected to the output terminal A10 via the relay Ry10. That is, when relays Ry5, ..., Ry10 are in the ON state, output terminals A5, ..., A10 are conductive to output terminal A4. In other words, output terminals A2, A3, A5 to A10 of terminal block 34A output no-voltage signals in response to the opening and closing of contacts of relays Ry2, Ry3, Ry5 to Ry10. However, this is not limited to this, and output unit 347 may be modified to output voltage signals in response to the opening and closing of contacts of relays Ry2, Ry3, Ry5 to Ry10 from the output terminals of terminal block 34A. In this case, output unit 347 may generate voltage signals using power supplied from control power supply unit 341.

On the other hand, as shown in Figs. 2 and 3, the communication device 40 includes an input board 41 on which an input unit 411 is mounted, and a communication board 42 on which a communication unit 421 is mounted. As shown in Fig. 4, the communication device 40 may have the communication board 42, which is arranged opposite the input board 41, detachably connected to the input board 41 via a connector 43. In this case, it is preferable that the four corners of the communication board 42 are fixed by supports 44. The support 44 may be configured, for example, by fixing a structure in which a cylindrical member is arranged between the input board 41 and the communication board 42 with bolts and nuts.

In addition, when the communication board 42 is capable of linking with a new model of pump device that supports serial communication, the communication board 42 may further include a connector (not shown) capable of serial communication with the new model of pump device. In other words, the communication board 42 may be configured to include a connector 43 that can be connected to an input board 41 for connecting to an old model of pump device 10 that does not support serial communication, and the aforementioned connector (not shown) capable of serial communication. According to this configuration, the communication board 42 uses either the connector 43 or the connector (not shown) depending on whether the model of the pump device is new or old, but does not use the other connector.

For example, when the connector 43 is used, the communication board 42 has the communication unit 421 connected to the old model pump device 10 via the connector 43 and the input board 41, but the communication board 42 has the aforementioned connector capable of serial communication (not shown) which is not used. Also, for example, when a connector capable of serial communication (not shown) is used, the communication board 42 has the communication unit 421 connected to the new model pump device via a connector (not shown) and a serial communication cable, but the communication board 42 has the connector 43 which is not used. Note that when the connector 43 is not used, the communication device 40 does not have the input board 41 and only has the communication board 42.

Note that the old model pump device 10 does not have a serial communication function and can only notify on/off signals. For example, if pump No. 1 of the pump section 20 having pumps No. 1 and No. 2 breaks down, the old model pump device 10 outputs an on/off signal that only conveys the fact of the failure (failure of pump No. 1) from an output terminal to the communication device 40. When the output on/off signal is input from an input terminal, the communication device 40 transmits output information including, for example, the terminal number of the input terminal and the on/off state of the on/off signal to the management server 70 via serial communication. However, the output information does not necessarily have to include the on/off state as long as it includes the terminal number. The management server 70 previously sets the terminal number of each of the multiple input terminals in association with the event indicated by the signal input to the input terminal, and manages the event based on the transmitted output information.

On the other hand, the new model pump device has a serial communication function, so it outputs information about the details of the fault (overcurrent in Unit 1) to the communication device 40 via serial communication. The communication device 40 then transmits output information about the details of the fault (items such as "overcurrent in Unit 1") via serial communication to the management server 70. The management server 70 manages events based on the transmitted output information. Note that in the case of a new model pump device, the output information includes the details of the fault, so unlike the old model, the management server 70 can manage events without having to configure an association between a terminal number and an event.

2 and 3, the input unit 411 includes a terminal block 41B having multiple input terminals, a power supply unit 412, and a signal detection unit 413. The terminal block 41B includes multiple input terminals B1 to Bn (n: any natural number) that can be connected to the output terminals A1 to A10 of the terminal block 34A of the control device 30 via wiring cables or the like. The multiple input terminals B1 to Bn are electrically connected individually to the multiple output terminals A1 to A10, so that signals are input individually from the multiple output terminals A1 to A10. The multiple signals input individually to the multiple input terminals B1 to Bn may include at least one of a signal corresponding to an event related to the operation of the pump, a signal corresponding to an event related to a pump failure, and a signal corresponding to an event related to the water level of the water tank to which the pump is connected. The input terminals B1 to Bn are electrically connected to the signal detection unit 413.

The power supply unit 412 adjusts the voltage of the power supply supplied from the terminal block 343 of the control device 30 and supplies it to the signal detection unit 413 and the communication unit 421. For example, as shown in FIG. 5, the power supply unit 412 includes a first common power supply E1 that supplies a first voltage to the signal detection unit 413, a second common power supply E2 that supplies a second voltage to the signal detection unit 413, and a communication power supply E3 that supplies a communication voltage to the communication unit 421.

The signal detection unit 413 is a detection unit that individually detects signals input from each of the multiple input terminals B1 to Bn. The signal detection unit 413 may send the detection result of the detected signal to the communication unit 412. The signal detection unit 413 may also send each of a first detection result that detects a rising edge of a signal and a second detection result that detects a falling edge of a signal to the communication unit 412. The signal detection unit 413 also includes, for example, a power setting switch 413a, a detection setting switch 413b, a connection line/detection circuit 413c, and an output unit 413d.

The power supply setting switch 413a is a group of switches provided corresponding to each of the input terminals B1 to Bn, and switches the electrical connection between the connection line/detection circuit 413c and the first common power supply E1 or the second common power supply E2 in response to the operator's operation. Note that the operator can, for example, refer to the explanation of the external output terminal in the instruction manual for the pump device 10 and switch the setting of the power supply setting switch 413a so that the power supplies are unified to the common power supply.

The detection setting switch 413b switches the electrical connection between each of the input terminals B1 to Bn and each of the connection lines or detection circuits dc1, ... in the connection line/detection circuit 413c in response to the operator's operation. For example, the operator can refer to the explanation of the external output terminals in the instruction manual for the pump device 10 and switch the setting of the detection setting switch 413b so that the input terminal B1 connected to multiple relays Ry2, Ry3 is connected to the connection line and the input terminals B2, B3 connected to one relay Ry2, Ry3 are connected to the detection circuit dc2, dc3.

The connection line/detection circuit 413c is provided between the power setting switch 413a and the detection setting switch 413b, and is equipped with a connection line and detection circuit dc1, ... that individually connects both switches for each of the input terminals B1 to Bn.

In the example of FIG. 5, the power setting switch 413a includes a group of switches corresponding to the input terminals B1 to B3 that electrically connect the connection line/detection circuit 413c to the first common power source E1. The detection setting switch 413b electrically connects the input terminal B1 to the connection line in the connection line/detection circuit 413c, and electrically connects each of the input terminals B2 and B3 to each of the detection circuits dc2 and dc3 in the connection line/detection circuit 413c. In this case, as shown in FIG. 6, an electric circuit is formed that includes detection circuits dc2 and dc3 that can individually detect the on/off state of the relays Ry2 and Ry3.

Similarly, in the example of FIG. 5, the switch group of the power setting switch 413a corresponding to each of the input terminals B4 to B10 electrically connects the connection line/detection circuit 413c and the second common power source E2. Also, the detection setting switch 413b electrically connects the input terminal B4 to the connection line in the connection line/detection circuit 413c, and electrically connects each of the input terminals B5 to B10 to each of the detection circuits dc5 to dc10 in the connection line/detection circuit 413c. In this case, as shown in FIG. 7, an electric circuit is formed that includes detection circuits dc5, ..., dc10 that can individually detect the on/off state of the relays Ry5, ..., Ry10. Note that the electric circuits shown in FIG. 6 and FIG. 7 are only examples, and different electric circuits can be formed depending on the settings of the power setting switch 413a and the detection setting switch 413b.

The detection circuits dc1, ... may be, for example, simple circuits having resistors and photocouplers. The detection result of the photocoupler corresponding to the on/off state of the relay Ry is sent to, for example, the output section 413d.

Based on the settings of the power supply setting switch 413a and the detection setting switch 413b, the output unit 413d outputs the detection results of the detection circuits dc1, ... in the connection line/detection circuit 413c to the communication unit 421. For example, the output unit 413d outputs only the detection results from the detection circuits dc2, dc3, dc5 to dc10 connected to the input terminals B2, B3, B5 to B10 by the detection setting switch 413b to the communication unit 421. Here, the output unit 413d may output the detection results by attaching the terminal numbers of the input terminals B2, B3, B5 to B10. In addition, the output unit 413d may output the detection results from the detection circuits dc2, dc3 connected to the first common power supply E1 and the detection results from the detection circuits dc5 to dc10 connected to the second common power supply E2 by the power supply setting switch 413a with separate power supply identification information. Furthermore, the output unit 413d may send each of a first detection result that detects a rising edge of a signal and a second detection result that detects a falling edge of a signal to the communication unit 421. Alternatively, the output unit 413d may send a detection result that detects an on/off state of a signal, not limited to the rising/falling edge of a signal, to the communication unit 421.

Based on the detection result of the signal detection unit 413, the communication unit 421 transmits to the management server 70 output information corresponding to the event, including the terminal number of the input terminal B2, B3, B5 to B10 to which the signal is input. The communication unit 421 is, for example, a communication circuit that performs serial communication in a wired or wireless manner, and transmits the output information including the detection result and the terminal number output from the signal detection unit 413 to the management server 70 by serial communication. In addition, as a standard for serial communication, for example, RS-232C, RS-422, RS-485, etc. can be used as appropriate. In addition, the communication unit 421 may use, for example, SPP (Serial Port Profile) of Bluetooth (registered trademark) as a standard for performing serial communication wirelessly. In addition, the communication unit 421 performs wired or wireless serial communication to the management server 70 via a base station and a network according to a predetermined standard communication standard as appropriate. In the case of wireless communication, if the management server 70 is within the range of wireless communication, wireless serial communication between the communication unit 421 and the management server 70 is possible. However, since the management server 70 is usually not within the range of wireless communication, wireless serial communication is performed between the communication unit 421 and the base station, and wired serial communication is performed between the base station and the management server 70. In addition, when the communication unit 421 receives a first detection result that detects a rising edge of a signal and a second detection result that detects a falling edge of a signal, the communication unit 421 may measure the time from the first detection result to the second detection result using a counter or the like, and transmit the measurement result including the count value or its time equivalent value in the detection result. For example, if the event is related to the operation of a pump, the measurement result corresponds to the operation time. Such an operation time is, for example, a guideline for the maintenance timing of parts, and is managed on the management server 70 side. In addition, if the event is related to a pump failure, the measurement result corresponds to the failure time. Such a failure time is, for example, a guideline for the degree of urgency for dispatching a worker, and is managed on the management server 70 side. The communication unit 421 may also turn on an LED (not shown) based on a signal received from the management server 70.

On the other hand, the user terminal 50 is an information processing device capable of communicating with the pump device 10 that supplies water to the building and the management server 70 that manages the pump device 10. The user terminal 50 may be, for example, a PC or a mobile terminal (e.g., a tablet, a smartphone, a laptop, a feature phone, etc.), but is not limited to these.

As shown in FIG. 8, such a user terminal 50 includes a communication unit 51, an input unit 52, a display unit 53, a memory 54, and a processor 55. The processor 55 is capable of implementing the functions of a communication control unit 55a, a processing unit 55b, etc., as described below. The division of functions among the various units within the processor 55 is for convenience and can be changed as appropriate. The division of functions between the communication control unit 55a and the communication unit 51 is also for convenience and can be changed as appropriate.

The communication unit 51 is an arbitrary communication interface that is controlled by the processor 55 and can communicate with an external device such as the management server 70, for example, using long-distance communication technology. Specifically, the communication unit 51 can connect to an external device such as the management server 70 via a base station and a network, for example, using wireless communication technology such as mobile communication (3G, 4G, 5G) and Wimax.

The input unit 52 is an input I/F for accepting user input, and may be built into the user terminal 50 or may be externally attached to the user terminal 50. The input unit 52 may include, for example, a keyboard, a mouse, a numeric keypad, a microphone, a camera, etc., and may also have an output I/F function such as a touch screen. User input may typically be a tap, a click, a drag, or the pressing of a specific key. In addition, user input may also include, for example, a voice captured by a microphone.

The display unit 53 is an example of an output I/F for outputting images and/or audio in response to processing by the processor 55, and may include a display device for displaying moving images, still images, text, etc. Examples of the display device include a liquid crystal display, an organic EL (electroluminescence) display, and a CRT (cathode ray tube) display. The display device displays display data including content. The display device may also have an input I/F function, such as a touch screen.

Memory 54 stores programs executed by processor 55 to realize each process, data used by processor 55, and the like. Memory 54 may include a RAM having a work area in which such programs/data are deployed. As programs, for example, firmware, an OS, communication programs, and the like are stored as appropriate. As data, for example, codes, operating data, tables, and the like are stored as appropriate.

The processor 55 is typically a CPU, but may also be a microcomputer, a GPU, an FPGA, a DSP, or other general-purpose or dedicated processor. The processor 55 can function as the communication control unit 55a and the processing unit 55b in FIG. 8 by executing a program stored in the memory 54.

The communication control unit 55a performs long-distance communication with the management server 70 via the communication unit 51.

The processing unit 55b executes information processing according to the work of the worker, such as inspection, maintenance, and management of the pump device 10. For example, the processing unit 55b supports the worker in collecting operation data from the pump device 10. For example, the processing unit 55b accesses the management server 70 in response to the operation of the operator, and transmits the serial number of the pump device 10, the terminal numbers of the input terminals B1 to B10 of the communication device 40, and the signal name to the management server 70. Note that the "signal name" may be any information that identifies an event, and may be changed to any name, such as "signal type," "signal item," "signal content," "event name," "event type," "event item," or "event content." This is also true for the management server 70, which will be described later. The processing unit 55b also causes the display unit 53 to display the content received from the management server 70.

The management server 60 is, for example, an on-premise server operated by a company that produces, sells and/or maintains the pump device 10. The management server 60 may cooperate with the management server 70 to centrally manage and utilize the operating data. The management server 60 may, for example, request the management server 70 to register the serial number of a newly manufactured pump device 10.

The management server 70 is an in-house server or cloud server for managing the pump device 10, and is capable of communicating with the communication device 40 and the user terminal 50. Note that using a cloud server and an on-premise server together is optional, and the management server 60 and the management server 70 can be integrated into either one of them. Also, for example, AWS (registered trademark) of Amazon (registered trademark) may be used as the cloud server and on-premise server. AWS is an abbreviation for Amazon Web Services (registered trademark). In this specification, for ease of understanding, an example is described in which the pump device 10 is managed by the management server 70 integrated with the management server 60.

The management server 70 includes a communication unit 71, an interface 72, a memory 73, and a processor 74. The processor 74 is capable of implementing the functions of a management unit 74a and a processing unit 74b, etc.

Here, the communication unit 71 is an arbitrary communication interface that is controlled by the processor 74 and can communicate with the user terminal 50, for example, using long-distance communication technology. Specifically, the communication unit 71 can connect to the user terminal 50 via a base station and a network (not shown), for example, using wireless communication technology such as mobile communication (3G, 4G, 5G) and Wimax.

Interface 72 is a communication interface that communicates with other devices (not shown, such as communication device 40 or other management servers) via a network, typically the Internet.

The memory 73 stores programs executed by the processor 74 to realize each process, and data used by the processor 74. Examples of data include codes, operating status data, maintenance information, and a setting table 73a as shown in FIG. 10. The setting table 73a associates the terminal numbers of the input terminals B1 to Bn in the retrofitted communication device 40 with the signal names of the signals input to the input terminals B1 to Bn for each serial number of the pump device 10. The "signal name of the signal" means the "event indicated by the signal." In the example of FIG. 10, the terminal number "B1" of the input terminal B1 is associated with the signal name "first common power source." The terminal numbers "B2" and "B3" of the input terminals B2 and B3 are associated with the signal names "Unit 1 operation" and "Unit 2 operation." The terminal number "B4" of the input terminal B4 is associated with the signal name "second common power source." Moreover, the terminal numbers "B5" and "B6" of the input terminals B5 and B6 correspond to the signal names "Unit 1 failure" and "Unit 2 failure". Furthermore, the terminal numbers "B7" and "B8" of the input terminals B7 and B8 correspond to the signal names "Suction pressure drop" and "Inspection in progress". Furthermore, the terminal numbers "B9" and "B10" of the input terminals B9 and B10 correspond to the signal names "Elevated water tank liquid level abnormality" and "Control board pressure transmitter abnormality". Furthermore, the terminal numbers "B11", ..., "Bn" of the input terminals B11 to Bn correspond to the signal names "Not in use", ..., "Not in use". Here, the signal names "Unit 1 in operation", "Unit 2 in operation", and "Inspection in progress" are the signal names of signals corresponding to events related to the operation of the pump. In addition, the signal names "Unit 1 failure", "Unit 2 failure", "Suction pressure drop", and "Control board pressure transmitter abnormality" are the names of signals corresponding to events related to pump failure. In addition, the signal name "Elevated water tank liquid level abnormality" is the name of a signal corresponding to an event related to the water level of the receiving tank to which the pump is connected.

Additionally, the relay output of the control device 30 (control panel) is an on/off signal, and is sent to the communication device 40 via the terminal block 34A. The control device 30 also has multiple output terminals A1-A10, and the communication device 40 also has multiple input terminals B1-Bn. For this reason, it is not known which output terminal A1-A10 of the control device 30 is connected to which input terminal B1-Bn of the communication device 40. In addition, since the information (whether operation or failure) held by the output terminals A1-A10 differs for each control device 30 (control panel), it is necessary to freely change the information assigned to the input terminals B1-B10 of the communication device 40. Accordingly, the management server 70 is configured to be able to set information for each input terminal B1-B10 of the communication device 40, and can be freely changed for each individual pump device 10.

For example, a pump device (#1) has two relay outputs, which are 1/2 failure, and a pump device (#2) has three relay outputs, which are 1/2/3 operation, and are connected to input terminals B1 to B3 of the communication device 40. In the case of a pump device (#1), input terminals B1 and B2 of the communication device 40 are connected to 1 failure/2 failure, respectively, and input terminal B3 is not connected, and B1 = 1 failure, B2 = 2 failure, B3 = not used is set in the management server 70. In the case of a pump device (#2), input terminals B1 to B3 of the communication device 40 are connected to 1 operation/2 operation/3 operation, respectively, and B1 = 1 operation, B2 = 2 operation, B3 = 3 operation is set in the management server 70. If this example is followed, it becomes possible to freely determine the output information regardless of the type of control device 30 (control panel) to be connected. The combination of the input terminal of the communication device 40 and the signal name of the control device 30 can be set in the communication device 40 without being set in the management server 70, but it is preferable to set it in the management server 70 because it is not necessary to configure an operation unit and a display in the communication device 40. However, while the setting table 73a can be freely set, the initial value of the signal name indicating the external output of the control device 30 may be set based on the serial number or model number/product number of the pump device 10.

The processor 74 is typically a CPU, but may also be a microcomputer, a GPU, an FPGA, a DSP, or other general-purpose or dedicated processor. The processor 74 executes processes for managing the pump device 10. The processor 74 can function as the management unit 74a and the processing unit 74b of FIG. 9 by executing a program stored in the memory 73.

The management unit 74a manages the pump device 10. For example, the management unit 74a stores operation status data received from the communication device 40 or the user terminal 50, and stores maintenance information such as the time when the pump device 10 was overhauled. The processing unit 74b associates the terminal numbers of the input terminals B1 to Bn with the signal names corresponding to the input terminals B1 to Bn for each serial number of the pump device 10 received from the user terminal 50, and stores (sets) them in the setting table 73a. The processing unit 74b also manages events of the pump based on output information transmitted from the communication device 40. For example, the processing unit 74b refers to the setting table 73a based on the serial number of the pump device 10, the terminal numbers of the input terminals B1 to Bn, and the on/off state of the signal corresponding to the terminal number received from the communication device 40, and detects the on/off state of the signal as the on/off state of the signal name of the pump device 10. As a result, the processing unit 74b manages the occurrence/disappearance state of events of the pump device 10 according to the on/off state of the signal name of the pump device 10.

Below, with reference to FIG. 11, an example of operation when serial communication is performed by retrofitting the communication device 40 will be described. This example of operation includes step S10 during retrofitting and step S20 during communication. Step S10 during retrofitting is performed only once at the beginning. Step S20 during communication is performed repeatedly as appropriate.

(Step S10: Retrofitting)
First, step S10 of retrofitting the communication device 40 is executed by steps S11 to S14. First, an operator performs retrofitting work of retrofitting the communication device 40 to the existing pump device 10 (step S11). For example, the input terminals B1 to B10 of the communication device 40 are connected to the output terminals A1 to A10 of the control device 30 via a wiring cable. Also, the power supply unit 412 of the communication device 40 is connected to the power supply terminal of the terminal block 343 of the control device 30 via a wiring cable. The power supply terminal of the terminal block 343 is on the secondary side of the power supply board that filters power supply noise. The power supply unit 412 acquires power from such a power supply terminal, adjusts the voltage of the acquired power supply, and supplies it to the signal detection unit 413 and the communication unit 412. After step S11, the user terminal 50 transmits a setting request including the serial number of the pump device 10, the terminal numbers of the input terminals B1 to B10 of the communication device 40, and the signal names of the signals input to the input terminals B1 to B10 to the management server 70 in response to the operator's operation (step S12). The names of the signals to be input may be, for example, the names of the signals at the output terminals A1 to A10 of the pump device 10 that are electrically connected to the input terminals B1 to B10, with reference to the instruction manual for the pump device 10.

After step S12, the management server 70 stores the serial number, terminal number, and signal name received from the user terminal 50 in the setting table 73a in the memory 73 (step S13).

After step S13, the management server 70 notifies the user terminal 50 that the settings have been completed (step S14). Step S10 ends when steps S11 to S14 are performed.

(Step S20: During communication)
After step S10 is completed, the control device 30 outputs a signal for each event from the output terminals A2, A3, A5 to A10 (step S21). The output signal is input to the communication device 40 via the input terminals B2, B3, B5 to B10. The event includes, for example, at least one of an event related to the operation of the pump, an event related to a pump failure, and an event related to the water level of a water tank connected to the pump.

After step S21, the communication device 40 detects the input signal and transmits output information corresponding to the event to the management server 70 based on the detection result (step S22). The output information includes the terminal number of the input terminal to which the signal is input. For example, the output information can include the serial number of the pump device 10 and information indicating the on/off state for each terminal number of the input terminals B2, B3, B5 to B10. However, if the normal state is the off state, it is possible to transmit the terminal number only when the state is on, without having to transmit information indicating the on/off state separately. Conversely, if the normal state is the on state, it is possible to transmit the terminal number only when the state is off, without having to transmit information indicating the on/off state separately. The information indicating the on/off state may be either the first detection result of detecting the rising edge of the signal or the second detection result of detecting the falling edge of the signal. The communication device 40 may transmit the output information to the management server 70 by serial communication.

After step S22, when the management server 70 receives the output information, it refers to the setting table 73a based on the output information to determine whether or not there is a malfunction and the operating status (step S23).

After step S23, the management server 70 transmits the determination result to the communication device 40 (step S24). The management server 70 may also transmit the determination result to the user terminal 50 (step S25). This completes step S20. Step S20 during communication is repeatedly executed periodically or irregularly, such as at the rising/falling edge of a signal.

As described above, according to one embodiment, the communication device is a device that can be attached to a pump device having a plurality of output terminals that can output a signal for each pump event. The communication device includes a plurality of input terminals, a detection unit, and a communication unit. The plurality of input terminals are electrically and individually connected to each of the plurality of output terminals, so that a signal is individually input from each of the plurality of output terminals. The detection unit individually detects the signal input from each of the plurality of input terminals. Based on the detection result of the detection unit, the communication unit transmits output information corresponding to an event, the output information including the terminal number of the input terminal to which the signal is input, to the management device. This makes it possible to provide a communication device that can be retrofitted to an existing pump device. Therefore, by retrofitting such a communication device, it is possible to realize communication compatibility even in an existing pump device that is not communication compatible. In addition, the management device can previously associate and set the terminal number of each of the plurality of input terminals with an event indicated by a signal input to the input terminal, and manage the event based on the transmitted output information.

Additionally, due to the aging of workers and a lack of successors, remote monitoring using long-distance communication is desired for pump equipment maintenance work. It is desirable to obtain information on malfunctions and information for predicting malfunctions through long-distance communication, but pump equipment generally has a product lifespan of about 10 years, and it is difficult to bring products that incorporate long-distance communication to the market in advance. Rather than replacing with new models, it is desirable to retrofit remote monitoring support for existing pump equipment that is nearing the end of its product lifespan. Furthermore, what is desired in remote monitoring is often abnormality monitoring, and there is a need to respond quickly to abnormalities. Many pump equipment have a tendency to have more abnormalities as they deteriorate over time, and it is also desirable to respond to them with the old model rather than by replacing them with a new product. In response to this type of request, one embodiment provides a communication device that can be retrofitted to existing pump equipment, which is preferable.

According to one embodiment, the multiple signals input individually to the multiple input terminals may include at least one of a signal corresponding to an event related to the operation of the pump, a signal corresponding to an event related to a failure of the pump, and a signal corresponding to an event related to the water level of the water tank to which the pump is connected. In this case, output information corresponding to an event related to at least one of the operation, failure, and water level can be transmitted to the management device.

As a supplementary note, in plants or large facilities that use older models of pump equipment, the operating state (operating, malfunctioning) of the pump equipment and the water level in the water tank (full, low, low water) are sometimes relay-output, and malfunction detection is performed in the integrated control panel. In contrast, in one embodiment, instead of the integrated control panel, the relay output information is input to a communication device that can be retrofitted to the pump equipment, and when the communication device receives the input, it performs long-distance communication with the management device. As a result, in one embodiment, it is possible to provide a communication device that can quickly notify users of event information without building a system such as an integrated control panel.

In one embodiment, the detection unit may send to the communication unit a first detection result that detects a rising edge of the signal and a second detection result that detects a falling edge of the signal. In this case, output information is sent to the management device via the communication unit only when the state of the signal changes, thereby reducing the load of communication processing.

According to one embodiment, the communication device may include an input board and a communication board, with the input board having a plurality of input terminals and a detection unit mounted thereon, and the communication board having a communication unit mounted thereon. In this case, it is expected that among existing pump devices, the input board and communication board can be retrofitted to relatively older models, and only the communication board can be retrofitted to relatively newer models, allowing for different uses.

Additionally, if the communications device can be used for both old and new pump equipment, costs can be reduced by making it compatible. For this reason, if the circuitry in the communications device that can accept relay inputs is configured on a separate board so that it can be removed, costs can be reduced when it is used in the new product (relays are generally mounted on terminal blocks and tend to require larger board sizes, so are not used in new products).

According to one embodiment, the communication device may include a power supply unit for a pump device having a power supply terminal on the secondary side of a power supply board that filters power supply noise. The power supply unit is electrically connected to the power supply terminal of the pump device to obtain power from the power supply terminal, adjust the voltage of the obtained power supply, and supply it to the detection unit and communication unit. In this case, the communication device can obtain power from the secondary side of the power supply board of the pump device.

As an added note, since the communication device is intended to be installed in the control panel configured for the pump device, if power is obtained from the secondary side filtered by the control panel, there is no need to provide an extra filter circuit in the communication device, making it possible to provide a compact, inexpensive product.

In one embodiment, the communication unit may transmit the output information to the management device via serial communication. In this case, a simpler configuration can be achieved compared to parallel communication. In addition, the communication board is shared and used in new pump devices, so the communication device only needs to be compatible with serial communication.

The above-described embodiments are merely illustrative examples to aid in understanding the concept of the present invention, and are not intended to limit the scope of the present invention. Various components may be added, deleted, or modified in the embodiments without departing from the spirit of the present invention.

In the above embodiment, several functional units have been described, but these are merely examples of implementation of each functional unit. For example, multiple functional units described as being implemented in one device may be implemented across multiple separate devices, and conversely, functional units described as being implemented across multiple separate devices may be implemented in one device.

The various functional units described in each of the above embodiments may be realized by using a circuit. The circuit may be a dedicated circuit for realizing a specific function, or may be a general-purpose circuit such as a processor.

At least a part of the processing of each of the above embodiments can be realized by using, for example, a processor installed in a general-purpose computer as basic hardware. The program that realizes the above processing may be provided by being stored in a computer-readable recording medium. The program is stored in the recording medium as a file in an installable format or an executable format. Examples of the recording medium include magnetic disks, optical disks (CD-ROM, CD-R, DVD, etc.), magneto-optical disks (MO, etc.), and semiconductor memories. Any recording medium can be used as long as it can store the program and is computer-readable. In addition, the program that realizes the above processing may be stored on a computer (server) connected to a network such as the Internet, and downloaded to a computer (client) via the network.

Furthermore, the above communication device may be expressed as shown in [1] to [4] below.

[1] A communication device that can be attached to a pump device that has a pump, a control unit that controls the pump, and an output terminal that can output a signal for each pump event, the communication device has an input terminal that can input each signal output from the output terminal of the pump device, and can transmit the signal input to the input terminal to a management device that is configured to be able to assign an event to each input terminal.

[2] The communication device described in [1] above, in which the signals that can be output for each event include pump operation information, pump failure information, and water level information for a water tank to which the pump is connected, and the communication device transmits signals to a management device when a signal is input and when the input is no longer input.

[3] The communication device described in [1] or [2] above is composed of a communication board having a communication unit and an input board having an input unit.

[4] The communication device described in any one of [1] to [3] above, in which the control panel further has a power supply board that filters power supply noise, and the communication device obtains power from the secondary side of the power supply board.

The present invention is not limited to the above-described embodiment, and various modifications can be made in the implementation stage without departing from the gist of the invention. The embodiments may be implemented in appropriate combination, in which case the combined effects can be obtained. Furthermore, the above-described embodiment includes various inventions, and various inventions can be extracted by combinations selected from the multiple constituent elements disclosed. For example, if the problem can be solved and an effect can be obtained even if some constituent elements are deleted from all the constituent elements shown in the embodiment, the configuration from which these constituent elements are deleted can be extracted as an invention.

10, 10-1, 10-2, 10-3... Pump device, 20... Pump section, 21... Sensor, 30... Control device, 31... Inverter, 32... Power supply section, 321... Noise filter, 33... Operation display section, 34... Control input/output board, 341... Control power supply section, 342... Switch, 343, 34A, 41B... Terminal block, 344... Input section, 345... Memory, 346... Control section, 347... Output section, 34A1 to 34A10... Output terminal, 40... Communication device, 41... Input board, 411... Input section, 412... Power supply section, 413... Signal detection section, 413a... Power supply setting switch, 41 3b: detection setting switch, 413c: connection line/detection circuit, 413d: output section, 42: communication board, 43: connector, 44: support, 421: communication section, 50, 50-1, 50-2: user terminal, 51, 71: communication section, 52: input section, 53: display section, 54, 73: memory, 55, 74: processor, 55a: communication control section, 55b, 74b: processing section, 60, 70: management server, 74a: management section, dc1 to dc10: detection circuit, E1: first common power supply, E2: second common power supply, E3: communication power supply, Ry2, Ry3, Ry5 to Ry10: relays.

Claims (6)

A communication device that can be attached to a pump device having a plurality of output terminals that can output a signal for each pump event,
a plurality of input terminals each electrically connected to the plurality of output terminals, to receive the signal from each of the plurality of output terminals;
a detection unit that individually detects signals input from each of the plurality of input terminals;
a communication unit that transmits output information corresponding to the event based on a detection result of the detection unit, the output information including a terminal number of an input terminal to which the signal is input, to a management device;
Equipped with
The management device pre-associates and sets each terminal number of the multiple input terminals with an event indicated by a signal input to the input terminal, and manages the event based on the transmitted output information. The plurality of signals individually input to the plurality of input terminals include at least one of a signal corresponding to an event related to the operation of the pump, a signal corresponding to an event related to a failure of the pump, and a signal corresponding to an event related to a water level of a water tank connected to the pump.
The communication device according to claim 1 . the detection unit transmits to a communication unit a first detection result of detecting a rising edge of the signal and a second detection result of detecting a falling edge of the signal.
3. A communication device according to claim 1 or 2. An input board;
A communication board;
Equipped with
the input board has the input terminals and the detection unit mounted thereon,
The communication board has the communication unit mounted thereon.
A communication device according to any one of claims 1 to 3. a power supply unit electrically connected to the power supply terminal of the pump device, the power supply terminal being provided on a secondary side of a power supply board that filters power supply noise, to obtain power from the power supply terminal, adjust the voltage of the obtained power supply, and supply the voltage to the detection unit and the communication unit;
A communication device according to claim 1 , comprising: The communication device according to claim 1 , wherein the communication unit transmits the output information to the management device by serial communication.