Patent Application
20190339162
The present invention relates to a sensor assembly for detecting both motor bearing faults and cavitation. The present invention furthermore relates to a method for detection of both motor bearing faults and cavitation in pumps. The invention also relates to a pump comprising such sensor assembly.
It is known to provide pumps with sensors for detecting various faults having impact on pump performance. Some faults are very critical for the pump and thus important to detect in due time. Sensors have been developed to detect parameters including bearing status, motor speed, water hammering, unbalance level, cavitation status and dry run.
Due to the different origins and characteristics of these fault indication parameters, a lot of different sensors for detecting relevant parameters and faults have been developed. The optimal arrangement of a fault-indicating sensor depends heavily on the type of sensor. E.g. a dry run sensor should be arranged in the upper region of the conduct in which the fluid is expected to be present (due to the low density of air), whereas a cavitation sensor should be arranged near the impeller in a centrifugal pump, and the optimal position of a motor bearing fault sensor is at the motor. Faults in the electric motors of a pump can have huge financial consequences when the pump is used in a vital process. Bearing faults are one of the major motor failures, and therefore it is important to be able to detect bearing faults.
EP0742372B1 discloses a cavitation sensor arranged at the suction inlet close to the impeller of a centrifugal pump. This position is beneficial because it is possible to detect a powerful cavitation signal (large signal-to-noise ratio) and hereby detect cavitation.
EP1972793B1 discloses a pump assembly comprising a vibration sensor attached to a control box fastened to the motor housing. By mechanically 2 attaching the vibration sensor in the proximity of the motor, it is possible to detect vibration signals that can be processed in order to detect motor bearing faults.
EP1298511A1 discloses a motorized pump system comprising an electrically driven pump and a plurality of sensors connected to a control system comprising a controller and diagnostics. It is required to apply several sensors arranged in various separate positions on the pump and the electrical motor, respectively. Since the different sensors require different positioning, it is not possible to arrange the sensors in the same position. In order to detect both motor bearing faults and cavitation in a pump assembly by using the system disclosed in EP1298511A1 it is required to have two separate sensors: one sensor for motor bearing fault detection and another sensor for cavitation.
Accordingly, it would be desirable to be able to use a single sensor assembly to detect both motor bearing faults and cavitation.
WO2015197141A1 discloses a method for detecting faults or operational parameters in a pump assembly by use of a handheld communication device that is arranged outside the pump housing. A microphone integrated in or connected to the handheld device is applied to detect sound signal. The handheld device may comprise an additional sensor such as an accelerometer. One problem associated with this method is that the sound signals must be collected in the same way in order to be capable of processing the data and provide useful results. In practice, it is not possible to control the position of the external device and the signals from the surroundings, in a manner sufficiently accurate, in order to apply the method to detect both motor bearing faults and cavitation. Even if the user tries to make several measurements independently of each other, it would be very difficult, if not impossible, to detect motor bearing faults and cavitation, if at all. Accordingly, it would be desirable to provide a single sensor and a method applying a single sensor that enables detection of both motor bearing faults and cavitation detection.
It is an object of the present invention to provide a single sensor assembly that can detect both motor bearing faults and cavitation. It is also an object of the present invention to provide an improved method for detection of faults in a pump assembly comprising an electric motor and a fluid pump.
The sensor assembly according to the invention is a sensor assembly configured to perform fault detection in a pump assembly comprising an electric motor and a fluid pump, wherein the sensor assembly comprises a housing configured to be attached into a bore provided in the pump, wherein one or more vibration sensing element(s) are arranged in the housing and that the sensor assembly comprises a calculation unit or is connected to a calculation unit arranged outside the housing through a wired or wireless connection, wherein the calculation unit is configured to receive sensor signals from the vibration sensing element(s), wherein the calculation unit is configured to perform calculations and hereby detect both motor bearing faults and cavitation on the basis of the sensor signals provided by the one or more vibration sensing element(s).
Hereby it is possible to provide a single sensor assembly capable of detecting both motor bearing faults and cavitation based on the sensor signals provided by the one or more vibration sensing element(s). It is possible to apply a single sensor assembly capable to detect a plurality of parameters e.g. both motor bearing faults and cavitation.
In one embodiment the calculation unit is configured to carry out detection of motor bearing faults and cavitation at the same time.
In one embodiment the calculation unit is configured to carry out detection of motor bearing faults and cavitation on the basis of sensor signals provided by a single vibration sensing element. Said sensor signals will contain sufficient information to detect both motor bearing faults and cavitation by letting the calculation unit perform calculations and hereby detect both motor bearing faults and cavitation. Detection of motor bearing faults and cavitation may be carried out simultaneously or alternately. In a preferred embodiment, the calculation unit is configured to perform calculations and hereby detect motor bearing faults independently on the detection of cavitation. Accordingly, bearing faults and cavitation may be detected independently of each other at any desired time.
In one embodiment, a single vibration sensing element is arranged in the housing.
The calculation unit may be arranged inside the housing.
In a preferred embodiment according to the invention, the calculation unit is arranged outside the housing.
In one embodiment according to the invention the calculation unit is arranged outside the housing and is electrically connected to the one or more vibration sensing element(s).
In another embodiment, a communication unit configured to wirelessly transmit the sensor signals from the vibration sensing elements directly or indirectly to an external receiving unit is arranged in the housing or attached to the outside of the housing.
The external receiving unit may be arranged or be attached to the outside of the pump.
In a preferred embodiment, the sensor assembly is configured to communicate with a cloud-based server constituting a calculation unit.
The calculation unit is configured to detect both motor bearing faults. The calculation unit is provided with sensor signals provided by the one or more vibration sensing element(s). The calculation unit analyses (carries out calculations) the sensor signals and hereby the calculation unit detects when there is a motor bearing fault and when there is cavitation.
In one embodiment according to the invention, the sensor assembly is configured to communicate directly with a cloud-based server constituting a calculation unit. The communication may be carried out by means of a communication unit arranged in the housing or connected to the housing.
In another embodiment according to the invention, the sensor assembly is configured to communicate indirectly with a cloud-based server constituting a calculation unit. The communication may be carried out by means of an intermediate unit arranged outside the housing. Wherein, the intermediate unit comprising a communication unit and wherein the intermediate unit is connected to one or more structures (e.g. sensors) inside the housing through a wired or a wireless connection.
In a preferred embodiment, the calculations made by the calculation unit in order to detect both motor bearing faults and cavitation are carried out outside the housing.
It may be an advantage that the housing is configured to be arranged in a bore of a multistage pump.
The calculation unit is configured to receive sensor signals from vibration sensing elements and perform calculations and hereby detect motor bearing faults and cavitation.
The sensor assembly according to the invention is a sensor assembly configured to be mechanically attached to a pump and hereby enable vibration signals to travel from the motor bearing to the one or more vibration sensing elements and enable vibration signals to travel from the cavitation origin area near the inlet of the pump to the one or more vibration sensing elements. Accordingly, vibration signals from the faulty areas are capable of reaching the vibration sensing elements.
The pump assembly may be any type of pump that can experience cavitation. The electric motor may by any suitable type of motor connected and configured to drive the pump.
The sensor assembly comprises a housing having a geometric shape enabling the housing to be mechanically attached to the pump. The housing may have any suitable size and shape and may be attached to the pump by any suitable attachment means including bolts, hose clamps, corresponding tracks and protrusions or other mechanical engagement structures.
The one or more vibration sensing element(s) is/are arranged in or attached to the housing. It may be an advantage that the vibration sensing elements are arranged in the housing. In one embodiment according to the invention, a portion of the one or more vibration sensing element(s) protrudes from the housing. In one embodiment according to the invention, the one or more vibration sensing element(s) is/are directly or indirectly attached to the outside surface of the housing. In a preferred embodiment according to the invention the one or more vibration sensing element(s) is/are arranged inside the housing in such a manner that the housing encases the one or more vibration sensing element(s).
The sensor assembly comprises a calculation unit configured to receive sensor signals from the one or more vibration sensing element(s) and perform calculations and hereby detect motor bearing faults and cavitation.
The calculation unit may be arranged inside the housing. The calculation unit may be arranged outside the housing. In a preferred embodiment according to the invention the calculation unit is arranged outside the housing and is electrically connected to the one or more vibration sensing element(s).
In another embodiment according to the invention, the calculation unit is provided as a cloud computing solution. It may be an advantage that the calculations are carried out at one or more predefined servers. Hereby, it is possible to access the data externally. Moreover, it is possible to lower the cost for the end user of the sensor assembly because the end user does not have to pay for a calculation unit being a separate hardware component.
The sensor assembly according to the invention constitutes a fault detection system comprising a number of sensors and a calculation unit.
The housing is configured to be attached to a bore provided in the pump. Hereby, it is possible to attach the housing to the pump in an easy and reliable manner.
In one embodiment, according to the invention, the housing comprises an outer threaded portion configured to fit a threaded bore provided in the pump. Hereby, it is possible to attach the housing in an easy and safe manner. Moreover, vibration signals can be detected by the one or more vibration sensing element(s).
It may be beneficial that the housing is configured to be attached to the pump in a zone in which the amplitude of signals of the vibrations generated by faulty motor bearings and the amplitude of signals generated in case of cavitation in the suction side of the pump have a magnitude sufficiently large to be detected by the vibration sensing element(s).
In a preferred embodiment according to the invention, the housing is configured to be inserted into a bore placed in a zone of the pump, in which zone the amplitude of signals of the vibrations generated by faulty motor bearings and the amplitude of signals generated in case of cavitation in the suction side of the pump have a magnitude sufficiently large to be detected by the vibration sensing element(s). Hereby, it is possible to provide vibration signal detection having a signal-to-noise ratio allowing the vibration signals to be filtered and processed in order to carry out motor bearing fault detection and cavitation detection.
It may be beneficial that a thermosensitive sensor is arranged in the housing, wherein the thermosensitive sensor is arranged to detect the temperature of fluid being pumped by the pump. The thermosensitive sensor may preferably be attached in the distal end of a housing inserted into a bore in the pump. It may be an advantage that the thermosensitive sensor is brought into contact with a material having a high thermal conductance in order to provide a valid temperature measurement.
It may be beneficial that the housing is a one-piece body.
It may be advantageous that the sensor assembly is configured to perform fault detection in a pump assembly comprising an electric motor and multistage centrifugal pump.
In one embodiment according to the invention, the sensor assembly is configured to perform fault detection in a pump assembly comprising an electric motor and a multistage centrifugal pump configured to be vertically arranged.
In another embodiment according to the invention, the sensor assembly is configured to perform fault detection in a pump assembly comprising an electric motor and a multistage centrifugal pump configured to be horizontally arranged.
It may be an advantage that the housing is arranged in the top portion of the housing (e.g. the pump head) of the pump in order to be able to collect vibration signals originating from both motor bearing faults and cavitation.
In one embodiment of the invention, the housing is arranged in the pump head of a multistage centrifugal pump. Hereby, it is possible to collect vibration signals originating from both motor bearing faults and cavitation, in a manner in which the signals have sufficiently large amplitude (magnitude).
It may be advantageous that the sensor assembly is configured to detect the speed of the pump by means of the calculation unit and sensor signals from the vibration sensing element(s) or another sensing element(s).
It may be beneficial that the vibration sensitive element is an accelerometer configured to detect accelerations in at least one dimension. It may be an advantage that the accelerometer is mechanically attached to the housing by means of a rigid connection.
It one embodiment of the invention, the vibration sensitive element is a microphone. By attaching the microphone mechanically to the housing, it is possible to detect vibration signals by using the microphone. By mechanically attaching the microphone to the housing, the microphone will experience vibrations corresponding to the vibrations that the housing is exposed to.
It may be beneficial that the calculation unit is configured to receive raw (unprocessed/unfiltered) sensor signals from the sensing elements and perform calculations on the basis of these signals.
In one embodiment according to the invention, the sensor signals are processed before they are received by the calculation unit. It is possible to apply any suitable type of signal processing including digital filters.
It may be an advantage that the calculation unit comprises a processing unit configured to receive the signals from the sensing elements, wherein the calculation unit is further configured to process the signals and hereby carry out bearing fault detection by using a frequency analysis, wherein the calculation unit furthermore is configured to carry out cavitation detection by using spectral analysis and determining if the spectral level increases in a predefined frequency band.
Hereby, it is possible to carry out both bearing fault detection and cavitation detection based on vibration signals detected by a single vibration sensing element.
In one embodiment, the frequency analysis is a Cepstral analysis.
It may be beneficial that the predefined frequency band is within the range 10-20 kHz. In one embodiment according to the invention the calculation unit is configured to carry out cavitation detection by using spectral analysis and determining if the spectral level increases within the range 10-20 kHz.
In one embodiment according to the invention, the sensor assembly comprises two vibration sensing elements. Accordingly, it is possible to apply different vibration sensing elements to detect motor bearing faults and cavitation, respectively.
It may be advantageous that the calculation unit is arranged in a separate box arranged outside the pump, wherein the calculation unit is electrically connected to the vibration sensing element through an electric cable. Hereby, it is possible to supply the vibration sensing element with electric power via the cable. Moreover, it is possible to service the calculation unit without affecting the housing or the sensing elements. Further, it is possible to replace the calculation unit and still apply the same housing. In one embodiment, the calculation unit is arranged in a control box attached to the motor housing.
It may be beneficial that a transmitter unit configured to wirelessly transmit the sensor signals directly or indirectly (e.g. via the Internet) from the vibration sensing elements directly or indirectly (e.g. via the Internet) to an external receiving unit is arranged in the housing or attached to the outside of the housing. Hereby, it is possible to wirelessly transmit signals from the vibration sensing elements to an external receiving unit that can process the signals. The transmitter unit may comprise a radio transmitter configured to communicate with a communication module in the receiving unit.
In one embodiment according to the invention, a communication unit configured to communicate (including to transmit and receive signals) with an external communication unit is arranged in the housing or attached to the outside of the housing. Hereby, it is possible to send signals wirelessly from the vibration sensing elements to the receiving unit and to receive information (e.g. a stop signal) transmitted from the external communication unit.
Signals sent from a transmitter unit or a communication unit may be filtered by using any suitable filter including a low-pass filter or a high-pass filter.
It may be an advantage that the sensor assembly comprises an intermediate box provided with a communication unit configured to communicate wirelessly, wherein the intermediate box is electrically connected to the sensing elements through an electric cable, wherein the intermediate box is configured to communicate wirelessly, either directly with an external receiving unit or indirectly with an external receiving unit via the Internet.
Hereby, it is possible to carry out calculations (processing) on an external device (e.g. a server or a smartphone). Accordingly, it is possibly to reduce the complexity and cost of the sensor assembly because an external device (e.g. a server or a smartphone) can be used as the calculation unit.
The communication unit may preferably be configured to receive signals from an external device. Such signals may include a stop signal sent to a control box electrically connected to the motor in case of detection of a motor bearing fault or cavitation.
The external receiving unit may be a smartphone, a server, a laptop computer (PC), a personal digital assistant (PDA), a tablet or a smartwatch.
It may be beneficial that the sensor assembly comprises a display unit configured to display one or more of the parameters calculated by the calculation unit. The sensor assembly may comprise a display unit attached to the housing.
In one preferred embodiment according to the invention, a display unit is an integrated part of or attached to a box arranged outside the pump, wherein the box is electrically connected to the vibration sensing element through an electric cable. It may be beneficial that the display unit is an integrated part of or attached to a box comprising a calculation unit, wherein the box is arranged outside the pump, and wherein the box is electrically connected to the vibration sensing element by means of an electric cable.
It may be advantageous that the calculation unit is arranged in a separate box arranged outside the pump, wherein the calculation unit is electrically connected to the vibration sensing element through an electric cable. Hereby, it is possible to supply the vibration sensing element with electric power via the cable. Moreover, it is possible to service the calculation unit without affecting the housing or the sensing elements. Furthermore, it is possible to replace the calculation unit and still apply the same housing. In one embodiment, the calculation unit is arranged in a control box attached to the motor housing.
In one embodiment according to the invention, the calculation unit and the display unit are attached to the housing. Hereby, it is possible to provide a compact sensor assembly.
It may be beneficial that the calculation unit and the display unit are arranged in a one-piece body.
In one embodiment according to the invention, the calculation unit, the display unit and the housing are shaped as a one-piece body.
It may be advantageous that a printed circuit board (PCB) is provided in the housing, and that the sensing elements are electrically connected to the printed circuit board. It is possible to carry out a filtering process by means of the electronic components of the PCB.
It may be an advantage that a socket is arranged in the proximal end of the housing, wherein the sensor assembly comprises a plug configured to be mechanically and electrically connected to the socket. Hereby, it is possible to electrically and mechanically connect the housing and the sensing elements to an external box through an electric cable provided with said plug. Accordingly, the invention provides a simple and user-friendly way of electrically connecting the housing and the sensing elements to an external box. Moreover, the sensing elements may be energized through the cable. Thus, the cable may be used to transfer electrical signals from the sensing elements and simultaneously be used to provide electrical power to the sensing elements.
It may be beneficial that the housing is provided with a transmitter unit configured to wirelessly transmit signals received from the sensing elements. The transmitter unit may transmit wireless signals to an external device such as a smartphone or another device capable of forwarding the signals to an additional receiving device (e.g. a server). In this manner, it is possible to perform processing and calculations in the external device or the additional receiving device.
In one embodiment according to the invention, the calculation module is arranged in the housing. Accordingly, the signal processing can be carried out in the calculation module in the housing, and thus these processed signals can be transferred to a box comprising a display unit configured to display one or more predefined parameters.
It may be an advantage that the housing is provided with an inner threaded portion in its proximal end. Hereby, the housing can be threaded into a threaded bore in order to firmly attach the housing to a mechanical structure of the pump assembly. Accordingly, vibration signals can be transmitted through the mechanical structures of the pump assembly towards the housing. Therefore, the vibration sensing elements can detect the vibration signals.
In a preferred embodiment according to the invention, the housing comprises a bottom wall provided in the distal end of the housing, wherein the thickness of the bottom wall is smaller than the thickness of the remaining wall portions of the housing. Hereby, it is possible to provide optimum conditions in order to carry out temperature measurements by using a thermosensitive sensor arranged in the housing. Moreover, when the housing is provided with a thin distal wall structure, it is possible to detect dry run by means of an ultrasonic sensor provided in the distal end of the housing.
It may be an advantage that a nut structure is integrated in the proximal end of the housing. Hereby, the nut structure can be applied as an engagement structure during tightening of the housing while the housing is being attached in a threaded bore in a pump. It may be an advantage that the nut structure is hexagonal.
In an embodiment according to the invention, the sensor assembly comprises a housing configured to be mechanically attached to a pump head provided with a threaded bore configured to receive the housing. By arranging the housing in a bore arranged in the pump head, it is possible to receive significantly large vibration signals originating from the motor bearing and from cavitation.
It may be an advantage that an ultrasonic dry run sensing element is arranged in the distal end of the housing. Hereby, it is possible to carry out dry run detection in an efficient manner.
In a preferred embodiment according to the invention, an ultrasonic dry run sensing element and a thermosensitive sensor are arranged in the same die. Hereby, it is possible to reduce the size and the total production costof the ultrasonic dry run sensing element and the thermosensitive sensor. It may be beneficial that the ultrasonic dry run sensing element and the thermosensitive sensor are arranged in the same die and arranged in the distal end of the housing, wherein the housing is configured to be inserted into a bore provided in the pump, wherein the bore creates access to the fluid being pumped by the pump.
It may be advantageous that an ultrasonic dry run sensing element and a vibration sensitive element are arranged in the same die. Hereby, it is possible to reduce the size and production cost of the ultrasonic dry run sensing element and the vibration sensitive element. It may be beneficial to arrange the ultrasonic dry run sensing element and the vibration sensitive element in the same die at the distal end of the housing in order to provide the most optimum detection conditions.
In one embodiment according to the invention, an ultrasonic dry run sensing element, a vibration sensitive element and a thermosensitive sensor are arranged in the same die. Hereby, it is possible to provide a compact and cost-efficient sensor assembly capable of detecting dry run, motor bearing faults, cavitation and the temperature of the fluid being pumped.
It may be an advantage that the ultrasonic dry run sensing element is arranged in an ultrasound gel. Hereby, it is possible to achieve a good acoustical connection between the ultrasonic dry run sensing element and the wall member being in contact with the fluid being pumped.
It may be beneficial that the housing is at least partly filled with resin in order to make the sensor assembly suitable for vibration measurements. In a preferred embodiment according to the invention, the housing is totally filled with resin in order to optimize the mechanical properties of the housing and thereby enable vibration signals to be detected by the vibration sensors in the most efficient manner.
In one embodiment according to the invention, the housing comprises a battery. Hereby, it is possible to provide the sensing elements (vibration sensing elements, an ultrasonic dry run sensing element and a thermosensitive sensor) with electric power from the battery.
In another embodiment according to the invention, the display unit comprises a battery. Hereby, the sensing elements (vibration sensing elements, an ultrasonic dry run sensing element and a thermosensitive sensor) can be provided with electric power from the battery by means of an electric connection (e.g. a wired connection) between the battery and the sensing elements.
In a preferred embodiment according to the invention, a separate box is connected to the power circuit of the pump or of the motor and to the sensing elements (vibration sensing elements and optionally an ultrasonic dry run sensing element and/or a thermosensitive sensor) in the housing. Hereby, the sensing elements can be powered by the same power source as the pump.
It may be an advantage that the sensor assembly comprises a display unit being electrically connected to the power circuit of the pump or of the motor and to the sensing elements (vibration sensing elements and optionally an ultrasonic dry run sensing element and/or a thermosensitive sensor) in the housing. Accordingly, the pump and the sensing elements can be powered by the same power source.
It may be an advantage to apply a pump having a sensor assembly according to the invention. Such a pump is safe to use due to the sensor assembly.
The method according to the invention is a method for detection of faults in a pump assembly comprising an electric motor and a fluid pump, wherein the method comprises the steps of providing sensor signals from at least one vibration sensing element, wherein the method comprises the following steps:
Hereby, it is possible to provide an improved method for detection of faults in a pump assembly comprising an electric motor and a fluid pump. The method can be carried out by applying a single sensor assembly (e.g. a single vibration sensing element) attached to the pump.
The method according to the invention is a method for detection of faults including motor bearing faults and cavitation in a pump assembly comprising an electric motor and a fluid pump.
The method may, however, also be configured to detect additional parameters, including detection of dry run and the temperature of the fluid being pumped by the fluid pump.
The method comprises the step of providing sensor signals from at least one vibration sensing element. The sensor signals are detected by means of a vibration sensing element mechanically attached to the pump. Accordingly, it is possible to provide a method that does not require involvement of a user. Accordingly, the method is suitable for being implemented as an autonomous system, whereas the prior art methods require involvement of a user.
The method applies a calculation unit that is configured to receive sensor signals from the vibration sensitive element(s). Hereby, the calculation unit can process the sensor signals. Processing of the sensor signals may include any suitable type of processing including low-pass filtering and high-pass filtering.
The sensor assembly comprises a housing having a geometric shape enabling the housing to be mechanically attached to the pump, wherein the housing is configured to be attached to a bore provided in the pump.
In a preferred embodiment according to the invention the method comprises the step of arranging the sensor assembly in a threaded bore provided in the pump. Hereby, a firm attachment of the sensor assembly. Moreover, the sensor assembly is always position in the correct place, hereby enabling optimum measurements.
The method furthermore uses a frequency analysis to detect motor bearing faults. Hereby, it is possible to separate noise (e.g. from the motor and the pump) and detect periodic signals representing motor bearing faults.
In one embodiment, the frequency analysis is Cepstral analysis. Cepstral analysis of a vibration signal can be carried out by taking the inverse Fourier transform of the log-magnitude Fourier spectrum of the vibration signal. It may be beneficial to apply a high-pass filtering of the frequency domain before carrying out the Fourier transformation of the frequency domain in order to eliminate influences of the motor design.
In a preferred embodiment according to the invention, the method comprises the step of using spectral analysis to detect cavitation by determining if the spectral level increases in a predefined frequency band.
Hereby, it is possible to detect cavitation.
In a preferred embodiment according to the invention, the method comprises the step of using spectral analysis to detect cavitation by determining if the spectral level increases within the range 10-20 kHz.
It may be beneficial to apply a method that comprises the step of applying a bearing fault detection method based on a predefined sound analysis carried out to categorize sound signals into a plurality of classes/groups, wherein corresponding sensor signals are recorded, wherein the sound signals are evaluated by using a predefined benchmarking method, benchmarking each sound signal with a score or category, hereby categorizing the sound signals and the corresponding sensor signals into the classes/groups.
Hereby, it is possible to apply the predefined sound analysis as a tool to carry out bearing fault detection.
The sound analysis may be carried out in different ways. In one embodiment according to the invention, the sound analysis may be human-assisted, wherein a number of trained motor bearing service employees (preferably a plurality of employees) carry out sound analysis based on their experiences in order to categorize sound signals into a plurality of classes/groups, wherein corresponding (vibration) sensor signals are recorded, wherein the sound signals are evaluated by using a predefined benchmarking method, benchmarking each sound signal with a score or category, hereby categorizing the sound signals and the corresponding (vibration) sensor signals into the classes/groups.
The sound analysis may alternatively be based on an automated method based on data provided by a human-assisted method.
It may be an advantage that the method comprises the step of applying a data table comprising pre-recorded signals or signal patterns associated with known pump error types, wherein the method moreover comprises the step of comparing sensor signals with pre-recorded signals or signal patterns in order to associate the sensor signals with a known sensor error type.
Hereby, it is possible to identify errors/faults by making a comparison of prerecorded signals or signal patterns and sensor signals.
The sensor signals may be provided as real time signals.
In one embodiment of the method according to the invention, a feature matrix is generated on the basis of the predefined sound analysis, wherein the feature matrix comprises a plurality of rows or columns corresponding to a number of feature vectors, wherein each feature vector is generated on the basis of a detected sensor signal, wherein the detected sensor signal is converted to a feature vector, wherein the measured sensor signal detected by the at least one vibration sensing element is converted to a measured feature vector and compared to the feature vectors of the feature matrix by using a distance measurement, wherein the distance measurement determines the distances between the point defined by the measured feature vector and the points defined by the feature vectors of the feature matrix, wherein the point defined by the feature vector of the feature matrix having the smallest distance to the point defined by the measured feature vector is found, and wherein its score or category is adapted by the feature vector converted on the basis of the measured sensor signal detected by the at least one vibration sensing element.
In another embodiment of the method according to the invention, a feature matrix is generated on the basis of the predefined sound analysis, wherein the feature matrix comprises a plurality of rows or columns corresponding to a number of feature vectors, wherein each feature vector is generated on the basis of a detected sensor signal, wherein the detected sensor signal is converted to a feature vector, wherein the measured sensor signal detected by the at least one vibration sensing element is converted to a measured feature vector and compared to the feature vectors of the feature matrix by using a distance measurement, wherein the distance measurement determines the distances between the point defined by the measured feature vector and the points defined by the feature vectors of the feature matrix, wherein a predefined number of points defined by the feature vector of the feature matrix having the smallest distance to the point defined by the measured feature vector are found, and wherein the score(s) or categories or a calculated average of these is adapted by the feature vector converted on the basis of the measured sensor signal detected by the at least one vibration sensing element.
Hereby, it is possible to apply a number of validated and pre-categorized signals to categorize detected sensor signals in an automated manner. As the number of pre-categorized signals increases, the validity of the method increases. Accordingly, it is possible to provide an extremely valid method by increasing the number of pre-categorized signals.
It may be beneficial that the feature vector comprises a number of components each representing a scalar derived on the basis of a sensor signal or a signal processed on the basis of the sensor signal.
Accordingly, the components of the components may include Cepstral, coefficients, spectral coefficients or parameters such as skewness, kurtosis, variance, moment, median, root mean square (RMS) or combinations hereof. The parameters such as skewness, kurtosis, variance, moment, median and RMS may be calculated of any predefined section of either the sensor signal or a signal processed on the basis of the sensor signal.
Accordingly, it is possible to extract the important information from the Cepstral analysis and apply the information when applying the feature matrix to categorize incoming sensor signals.
Based on the power spectrum (also called “spectral diagram”; made by a spectral analysis) and on the Cepstral diagram (also referred to as “Cepstrum”; made by a Cepstral analysis), it is possible to extract a number of predefined features. These features are scalars constituting a feature vector. Each feature represents information extracted on the basis of either the power spectrum or the Cepstrum. In one embodiment according to the invention, the features represent values calculated on the basis of integration or the sum of predefined areas of the power spectrum or the Cepstrum. These values may be calculated by dividing the power spectrum and the Cepstrum in a predefined number of sections and using each section to calculate a feature. Accordingly, the number of features may be selected in order to achieve sufficient information to carry out a categorization of the vibration signal on the basis of the feature vector. In one embodiment according to the invention the feature vector contains 10-1000 features. It may be beneficial that the feature vector contains 20-500 features. In one embodiment according to the invention, the feature vector contains 30-300 features. In another embodiment according to the invention, the feature vector contains 50-150 features. In a further embodiment according to the invention the feature vector contains 80-120 features.
It may be an advantage that the fault detection is carried out by using a remotely arranged calculation unit by using one or more external devices.
Hereby, it is possible to achieve a flexible method that enables the verification data (achieved on the basis of the predefined sound analysis) to be regularly updated (including adding additional data).
It may be advantageous that a distance measurement is carried out by using a remotely arranged calculation unit by using one or more external devices. Hereby, it is possible to achieve great freedom of design when carrying out the method.
It may be beneficial that the method comprises the step of establishing and training an artificial neural network or a fuzzy network to carry out bearing fault detection, wherein the artificial neural network or fuzzy network comprises information established on the basis of the predefined sound analysis. Hereby it is possible to optimize the method.
It may be an advantage that the method comprises the step of applying data from an ultrasonic sensor to detect dry run conditions. Hereby, it is possible to provide an improved method that also provides dry run detection.
It may be beneficial that the method comprises the step of applying data from a thermosensitive sensor. Hereby, it is possible to provide an improved method that also detects the temperature of the fluid being pumped by the pump.
It may be advantageous that the method comprises the step of sending a stop signal in order to stop the electric motor of the fluid pump. This feature may protect the pump assembly in case of a critical fault such as dry run, cavitation or motor bearing faults.
It may be beneficial that the method comprises the step of establishing an envelope on the basis of the Cepstral domain signal, wherein a motor bearing fault is defined to be present when the amplitude of the envelope exceeds a predefined level.
It may be advantageous that the sensor assembly is configured to carry out a method according to the invention.
The invention will become more fully understood from the detailed description given herein below. The accompanying drawings are given by way of illustration only, and thus, they are not limitative of the present invention. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
In the drawings:
Referring to the drawings, for the purpose of illustrating preferred embodiments of the present invention, a housing 4 of a sensor assembly 2 of the present invention is illustrated in
A sensing element 20 comprising an ultrasonic sensor 20 is arranged in the distal portion of the hollow inner portion 26. The sensing element 20 is brought into contact with the bottom wall 8 in the distal end 46 of the housing 4. Accordingly, the position enables optimal conditions for providing dry run detection by using the ultrasonic sensor of the sensing element 20. A thermosensitive sensor 14 is provided in a bore extending parallel to the longitudinal axis of the housing 4. The thermosensitive sensor 14 is electrically connected to the PCB 12 by means of legs 18″. A connection ring 13 is sandwiched between a cork plate 100 and an inner support structure of the housing 4. The connection ring 13 is electrically connected to the PCB 12 and to the sensing element 20. The bottom portion of that part of the hollow inner portion 26 of the housing 4 that is arranged above the cork plate 100 is filled with a first filler material (e.g. a resin). Similarly, the top portion of that part of the hollow inner portion 26 of the housing 4 that is arranged above the cork plate 100 is filled with a second filler material (e.g. a resin) ensuring that mechanical vibrations can be transferred from the pump through the housing 4 to the vibration sensing element 16 in an effective manner. Even though not shown, the housing 4 may comprise two sections to be assembled. Hereby, it is possible to ease the mounting of the sensing element 20.
The ultrasonic sensor of the sensing element 20 is configured to be used for dry run detection, whereas the thermosensitive sensor of the sensing element 20 is adapted to measure the temperature of a fluid being in contact with the outside surface of the bottom wall 8. The sensing element 20 is electrically connected to the PCB 12 by means of two legs 18, 18′. The sensing element 20 is arranged in an air-filled cavity.
When
The pump 30 comprises a pump housing 32 having a flanged inlet port (arranged to the left) and a flanged outlet port (arranged to the right).
The sensor assembly 2 comprises a display unit 28 being electrically connected to the housing of the sensor assembly 2 by means of an electric cable 27. The electric cable 27 is connected to the housing by means of an electric plug provided in the distal end of the cable 27.
The display unit 28 comprises a display 29 and a calculation unit 84 configured to carry out calculations on the basis of sensor data received from the sensor elements arranged in the housing of the sensor assembly 2. Calculations may include any processing task. Such processing task may include comparison with stored data or comparison with data that the calculation unit 84 has access to through one or more externally arranged devices (including a server accessible via the internet). The calculation unit 84 may comprise a battery providing electrical power to the calculation unit 84 and to the housing of the sensor assembly 2 via the cable 27. Although not shown, the display unit 28 may be electrically powered through an additional electrical cable. Electrical power may be supplied from the electrical motor coupled to the shaft 50.
The display unit 28 may comprise a separate user interface (e.g. a keypad). However, in a preferred embodiment according to the invention, the display unit 28 may comprise a touch screen that can display a number of parameters and be used as user interface. The display unit 28 may be a smartphone, a tablet, a PDA or another suitable device.
The housing of the sensor assembly 2 is inserted into a threaded bore provided in the pump head 36. The distal portion of the housing of the sensor assembly 2 protrudes into an inner space 40 of the pump head 36. Accordingly, there is access to the inner space 40 that will be filled with the liquid being pumped by the pump 30 under normal operation. Since the housing of the sensor assembly 2 is screwed into a threaded bore provided in a mechanical structure of the pump 30, vibration signals originating from the motor bearing and from cavitation can reach the sensing elements inside the housing of the sensor assembly 2 as the vibration signals travel along the mechanical structures of the pump housing 32, the sleeve 34, the pump head 36 and the motor stool 38.
It is possible to provide a processing unit inside the housing. Such processing unit may be capable of carrying out any desirable processing signals received by means of sensing elements provided inside the housing of the sensor assembly 2. Processing may include filtering or carrying out any analysis.
In one embodiment of a method according to the invention, a definition of a motor bearing fault can be made on the basis of the Cepstral diagram. A motor bearing fault may be defined to be present when a portion of the envelope 98 exceeds a predefined threshold level T.
When using the method referred to with reference to
When comparing
It can be seen that the spectral diagram reveals that there is a relatively high level increase in the frequency band II during cavitation. There seems to be a level increase in the lower frequency band I, however, the relative increase is larger in the higher frequency band II. Therefore, in one embodiment of the method according to the invention, cavitation is defined to be present when the spectral level 52 increases in a predefined frequency band II. The predefined frequency band II may lie within the range 10-20 kHz. In one embodiment of the method according to the invention, cavitation is defined to be present when the spectral level 52 increases in the frequency 15-20 kHz.
The spectral diagram contains a cavitation signal 66 based on spectral analysis of data during cavitation and a normal operation signal 68 based on spectral analysis of data during normal operation.
The spectral diagram shows that there is a relatively high level increase in the frequency band II during cavitation. Even though there is a level increase in the lower frequency band I, it can be seen that the relative increase is larger in the higher frequency band II. Accordingly, in a preferred embodiment of the method according to the invention, cavitation is defined to be present when the spectral level 52 increases in a predefined frequencyband II e.g. within the range 10-20 kHz. Thus, in one embodiment of the method according to the invention, cavitation is defined to be present when the spectral level 52 increases in the frequency 15-20 kHz.
The communication unit 84 may comprise a processing unit and a storage for storing one or more software programs to carry out any desirable processing. The display unit 29 may be of any suitable type, including a touch screen that may be used to display one or more parameters and as a user interface. The processing unit may preferably be capable of processing data received from the sensing elements in the housing 4 in real time.
The housing 4 is electrically connected to an intermediate box 78 attached to a control box fixed to the motor housing of the motor 70 by means of an electrical cable 27. Accordingly, the sensors in the housing 4 can be powered through the cable 27, and sensor signals received by the sensors can be transferred to the intermediate box 78. It is possible to have a processing unit inside the intermediate box 78 so that the vital calculation can be carried out without any external device. If this is the case, communication with the receiving unit 72 (e.g. a smartphone) and the calculation unit 84 via the Internet 74 may be carried out in order to exchange data or carry out comparisons.
A communication unit configured to wirelessly communicate via the Internet 74 (e.g. to a calculation unit 84 being part of a server or to a receiving unit 72 having a display and a calculation unit 84) is arranged in the intermediate box 78.
Accordingly, calculations and processing may be carried out in either the calculation unit 84 accessible through the Internet 74 or in the calculation unit 84 arranged to wirelessly communicate with the intermediate box 78.
The receiving unit 72 and the internet-based calculation unit 84 are capable of communicating with each other.
The housing 4 is provided with a number of sensors and a communication unit configured to wirelessly communicate with the cloud-based server 84 constituting the calculation unit 84 and with a calculation unit 84 of a receiving unit 72 (e.g. a smartphone, a tablet or a PDA). The receiving unit 72 comprises a display 29 and a calculation unit 84. The housing 4 may comprise a battery for providing electric power to the sensor elements and the communication unit. Alternatively, electric power may be supplied to the housing 4 via an electric cable (not shown) or via an energy harvesting unit (e.g. a thermoelectric generator).
The method according to the invention may be carried out by using a sensor assembly 2 like the one shown in
The display device 76 and the housing 4 may be powered by the motor 70 via an electric cable (not shown) or by a battery arranged in the display device 76.
The sensing element 20 is brought into contact with the bottom wall 8 in the distal end 46 of the housing 4 in order to minimize the thermal resistance for achieving the most valid temperature measurement conditions by using the thermosensitive sensor and for achieving optimal conditions for providing dry run detection by using the ultrasonic sensor of the sensing element 20.
The sensing element 20 is electrically connected to the PCB 12 by two legs 18, 18′. The housing 4 and the socket structure attached to its proximal end portion have the same shape as shown in
The sensor assembly 2 comprises a display unit 28 electrically connected to the housing of the sensor assembly 2 via an electric cable 27. The display unit 28 comprises a display 29 and a calculation unit 84 for carrying out calculations on the basis of sensor data from the sensor elements arranged in the housing of the sensor assembly 2.
The housing of the sensor assembly 2 is mounted in a threaded bore provided in the pump head 36. Vibration signals V1 originating from the motor bearing travel along a vibration travel path 86 extending along the motor stool 38 and the pump head 36 and are eventually received by a vibration sensing element in the housing of the sensor assembly 2. Likewise, vibration signals V2 originating from cavitation travel along a vibration travel path 88 extending along the sleeve 34 and are eventually received by a vibration sensing element in the housing of the sensor assembly 2. The vibration signals V2 originating from cavitation also travel along another vibration travel path 90 going through the mechanical structures of the stages and the fluid being pumped by the pump 30.
In order to be able to detect vibration signals V1, V2 having sufficiently large amplitude, the housing of the sensor assembly 2 may be mechanically attached to the pump 30 within a zone Z defined by an upper line L2 and a lower line L1. It can be seen that the housing of the sensor assembly 2 is mounted in a threaded bore provided in the pump head 36 inside the zone Z. By mounting the housing of the sensor assembly 2 in a threaded bore, it is possible to fasten the housing firmly to the pump 30. Accordingly, the risk of experiencing a self-loosening housing is minimized.
In order to categorize sound signals S1, S2, S3 into a plurality of predefined classes/groups G1, G2, G3, G4 trained service staff 92 having experience with motor bearing faults are presented for the sound signals S1, S2, S3. These trained staff put every sound signals S1, S2, S3 into one of the predefined classes/groups G1, G2, G3, G4 on the basis of their experience. The classes/groups G1, G2, G3, G4 may be:
G1: the bearing is not damaged;
G2: the bearing is slightly damaged; but can be used for some time;
G3: the bearing is moderately damaged and should be replaced;
G4: the bearing is completely damaged and must immediately be replaced.
Instead of using trained service staff 92 to categorize the sound signals S1, S2, S3 into one of the predefined classes/groups G1, G2, G3, G4, it is possible to apply an algorithm. The algorithm may be defined by theoretic considerations. The algorithm may be defined on the basis of data collected by trained service staff and be built by using an artificial neural network or a fuzzy network.
A sensor signal V3 is detected e.g. by using a sensor assembly according to the invention. Hereafter, a feature extractor 94 is used to extract features from the sensor signal V3, hereby generating a feature vector
In
Instead of selecting a single point Pi, to categorize the point P, it is possible to select a predefined number (e.g. two, three, four, five or more) of points being located in the shortest distance to the point P. In one embodiment according to the method of the invention, the three points Pi, Pn, Pm located with the shortest distance to P, are selected, and the average category is calculated. In
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
| Number | Date | Country | Kind |
|---|---|---|---|
| 16207518.8 | Dec 2016 | EP | regional |
This application is a United States National Phase Application of International Application PCT/EP2017/083202, filed Dec. 18, 2017, and claims the benefit of priority under 35 U.S.C. § 119 of European Application 16207518.8, filed Dec. 30, 2016, the entire contents of which are incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2017/083202 | 12/18/2017 | WO | 00 |
