School of Mechanical and Power Engineering, Zhengzhou University, No. 100 Science Street, Zhengzhou 450001, China.
Sensors (Basel). 2022 Mar 9;22(6):2106. doi: 10.3390/s22062106.
Centrifugal pumps have a wide range of applications in industrial and municipal water affairs. During the use of centrifugal pumps, failures such as bearing wear, blade damage, impeller imbalance, shaft misalignment, cavitation, water hammer, etc., often occur. It is of great importance to use smart sensors and digital Internet of Things (IoT) systems to monitor the real-time operating status of pumps and predict potential failures for achieving predictive maintenance of pumps and improving the intelligence level of machine health management. Firstly, the common fault forms of centrifugal pumps and the characteristics of vibration signals when a fault occurs are introduced. Secondly, the centrifugal pump monitoring IoT system is designed. The system is mainly composed of wireless sensors, wired sensors, data collectors, and cloud servers. Then, the microelectromechanical system (MEMS) chip is used to design a wireless vibration temperature integrated sensor, a wired vibration temperature integrated sensor, and a data collector to monitor the running state of the pump. The designed wireless sensor communicates with the server through Narrow Band Internet of Things (NB-IoT). The output of the wired sensor is connected to the data collector, and the designed collector can communicate with the server through 4G communication. Through cloud-side collaboration, real-time monitoring of the running status of centrifugal pumps and intelligent diagnosis of centrifugal pump faults are realized. Finally, on-site testing and application verification of the system was conducted. The test results show that the designed sensors and sensor application system can make good use of the centrifugal pump failure mechanism to automatically diagnose equipment failures. Moreover, the diagnostic accuracy rate is above 85% by using the method of wired sensor and collector. As a low-cost and easy-to-implement solution, wireless sensors can also monitor gradual failures well. The research on the sensors and pump monitoring system provides feasible methods and an effective means for the application of centrifugal pump health management and predictive maintenance.
离心泵在工业和市政水务中有广泛的应用。在离心泵的使用过程中，经常会出现轴承磨损、叶片损坏、叶轮不平衡、轴不对中、汽蚀、水锤等故障。利用智能传感器和数字物联网 (IoT) 系统监测泵的实时运行状态并预测潜在故障，对于实现泵的预知性维护和提高机器健康管理的智能化水平具有重要意义。首先介绍了离心泵的常见故障形式和发生故障时的振动信号特征。其次设计了离心泵监测物联网系统。该系统主要由无线传感器、有线传感器、数据采集器和云服务器组成。然后，利用微机电系统 (MEMS) 芯片设计了一种无线振动温度集成传感器、一种有线振动温度集成传感器和一个数据采集器，以监测泵的运行状态。设计的无线传感器通过窄带物联网 (NB-IoT) 与服务器进行通信。有线传感器的输出连接到数据采集器，设计的采集器可以通过 4G 通信与服务器进行通信。通过云端协作，实现了对离心泵运行状态的实时监测和离心泵故障的智能诊断。最后对系统进行了现场测试和应用验证。测试结果表明，设计的传感器和传感器应用系统可以充分利用离心泵的故障机理，自动诊断设备故障。并且，使用有线传感器和采集器的方法，诊断准确率在 85%以上。作为一种低成本且易于实施的解决方案，无线传感器也可以很好地监测逐渐发生的故障。传感器和泵监测系统的研究为离心泵健康管理和预知性维护的应用提供了可行的方法和有效的手段。
