Pump cloud-based management and control technique customized hydronic components

Abstract

A pumping system featuring a pump, motor, a bearing assembly, integrated data acquisition system and combined programmable logic controller (PLC), data acquisition and modem. The pump couples to a pump shaft that responds to a pump shaft force to pump a liquid. The motor couples to the pump shaft, responds to VFD/VSD control signaling and provides the pump shaft force to drive the pump shaft. The bearing assembly includes a bearing with the pump shaft arranged therein and couples the pump and the motor. The variable frequency/speed drive (VFD/VSD) receives PLC control signaling and provides the VFD/VSD control signaling to drive the motor. The integrated data acquisition system responds to PLC data acquisition signaling, and provides integrated data acquisition system signaling containing information about an integrated set of pumping system parameters related to the pump, the bearing assembly, the motor and the VFD/VSD in the pump system. The combined programmable logic controller (PLC), data acquisition and modem provides the PLC data acquisition signaling and receive the integrated data acquisition signaling, provides PLC data acquisition modem signaling that exports performance data to the Internet to allow remote manual monitoring of the pump system, and provides the PLC control signaling to control the VFD/VSD and operate the pumping system as a controlled, closed loop system.

Claims

1. A pumping system comprising: a pump coupled to a pump shaft configured to respond to a pump shaft force applied to pump a liquid; a motor coupled to the pump shaft and configured to respond to a VFD/VSD control signaling and provide the pump shaft force to drive the pump shaft; a bearing assembly having a bearing with the pump shaft arranged therein and configured to couple the pump and the motor; a variable frequency/speed drive (VFD/VSD) configured to receive a PLC control signaling, and provide the VFD/VSD control signaling to drive the motor; an integrated data acquisition system configured to respond to a PLC data acquisition signaling, and provide an integrated data acquisition system signaling containing information about an integrated set of pumping system parameters related to the pump, the bearing assembly, the motor and the VFD/VSD in the pumping system; and a combined programmable logic controller (PLC), data acquisition and modem, configured to: provide the PLC data acquisition signaling and receive the integrated data acquisition system signaling, in response to a cloud-based PLC data acquisition modem request signaling received from the Internet and/or Cloud, provide a PLC data acquisition modem signaling that exports performance data, including the integrated data acquisition system signaling, to the Internet and/or Cloud to allow remote manual monitoring of the pumping system, and provide the PLC control signaling to control the VFD/VSD and operate the pumping system as a controlled, closed loop system.

2. A pumping system according to claim 1, wherein the integrated data acquisition system comprises integrated sensors, including: pump pressure, temperature and flow sensors coupled to the pump, and configured to respond to the PLC data acquisition signaling and provide pump pressure, temperature and flow integrated sensor signaling containing information about one or more pressures, temperature or flows sensed in relation to the pump; bearing assembly temperature and vibration sensors coupled to the bearing assembly, and configured to respond to the PLC data acquisition signaling and provide bearing assembly temperature and vibration integrated sensor signaling containing information about one or more temperatures or vibrations sensed in relation to the bearing assembly; and motor temperature and vibration sensors coupled to the motor, and configured to respond to the PLC data acquisition signaling and provide motor temperature and vibration integrated sensor signaling containing information about one or more temperatures or vibrations sensed in relation to the motor.

3. A pumping system according to claim 2, where the pumping system comprises an array of communication devices, including one or more Supervisory Control and Data Acquisition (SCADA-based) device, Computer devices, advanced metering infrastructures (AMI-based), Open Platform Communication (OPC-based) devices, Dataloggers; and the integrated sensors on the pump, the motor, the bearing assembly are connected via the combined programmable logic controller (PLC), data acquisition and modem to the array of communication devices.

4. A pumping system according to claim 1, wherein the VFD/VSD is configured to respond to the PLC data acquisition signaling and provide VFD/VSD data acquisition signal, including the VFD/VSD control signaling, back to the combined programmable logic controller, data acquisition and modem.

5. A pumping system according to claim 1, wherein the pumping system is configured to couple to the Cloud and/or Internet for remote monitoring and control, including where the pumping system forms part of a building, and the Cloud and/or Internet includes a building management system to monitor and control the pumping system remotely.

6. A pumping system according to claim 1, wherein the pumping system comprises a cloud-based VFD/VSD controller configured to receive the PLC data acquisition modem signaling, and provide cloud-based VFD/VSD control signaling containing information to control the VFD/VSD and operate the pumping system as the controlled, closed loop system.

7. A pumping system according to claim 1, wherein the combined programmable logic controller (PLC), data acquisition and modem is configured to respond to cloud-based VFD/VSD control signaling received from the Cloud and/or Internet, and provide the PLC control signaling to control the VFD/VSD and operate the pumping system as the controlled, closed loop system.

8. A pumping system according to claim 5, wherein the building management system is configured to receive user commands, including commands to start, stop or adjust some part of the pump system.

9. A pumping system according to claim 5, wherein the building management system is configured to receive user commands, including commands to allow a user to monitor run hours, pump speed, and/or pumping system pressure in the pumping system.

10. A pumping system according to claim 1, wherein the pumping system is coupled to a pumping system condition monitoring device configured to receive the PLC data acquisition modem signaling, and provide pumping system condition monitoring signaling containing information about condition monitoring and analysis results about the pumping system, including providing predictive/prescriptive monitoring of pump statuses and sending alerts or maintenance requests.

11. A pumping system according to claim 10, wherein the pumping system condition monitoring device is configured to monitor the status of the pump, the motor or bearing assembly and compare the status to pump, motor or bearing assembly historical data to provide predictive/prescriptive analysis for the user to make determinations regarding the maintenance of the pump, the motor or bearing assembly.

12. A pumping system according to claim 1, wherein the pumping system includes, or take the form of, an HVAC system, a potable water system, a fire suppression system, or a building system.

13. A cloud-based pumping system monitoring and controlling system for remotely monitoring and controlling at least one pump, comprising: at least one pump having a variable speed drive (VSD) and integrated sensors for monitoring pump parameters, and for providing, to a remote cloud-based server, an integrated sensor signaling containing information about pump parameters sensed for the at least one pump, including run hours, a speed and a system pressure, in response to a data acquisition request signaling received from the remote cloud-based server; a bi-directional network for communicating the integrated sensor signaling, and for receiving a remote variable speed drive control signaling for controlling the variable speed drive for the at least one pump; and the remote cloud-based server having a historical database containing historical pump parameter data for the at least one pump, configured to receive the integrated sensor signaling, compare the pump parameters received to the historical pump parameter data stored for each the at least one pump, and provide the remote variable speed drive control signaling for controlling the variable speed drive for the at least one pump in a controlled closed loop system that allows a remote user manual monitoring using predictive/prescriptive monitoring algorithms, including starting or stopping the at least one pump, making adjustments to pump control settings, and sending alerts or maintenance requests, when needed.

14. A cloud-based pumping system monitoring and control system according to claim 13, wherein the at least one pump comprises multiple pumps.

15. A cloud-based pumping system monitoring and control system according to claim 13, wherein the bi-directional network comprises a supervisory control and data acquisition (SCADA) coupled to the at least one pump, and an advanced metering infrastructure (AMI) coupled to the SCADA for providing cloud-based SCADA/AMI signaling for communicating the integrated sensor signaling, and for receiving the remote variable speed drive control signaling for controlling the variable speed drive for the at least one pump.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) The drawing, which is not necessarily drawn to scale, includes the following Figures:

(2) FIG. 1 shows a typical pump assembly arranged on a base, e.g., having a pump with a pump inlet, a pump discharge; a motor having a motor with a front end bell and a rear end bell arranged on each end; and a bearing housing and a coupling device for coupling the pump and motor together.

(3) FIG. 2 shows the Cloud and a pumping system having a combined programmable Logic Controller (PLC), data acquisition and modem for receiving data acquisition system signaling from a system of integrated sensors having sensor placements that includes being placed in relation to the pump, the bearing assembly, and motor, according to some embodiments of the present invention.

(4) FIG. 3 shows pumping systems PS1, PS2, PS3 connected via a serial network to the combined programmable Logic Controller (PLC), data acquisition and modem to an array of communication devices (e.g., using SCADA, AMI, OPC) to the Cloud C and various computer-based devices (e.g., like a laptop LT, desktop DT, server S, tablet T), according to some embodiments of the present invention.

(5) FIG. 4 shows a pumping system coupled to a combined PLC, data acquisition and modem for receiving data acquisition system signaling from a system of sensors like that shown in FIG. 2, where the combined PLC, data acquisition and modem is connected to a central database (DB) for exchanging data/configuration signaling, e.g., that is coupled to a condition monitoring software that receives data signaling from the pump/pumping system and provides analysis results signaling, that is coupled to a computer for exchanging data/configuration signaling, that is also coupled to a laptop for exchanging data/configuration signaling, and that is also coupled to a tablet, a laptop or mobile phone that receive reporting and communications signaling, all according to some embodiments of the present invention.

(6) FIG. 5 shows a pump/pumping assembly with a VFD/VSD support bracket having a sensor control panel and VFD/VSD mounted thereon, according to some embodiments of the present invention.

(7) FIG. 6 includes FIGS. 6A thru 6E and show five (5) different pump/pumping assembly with a VFD/VSD support bracket having a sensor control panel and VFD/VSD mounted thereon, according to some embodiments of the present invention.

(8) FIG. 7 shows a combined PLC, data acquisition and modem having a signal processor and other circuits, circuitry or components for implementing the signal processing functionality, according to some embodiments of the present invention.

(9) Similar parts in Figures are labeled with similar reference numerals and labels for consistency. Every lead line and associated reference label for every element is not included in every Figure of the drawing to reduce clutter in the drawing as a whole.

DETAILED DESCRIPTION OF THE INVENTION

(10) This disclosure details the integration of sensors within a pumping system to create a controlled, closed loop system that accurately controls the VFD/VSD, exports performance data to the Cloud and/or Internet to allow remote manual monitoring, provides predictive/prescriptive monitoring of the pump units status and sensed parameters, and sends alerts or maintenance requests when necessary. By way of example, the controlled, closed loop system is understood to include, or take the form of, an automatic control system in which the pumping system's operation, processor or mechanism is regulated by feedback, e.g., including from some combination of the integrated sensors, Cloud-based condition monitoring, and/or user/operator remote monitoring or control.

(11) FIG. 2 shows a pumping system generally indicated as 5, e.g., including a combined PLC, data acquisition system and modem 10 for coupling a pumping assembly PA to the Cloud C and/or Internet. The pumping assembly PA may include a pump P, a motor M, a coupling device CD, a bearing assembly BA and a shaft S connected between the motor and pump P. In effect, FIG. 2 outlines the inclusion of integrated sensors in the pumping assembly PA, e.g., including a condition monitoring device CM coupled to the bearing assembly BA for monitoring temperature and vibration (X/Y/Z axes), and a flow meter FM coupled to the pump P to allow for communication of status and parameter information in the pumping unit/system 5 to the user/operator, e.g., via a Cloud-based data acquisition and provisioning scheme. The PLC, data acquisition system and modem 10 may be configured to receive the status and/or sensed parameter information, e.g., in response to the provisioning of data acquisition system signaling to the integrated sensors, or the VFD/VSD, or both, etc. By way of example, FIG. 2 provides a list of sensors that the PLC, data acquisition system, modem 10 receives data acquisition system signaling from, and that may be used in the pumping system 5; which is not necessarily deemed to be a complete list and is provided by way of example only. By way of further example, the integrated sensors may include temperature, pressure and flow sensors placed or configured in relation to the pump P; temperature and vibration sensors like element CM (X/Y/Z axes) placed or configured in relation to the bearing assembly BA; and temperature and vibration sensors placed or configured in relation to the motor M. (In FIG. 2, the placement or configuration of the integrated sensor is represented by the end of the arrow, e.g., consistent with that shown.) By way of still further example, the VFD/VSD may also include a circuit, circuitry or component configured to respond to data acquisition system signaling, e.g., from the PLC, data acquisition and modem 10, and provide suitable VFD/VSD data acquisition signaling, e.g., containing information about the operation of the VFD/VSD, such as the control signaling provided for driving the motor M, as well as motor signaling containing information received back from the motor M (e.g., motor voltage, motor current, etc.).

(12) Furthermore, the integrated sensors placed on, or in relation to, the various components in the pumping unit/system 5 allow the pumping unit/system 5 to be connected to an array of communication devices, including but not limited to SCADA-based, AMI-based, OPC-based, Computer-based, Dataloggers, etc., e.g., like that shown in FIG. 3. These sensors are an integral part of the pumping unit/system 5 as a whole.

(13) FIG. 3 shows how the pumping unit/system 5 may be connected to the cloud C for implementing remote monitoring and control, e.g., via the PLC, data acquisition and modem 10 using SCADA, AMI, OPC communication-based devices, e.g., to one or more devices like a laptop LT, a tablet T, a server S coupled via a local network to a desktop computer DT, etc. As shown, and by way of example, the pump systems PS1, PS2, PS3 are connected via a serial network to may be coupled to the PLC, data acquisition system, modem 10, and further connected through the PLC, data acquisition system, modem 10 to the laptop LT via or using an Open Platform Communication (OPC-based) and AMI-based communication devices/protocols to the Cloud C; and may also be connected to the server S and and tablet T via SCADA-based and AMI-based communication device/protocols to the Cloud. The server S may be coupled to the desktop DT, as shown. This Cloud-based implementation can then be connected, e.g., to a building maintenance system for monitor and control of the unit/pumping system 5 remotely. This also allows for remote monitoring and operation for the user/operator from anywhere in the world there is access to the Cloud C. For example, the user/operator can monitor run hours, speed, system pressure, etc., of the unit/pumping system 5, or the user/operator can start, stop, adjust/modify, etc. the unit/pumping system 5 as needed from anywhere they have Cloud access. This allows the user/operator to monitor the status of the unit/pumping system 5 with flexibility, so as not to be tied to any particular location. The user/operator can also remotely operate the unit/pumping system 5 and make adjustments to the pumping system settings as required. As one skilled in the art would appreciate, once user/operator adjustments are made, the VFD/VSD can implement modified or adjusted control functionality to to run the pumping system as in the controlled, closed loop system.

(14) FIG. 4 shows how sensor integration allows for the unit/pumping system 5 to be connected to a Condition Monitoring software device CMSD for implementing pump system condition monitoring. This software may be implemented to monitor the status of the unit/pumping system 5 and compare this status information to historical data to provide predictive/prescriptive analysis for the user/operator to make determinations regarding the maintenance of the unit/pumping system 5. This allows the user/operator to service the pump P prior to conditions that would previously lead to pump failure and costly shut downs due to needed maintenance. Simply put, condition monitoring collects the data from the unit/pumping system 5 and runs the data through an algorithm to provide analysis that compares the history of the data versus the current status. This analysis is able to tell if the conditions have changed and the unit/pumping system 5 has deviated from its normal operating conditions. The user/operator then can be updated and provided with a report to allow them to understand the status of the unit/pumping system 5. Savings are also recognized in that maintenance is conducted prior to major mechanical issues and is there for proactive versus reactive. This allows the user/operator to proactively provide appropriate maintenance for the unit/pumping unit 5.

(15) In FIG. 4, the PLC, data acquisition system, modem 10 is configured to couple a central database (DB) server CDBS to the pumping assembly PA, e.g., and exchange data/configuration signaling to implement the present invention. The central database server CDBS may be coupled/connect to various types of components, e.g., including a mobile phone MP, a laptop LT, a tablet T, for receiving reporting and communication signaling for a mobile user/operator/monitor. The central database server CDBS may also be coupled/connect to various other types of components, e.g., including a laptop for exchanging data/configuration signaling, as well as the condition monitoring software device CMSD for receiving/exchanging data signaling from the pump P and providing/exchanging analysis results signaling, all according to some embodiments of the present invention.

(16) FIGS. 5 and 6 show shows various pumping units/systems with a fixed mounting method for the VFD/VSD and any sensor processing equipment to be integrated into the pump assembly. For example, FIG. 5 shows a pumping system 5 having a pumping assembly with the pump P, the bearing assembly BA, the shaft S, the coupling device CD and the motor M are arranged/configured on a base B. The base B has a support bracket extending vertically from it, e.g., having a sensor control panel and a VFD/VSD mounted thereon. By way of example, the sensor control panel may include the PLC, data acquisition, modem 10. FIG. 6 show various pumping units/systems with the built-in VFD/VSD mounting arrangement/configuration.

FIG. 7: Implementation of Signal Processing Functionality

(17) By way of example, FIG. 7 shows the PLC, data acquisition, modem 10 according to some embodiments of the present invention, e.g., featuring a signal processor or processing module 10a configured at least to: provide PLC data acquisition signaling and receive the integrated data acquisition signaling, e.g., back from motor, pump and bearing assembly sensors, as well as from the VFD/VSD, provide PLC data acquisition modem signaling that exports performance data to the Internet and/or Cloud to allow remote manual monitoring of the pump system, e.g., including in response to cloud-based PLC data acquisition modem request signaling received from the Cloud or Internet, and provide the PLC control signaling to control the VFD/VSD and operate the pumping system as a controlled, closed loop system, e.g., including in response to cloud-based VFD/VSD control signaling received from the Cloud or Internet.

(18) In operation, the signal processor or processing module may be configured to provide the corresponding signaling as control signaling. The corresponding signaling may contain information used to control a pumping hydronic system.

(19) The signal processor or processing module 10a may be configured in, or form part of, the PLC data acquisition system, e.g., which may include or be implemented in conjunction with a VFD/VSD control configured therein.

(20) By way of example, the functionality of the PLC, data acquisition, modem 10 may be implemented using hardware, software, firmware, or a combination thereof. In a typical software implementation, the PLC, data acquisition, modem 10 would include one or more microprocessor-based architectures having, e.g., at least one signal processor or microprocessor like element 10a. One skilled in the art would be able to program with suitable program code such a microcontroller-based, or microprocessor-based, implementation to perform the functionality described herein without undue experimentation. For example, the signal processor or processing module 10a may be configured, e.g., by one person skilled in the art without undue experimentation, to provide PLC data acquisition signaling and receive the integrated data acquisition signaling, e.g., back from motor, pump and bearing assembly sensors, as well as from the VFD/VSD, consistent with that disclosed herein.

(21) Moreover, the signal processor or processing module 10a may be configured, e.g., by one skilled in the art without undue experimentation, to provide PLC data acquisition modem signaling that exports performance data to the Internet to allow remote manual monitoring of the pump system, e.g., including in response to cloud-based PLC data acquisition modem request signaling received from the Cloud, consistent with that disclosed herein. For example, the integrated data acquisition signaling received from the integrated sensors may be stored in memory, and provided to the Cloud from time-to-time, or in response to the PLC data acquisition modem request signaling received from the Cloud, consistent with that disclosed herein.

(22) Moreover still, the signal processor or processing module 10a may be configured, e.g., by one skilled in the art without undue experimentation, to provide the PLC control signaling to control the VFD/VSD and operate the pumping system as a controlled, closed loop system, e.g., including in response to cloud-based VFD/VSD control signaling received from the Cloud, consistent with that disclosed herein.

(23) The scope of the invention is not intended to be limited to any particular implementation using technology either now known or later developed in the future. The scope of the invention is intended to include implementing the functionality of the processors 10a as stand-alone processor, signal processor, or signal processor module, as well as separate processor or processor modules, as well as some combination thereof.

(24) The PLC, data acquisition, modem 10 may also include, e.g., other signal processor circuits or components 10b, including random access memory or memory module (RAM) and/or read only memory (ROM), input/output devices and control, and data and address buses connecting the same, and/or at least one input processor and at least one output processor, e.g., which would be appreciate by a person skilled in the art.

Possible Applications

(25) By way of example, possible applications of the invention may include: HVAC, potable water systems, fire suppression systems, etc.

The Scope of the Invention

(26) Further still, the embodiments shown and described in detail herein are provided by way of example only; and the scope of the invention is not intended to be limited to the particular configurations, dimensionalities, and/or design details of these parts or elements included herein. In other words, one skilled in the art would appreciate that design changes to these embodiments may be made and such that the resulting embodiments would be different than the embodiments disclosed herein, but would still be within the overall spirit of the present invention.

(27) It should be understood that, unless stated otherwise herein, any of the features, characteristics, alternatives or modifications described regarding a particular embodiment herein may also be applied, used, or incorporated with any other embodiment described herein.

(28) Although the invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein and thereto without departing from the spirit and scope of the present invention.