Technical Field
[0001] The present invention relates to a remote monitoring system that uses a network of
a wireless intercommunication type so as to enable remote monitoring on operating
conditions of a plurality of installed uniaxial eccentric screw pumps.
Background Art
[0002] In the related art, a measure to detect abnormalities of pumps has been taken, for
example, by using a manhole pump station management system as disclosed in Patent
Literature 1. The management system according to Patent Literature 1 facilitates prediction
of malfunctions of the manhole pump station so as to reduce a burden on a maintenance
engineer. This management system prompts inspection based on determination that there
is a high risk of malfunctions of the pumps, for example, in a case where an average
operation time period per day of each of the pumps provided in the manhole pump station
is predetermined times or more as long as an initial average operation time period
per day in a predetermined period from installation.
Citation List
Patent Literature
Summary of Invention
Technical Problems
[0004] However, the management system disclosed in Patent Literature 1 merely performs the
prediction of malfunctions of the pumps in an installation location of the pumps,
and is incapable of monitoring operating conditions of the pumps from a remote site.
Further, in general, a plurality of pumps, such as uniaxial eccentric screw pumps,
are installed in a single installation region in many cases, and hence there have
been demands for a system that is capable of integrally monitoring the pumps. However,
such problems or measures to solve the problems are not disclosed or suggested at
all in Patent Literature 1.
[0005] Further, in a case where the technology disclosed in Patent Literature 1 is applied
to monitor the plurality of pumps with monitoring means provided in a remote site,
there may be given a measure to perform one-to-one information communication between
each of the pumps or sensors and the like provided to the pumps and the monitoring
means. When such a measure is employed, information communication links are required
as many as the pumps in order to integrally monitor the plurality of pumps. As a result,
there is a problem in that a complex information communication network needs to be
established. Further, there is another problem in that high initial cost for installing
the information communication links as many as the pumps and high running cost for
performing information communication for detecting abnormalities of the pumps are
required.
[0006] In view of the circumstances, it is an object of the present invention to provide
a remote monitoring system for a plurality of uniaxial eccentric screw pumps that
are installed in a predetermined region, the system enabling operating conditions
of the uniaxial eccentric screw pumps to be monitored with monitoring means installed
in a remote site, and enabling initial cost and running cost that are required for
the monitoring to be suppressed to the minimum.
Solution to Problems
[0007] According to one embodiment of the present invention, which is provided to solve
the above-mentioned problems, there is provided a remote monitoring system for a uniaxial
eccentric screw pump, including: monitoring means for monitoring operating conditions
of a plurality of uniaxial eccentric screw pumps that are installed in a predetermined
region, the monitoring means being connected to an Internet and provided out of the
predetermined region. The remote monitoring system according to one embodiment of
the present invention includes wireless intercommunication means that are capable
of wireless intercommunication; Internet connection means that is capable of connection
to the Internet; and operating condition detecting means that is capable of detecting
the operating conditions of the plurality of uniaxial eccentric screw pumps and outputting
the operating conditions of the plurality of uniaxial eccentric screw pumps as the
operating condition detection information items. In the remote monitoring system according
to one embodiment of the present invention, the wireless intercommunication means
are provided to the respective plurality of uniaxial eccentric screw pumps so as to
establish a communication network to enable sending and receiving of the operating
condition detection information items through intercommunication via the wireless
intercommunication means. Further, the operating condition detection information items
that are sent and received within the communication network are aggregated to information
aggregation means that is constructed of one of the wireless intercommunication means
and sent to the Internet via the Internet connection means, to thereby be monitored
with the monitoring means.
[0008] In the remote monitoring system for a uniaxial eccentric screw pump according to
one embodiment of the present invention, an independent communication network is established
by the wireless intercommunication means provided to the respective uniaxial eccentric
screw pumps, and the operating condition detection information items indicating the
operating conditions of the uniaxial eccentric screw pumps can be sent and received
via the communication network. Further, one of the plurality of wireless intercommunication
means functions as the information aggregation means, and hence the operating condition
detection information items sent and received within the above-mentioned communication
network can be aggregated. In addition, the operating condition detection information
items aggregated to the information aggregation means are sent via the Internet connection
means, to thereby be monitored with the monitoring means. Thus, in the remote monitoring
system according to one embodiment of the present invention, even when the Internet
connection means is not provided to each of the plurality of uniaxial eccentric screw
pumps, the operating conditions of the respective uniaxial eccentric screw pumps can
be monitored with the monitoring means. Thus, the remote monitoring system according
to one embodiment of the present invention enables installation cost and communication
cost of the Internet communication means to be suppressed to the minimum.
[0009] Further, the remote monitoring system according to one embodiment of the present
invention can be used not only for detecting abnormal states of the uniaxial eccentric
screw pumps but also for detecting decreases in output of the uniaxial eccentric screw
pumps so as to notify of in advance, for example, whether or not maintenance such
as replacement of components is required to be performed. When the necessity of maintenance
can be notified of in advance in this way, a period in which the uniaxial eccentric
screw pumps need to be stopped can be suppressed to the minimum. As a result, a risk
of an inevitable stoppage of a line in a factory and the like can be prevented.
[0010] Further, according to one embodiment of the present invention, which is provided
based on similar findings, there is provided a remote monitoring system for a uniaxial
eccentric screw pump, the uniaxial eccentric screw pump including: a driving machine
that is capable of generating rotational power; a male screw type rotor that is eccentrically
rotated by the rotational power transmitted from the driving machine side; and a stator
that allows the male screw type rotor to be inserted therethrough and has an inner
peripheral surface formed into a female screw shape. The remote monitoring system
for the uniaxial eccentric screw pump according to one embodiment of the present invention
includes: operating condition detecting means that is capable of detecting an operating
condition of the uniaxial eccentric screw pump as an operating condition detection
information item; wireless intercommunication means that are provided to a part or
all of a plurality of uniaxial eccentric screw pumps that are installed in a predetermined
region and are capable of sending and receiving the operating condition detection
information items through wireless intercommunication; and Internet connection means
for connecting a local network and an Internet to each other, the local network including
the wireless intercommunication means each serving as a node. In this remote monitoring
system, at least one of the wireless intercommunication means has a function of information
aggregation means for aggregating the operating condition detection information items
that are sent and received within the local network. The operating condition detection
information items that are aggregated to the at least one of the wireless intercommunication
means having the function of the information aggregation means are sent to the Internet
via the Internet connection means. In this manner, the operating conditions of the
uniaxial eccentric screw pumps can be monitored with monitoring means that is connected
to the Internet and provided out of the predetermined region.
[0011] In the remote monitoring system for a uniaxial eccentric screw pump according to
one embodiment of the present invention, the operating conditions of the uniaxial
eccentric screw pumps that are installed in the predetermined region can be detected
with the operating condition detecting means, and output as the operating condition
detection information items. Further, in this remote monitoring system, the operating
condition detection information items output from the operating condition detecting
means are sent and received within the local network that is established by the wireless
intercommunication means as nodes, and aggregated to the at least one of the wireless
intercommunication means that functions as the information aggregation means. Further,
in this remote monitoring system, the operating condition detection information items
aggregated to the predetermined one of the wireless intercommunication means are sent
via the Internet connection means. With this, the operating condition detection information
items can be monitored with the monitoring means. Thus, in the remote monitoring system
according to one embodiment of the present invention, even when the Internet connection
means is not provided to each of the plurality of uniaxial eccentric screw pumps,
the results of the detection of the operating conditions of the uniaxial eccentric
screw pumps can be grasped with the monitoring means. Thus, the remote monitoring
system according to one embodiment of the present invention enables installation cost
and communication cost of the Internet communication means to be suppressed to the
minimum.
[0012] Further, the remote monitoring system according to one embodiment of the present
invention can be used not only for detecting abnormal states of the uniaxial eccentric
screw pumps but also for sensing behavior such as the decreases in output of the uniaxial
eccentric screw pumps so as to determine or notify of in advance whether or not the
maintenance such as replacement of components needs to be performed, for example.
When the necessity of maintenance can be determined or notified of in advance in this
way, a stoppage period of the uniaxial eccentric screw pumps can be suppressed to
the minimum. As a result, a risk of an inevitable stoppage of, for example, a line
in a factory can be prevented.
[0013] In the remote monitoring system for a uniaxial eccentric screw pump according to
one embodiment of the present invention described above, it is desired that each of
the wireless intercommunication means wait in a de-energized state, and be switched
to an energized state to send and receive the operating condition detection information
items that are detected by the operating condition detecting means.
[0014] With such a configuration, power consumption of the wireless intercommunication means
can be suppressed to the minimum. With this, running cost of the remote monitoring
system for a uniaxial eccentric screw pump according to the present invention can
be suppressed to the minimum. Further, also when a portable power source such as a
dry cell is used as a power source for the wireless intercommunication means, the
wireless intercommunication means can be used over a long time period without replacement
of the power source. With this, time and effort for maintenance can be suppressed
to the minimum.
[0015] Here, the uniaxial eccentric screw pumps as monitoring objects in the remote monitoring
system according to the present invention each pump a fluid substance by rotating
the male screw type rotor inserted in the female screw type stator. Thus, the operating
condition of each of the uniaxial eccentric screw pumps can be monitored by detecting
a driving condition of the driving machine for rotating the rotor, specifically, rotational
torque, a rotational frequency, or the number of revolutions of the driving machine.
[0016] In the remote monitoring system for a uniaxial eccentric screw pump according to
one embodiment of the present invention, which is provided based on the above-mentioned
findings, the operating condition detecting means is capable of detecting at least
one of rotational torque, a rotational frequency, and a number of revolutions of the
driving machine for driving the uniaxial eccentric screw pump.
[0017] With such a configuration, the operating condition of the uniaxial eccentric screw
pump can be appropriately monitored.
[0018] Note that, the uniaxial eccentric screw pumps each pump a fluid substance by rotating
the rotor inserted in the stator, and hence it is assumed that the stator or the rotor
is abraded by use over a long time period. Further, by influence of the abrasion and
the like of the stator or the rotor, it is assumed that the rotational torque, the
rotational frequency, or the number of revolutions of the driving machine required
for rotating the rotor fluctuates. Thus, in each of the uniaxial eccentric screw pumps,
an appropriate value of the rotational torque, the rotational frequency, or the number
of revolutions of the driving machine also fluctuates along with operating conditions.
As a result, when the operating conditions of the uniaxial eccentric screw pumps are
monitored based on the rotational torque, the rotational frequency, or the number
of revolutions of the driving machine, monitoring accuracy can be further enhanced
by performing abnormality determination while taking measures considering the operating
conditions, such as adjustment of a threshold in accordance with an elapsed operation
time period, the threshold being set as a reference of the abnormality determination.
[0019] In the remote monitoring system for a uniaxial eccentric screw pump according to
one embodiment of the present invention, the operating condition detecting means may
be capable of detecting an information item on a fluid substance that flows in and
out from the uniaxial eccentric screw pump. Specifically, the operating condition
detecting means may be capable of detecting at least one of a discharge pressure and
an inflow pressure of the uniaxial eccentric screw pump, and information items on
the fluid substance as a pumping obj ect, such as physical properties of the fluid
substance, and a flow rate of the fluid substance.
[0020] With such a configuration, based on the information items on the fluid substance
that flows in and out from the uniaxial eccentric screw pump, the operating condition
of each of the uniaxial eccentric screw pumps can be accurately monitored. Further,
according to the above-mentioned configuration, a failure of pumping of the fluid
substance in a transportation system to which the uniaxial eccentric screw pumps are
connected also can be monitored.
[0021] In the remote monitoring system for a uniaxial eccentric screw pump according to
one embodiment of the present invention described above, it is preferred that the
operating condition detecting means be capable of performing determination as to whether
or not the operating condition of the uniaxial eccentric screw pump is abnormal, and
a result of the determination be sent and received as one of the operating condition
detection information items.
[0022] In the remote monitoring system according to one embodiment of the present invention,
detection data items indicating the operating conditions of the uniaxial eccentric
screw pumps are not sent and received as they are. Instead, the operating condition
detecting means performs the determination on the operating condition of the uniaxial
eccentric screw pump, and the result of the determination is sent. Thus, in the remote
monitoring system according to one embodiment of the present invention, a communication
data volume in the local network can be minimized. As a result, occurrence of failures
of communication and the like can be prevented.
[0023] Further, in the remote monitoring system for a uniaxial eccentric screw pump according
to one embodiment of the present invention, a part of the plurality of uniaxial eccentric
screw pumps may include the Internet connection means instead of the wireless intercommunication
means, and the operating condition detection information items that are sent and received
within the local network may be sent to the Internet via the Internet connection means.
[0024] With such a configuration, the Internet connection means provided to the uniaxial
eccentric screw pump which does not include the wireless intercommunication means
can be utilized as means for sending the operating condition detection information
items that are sent and received within the local network established by the wireless
intercommunication means to the Internet. Further, wireless intercommunication means
needs not be additionally provided to the uniaxial eccentric screw pump which does
not comprise the wireless intercommunication means. Thus, according to the above-mentioned
configuration, the remote monitoring system for a uniaxial eccentric screw pump can
be simplified in configuration. As a result, installation cost can be suppressed to
the minimum.
[0025] In the remote monitoring system for a uniaxial eccentric screw pump according to
one embodiment of the present invention, it is desired that the Internet connection
means be capable of performing information communication via a mobile communication
system.
[0026] With such a configuration, from a region in which the uniaxial eccentric screw pumps
are installed, the operating condition detection information items of the uniaxial
eccentric screw pumps can be sent via the Internet connection means without using
a communication network that is installed independently of the remote monitoring system
according to the present invention, such as a local area network (LAN) or an intranet.
In this way, the remote monitoring system according to one embodiment of the present
invention can be installed without considering connection to the separately provided
local area network or the like.
Advantageous Effects of Invention
[0027] According to one embodiment of the present invention, it is possible to provide the
remote monitoring system for a plurality of uniaxial eccentric screw pumps that are
installed in a predetermined region, the system enabling the operating conditions
of the uniaxial eccentric screw pumps to be monitored with the monitoring means installed
in a remote site, and enabling the initial cost and the running cost that are required
for the monitoring to be suppressed to the minimum.
Brief Description of Drawings
[0028]
FIG. 1 is a system schematic view of a remote monitoring system for uniaxial eccentric
screw pumps according to an embodiment of the present invention.
FIG. 2 is a sectional view of the uniaxial eccentric screw pump.
FIG. 3 (a) is a configuration block diagram of a computer that is connected to the
uniaxial eccentric screw pump, and FIG. 3(b) is a configuration block diagram of a
cell computer that is connected to the uniaxial eccentric screw pump.
FIGS. 4(a) to 4(d) are images each showing an example of a pictogram that is displayed
on monitoring means in a case where an abnormality in the uniaxial eccentric screw
pump is detected.
FIG. 5 is a system schematic view of a remote monitoring system for uniaxial eccentric
screw pumps according to a modification.
FIG. 6 (a) is an image showing a method of displaying locations of uniaxial eccentric
screw pumps in which an abnormality has occurred, FIG. 6 (b) is an image showing operational
behavior of the uniaxial eccentric screw pump in an abnormal condition, and FIGS.
6(c) to 6(e) are images each showing an example of a pictogram indicating an abnormal
part or an abnormal condition of the uniaxial eccentric screw pump.
Description of Embodiment
[0029] Next, with reference to the drawings, detailed description is made of a remote monitoring
system 1 for uniaxial eccentric screw pumps according to an embodiment of the present
invention (hereinafter also abbreviated as "remote monitoring system 1"). Note that,
in the following, prior to detailed description of the remote monitoring system 1,
description is made of an outline of a structure of a uniaxial eccentric screw pump
100 as objects of monitoring by the remote monitoring system 1 according to this embodiment.
(Uniaxial eccentric screw pump 100)
[0030] As illustrated in FIG. 2, the uniaxial eccentric screw pump 100 is a pump of what
is called a rotary displacement type including a uniaxial eccentric screw pump mechanism
110 as a main part. As illustrated in FIG. 2, in the uniaxial eccentric screw pump
110, a casing 152 houses therein a stator 166, a rotor 172, a power transmission mechanism
178, and the like. The casing 152 is a cylindrical metal member, and includes a first
opening portion 154 on one longitudinal end side. Further, a second opening portion
164 is provided through an outer peripheral part of the casing 152. The second opening
portion 164 communicates to an interior space of the casing 152 at an intermediate
portion 160 located at a longitudinal intermediate part of the casing 152.
[0031] The first opening portion 154 and the second opening portion 164 each function as
a suction port and a discharge port of the pump mechanism 110. In the uniaxial eccentric
screw pump 100, the rotor 172 is rotated in a forward direction so as to cause the
first opening portion 154 and the second opening portion 164 to function respectively
as the discharge port and the suction port. Further, the rotor 172 is rotated in a
reverse direction so as to cause the first opening portion 154 and the second opening
portion 164 to function respectively as the suction port and the discharge port.
[0032] The stator 166 is a member obtained by forming an elastic body such as rubber, a
resin, or the like into a substantially cylindrical external shape. An inner peripheral
wall 170 of the stator 166 is formed into a single-stage or multistage female screw
shape having "n" starts. In this embodiment, the stator 166 is formed into a multistage
female screw shape having two starts. Further, a through-hole 168 of the stator 166
is formed to have a substantially oblong shape in cross-section (opening shape) at
any longitudinal position of the stator 166.
[0033] The rotor 172 is a metal shaft body formed into a single-stage or multistage female
screw shape having n-1 starts. In this embodiment, the rotor 172 is formed into an
eccentric male screw shape having a single start. The rotor 172 is formed to have
a substantially perfect circular shape in cross-section at any longitudinal position.
The rotor 172 is inserted through the through-hole 168 that is formed through the
stator 166 in a freely eccentrically rotatable manner in the through-hole 168.
[0034] When the rotor 172 is inserted through the stator 166, an outer peripheral wall 174
of the rotor 172 and the inner peripheral wall 170 of the stator 166 are held in close
contact with each other at tangents therebetween. In this state, a fluid transport
path (cavity) 176 is formed between the inner peripheral wall 170 of the stator 166
and the outer peripheral wall of the rotor 172. The fluid transport path 176 helically
extends in the longitudinal direction of the stator 166 and the rotor 172.
[0035] When the rotor 172 is rotated in the through-hole 168 of the stator 166, the fluid
transport path 176 shifts in the longitudinal direction of the stator 166 while being
rotated in the stator 166. Thus, when the rotor 172 is rotated, a fluid can be sucked
from one end side of the stator 166 into the fluid transport path 176, and the fluid
can be sealed in the fluid transport path 176. In this state, the fluid can be transported
toward another end side of the stator 166, and discharged on the another end side
of the stator 166. The pump mechanism 110 in this embodiment is used by rotating the
rotor 172 in the forward direction so that a viscous liquid sucked through the second
opening portion 164 can be pumped to and discharged from the first opening portion
154.
[0036] The power transmission mechanism 178 transmits power from a driving machine 196 to
the rotor 172. The power transmission mechanism 178 includes a power transmission
portion 180 and an eccentric rotary portion 182. The power transmission portion 180
is provided on one longitudinal end side of the casing 152. Further, the eccentric
rotary portion 182 is provided in the intermediate portion 160 formed between the
power transmission portion 180 and a stator mounting portion 156. The eccentric rotary
portion 182 is a part connecting the power transmission portion 180 and the rotor
172 to each other so that power can be transmitted therebetween. The eccentric rotary
portion 182 includes a coupling shaft 188 formed of a related-art well-known coupling
rod, a screw rod, or the like. With this, the eccentric rotaryportion 182 is capable
of transmitting rotational power generated by actuating the driving machine 196 to
the rotor 172. In this way, the rotor 172 can be eccentrically rotated.
[0037] Further, as illustrated in FIG. 1, a controller 200 for operational control is connected
to each of the uniaxial eccentric screw pumps 100. The controller 200 includes an
inverter circuit 202 and a programmable logique controller (PLC) 204. Further, for
one of the plurality of uniaxial eccentric screw pumps 100 that are provided as objects
of monitoring by the remote monitoring system 1, a controller 200 including a computer
210 described in detail below is used (hereinafter also referred to as "controller
200a"). Further, for others of the plurality of uniaxial eccentric screw pumps 100,
controllers 200 each including a cell computer 220 described in detail below instead
of the computer 210 are used (hereinafter also referred to as "controllers 200b").
(Remote monitoring system 1)
[0038] The remote monitoring system 1 is used, for example, by a manufacturer or maintenance/inspection
engineers of the uniaxial eccentric screw pumps 100 so as to monitor, from a remote
site, the plurality of uniaxial eccentric screw pumps 100 that are installed in premises
of a factory of a client user of the uniaxial eccentric screw pumps 100. The manufacturer
or the maintenance/inspection engineers of the uniaxial eccentric screw pumps 100
can use the remote monitoring system 1 for the purpose of successively grasping operating
conditions of the uniaxial eccentric screw pumps 100 used by the client so as to suggest
appropriate maintenance timings or to immediately cope with troubles, for example.
[0039] Next, description is made of a specific configuration of the remote monitoring system
1. As illustrated in the system schematic view of FIG. 1, the remote monitoring system
1 is a system for monitoring, with monitoring means 50 installed in a remote site,
the operating conditions of the plurality of uniaxial eccentric screw pumps 100 that
are installed in a predetermined region such as a factory or a work place. The remote
monitoring system 1 mainly includes wireless intercommunication means 10, operating
condition detecting means 20, and Internet connection means 30 that are installed
on the uniaxial eccentric screw pump 100 side, and the monitoring means 50 that is
installed in the remote site.
[0040] The wireless intercommunication means 10 is a terminal installed to each of the plurality
of uniaxial eccentric screw pumps 100 that are installed in a local area, and functions
as a node that establishes an independent multi-hop network in the local area (hereinafter
also referred to as "communication network N"). Examples of the wireless intercommunication
means 10 may include node terminals that establish a wireless personal area network
(PAN) . In this embodiment, ZigBee (trademark) is employed as a standard of the wireless
PAN that is established in the local area. Further, the communication network N is
a communication network that is uniquely established for remote monitoring on the
uniaxial eccentric screw pumps 100, and hence is independent of a network existing,
for example, in the factory in which the uniaxial eccentric screw pumps 100 are installed,
such as a local area network (LAN).
[0041] Specifically, in the example in which the manufacturer or the maintenance/inspection
engineers of the uniaxial eccentric screw pumps 100 use the remote monitoring system
1 so as to monitor the uniaxial eccentric screw pumps 100 installed, for example,
in the premises of the factory on the client (user) side, the communication network
N is established as a communication network for communicating monitoring data in addition
to the local area network (LAN) that is established in the premises by the client.
Thus, in principle, the monitoring data of the uniaxial eccentric screw pumps 100
is communicated without using an information infrastructure such as the local area
network (LAN) on the client side.
[0042] The wireless intercommunication means 10 mounted respectively to the uniaxial eccentric
screw pumps 100 are mainly classified as a coordinator 10a (information aggregation
means), a router 10b, and an end device 10c based on their functions. The wireless
intercommunication means 10 that is classified as the coordinator 10a (hereinafter
also abbreviated as "coordinator 10a") has an information aggregation function to
aggregate information items that are sent and received within the communication network
N. Further, the wireless intercommunication means 10 that is classified as the router
10b (hereinafter also abbreviated as "router 10b") exerts a relay function in the
communication network N. Still further, the wireless intercommunication means 10 that
is classified as the end device 10c (hereinafter also abbreviated as "end device 10c")
serves as a terminal in the communication network N, and does not exert the relay
function, which is different from the router 10b.
[0043] The coordinator 10a is capable of exerting a function to start up the communication
network N and a function of the router. In this way, the coordinator 10a is capable
of managing operations of all the wireless intercommunication means 10 that function
as the nodes in the communication network N. Further, the router 10b is incapable
of starting up the communication network N, but capable of exerting the function of
the router and managing an operation of the wireless intercommunication means 10 that
functions as a child node of its own. The end device 10c is capable of managing an
operation of its own, but incapable of starting up the communication network N or
exerting the function of the router. The wireless intercommunication means 10 other
than the coordinator 10a normally wait in a de-energized state, and are switched to
an energized state only when information is sent and received and the like.
[0044] The operating condition detecting means 20 detect the operating conditions of the
uniaxial eccentric screw pumps 100 and output the operating conditions as operating
condition detection information items. The operating condition detecting means 20
are provided correspondingly to the uniaxial eccentric screw pumps 100. The operating
condition detecting means 20 each mainly include a detection unit 22 including various
sensors, and an abnormality determination unit 24 for executing abnormality determination
based on data detected by the detection unit 22.
[0045] Examples of the detection unit 22 may include a unit that is capable of detecting
rotational torque, a rotational frequency, or the number of revolutions of the driving
machine 196 of the uniaxial eccentric screw pump 100. Specifically, the unit as an
example of the detection unit 22 is capable of detecting the rotational torque, the
rotational frequency, or the number of revolutions based on data acquired from an
inverter for controlling the drive of the driving machine 196. Alternatively, the
examples of the detection unit 22 may include a sensor that is capable of detecting
a discharge pressure and an inflow pressure of the uniaxial eccentric screw pump 100,
and information items on a fluid substance as a pumping object, such as physical properties
(temperature, viscosity, ph, and the like) of the fluid substance, and a flow rate
of the fluid substance.
[0046] The abnormality determination unit 24 determines whether or not the operating condition
of the uniaxial eccentric screw pump 100 is abnormal based on the data acquired by
the detection unit 22. Specifically, when a data item (rotational torque, rotational
frequency, number of revolutions, or the like) that indicates a drive state of the
driving machine 196 does not fall within a predetermined permissible range, the abnormality
determination unit 24 can determine that the operating condition of the uniaxial eccentric
screw pump 100 is abnormal. Further, when the information (discharge pressure, inflow
pressure, physical properties, flow rate, or the like) on the fluid substance that
flows in and out from the uniaxial eccentric screw pump 100 does not fall within a
predetermined permissible range, the abnormality determination unit 24 can determine
that the operating condition of the uniaxial eccentric screw pump 100 is abnormal.
[0047] The operating condition detecting means 20 is capable of outputting, as the operating
condition detection information, any one or both of the above-mentioned detected data
that is acquired by the detection unit 22 and data that is obtained by processing
the detected data. Examples of the data obtained based on the detected data include
data that is obtained by the abnormality determination unit 24 and indicates an abnormality
determination result (hereinafter also referred to as "abnormality determination data").
In this embodiment, the abnormality determination data obtained by the abnormality
determination unit 24 is output as the operating condition detection information from
the operating condition detecting means 20.
[0048] The above-mentioned wireless intercommunication means 10 and abnormality determination
unit 24 of the operating condition detecting means 20 are unified as the cell computer
220 together with an external I/O connector and the like, and provided in this state
to each of the uniaxial eccentric screw pumps 100. Further, the detection unit 22
of the operating condition detecting means 20 is electrically connected to the cell
computer 220. The cell computer 220 is connected to a separately provided power source
such as an electric cell.
[0049] The Internet connection means 30 has a function of a gateway 32 for connecting the
communication network N and the Internet to each other, and a function of a communication
terminal 34 that enables information communication via the Internet by using a mobile
communication system. The Internet connection means 30 may be provided in the computer
210 of the controller 200 of one of the plurality of uniaxial eccentric screw pumps
100 that are provided as monitoring objects (hereinafter also referred to as "extra-system
uniaxial eccentric screw pump 101").
[0050] Specifically, as illustrated in FIGS. 3, the computer 210 includes the Internet communication
means 30 instead of the wireless intercommunication means 10 of the computer 220.
Thus, the communication network N cannot be established between the extra-system uniaxial
eccentric screw pump 101 and any of the other uniaxial eccentric screw pumps 100.
Meanwhile, the gateway 32 provided in the Internet communication means 30 is capable
of receiving operating condition detection information items that are aggregated to
and output from the wireless intercommunication means 10 having the function of the
coordinator 10a in the communication network N. Further, as well as the cell computers
220, the operating condition detecting means 20 is provided also in the computer 210
for the extra-system uniaxial eccentric screw pump 100. Thus, the Internet communication
means 30 can transmit, together with operating condition detection information items
of the extra-system uniaxial eccentric screw pump 101, the operating condition detection
information items that are received by the gateway 32 to the Internet via the communication
terminal 34.
[0051] The monitoring means 50 is a terminal such as a server or a personal computer that
is connected to the Internet. In this embodiment, in the monitoring means 50, a client
terminal 50b (client computer) that is a personal computer is connected in a wired
or wireless manner to a server 50a so that data communication can be performed therebetween.
In the monitoring means 50, the server 50a can receive the above-mentioned operating
condition detection information items that are sent to the Internet via the communication
terminal 34, and the operating conditions of the uniaxial eccentric screw pumps 100
can be monitored on the client terminal 50b by using a predetermined viewer and the
like.
[0052] The operating conditions of the uniaxial eccentric screw pumps 100 may be displayed
as letters, graphs, or what is called pictograms on the monitoring means 50. Specifically,
the uniaxial eccentric screw pumps 100 as monitoring objects may be displayed as the
pictograms, and a pictogram corresponding to a uniaxial eccentric screw pump 100 in
which an abnormality is detected may be displayed in a different display pattern.
More specifically, the pictogram corresponding to the uniaxial eccentric screw pump
100 in which the abnormality is detected may be displayed in a different color, or
may be flashed. Alternatively, warning signs using the pictograms, warning signs of
other types such as the letters and the graphs, and warning using sound and the like
may be used in combination. When warning is issued by using the pictograms in this
way, one of a large number of the uniaxial eccentric screw pumps 100, in which an
abnormality has occurred, can be intuitively grasped.
[0053] Alternatively, the abnormality that is detected in the uniaxial eccentric screw pump
100 may be notified of by displaying the pictograms as shown in FIGS. 4(a) to 4(d).
Specifically, when jamming occurs in the suction port (second opening portion 164)
of the uniaxial eccentric screw pump 100, the rotational torque of the driving machine
196 exceeds the permissible range. In this case, as shown in FIG. 4 (a), a pictogram
of the suction port (second opening portion 164) is displayed on the monitoring means
50. With this, occurrence of jamming with the fluid substance can be notified of so
as to be intuitively and accurately grasped.
[0054] Similarly, in a case where the flow rate sensor is provided as the detection unit
22, when the flow rate of the fluid substance is not detected, it is assumed that
the fluid substance is not flowing through the uniaxial eccentric screw pump 100,
that is, the uniaxial eccentric screw pump 100 is in a state of a liquidless operation.
Thus, in this case, as shown in FIG. 4(b), a pictogram of the liquid transport path
176 is displayed on the monitoring means 50. With this, the state of the liquidless
operation can be notified of so as to be intuitively grasped. Further, when clogging
occurs in a pipe connected to the uniaxial eccentric screw pump 100, it is assumed
that the flow of the fluid substance cannot be detected by the detection unit 22.
In this case, a pictogram indicating the pipe clogging is displayed as shown in FIG.
4(c). With this, the pipe clogging state can be notified of. Still further, in a case
where a valve that is provided to the pipe connected to the uniaxial eccentric screw
pump 100 is closed, it is assumed that pressure exceeds a predetermined range. Thus,
when a state of the high pressure exceeding the predetermined range is detected by
the detection unit 22, a pictogram schematically indicating that the valve is closed
is displayed as shown in FIG. 4(d). With this, the closed state of the valve can be
notified of.
[0055] Further, in a case where at which part in the uniaxial eccentric screw pump 100 as
a monitoring object an abnormality has occurred can be specified, as shown in FIG.
4(b), in the pictogram of the uniaxial eccentric screw pump 100 in which the abnormality
has occurred, apart corresponding to the abnormality may be displayed in a display
pattern different from those of other parts. In this way, when the uniaxial eccentric
screw pump 100 is displayed as the pictograms that are variously classified to indicate
parts at which occurrence of an abnormality is suspected, an engineer who is in charge
of monitoring can intuitively and accurately grasp the parts at which the abnormality
has occurred.
[0056] Still further, the uniaxial eccentric screw pump 100 in which an abnormality is detected
may be displayed on the monitoring means 50, and then a pictogram indicating the uniaxial
eccentric screw pump 100 may be selected, for example, by clicking thereon, to thereby
display the pictogram for indicating the abnormal part as shown in FIG. 4(b). With
such a configuration, in which of the plurality of uniaxial eccentric screw pumps
100 as monitoring objects an abnormality has occurred can be specified first, and
then at which part the abnormality has occurred can be sequentially specified. With
this, operations of specifying parts and causes of occurrence of abnormalities can
be more smoothly performed.
[0057] As described above, in the remote monitoring system 1 according to this embodiment,
the operating condition detection information items of the uniaxial eccentric screw
pumps 100 can be sent and received within the communication network N that is established
by the wireless intercommunication means 10, and can be aggregated to the coordinator
10a. Further, in the remote monitoring system 1, the operating condition detection
information items aggregated to the coordinator 10a are sent via the Internet connection
means 30. With this, the operating condition detection information items can be monitored
with the monitoring means 50. Thus, according to the remote monitoring system 1, even
when communication means via the Internet is not provided to each of the plurality
of uniaxial eccentric screw pumps 100, the operating conditions of the uniaxial eccentric
screw pumps 100 can be grasped with the monitoring means 50. Thus, the remote monitoring
system 1 according to this embodiment is capable of suppressing installation cost
and communication cost of the Internet communication means to the minimum.
[0058] Further, in the remote monitoring system 1 according to this embodiment, the wireless
intercommunication means 10 normally wait in the de-energized state, and are switched
to the energized state to send and receive the information items detected by the operating
condition detecting means 20. Thus, according to the remote monitoring system 1, power
consumption of the wireless intercommunication means 10 can be suppressed to the minimum.
As a result, running cost of the remote monitoring system 1 can be minimized. Further,
also when a portable power source such as a dry cell or a small-capacity power source
is used as a power source for the cell computer 220 including the wireless intercommunication
means 10, the cell computer 220 can be used over a long time period without replacement
of the power source. With this, time and effort for maintenance of the wireless intercommunication
means 10 and the cell computers 220 including the same can be suppressed to the minimum.
[0059] Note that, in the example described in this embodiment, an electric cell is used
as the power source for the cell computer 220. However, the present invention is not
limited thereto. For example, a power source connected to the driving machine 196
of the uniaxial eccentric screw pump 100 may also be used as that for the cell computer
220. Further, in the example described in this embodiment, the wireless intercommunication
means 10 normally wait in the de-energized state for power saving. However, the present
invention is not limited thereto, and the wireless intercommunication means 10 may
always wait in the energized state.
[0060] As described above, in the remote monitoring system 1, when the rotational torque,
the rotational frequency, or the number of revolutions of the driving machine 196
of the uniaxial eccentric screw pump 100 can be detected with the detection unit 22
of the operating condition detecting means 20, the operating condition of the uniaxial
eccentric screw pump 100 can be appropriately monitored. Further, also when the information
items on the fluid substance as the pumping object, which flows in and out from the
uniaxial eccentric screw pump 100, specifically, the discharge pressure, the inflow
pressure, the physical properties and the flow rate of the fluid substance, and the
like can be detected with the detection unit 22, the operating condition of the uniaxial
eccentric screw pump 100 can be appropriately monitored. Still further, by monitoring
the condition of the fluid substance that flows in and out from the uniaxial eccentric
screw pump 100, for example, a failure of pumping in a fluid substance transportation
system to which the uniaxial eccentric screw pump 100 is connected can also be monitored.
[0061] Note that, only one of the data items such as the rotational torque, the rotational
frequency, or the number of revolutions, may be detected from the driving machine
196. However, when a plurality of the data items are acquired, monitoring accuracy
can be further enhanced. Similarly, only one of the information items of the fluid
substance that flows in and out from the uniaxial eccentric screw pump 100 may be
detected. However, when a plurality of the information items are acquired, higher
monitoring accuracy can be expected. Further, only one of the information items on
the driving machine 196, such as the rotational torque, and the information items
on the fluid substance, such as the flow rate of the fluid substance, may be detected
by the detection unit 22. However, when those information items are acquired in combination,
the operating condition of the uniaxial eccentric screw pump 100 can be multilaterally
analyzed. As a result, much higher monitoring accuracy can be expected.
[0062] Further, in the remote monitoring system 1 according to this embodiment, the abnormality
determination unit 24 is provided to each of the operating condition detecting means
20 so that whether or not the operating condition of the uniaxial eccentric screw
pump 100 is abnormal can be determined based on the detected data that is acquired
by the detection unit 22. Further, in the remote monitoring system 1, results of the
determination by the abnormality determination units 24 are sent and received as the
operating condition detection information items via the wireless intercommunication
means 10. Thus, in the remote monitoring system 1, a communication data volume in
the communication network N can be suppressed to the minimum. As a result, occurrence
of failures of communication and the like can be prevented.
[0063] Note that, in the configuration exemplified in this embodiment, the abnormality determination
unit 24 is provided to the cell computer 220 that is provided to each of the uniaxial
eccentric screw pumps 100, and the results of the determination obtained by the abnormality
determination units 24 are sent and received. However, the present invention is not
limited thereto. Specifically, the abnormality determination unit 24 may be provided
on the monitoring means 50 side that is provided in a site out of the communication
network N, and the abnormality determination of the uniaxial eccentric screw pump
100 can be performed on the monitoring means 50 side. In this case, the information
items detected by the detection units 22 are successively sent to the monitoring means
50 side via the communication network N and the Internet. With this, whether or not
the operating conditions of the uniaxial eccentric screw pumps 100 are abnormal can
be monitored. With such a configuration, determinations of abnormalities in operations
of the uniaxial eccentric screw pumps 100 can be intensively performed on the monitoring
means 50 side. With this, the cell computers 220 can be simplified in configuration,
and hence burden required for information processes in the cell computers 220 can
be reduced.
[0064] Further, in the configuration exemplified in this embodiment, the abnormality determination
unit 24 is provided so that whether or not the operating condition of the uniaxial
eccentric screw pump 100 is abnormal can be determined. However, the present invention
is not limited thereto. Specifically, without providing a unit for performing the
abnormality determination, such as the abnormality determination unit 24, the information
items detected by the detection unit 22 may be checked on the monitoring means 50
side.
[0065] In the above-mentioned remote monitoring system 1, an abnormal condition of the uniaxial
eccentric screw pump 100 can be detected by the abnormality determination unit 24,
and checked with the monitoring means 50. However, the present invention is not limited
thereto. Specifically, a decrease in output of the uniaxial eccentric screw pump 100
maybe detected based on the detected data items such as the rotational torque of the
driving machine 196 or the detected data items such as the discharge pressure of the
uniaxial eccentric screw pump 100, and necessity of maintenance may be notified of
in the monitoring means 50 before the operating condition of the uniaxial eccentric
screw pump 100 becomes abnormal. When the necessity of maintenance can be notified
of in advance in this way, a stoppage period of the uniaxial eccentric screw pump
100 can be suppressed to the minimum. As a result, a risk of an inevitable stoppage
of, for example, a line in a factory can be prevented.
[0066] Further, a single or a plurality of references (thresholds) may be used for abnormality
determination by the above-mentioned abnormality determination unit 24. Further, when
the plurality of references (thresholds) are set, the plurality of references (thresholds)
may be set for each use such as a reference for detecting that the operating condition
of the uniaxial eccentric screw pump 100 has become completely abnormal, and a reference
for whether or not to prompt the maintenance of the uniaxial eccentric screw pump
100.
[0067] In the above-mentioned remote monitoring system 1, one of the plurality of uniaxial
eccentric screw pumps 100 installed in a predetermined region such as premises of
a factory (extra-system uniaxial eccentric screw pump 101) includes the computer 210
including the Internet communication means 30 instead of the cell computer 220 including
the wireless intercommunication means 10. The computer 210 is utilized as a device
for sending and receiving the operating condition detection information items via
the Internet. Thus, in the remote monitoring system 1, a configuration that is necessary
for communication via the Internet, such as the gateway 32, needs not be additionally
provided. As a result, installation cost can be suppressed to the minimum.
[0068] Note that, in the example described in this embodiment, the extra-system uniaxial
eccentric screw pump 101 including the computer 210 having the Internet communication
means 30 is provided outside the communication network N, and the Internet connection
means 30 of the computer 210 is connected to the Internet. However, the present invention
is not limited thereto.
[0069] Specifically, instead of providing the extra-system uniaxial eccentric screw pump
101 including the computer 210, there may be additionally provided equivalents of
the gateway 32 and the communication terminal 34 that serve as the Internet communication
means 30. In such a configuration, when the cell computer 220 is provided to each
of the uniaxial eccentric screw pumps 100, all the uniaxial eccentric screw pumps
100 can be arranged within the communication network N. Also in this case, the operating
condition detection information items that are sent and received within the communication
network N can be aggregated to the wireless intercommunication means 10 having the
function of the coordinator 10a, and can be sent and received via the gateways 32
and the communication terminals 34.
[0070] The Internet connection means 30 employed in the above-mentioned remote monitoring
system 1 is capable of information communication via the mobile communication system.
Thus, without using communication networks such as an existing local area network
(LAN) or an intranet, the operating condition detection information items can be sent
and received via the Internet. In this way, the remote monitoring system 1 according
to this embodiment can be installed without considering connection to the separately
provided local area network or the like. Note that, in the example described in this
embodiment, a unit capable of information communication via the mobile communication
system is employed as the Internet connection means 30. However, the present invention
is not limited thereto. Specifically, when the connection to the Internet can be established
even without performing the information communication via the mobile communication
system, for example, in a case where the existing local area network can be used for
connection to the Internet, the mobile communication system needs not be used.
[0071] In the example described in this embodiment, ZigBee (trademark) is employed as the
standard of the wireless personal area network (PAN) N. However, communication configurations
compliant with other standards may be employed. Specifically, the wireless intercommunication
means 10 is not particularly limited as long as wireless intercommunication can be
performed, and may include not only a wireless communication terminal compliant with
Zigbee (trademark) but also a wireless LAN terminal.
[0072] Further, in the configuration exemplified in this embodiment, the computers 210 and
220 serve as part of the controllers 200a and 200b. However, the present invention
is not limited there to. The computers 210 and 220 may be provided separately from
the controllers 200a and 200b (refer to FIG. 5). With such a configuration, also in
a case where the controllers 200a and 200b, which do not have the functions equivalent
to those of the computers 210 and 220, are separately prepared for operating the uniaxial
eccentric screw pumps 100, when the computers 210 and 220 are provided in addition
to the controllers 200a and 200b, the remote monitoring system 1 as in the above description
can be established. With this, the operations of the uniaxial eccentric screw pumps
100 can be monitored via the Internet.
[0073] Further, in the configuration exemplified in this embodiment, the cell computer 220
includes the wireless intercommunication means 10. However, the cell computer 220
needs not necessarily include the wireless intercommunication means 10. Specifically,
the wireless intercommunication means 10 may be independent of the cell computer 220
and the controllers 200a and 200b. Alternatively, the wireless intercommunication
means 10 as a component separate from the cell computer 220 may be mounted to the
controller 200a or 200b.
[0074] In this embodiment, the data items such as the rotational torque of the driving machine
196 of each of the uniaxial eccentric screw pumps 100 are received on the monitoring
means 50 side from a predetermined region side such as a factory so that a manager
of the remote monitoring system 1 can read results of analysis on the operating conditions
of the uniaxial eccentric screw pumps 100. However, the present invention is not limited
thereto. Specifically, a mobile phone, a personal digital assistant (PDA) terminal,
a smartphone, and the like belonging to a user of the uniaxial eccentric screw pumps
100 or an engineer who is in charge of maintenance may be used as the client terminal
50b so that an access to the server 50a side can be made when necessary by using an
ID number or a password that is assigned in advance. In this way, the user, the maintenance
engineer, and others may also be allowed to grasp the operating conditions of the
uniaxial eccentric screw pumps 100. Alternatively, when an abnormality occurs in the
uniaxial eccentric screw pump 100 as a monitoring object, notification data for notifying
of occurrence of the abnormality may be sent to the client terminal 50b belonging
to the user of the uniaxial eccentric screw pumps 100, the maintenance engineer, or
others, who are preregistered.
[0075] Further, in the configuration exemplified in this embodiment, the abnormality determination
units 24 provided to the computers 210 and 220 perform determination of abnormalities
of the uniaxial eccentric screw pumps 100 on the predetermined region side such as
a factory, and results of the determination are sent to the monitoring means 50 side.
However, the present invention is not limited thereto. Specifically, the server 50a
may have a function equivalent to those of the abnormality determination units 24.
With this, the data items of the operating conditions of the uniaxial eccentric screw
pumps 100 are aggregated to the server 50a side of the monitoring means 50, and the
determination of an abnormality is performed thereon. In this way, results of the
determination can be read on the client terminal 50b.
[0076] The above-mentioned abnormality notification method using display of the pictograms
is merely an example of the present invention, and an abnormality can be notified
of in various other patterns using pictograms. Specifically, in a case where installation
regions of the uniaxial eccentric screw pumps 100 as monitoring objects are located
at various sites in Japan, as shown in FIG. 6(a), marks (location indicators) that
indicate locations of the installation regions on a map are displayed on a monitor
of the client terminal 50b. Further, when an abnormality of the uniaxial eccentric
screw pump 100 occurs, a pattern of the display is changed, for example, by flashing
the location indicator corresponding to the location, or changing a display color
of the location indicator. At this time, existence of the uniaxial eccentric screw
pump 100 in the abnormal condition may be notified of by means of voice and the like.
[0077] Further, in the configuration in which the locations of the uniaxial eccentric screw
pumps 100 are displayed on the map as in FIG. 6 (a), numerical values, graphs, or
the like of data items indicating operational behavior of the uniaxial eccentric screw
pump 100 in the abnormal condition may be checked, for example, by selecting (clicking
on) the location indicator indicating the occurrence of the abnormality on the monitoring
means 50 side as shown, for example, in FIG. 6(b). Alternatively, there may be employed
a configuration in which the pictograms as shown, for example, in FIGS. 6(c) and 6(d)
may be displayed by selecting (clicking on) the "ABNORMALITY CHECK" icon displayed
as in FIG. 6(b) so that at which part in the uniaxial eccentric screw pump 100 the
abnormality has occurred and of what type the abnormality is can be intuitively grasped.
Specifically, in a case where supply of the fluid substance has stagnated and the
uniaxial eccentric screw pump 100 has idled, as shown in FIG. 6(c), the idling can
be notified of by displaying the indicator (indicator of "DRY" in FIG. 6(c)). Further,
when clogging with the fluid substance occurs near the discharge port, a mark indicating
the occurrence of the clogging near the discharge port can be displayed in an overlapping
manner so that abnormal parts and abnormal conditions can be intuitively notified
of.
[0078] In addition, as shown in FIGS. 6(c) to 6(e), it is preferred that the pictogram indicating
the uniaxial eccentric screw pump 100 be appropriately changed in accordance with
apparatus configurations. Specifically, when the uniaxial eccentric screw pump 100
does not include a hopper for supplying the fluid substance, a pictogram as shown
in FIG. 6(c) may be displayed, and when the uniaxial eccentric screw pump 100 includes
the hopper for supplying the fluid substance, a pictogram as shown in FIG. 6 (d) may
be displayed. Alternatively, when a screw is provided in the intermediate portion
160 of the uniaxial eccentric screw pump 100, a pictogram as shown in FIG. 6 (e) may
be displayed. In this way, by changing pictograms in accordance with the apparatus
configurations of the uniaxial eccentric screw pumps 100, intuitive and appropriate
notifications can be issued in accordance with the apparatus configurations, such
as error indication at a part corresponding to the screw in a case where a trouble
occurs to the screw.
Industrial Applicability
[0079] The remote monitoring system of the present invention can be used effectively for
a service of performing maintenance inspection of a plurality of uniaxial eccentric
screw pumps that are installed in a predetermined region by monitoring operating conditions
of the uniaxial eccentric screw pumps with monitoring means that is installed in a
remote site.
[0080] Specifically, the remote monitoring system of the present invention can be used by
a manufacturer or maintenance/inspection engineers of uniaxial eccentric screw pumps
so as to monitor a plurality of uniaxial eccentric screw pumps that are installed
in premises of a factory of a client from a remote site for the purpose of suggesting
maintenance timings, or immediately coping with troubles. Further, in the remote monitoring
system of the present invention, a communication network for communication of monitoring
data is established by wireless intercommunication means. Thus, remote monitoring
on the uniaxial eccentric screw pumps can be performed without using an information
infrastructure that is installed, for example, in the premises of the factory on the
client side.
Reference Signs List
[0081]
- 1
- remote monitoring system
- 10
- wireless intercommunication means
- 10a
- coordinator
- 10b
- router
- 10c
- end device
- 20
- operating condition detecting means
- 22
- detection unit
- 24
- abnormality determination unit
- 30
- Internet connection means
- 32
- gateway
- 34
- communication terminal
- 50
- monitoring means
- 100
- uniaxial eccentric screw pump
- 220
- cell computer
- N
- communication network