Views: 0 Author: Site Editor Publish Time: 2026-11-12 Origin: Site
To address high‑frequency faults in long‑term running water pump units including bearing wear, coupling misalignment, rotor unbalance, cavitation, excessive vibration and abnormal temperature rise, a comprehensive online condition‑monitoring system featuring vibration‑temperature core measurement, integrated hardware‑software design and edge‑cloud collaboration shall be constructed. Through full‑dimensional data acquisition, real‑time visual monitoring, intelligent anomaly early‑warning and multi‑protocol cloud‑platform interconnection, the system implements full‑life‑cycle condition monitoring for key pump‑unit components. It detects hidden equipment hazards in advance, reduces unplanned shutdown risks, and provides scientific data support for lean equipment operation‑maintenance and planned overhaul. Ultimately, it improves operational reliability and service life of water pump units.
Real‑time online monitoring of key operating parameters with visual presentation of condition data;
Dynamic analysis of equipment operation trends to realize early fault warning and graded alarming;
Cross‑validation of multi‑parameter data including vibration, pressure and temperature for accurate fault‑type localization;
Support multi‑protocol uploading of monitoring data to customers’ private cloud platforms for unified data management;
Dual‑monitoring capability for on‑site and remote scenarios to reduce manual inspection workload and improve operation‑maintenance efficiency.
The system adopts a three‑layer architecture: Perception Layer – Acquisition & Transmission Layer – Cloud Application Layer. It covers the full link from sensor data acquisition and local real‑time monitoring to cloud‑side data aggregation. Each layer is deployed independently while collaborating synergistically, balancing on‑site visibility and cloud‑side scalability. The overall system consists of the following subsystems:
Vibration Monitoring System (core perception layer)
Bearing Temperature Monitoring System (perception layer)
Data Acquisition & Multi‑protocol Transmission System (acquisition‑transmission layer, with newly‑added multi‑protocol cloud interconnection)
On‑site Installation & Auxiliary Supporting Materials (supporting layer)
Online‑monitoring & Visualization Cloud Platform
As the core sensing unit of the system, it is configured according to typical vibration‑fault characteristics of water‑pump units to capture full‑dimensional vibration status of critical components such as rotors, bearings and couplings.
Sensor Type: IEPE vibration sensor
Main Technical Parameters
Frequency response range: 0.5 Hz ~ 1000 Hz (fully covers typical fault‑vibration frequency bands of water pumps)
Linear measurement range: ±16 g
Amplitude non‑linearity: ≤±5%
Operating temperature: −20 ℃ ~ +80 ℃ (adapted to complex thermal conditions on industrial sites)
Output: Standard IEPE signal; 10‑meter shielded cable supplied as standard for anti‑electromagnetic‑interference performance on‑site
Qualification: Calibrated by third‑party CNAS‑accredited laboratory for traceable and accurate measurement data
Installation Position & Quantity Allocation: scientifically deployed at high‑incidence fault points for tri‑axial full‑dimensional monitoring
Pump drive‑end bearing housing (monitor drive‑end bearing wear and abnormal radial force)
Pump non‑drive‑end bearing housing (monitor non‑drive‑end bearing condition and rotor deflection)
Motor (monitor motor rotor unbalance, foundation resonance and coupling misalignment)
Core Monitoring Contents
Mechanical deviation faults: rotor unbalance, coupling misalignment, structural looseness, etc.
Early‑stage bearing faults (rolling‑element pitting, inner/outer race pitting corrosion and wear)
Transmission‑system anomalies: coupling looseness, shaft misalignment and others
Structural issues: equipment foundation resonance, excessive housing vibration, etc.
It implements high‑precision contact / non‑contact temperature monitoring targeting faults such as insufficient bearing lubrication, overload friction and bearing seizure. Combined with vibration‑data linkage, it achieves accurate fault early warning.
Sensor Type: Pt100 platinum resistance thermal sensor (magnetic‑mount installation, no drilling required, non‑destructive and easy mounting)
Technical Parameters
Base resistance: Pt100 (100 ± 0.1 Ω at 0 ℃, industrial‑standard temperature‑sensing element)
Accuracy class: ≤ 0.1 ℃ (high‑precision for capturing minor temperature variation and early‑stage warning)
Measurement range: 120 % of maximum allowable operating temperature of measuring points (over‑range design to avoid high‑temperature damage)
Acquisition mode: Matched industrial‑grade temperature acquisition module supporting multi‑channel synchronous sampling
Measuring‑point Distribution
Water‑pump bearing temperature (covers all pump‑bearing positions for monitoring lubrication and friction conditions)
Motor bearing temperature (monitors motor‑bearing operation status and predicts motor overload)
Core Monitoring Significance
Early identification of insufficient bearing lubrication, grease aging, overload friction and other risks
Warning against severe faults including bearing seizure to prevent equipment damage
Cross‑validation together with vibration data: simultaneous “excessive vibration plus sharp temperature rise” at the same measuring point indicates severe bearing failure and improves early‑warning accuracy.
Serving as the system “data hub”, it realizes synchronous acquisition and local processing of multi‑type data including vibration, pressure and temperature. Supporting multi‑protocol uploading to customers’ private cloud platforms, it constitutes a core component for edge‑cloud collaboration.
Core System Configuration
Industrial‑grade multi‑channel data‑acquisition module: each unit supports simultaneous access of vibration, pressure and temperature signals; channel quantity matches measuring‑point requirements for single pump unit
Industrial‑grade communication interfaces: Ethernet, RS485/232 field‑bus interfaces as standard for on‑site industrial wiring environments
Local data storage: built‑in high‑capacity storage for caching historical data during network outage; automatic supplementary upload upon network recovery without data loss
Multi‑protocol cloud interconnection module (core optimization item): embedded mainstream industrial protocols including MQTT, WEBSOCKET, HTTP RESTful, MODBUS TCP/RTU for seamless docking with customers’ private cloud platforms
Core Functions
Real‑time acquisition: synchronously collect vibration and temperature data at configurable sampling intervals (1 s / 5 s /10 s)
Data pre‑processing: filtering, calibration and normalization for raw data to enhance data validity
Local alarm triggering: embedded threshold‑judgment logic; optional local audible‑visual alarm upon data over‑limit with synchronized message push to display terminals
Multi‑protocol cloud uploading: both scheduled uploading and trigger‑based uploading modes supported; upload frequency and data format configurable to satisfy customer cloud‑platform interface requirements
Custom protocol adaptation: personalized interface development available according to actual protocol specifications of customer cloud platforms to guarantee seamless data access
Custom supporting auxiliary materials are deployed to guarantee stable signal transmission and reliable sensor installation, adapted to harsh industrial‑site environments.
Signal cable for single unit: shielded twisted‑pair structure, specially designed for vibration and analog‑quantity signals with anti‑electromagnetic‑interference and anti‑mechanical‑pull performance
Special‑purpose installation accessories: stainless‑steel bases for vibration sensors, pressure‑transmitter mounting adapters, magnetic‑mount holders for Pt100 sensors, waterproof terminal blocks, cable trunking, fixing clips and other components
Protection accessories: waterproof sealant, insulating tape, cable nameplates, etc. for standardized cable routing and identification facilitating later‑stage maintenance
Integrating four core capabilities: on‑site real‑time monitoring, local data processing, multi‑protocol cloud uploading and intelligent early‑warning analysis, the system forms a full‑process closed loop from “data acquisition” to “operation‑maintenance application”. Specific functions are as follows:
Core parameters such as vibration severity (mm/s) and bearing temperature (℃) refresh at second‑level intervals to display data of all measuring points.
Three‑level status indicators are bound to each measuring point. Automatic alarm is triggered upon data over‑limit for precise fault‑point localization; equipment status can be obtained without on‑site manual inspection.
Custom naming of measuring‑points supported; actual component labels such as “Pump drive‑end bearing X‑direction” or “Motor temperature” can be displayed directly for better readability.
Dual‑level data storage by local display terminal plus acquisition module; historical‑data query by time stamp and measuring‑point; configurable data‑retention cycle.
Trend curves of arbitrary measuring‑points can be viewed over multiple time windows (5 min /15 min /30 min /60 min), intuitively reflecting changing rules of equipment operating conditions for detecting latent faults.
Hover‑view for detailed information on trend curves to accurately pinpoint abnormal time stamps and provide time‑sequence evidence for fault analysis.
Independent threshold configuration for each measuring‑point; warning value and alarm value can be set separately adapting to operating criteria for different components.
Alarm triggering mode: indicator‑light color change plus text prompt on local terminal upon threshold violation; optional linkage with on‑site audible‑visual alarm and alarm‑message push to cloud platform.
Graded alarm handling: Warning (Yellow) for minor over‑limit requiring attention; Alarm (Red) for severe over‑limit demanding immediate response. Graded fault management avoids excessive maintenance activities.
Synchronous acquisition and linked visualization of vibration, pressure and temperature data. Cross‑validation of “vibration plus temperature” for identical equipment positions improves fault‑judgment accuracy.
Example: Simultaneous “excessive vibration plus sharp temperature rise” on pump‑bearing positions indicates severe bearing wear rather than temporary fluctuation caused by working‑condition variation, furnishing data support for fault localization.
Core optimized function. Embedded mainstream industrial communication protocols realize data uploading to customers’ private cloud platforms without additional gateway hardware, supporting unified‑data‑management and remote monitoring.
Supported protocols:
MQTT (light‑weight IoT protocol for real‑time cloud‑side data reception)
WEBSOCKET (bidirectional real‑time communication)
HTTP RESTful (universal API interface compatible with various cloud platforms)
MODBUS TCP/RTU (industrial field‑bus protocol for customers’ existing industrial cloud platforms)
Upload configuration: configurable upload intervals (1 s /5 s /10 s /minute‑level), JSON‑formatted output, and upload content (full dataset / alarm‑only dataset) complying with customer cloud‑platform interface specifications.
Offline supplementary upload: locally cache historical data during network disconnection and auto‑resume uploading after network recovery to guarantee data integrity without loss.
Data compatibility: well‑structured and standardized uploaded fields can be parsed, stored and visualized directly on customer cloud platforms with no extra data conversion required.
On‑site: Industrial PLC display terminals provide local real‑time monitoring and historical‑data query to satisfy on‑site operation‑maintenance requirements.
Remote: Customers’ private cloud platforms implement centralized visualization, remote alarming and historical‑trend analysis for multiple pump units to fit group‑wide and cross‑regional operation‑maintenance management.
With integrated hardware‑software design, edge‑cloud‑collaboration architecture and multi‑protocol cloud‑interconnection capability, the system addresses pain points from traditional manual inspection for water‑pump units and delivers full‑dimensional equipment‑condition monitoring and data support for customers. Concrete benefits are shown below.
Realize early‑stage fault warning, shifting maintenance philosophy from breakdown‑repair to pre‑emptive warning and in‑process control. Detect latent hazards such as bearing wear and cavitation in advance and avoid production losses induced by unplanned shutdown.
Multi‑parameter cross‑validation enables accurate localization of fault types and positions, shortens fault‑troubleshooting time and enhances maintenance efficiency.
Real‑time monitoring of equipment working conditions prevents long‑term off‑design‑point operation and extends service life of pump units and accessories (bearings, couplings, etc.).
Substitute manual on‑site inspection, reduce staffing and inspection workload to lower labor‑based operation‑maintenance cost.
On‑site display terminals visualize all equipment status on one screen with precise fault‑point positioning, eliminating blind inspection and blind maintenance.
Data‑supported condition‑based maintenance replaces conventional time‑based periodic overhaul, avoiding resource waste from over‑maintenance and achieving optimized O&M‑cost control.
Monitoring data uploaded to customers’ private cloud platforms realize centralized and remote management of multiple pump units and raise digital‑management level of operation‑maintenance work.
Long‑term storage of full‑volume monitoring data builds operation databases for water‑pump units, furnishing scientific evidence for equipment‑performance analysis and process optimization.
Historical‑trend analysis summarizes operating patterns of pump units and provides references for equipment type‑selection and retrofitting & upgrading.
Multi‑protocol cloud‑interconnection realizes data fusion between monitoring datasets and customers’ existing production‑management / equipment‑management systems, lifting overall enterprise digital maturity and turning data into core production factors.
Comprehensive monitoring dimensions with precise fault coverage: vibration‑centric multi‑parameter monitoring of vibration, pressure and temperature covers all typical pump‑unit faults including mechanical faults, fluid‑induced faults and thermal faults. Scientific measuring‑point layout eliminates monitoring blind spots.
Integrated hardware‑software for convenient deployment: standardized configuration ranging from sensors and acquisition modules to on‑site display terminals. Each pump unit is equipped with an independent plug‑and‑play system requiring minimal on‑site commissioning.
Customizable and user‑friendly software interface: visualization interface specially optimized for 1024 × 600 industrial screens features compact layout and practical functions. On‑site O&M staff can operate proficiently without specialized training.
Edge‑cloud collaboration with multi‑protocol interconnection: mainstream protocols MQTT / WEBSOCKET / HTTP RESTful / MODBUS are supported for seamless docking with customers’ private cloud platforms. Dual‑capacity of on‑site monitoring and remote management breaks down data silos.
Industrial‑grade design adapted to field environments: all hardware components adopt industrial‑grade specifications with interference resistance, dust‑proof, water‑proof and wide‑temperature working performance for stable and reliable operation under complex pump‑site industrial environments.
High scalability suitable for large‑scale application: modular‑design system supports flexible scaling according to pump‑unit quantity, unified configuration and unified management. It is applicable for mass deployment of pump groups to lower overall implementation costs.
Yangzhou Xiyuan Electronic Technology Co.,Ltd.
#77 Yeqiao Road, Liandong U Valley slender West Lake Innovation port, building 10-2,Hanjiang District, Yangzhou,Jiangsu,China
Mobie Phone: +86 180-5105-8377
Tel: +86 514-82885589
Whatsapp:+86 182-6066-6867
Email: sale1@yzxyt.com
Fax: +86 514-82885089
