Pump Monitoring Using Acoustical Characterizations

Abstract

An audio detection unit inside of the pump can be used to capture acoustic waveforms from the pump during operation and, when compared to characterized data, can accurately determine an operating condition of the pump. Such operating conditions can include whether the pump is operating as expected, if it has lost prime, if it has a failure, or if it can be determined that failure is likely to occur in the near future.

What is claimed is: 
     
         1 . A method of detecting an operating condition of a pump comprising:
 detecting an acoustic waveform emitted by the pump during operation of the pump;   comparing the acoustic waveform with a signature waveform, the signature waveform representing normal operation; and
 generating an alert when the acoustic waveform deviates from the signature waveform. 
   
     
     
         2 . The method of  claim 1 , wherein the acoustic waveform is detected by an audio detection unit inside of the pump. 
     
     
         3 . The method of  claim 1 , wherein comparing the acoustic waveform comprising comparing one or more acoustic characteristics of the acoustic waveform, the one or more acoustic characteristics including one or more of an acoustic burst, an amplitude, a duration, a shape, and a period of the acoustic waveform. 
     
     
         4 . The method of  claim 3 , wherein the predetermined acoustic characteristic is based on an acoustic characteristic determined from an acoustic waveform of the pump operating in a normal condition over a select duration of time. 
     
     
         5 . The method of  claim 1 , further comprising sending the alert to a user. 
     
     
         6 . The method of  claim 1 , further comprising adjusting the operation of the pump if the acoustic waveform deviates from the signature waveform. 
     
     
         7 . The method of  claim 1 , further comprising determining a maintenance condition of the pump when the acoustic waveform deviates from the signature waveform. 
     
     
         8 . The method of  claim 1 , further comprising determining a loss of prime condition when the acoustic waveform deviates from the signature waveform. 
     
     
         9 . The method of  claim 8 , further comprising increasing a stroke speed of the pump for a select amount of time when the loss of prime condition is determined. 
     
     
         10 . The method of  claim 1 , further comprising determining a stalled condition when the acoustic waveform deviates from the signature waveform. 
     
     
         11 . A method of detecting an operating condition of a pump comprising:
 detecting an acoustic waveform of the pump during operation by an audio detection unit within the pump;   determining an acoustic characteristic of the acoustic waveform;   comparing the acoustic characteristic with a predetermined acoustic characteristic; and   determining the operating condition of the pump based on the compared acoustic characteristic.   
     
     
         12 . A pump comprising:
 a mechanical drive unit comprising a drive mechanism;   a liquid end comprising a diaphragm, wherein the drive mechanism is configured to translate the diaphragm;   an electronic drive unit coupled with the mechanical drive unit such that the electronic drive unit is configured to operate the mechanical drive unit; and   an audio detection unit positioned within the pump configured to detect audible noise emitted by the pump during operation, wherein the audio detection unit is coupled with the electronic drive unit such that the electronic drive unit is configured to receive the detected audible noise from the audio detection unit.   
     
     
         13 . The pump of  claim 12 , wherein the audio detection unit comprises a microphone. 
     
     
         14 . The pump of  claim 12 , wherein the audio detection unit is positioned near a select one or both of the liquid end and the mechanical drive unit. 
     
     
         15 . The pump of  claim 12 , wherein the detected audible noise comprises an acoustic waveform. 
     
     
         16 . The pump of  claim 15 , wherein the electronic drive unit is operable to compare the acoustic waveform with a characterized acoustic waveform. 
     
     
         17 . The pump of  claim 16 , wherein the electronic drive is operable to determine an operating condition of the pump. 
     
     
         18 . The pump of  claim 17 , wherein the operating condition comprises a select one or more of a normal condition, a loss of prime condition, a maintenance condition, and a stalled condition. 
     
     
         19 . The pump of  claim 17 , wherein the electronic drive is operable to alert a user of the determined operating condition. 
     
     
         20 . The pump of  claim 17 , wherein the electronic drive is operable to adjust the drive mechanism based on the determined operating condition.