Patent Description:
<CIT> relates to a unit for monitoring the oil level in an engine lubrication system. <CIT> relates to a predictive diagnostics system for monitoring mechanical seals. <CIT> relates to a digital infrared intelligent sensor which overcomes the shortage of frequent interference from reflected signals of a rear background object in the prior art.

The following detailed description refers to the accompanying drawings. Also, the following detailed description does not limit the invention.

An industrial pump system may include a reservoir that is filled with a lubricating fluid (e.g., water, a light oil, a water/propylene glycol mix, etc.), which is used to lubricate mechanical seal faces on the pump shaft in the event the pump is run "dry" (e.g., without any pumped liquid running though the pump). The reservoir is connected to the pump by a set of hoses which allows the fluid to flow from the reservoir through openings in the pump housing and onto the seal faces.

Fluid level changes in the lubrication reservoir can be evidence of seal leak or another problem with the seal lubrication system. Examples of situations when the level of the fluid in the reservoir can drop include: (<NUM>) fluid in the reservoir decreases over time due to natural evaporation, small leaks in the system, and the fluid evaporating at the seal face because of the increased temperature; and (<NUM>) a catastrophic seal failure occurs, causing rapid level changes in the reservoir. In either of the above situations, observation of the pump/reservoir would typically be required to see the level of the fluid in the reservoir. In the event a low reservoir level is observed, prompt responsive action may limit or prevent damage to the pump. Conversely, increased fluid levels in the lubrication reservoir may be indicative of a kink or clog in the lubrication distribution system.

Systems and methods described herein provide pump equipment with an integrated seal lubrication system and remote monitoring. A level sensor is installed in a lubrication reservoir. The level sensor is connected to a monitoring device or an industrial internet-of-things (IIoT) device to monitor the level of the lubricating fluid in the reservoir. The monitoring device gives pump users the ability to monitor lubrication reservoir levels, along with other pump metrics, remotely. The monitoring device provides a wireless connection to a remote equipment monitoring system. Using communications through a provider network, users may access a user portal to receive alerts and configure alert settings for the level sensor. For example, when threshold limits for reservoir levels are crossed, the equipment monitoring system can push an alert message (e.g., via email or text message) to a pump user, owner, or maintenance personnel. Additionally, the monitoring device may be configured to automatically shut down the pump equipment when low lubrication reservoir levels are detected.

System and methods are disclosed herein as specified in claims <NUM> and <NUM> and their corresponding dependent claims.

In contrast with conventional pump seal lubrication systems, systems and methods described herein allow the level of the fluid in the lubrication reservoir to be monitored without a person physically present at the pump site. Furthermore, automatic pump shutdowns may be configured to prevent seal damage when the pump is operated without pumped liquid running though the pump.

<FIG> and <FIG> are right and left side views, respectively, of pump equipment <NUM>, according to an implementation described herein. Pump equipment <NUM> may include a pump bearing frame <NUM> that supports a rotating shaft <NUM>. As shown in <FIG>, for example, an outer lip seal <NUM> and a mechanical seal assembly <NUM> surround a portion of shaft <NUM>. As described above, seals <NUM> and <NUM> require lubrication when the pump is run dry to prevent damage to seals <NUM> and/or <NUM> (collectively referred to herein as "shaft seals <NUM>/<NUM>").

A reservoir <NUM> is mounted to pump bearing frame <NUM> (or another external surface of pump equipment <NUM>). <FIG>, <FIG>, <FIG> are rear perspective, top, and front views of reservoir <NUM>, while <FIG> is a side cross-sectional view of reservoir <NUM> taken along section A-A of <FIG>. Referring collectively to <FIG>, reservoir <NUM> may include a container to hold lubricant fluid, such as water, oil, propylene glycol, or a mixture thereof. A feed line <NUM> is connected to an exit port <NUM> at a lower part of reservoir <NUM>, and a return line <NUM> is connected to an entry port <NUM> of reservoir <NUM> above the feed line <NUM> connection. Feed line <NUM> may include a flexible hose, for example, that feeds lubricant from reservoir <NUM> into a lubrication gland <NUM> located between seals <NUM> and <NUM>. Gland <NUM> may be housed within pump bearing frame <NUM> around shaft <NUM>. Gland <NUM> may be sealed on the drive end by outer lip seal <NUM> operating on a portion of shaft <NUM> and on the pump end by mechanical seal assembly <NUM>. Thus, gland <NUM> prevents a fluid from leaking away from shaft <NUM>. Gland <NUM> may contain two ports: a lower port for feed line <NUM> and an upper port for return line <NUM>. Return line <NUM> may include another flexible hose, for example, that returns lubricant from lubrication gland <NUM> back to reservoir <NUM>.

Lubrication reservoir <NUM> may be positioned above pump frame <NUM> with feed line <NUM> running down to gland <NUM>. Lubrication reservoir <NUM> may also include a vented cap <NUM> to allow gravity to draw lubricant through feed line <NUM>. In operation, lubricant leaves the lower portion of the reservoir through port <NUM> and feed line <NUM> and enters the bottom of gland <NUM>. Rotation of shaft <NUM> provides pumping action for continuous circulation of the lubricant from reservoir <NUM> into gland <NUM> through feed line <NUM> and back to reservoir <NUM> through return line <NUM> and port <NUM>. Through circulation of the lubricant, heat is transferred from mechanical seal assembly <NUM> back to reservoir <NUM>. The cycling of the lubricant through reservoir <NUM> allows the lubricant the opportunity to dissipate the heat and ensures that sufficient amount of lubricant is available for gland <NUM>. Continuous presence of the lubricant in gland <NUM> keeps the faces of shaft seals <NUM>/<NUM> lubricated during dry run operations, such as during priming, re-priming, or standby operations.

As further shown in <FIG>, for example, a monitoring device <NUM> may be mounted to pump bearing frame <NUM>. Monitoring device <NUM> may include a housing configured for physical attachment, as a single unit, to a mounting surface on the outside of pump bearing frame <NUM>. Monitoring device <NUM> may include an Internet of Things device (e.g., an IIoT device), a Machine Type Communication (MTC) device, a machine-to-machine (M2M) device, an enhanced MTC device (eMTC) (also known as Cat-M1), an end node employing Low Power Wide Area (LPWA) technology such as Narrow Band (NB) IoT (NB-IoT) technology, or some other type of wireless end node. According to various exemplary embodiments described further herein, monitoring device <NUM> may include hardware, such as a processor, application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or a combination of hardware and software (e.g., a processor executing software) to execute various types of functions. Monitoring device <NUM> may be a multipurpose device including calibrated sensors to collect vibration, temperature, and/or other pump data, and forward the collected data via a wireless interface for access by users. As described further herein, monitoring device <NUM> may also include a port to receive signals from a level sensor <NUM> for lubrication reservoir <NUM>. Monitoring device <NUM> may further include logic to forward and/or act on received signals from level sensor <NUM>.

Reservoir <NUM>, hoses <NUM>/<NUM>, and gland <NUM> collectively form a lubrication system <NUM> that acts as a near-closed loop system when the integrity of shaft seals <NUM>/<NUM> remains intact. Thus, the level of lubricant in reservoir <NUM> may be expected to remain constant unless there is a seal failure or an irregularity in lubrication system <NUM>.

Reservoir <NUM> may include level sensor <NUM> installed to detect a fluid level in reservoir <NUM>. According to one implementation, level sensor <NUM> may include a liquid level sensor, such as a self-calibrating capacitive level sensor. In other implementations, level sensor <NUM> may be implemented, for example, as an ultrasonic level sensor, a float level sensor, etc. Level sensor <NUM> may be mounted on reservoir <NUM>, as shown in <FIG> and <FIG>, or adjacent reservoir <NUM>. According to one implementation, level sensor <NUM> may be configured to measure liquid height in reservoir <NUM> in a specified range. For example, level sensor <NUM> may measure between a low and a high threshold, determine a volume percentage level, or provide a range among multiple threshold levels (e.g., low, medium, full, etc.). Level sensor <NUM> may include a communication interface <NUM> to transfer measurement data to monitoring device <NUM>.

According to an implementation, sensor <NUM> may transfer measurement data to monitoring device <NUM> via a wired connection (e.g., wired interface <NUM>) connected at one of ports <NUM>. According to another implementation, sensor <NUM> may transfer measurement data to monitoring device <NUM> via a wireless signal, using a short-range wireless standard, such as a Bluetooth connection. Monitoring device <NUM> may receive measurement data from sensor <NUM>. For example, monitoring device <NUM> may receive continuous fluid level readings or periodic fluid level readings. According to one implementation, monitoring device <NUM> may be configured to temporarily store, upload, and/or and generate alert signals based on the fluid level readings.

<FIG> is a diagram illustrating an exemplary environment <NUM> in which systems and/or methods described herein may be implemented. As illustrated, environment <NUM> may include pump equipment <NUM>-<NUM> through <NUM>-M (collectively and individually referred to herein as "pump equipment <NUM>"). Each of pump equipment <NUM> may be provided with a lubrication system <NUM> and a mounted monitoring device <NUM>. Pump equipment <NUM> with lubrication system <NUM> and monitoring devices <NUM> may be distributed/provided throughout customer premises <NUM>, such as an industrial, commercial, educational, or agricultural environment, for example. Environment <NUM> may also include a provider network <NUM> with a web server <NUM>, a database <NUM>, an eligibility server <NUM>, and an application server <NUM>; a global positioning system (GPS) <NUM>; and user devices <NUM>-<NUM> through <NUM>-N interconnected by a network <NUM>. Components of environment <NUM> may be connected via wired and/or wireless links.

Provider network <NUM> may include network devices, computing devices, and other equipment to provide services, including services for customers with monitoring devices <NUM>. For example, devices in provider network <NUM> may supply backend services to user devices <NUM> for remotely monitoring pump equipment <NUM>. Provider network <NUM> may include, for example, one or more private Internet Protocol (IP) networks that use a private IP address space. Provider network <NUM> may include a local area network (LAN), an intranet, a private wide area network (WAN), etc. According to an implementation, provider network <NUM> may use vendor-specific protocols to support IoT management. In another implementation, provider network <NUM> may include a hosting platform that provides an IoT data service. The IoT data service may include receiving packets that are transmitted by monitoring devices <NUM> and implementing models to collect, store, analyze, and/or present event data from monitoring devices <NUM>. The hosting platform may also provide data-driven applications and/or analytics services for user devices <NUM> that owners of monitoring devices <NUM> may use. Examples of hosting platforms that may use different protocols and commands include Amazon® Web Services (AWS), Microsoft Azure®, IBM Watson®, Verizon® ThingSpace®, etc. Although shown as a single element in <FIG>, provider network <NUM> may include a number of separate networks.

Web server <NUM> may include one or more network or computational devices to manage service requests from eligible user devices <NUM>. In one implementation, web server <NUM> may provide an application (e.g., an event data management application) and/or instructions to user device <NUM> to enable user device <NUM> to receive and respond to information related to pump equipment <NUM>. In another implementation, as described further herein, web server <NUM> may provide multiple types of browser-based user interfaces to facilitate individual pump monitoring, system monitoring, receive alerts, receive notifications, etc. Web server <NUM> may receive settings from user devices <NUM>, may process/collate the received settings, and may forward the settings to application server <NUM> for implementation.

Database <NUM> may include one or more databases or other data structures to store data uploads from monitoring devices <NUM>, reporting/monitoring configurations, device registrations (e.g., provided by user devices <NUM> via web server <NUM>) and/or user registrations. In one implementation, database <NUM> may also store data retrieved from and/or used by eligibility server <NUM>.

Eligibility server <NUM> may include one or more network or computational devices to provide backend support for authorizing monitoring devices <NUM> and/or user devices <NUM> to use provider network <NUM>. For example, eligibility server <NUM> may perform a provisioning process for a monitoring device <NUM>, including authentication, registration, and activation in network <NUM>. Additionally, or alternatively, eligibility server <NUM> may store identification information for registered users and/or user devices <NUM>. The information may be used to verify that a particular user/user device <NUM> has access to services and/or information provided by provider network <NUM>. Upon verifying eligibility of a user/user device <NUM>, eligibility server <NUM> may, for example, provide access to other devices in provider network <NUM>.

Application server <NUM> may include one or more network or computational devices to perform services accessed through web server <NUM>. For example, application server <NUM> may manage downloading applications provided to user devices <NUM>, may process incoming data (e.g., from monitoring devices <NUM>) for storage in database <NUM>, and/or provide configuration information to monitoring devices <NUM>. According to an implementation, application server <NUM> may use a series of application programming interfaces (APIs) to send and receive data from monitoring devices <NUM>. For example, monitoring device <NUM> may forward to application server <NUM> periodic uploads of fluid level data from level sensor <NUM>. In other aspects, monitoring device <NUM> may forward to application server <NUM> real-time alerts for low (or high) fluid level readings from level sensor <NUM>. Application server <NUM> may store historical data records from level sensor <NUM> in database <NUM>. Application server <NUM> may also report alerts to registered users.

Positioning system <NUM> may include one or more devices configured to provide location information to monitoring devices <NUM>. In some implementations, location information may include, for example, GPS information or another form of global navigation satellite system (GNSS) information. In one implementation, positioning system <NUM> may include one or more cellular towers, wherein user devices may retrieve location information in the form of cellular tower triangulation information. Additionally, or alternatively, positioning system <NUM> may include a GPS satellite to determine a location of monitoring device <NUM> and/or pump equipment <NUM>.

User device <NUM> includes a device that has computational and wireless communication capabilities. User device <NUM> may be implemented as a mobile device, a portable device, a stationary device, a device operated by a user, or a device not operated by a user. For example, user device <NUM> may be implemented as a smartphone, a computer, a tablet, a wearable device, or some other type of wireless device. According to various exemplary embodiments, user device <NUM> may be configured to execute various types of software (e.g., applications, programs, etc.). As described further herein, user device <NUM> may download and/or register a client application <NUM>. As described further herein, the client application <NUM> (or "app") may be designed to access, from provider network <NUM>, data reported by monitoring devices <NUM>. For example, client application <NUM> may provide a user interface (UI) to solicit configuration settings and data requests from a user. In another implementation, user device <NUM> may use a web browser to connect to web server <NUM> and perform similar functions of client application <NUM>.

Network <NUM> may include one or more wired, wireless and/or optical networks that are capable of receiving and transmitting data, voice and/or video signals. For example, network <NUM> may include one or more access networks, IP multimedia subsystem (IMS) networks, core networks, or other networks. The access network may include one or more wireless networks and may include a number of transmission towers for receiving wireless signals and forwarding wireless signals toward the intended destinations. The access network may include a wireless communications network that connects subscribers (e.g., monitoring devices <NUM>, user devices <NUM>, etc.) to other portions of network <NUM> (e.g., the core network). In one example, the access network may include a long-term evolution (LTE) network. In other implementations, the access network may employ other cellular broadband network standards such as 3rd Generation Partnership Project (3GPP) <NUM> and future standards. Network <NUM> may further include one or more satellite networks, one or more packet switched networks, such as an IP-based network, a local area network (LAN), a wide area network (WAN), a personal area network (PAN) (e.g., a wireless PAN), a wireless local area network (WLAN), an intranet, the Internet, or another type of network that is capable of transmitting data.

In <FIG>, the particular arrangement and number of components of environment <NUM> are illustrated for simplicity. In practice there may be more monitoring devices <NUM>, provider networks <NUM>, web servers <NUM>, databases <NUM>, eligibility servers <NUM>, application servers <NUM>, positioning systems <NUM>, user devices <NUM>, and/or networks <NUM>. For example, there may be hundreds or thousands of monitoring devices <NUM>.

<FIG> is a front perspective view of an exemplary monitoring device <NUM>. Monitoring device <NUM> may be mounted to a mounting surface of pump equipment <NUM>. For example, a mounting surface of monitoring device <NUM> may be a flat machined surface on pump bearing frame <NUM>. In one implementation, pump bearing frame <NUM> may include mounting holes configured to receive threaded mounting pins <NUM> (e.g., screws). Mounting pins <NUM> may be inserted through housing <NUM> of monitoring device <NUM> and secured in the mounting holes of pump bearing frame <NUM> to attach monitoring device <NUM>. When attached to pump bearing frame <NUM>, pump indicators, such a vibration and temperature, can be detected by sensors internal to monitoring device <NUM>.

Housing <NUM> may provide a dust-resistant and water-spray resistant enclosure to protect internal components described further herein. Housing <NUM> may also include covered access ports <NUM>, the covers <NUM> of which may be removed/opened to provide access to connectors/ports <NUM> for external sensors, such as wired connections to level sensor <NUM>. For example, connections to components internal to housing <NUM> may be accessed through covered access ports <NUM> (e.g., when covers <NUM> are opened) and used for wired connections to level sensor <NUM> or other external sensors. According to an implementation, one or more of covered access ports <NUM> may also provide for a direct current (DC) power connection to an external power source. Housing <NUM> may be generally compact in size and structurally rigid (e.g., hard plastic material) to allow for mounting on pump bearing frame <NUM>.

<FIG> is a block diagram of internal components of monitoring device <NUM>. As shown in <FIG>, monitoring device <NUM> may include a vibration sensor <NUM>, a temperature sensor <NUM>, a location monitor <NUM>, a processor <NUM>, a memory <NUM>, a communications module <NUM>, sensor interfaces <NUM>, an internal power supply <NUM>, and a power adaptor <NUM>. The internal components may be enclosed, for example, within housing <NUM>. According to an implementation, one or more components may be installed on a printed circuit board, an etched wiring board, or a printed circuit assembly.

Vibration sensor <NUM> may include accelerometers, signal amplifiers, and filters to detect and indicate sensed vibration in different directions. For example, vibration sensors <NUM> may include a set of three accelerometers to measure vibration along three respective axes. In another implementation, vibration sensors <NUM> may measure vibration along two axes.

Temperature sensor <NUM> may include a sensor to detect a temperature within housing <NUM>. The internal temperature of housing <NUM> may generally correspond to the temperature of the pump bearing fame <NUM> of pump equipment <NUM>. For example, changes in the temperature of pump bearing fame <NUM> will typically cause proportional temperature changes in the housing <NUM> of monitoring device <NUM>.

Location monitor <NUM> may communicate with positioning system <NUM>, for example, to detect a location of monitoring device <NUM>. For example, location monitor <NUM> may include a location identification system (e.g., global positioning system (GPS) or another assisted location determining system).

Processor <NUM> may include one or multiple processors, microprocessors, data processors, co-processors, application specific integrated circuits (ASICs), controllers, programmable logic devices, chipsets, field-programmable gate arrays (FPGAs), application specific instruction-set processors (ASIPs), system-on-chips (SoCs), central processing units (CPUs) (e.g., one or multiple cores), microcontrollers, and/or some other type of component that interprets and/or executes instructions and/or data. Processor <NUM> may be implemented as hardware (e.g., a microprocessor, etc.), a combination of hardware and software (e.g., a SoC, an ASIC, etc.) and may include one or multiple memories (e.g., memory <NUM>, cache, etc.).

Processor <NUM> may control the overall operation or a portion of operation(s) performed by monitoring device <NUM>. Processor <NUM> may collect sample readings from vibration sensor <NUM>, temperature sensor <NUM>, location monitor <NUM>, sensors (e.g., level sensor <NUM>) connected to sensor interfaces <NUM>, internal power supply <NUM>, and/or power adaptor <NUM>. Processor <NUM> may determine sampling rates and available functions based on whether internal battery power or external power is used. Processor <NUM> may cause sample data to be sent to provider network <NUM> on a periodic basis. Processor <NUM> may also be programmed to detect if readings from any sensors exceed a predetermined threshold value and generate an alert signal when a threshold is exceeded. Functions of processor <NUM> are described further in connection with, for example, <FIG>.

Memory <NUM> includes one or multiple memories and/or one or multiple other types of storage mediums. For example, memory <NUM> may include random access memory (RAM), dynamic random access memory (DRAM), cache, read only memory (ROM), a programmable read only memory (PROM), a static random access memory (SRAM), a single in-line memory module (SIMM), a dual in-line memory module (DIMM), a flash memory (e.g., a NAND flash, a NOR flash, etc.), and/or some other type of memory. Alternatively, or additionally, memory <NUM> may include a Micro-Electromechanical System (MEMS)-based storage medium, and/or a nanotechnology-based storage medium. Memory <NUM> may store data (e.g., from vibration sensor <NUM>, temperature sensor <NUM>, location monitor <NUM>, level sensor <NUM>, other sensors connected to sensor interfaces <NUM>, internal power supply <NUM>, and/or power adaptor <NUM>), software, and/or instructions related to the operation of monitoring device <NUM>. According to another implementation, memory <NUM> may store fluid level thresholds, such as maximum and/or minimum thresholds for level sensor <NUM>.

Communications module <NUM> permits monitoring device <NUM> to communicate with other devices, networks, systems, devices, and/or the like. According to implementations described herein, communications module <NUM> includes multiple wireless interfaces. For example, communications module <NUM> may include multiple transmitters and receivers, or transceivers. Communications module <NUM> may include one or more antennas. For example, communications module <NUM> may include an array of antennas. Communications module <NUM> may operate according to one or more communication standard.

According to one implementation, communications module <NUM> may include a cellular module, a wireless personal area network (WPAN) module, and a radio module. The cellular module may include a cellular radio transceiver, which may operate according to any known cellular standard, including the standards known generally as 3GPP Fourth Generation (<NUM>), <NUM> Generation (<NUM>), or Fifth Generation (<NUM>) mobile wireless standards. The cellular module may enable monitoring device <NUM> to conduct IoT communications with, for example, provider network <NUM>. The WPAN module may include a radio transceiver for a wireless personal area network (e.g., using IEEE <NUM> standards or Bluetooth®). The WPAN module may enable monitoring device <NUM> to transfer data to user device <NUM> when user device <NUM> is within a relatively short distance of monitoring device <NUM> (e.g., up to about <NUM> feet). The radio module may include a radio transceiver operating in an unlicensed spectrum (e.g., <NUM>, <NUM>). For example, the radio module may be based on an RJ45 Ethernet interface, a point-to-point radio interface, or a point-to-multipoint radio interface. The radio module may enable communications between different monitoring devices <NUM>, such as monitoring devices <NUM> in the same industrial, commercial, educational, factory, or agricultural space over a range of thousands of feet.

Sensor interface <NUM> may include one or more interfaces to receive analog or digital data from sensors and/or Modbus-enabled devices that are external to monitoring device <NUM>. For example, sensor interface <NUM> may include interfaces to accept hard-wired inputs (e.g., via wired interface <NUM>) from level sensor <NUM>, pump pressure sensors, flow sensors, rotation speed sensors, etc. (e.g., via wired connections when covers <NUM> of access ports <NUM> are removed). According to an implementation, multiple sensor interfaces <NUM> (e.g., <NUM>, <NUM>, <NUM>, etc.) may be used with monitoring device <NUM>. According to one implementation, level sensor <NUM> may use sensor interface <NUM> to periodically or continuously report fluid levels in reservoir <NUM>. Additionally, or alternatively, sensor interface <NUM> may enable level sensor <NUM> to report unscheduled reservoir level events, such as when a fluid level passes a monitored threshold for reservoir <NUM>. In another implementation, raw fluid level data reported via sensor interface <NUM> may be interpreted by logic in monitoring device <NUM>.

Internal power supply <NUM> may include one or more batteries (e.g., a rechargeable battery, a replaceable battery, etc.) to power other components of monitoring device <NUM>. Internal power supply <NUM> may include, for example, a conventional consumer-sized battery (e.g., size AA, <NUM>-volt, etc.). In one implementation, internal power supply <NUM> may include a voltage monitor to measure a battery level (e.g., voltage of a battery).

External power adaptor <NUM> may include a connection for a direct current (DC) power source (e.g., from a storage device such as an external battery) or another power source. Generally, when an external power source is connected to external power adaptor <NUM>, monitoring device <NUM> operates using the external power source instead of internal power supply <NUM>.

Although <FIG> shows exemplary components of monitoring device <NUM>, in other implementations, monitoring device <NUM> may contain fewer, different, differently-arranged, or additional components than depicted in <FIG>. Additionally, or alternatively, a component of monitoring device <NUM> may perform one or more other tasks described as being performed by another component of monitoring device <NUM>.

<FIG> is a diagram of exemplary logical components of monitoring device <NUM>. As shown in <FIG>, monitoring device <NUM> may include a mode selection manager <NUM>, upload assist logic <NUM>, notification logic <NUM>, and shutdown logic <NUM>. Functions of logical components of <FIG> may be performed, for example, by processor <NUM> configured to execute instructions stored in memory <NUM>.

Mode selection manager <NUM> may detect what power source (e.g., internal battery <NUM> or external power through DC adaptor <NUM>) is used by monitoring device <NUM> and select an appropriate operating mode for the current power source. Generally, mode selection manager <NUM> may select a mode with fewer features and less power consumption for internal battery power and a different mode with full features and greater power consumption for external power. For example, mode selection manager <NUM> may select a low power mode when only power from internal power supply <NUM> is available. Conversely, mode selection manager <NUM> may select a full feature mode when an external power source in connected through DC power adaptor <NUM>.

Mode selection manager <NUM> may apply configurable settings for sensor data sampling and data uploads that optimize performance and features of monitoring device <NUM>. For example, mode selection manager <NUM> may collect sensor data from both external sensors (e.g., level sensor <NUM> connected via wires through access ports <NUM>) and internal sensors (e.g., vibration sensor <NUM>, temperature sensor <NUM>, and location monitor <NUM>). In one aspect, mode selection manager <NUM> may obtain data samples from external sensors and internal sensors at configured periodic intervals, and provide data uploads at different configured intervals. In one implementation, mode selection manager <NUM> may include a default data reporting configuration, such as twenty samples per hour of any internal and external sensors and eight data uploads per day (e.g., via a broadband cellular connection). In another implementation, one or more data reporting settings may be configured by a user (e.g., using instructions provided to monitoring device <NUM> from provider network <NUM> via client application <NUM>).

Upload assist logic <NUM> may manage data uploads to provider network <NUM> based on settings selected by mode selection manager <NUM>. For example, upload assist logic <NUM> may initiate a data session with application server <NUM> (e.g., broadband cellular module via communications module <NUM> and network <NUM>) to perform an upload of data samples at periodic intervals governed by the currently selected mode. In another implementation, upload assist logic <NUM> may use a WPAN module to conduct data uploads (e.g., when a broadband cellular connection is not available) to a local user device <NUM>. For example, upload assist logic <NUM> may detect, via a Bluetooth component, a user device <NUM> with a client application <NUM>. If upload assist logic <NUM> detects stored data samples (e.g., from internal sensors or external sensors) that have not been uploaded from monitoring device <NUM>, upload assist logic <NUM> may use a WPAN connection with user device <NUM> to transfer data to client application <NUM>. Upload assist logic <NUM> may upload the stored data samples to user device <NUM>/client application <NUM>, which may automatically forward the data samples to provider network <NUM> whenever user device <NUM> has a broadband cellular connection. According to one implementation, the data samples uploaded from monitoring device <NUM> to user device <NUM> are not configured for presentation by user device <NUM>. Instead, user device <NUM>/client application <NUM> may access provider network <NUM> for access to data from monitoring device <NUM>. Thus, provider network <NUM> may maintain secure access to all uploaded data via eligibility server <NUM>.

Notification logic <NUM> may manage transmission of periodic reports or alert signals for detection of out-of-compliance behavior. For example, notification logic <NUM> may store and identify preset thresholds, which may be provided as part of a user configuration or factory defaults. Thresholds may include, for example, reservoir levels (e.g., certain percentages, high/low levels, etc.), vibration deviations, temperature limits, pressure limits, flow rates, etc. Notification logic <NUM> may determine when numerical values of each data samples from any of the internal sensors or external sensors exceed one of the corresponding thresholds. When a threshold is exceeded, notification logic <NUM> may send an alert signal to provider network <NUM>. The alert signal may include, for example, a time, a value (e.g., a threshold level or percentage), a sensor identifier (e.g., for level sensor <NUM>), an impacted component or system (e.g., lubrication system <NUM>), etc. Provider network <NUM> may, in turn, provide an alert message (e.g., an SMS message, email, etc.) to a user or client application <NUM>.

Shutdown logic <NUM> may manage pump shutdown actions in accordance with configured settings. For example, shutdown logic <NUM> may be configured to deactivate (e.g., cut power) or turn off/shut down pump equipment <NUM> if level sensor <NUM> reports low fluid levels for a certain time period or a configured number of readings. According to another implementation, shutdown logic <NUM> initiate a pump shutdown upon receiving a signal from provider network <NUM> (e.g., application server <NUM>).

<FIG> is a signal flow diagram illustrating typical communications in a portion <NUM> of environment <NUM> for using monitoring device <NUM> with level sensor <NUM>. More particularly, communications shown in <FIG> relate to periodic monitoring of reservoir <NUM>. As shown in <FIG>, network environment portion <NUM> may include monitoring device <NUM>, level sensors <NUM>, provider network <NUM>, and user device <NUM>. Communications shown in <FIG> provide simplified illustrations of communications in portion <NUM> and are not intended to reflect every signal or communication exchanged between devices.

Monitoring device <NUM> may collect analog and/or digital sensor data <NUM> from level sensor <NUM>. For example, monitoring device <NUM> may receive liquid level readings from level sensor <NUM> connected to sensor interface <NUM>. Monitoring device <NUM> may also collect internal sensor data <NUM> from internal sensors, such as local vibration sensor <NUM>, temperature sensor <NUM>, and location monitor <NUM>.

Monitoring device <NUM> may compile sensor data <NUM> and <NUM> as combined sensor data <NUM> and send combined sensor data <NUM> to provider network <NUM>, thus providing a consolidated data channel for multiple sensors. Monitoring device <NUM> may send data at configured upload intervals using, for example, a broadband cellular connection. Provider network <NUM> (e.g., application server <NUM>) may receive, process, and store <NUM> the combined sensor data <NUM> (e.g., store in database <NUM>).

After receiving combined sensor data <NUM>, a user of user device <NUM> may initiate an authentication procedure <NUM> with provider network <NUM> to access stored data for pump equipment <NUM>. In one implementation, authentication procedure <NUM> may be managed via client application <NUM> on user device <NUM>. In another implementation, authentication procedure <NUM> may be managed via a web browser interface on user device <NUM> to solicit user credentials.

Assuming the user is authenticated, user device <NUM> may submit a data request <NUM> to provider network <NUM> to access data from monitoring device <NUM>. In response, provider network <NUM> may retrieve corresponding data stored in database <NUM>, and provide the pump data (e.g., including data from level sensor <NUM>) to user device <NUM> via, for example, web server <NUM> and/or application server <NUM>. Maintenance personnel at user device <NUM> may then remotely determine whether any issues exist with respect to operations of pump equipment <NUM>.

<FIG> is a signal flow diagram illustrating alert-related communications in network portion <NUM> for using monitoring device <NUM> with level sensor <NUM>. More particularly, communications shown in <FIG> relate to providing alerts for low levels in reservoir <NUM>. Communications shown in <FIG> provides simplified illustrations of communications in portion <NUM> and are not intended to reflect every signal or communication exchanged between devices.

Referring to <FIG>, an authenticated user may use client application <NUM> on user device <NUM> to configure alert setting <NUM> for monitoring device(s) <NUM> on pump equipment <NUM>. Alert settings may include, for example, (a) threshold values related to reservoir <NUM> for each monitoring device <NUM> and/or (b) contact information for automated alerts (e.g., e-mail address, phone numbers, account names, etc.). Provider network <NUM> (e.g., application server <NUM>) may forward some of the alert settings <NUM>, such as the configuration thresholds (if applicable) to monitoring device <NUM>. Monitoring device <NUM> may store the alert settings <NUM> (e.g., in memory <NUM>). If level sensor <NUM> is connected to monitoring device <NUM>, monitoring device <NUM> may collect analog and/or digital liquid level data <NUM> from level sensor <NUM>.

Monitoring device <NUM> may compare <NUM> level sensor data <NUM> with the stored alert thresholds <NUM>. If monitoring device <NUM> identifies that a threshold had been met/exceeded for reservoir <NUM>, monitoring device <NUM> may send a level threshold alert <NUM> to provider network <NUM>. For example, monitoring device <NUM> may use a cellular or wired connection to provide level threshold alert <NUM> to application server <NUM>. In one implementation, monitoring device <NUM> may provide level threshold alert <NUM> immediately to application server <NUM> (e.g., without waiting for a configured periodic data upload interval). The level threshold alert <NUM> may include the data from level sensor <NUM> that triggered level threshold alert <NUM>. In another implementation, level threshold alert <NUM> may include a full data upload of any unreported sensor data (e.g., vibration, temperature, location data).

Upon receiving level threshold alert <NUM>, provider network <NUM> (e.g., application server <NUM>) may generate and send an alert message <NUM> in accordance with the configured alert settings <NUM>. For example, application server <NUM> may generate and send an SMS message to one or more contacts associated with an account for monitoring device <NUM>.

Although <FIG> and <FIG> show exemplary communications for monitoring and alerts using monitoring device <NUM>, in other implementations, fewer, different, or additional communications may be used. For example, in other implementation, monitoring device <NUM> may report data from multiple level sensors <NUM>, such as level sensors <NUM> connected to different pump equipment <NUM>. In addition, in some implementations, monitoring device <NUM> and/or user device <NUM> may send a signal to automatically shut down pump equipment <NUM> when a level threshold alert is detected.

A device, system, and methods are provided for remotely monitoring liquid lubricant levels for pump equipment. A system includes a reservoir to store lubricant and a lubrication gland to expose a shaft seal of the pump equipment to the lubricant. A feed line and a return line circulate the lubricant between the reservoir and the lubrication gland. A level sensor is configured to measure a fluid level in the reservoir. The level sensor uses a communication interface to transmit fluid level data a monitoring device mounted to the pump equipment. The monitoring device is configured to compare the fluid level data against stored alert thresholds and send, to a provider network, an alert signal when the fluid level data is below an alert threshold. If the fluid level data is not below an alert threshold, the monitoring device may store the fluid level data for periodic reporting.

According to another implementation, a method includes providing pump equipment that includes a lubrication system and a monitoring device. The lubrication system may include: a reservoir configured to store liquid lubricant, a lubrication gland configured to expose a shaft seal of the pump equipment to the liquid lubricant, a feed line configured to provide liquid lubricant from the reservoir to the lubrication gland, a return line to provide liquid lubricant from the lubrication gland to the reservoir, a liquid level sensor configured to measure a fluid level in the reservoir, and a communication interface to transmit fluid level data from the liquid level sensor to the monitoring device. The method further includes configuring the monitoring device to: store alert thresholds for the fluid level data; receive, from the liquid level sensor, fluid level data; compare the fluid level data against the stored alert thresholds; send, to a provider network, a level alert when the fluid level data is below one of the stored alert thresholds; and store the fluid level data when the fluid level data is not below one of the stored alert thresholds.

As set forth in this description and illustrated by the drawings, reference is made to "an exemplary embodiment," "an embodiment," "embodiments," etc., which may include a particular feature, structure or characteristic in connection with an embodiment(s). However, the use of the phrase or term "an embodiment," "embodiments," etc., in various places in the specification does not necessarily refer to all embodiments described, nor does it necessarily refer to the same embodiment, nor are separate or alternative embodiments necessarily mutually exclusive of other embodiment(s). The same applies to the term "implementation," "implementations," etc..

The foregoing description of embodiments provides illustration, but is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Accordingly, modifications to the embodiments described herein may be possible. For example, various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. Also, while a series of messages have been described with regard to <FIG> and <FIG>, the order of the message/operation flows may be modified in other embodiments. Further, non-dependent messages may be performed in parallel. The description and drawings are accordingly to be regarded as illustrative rather than restrictive.

The terms "a," "an," and "the" are intended to be interpreted to include one or more items. Further, the phrase "based on" is intended to be interpreted as "based, at least in part, on," unless explicitly stated otherwise. The term "and/or" is intended to be interpreted to include any and all combinations of one or more of the associated items. The word "exemplary" is used herein to mean "serving as an example. " Any embodiment or implementation described as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments or implementations.

Use of ordinal terms such as "first," "second," "third," etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another, the temporal order in which acts of a method are performed, the temporal order in which instructions executed by a device are performed, etc., but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.

Claim 1:
A pump system comprising:
a reservoir (<NUM>) configured to store liquid lubricant;
a lubrication gland (<NUM>) configured to expose a shaft seal (<NUM>/<NUM>) of the pump equipment (<NUM>) to the liquid lubricant;
a feed line (<NUM>) configured to provide liquid lubricant from the reservoir to the lubrication gland;
a return line (<NUM>) to provide liquid lubricant from the lubrication gland to the reservoir;
a liquid level sensor (<NUM>) configured to measure a fluid level in the reservoir;
a monitoring device (<NUM>) mounted to the pump equipment; and
a communication interface (<NUM>) to transmit fluid level data from the liquid level sensor to the monitoring device,
wherein the monitoring device is configured to:
compare the fluid level data against stored alert thresholds (<NUM>),
send, to a provider network, a level alert when the fluid level data is below one of the stored alert thresholds (<NUM>),
store the fluid level data when the fluid level data is not below one of the stored alert thresholds (<NUM>),
obtain, at a first periodic interval, data samples from one or more sensors internal to a housing of the monitoring device (<NUM>),
store the data samples with the stored fluid level data to form combined data (<NUM>),
establish, at a second periodic interval and via a wireless communications interface, a connection with the provider network (<NUM>), and
send, via the wireless communications interface, the combined data to the provider network (<NUM>).