Description:FIELD OF THE INVENTION

[0001] The present invention relates to a real-time pump failure prediction and prevention system designed to predict potential issues, such as empty tank condition or malfunctioning of an electric pump and accordingly mitigates the predicted issues to prevent dry-running condition of the pump leading to pump failure while ensuring optimal performance of the pump.

BACKGROUND OF THE INVENTION

[0002] Electric pumps are mechanical devices that are utilized for transferring fluids through mechanical actions which makes the device a fundamental requirement in many industrial applications. These pump plays a vital role in controlling flow of liquids in form of water, fuel or chemicals while maintaining required pressures along with ensuring efficient dispensing of fluids for various applications. Importance of pump are particularly evident in industrial and agricultural sectors due to the efficiency, automation and versatility of the pump. A few important tasks for which pumps are utilized includes transferring liquids in industrial environments, such as in the chemical, pharmaceutical, and manufacturing industries. They are used to move chemicals, solvents, lubricants, and other liquids from storage tanks to processing units, ensuring a steady and reliable flow of liquid in production lines. The accuracy and reliability of these pumps help maintain consistent production speeds and minimize downtime.

[0003] In various manufacturing processes, electric pumps are used to circulate coolants through machinery or equipment, ensuring that temperatures are controlled and that heat buildup does not damage sensitive parts. Another important application of the pumps includes wastewater treatment plants for moving water, sludge, or chemical additives between various stages of purification. These pumps help in maintaining the flow rate necessary for treatment and can handle varying viscosities and pressures. Fuel stations use electric pumps for safe and efficient dispensing of gasoline or diesel into vehicles, ensuring proper flow rates and preventing overflows. In dairy production, electric pumps move milk from tanks to pasteurization equipment, ensuring a smooth, continuous flow to maintain hygiene and processing efficiency.

[0004] Conventional electric pumps that employ flow rate sensors and level sensors for monitoring and control in various systems often face several challenges. These issues can impact the efficiency, reliability, and longevity of the pumping system. Over time, flow rate sensors can suffer from calibration drift, where the sensor's reading no longer accurately reflects the actual flow rate. This can lead to incorrect data, affecting the pump's performance and efficiency. Flow rate sensors are prone to errors due to debris accumulation, air bubbles, or viscosity changes in the liquid being pumped, causing inconsistent or inaccurate measurements. Level sensors provide false readings if the liquid is turbulent or if there is foam or air in the tank. This leads to incorrect readings of the liquid level, affecting the pump's operation (e.g., starting or stopping too early or too late). Temperature, humidity, and vibration affect the performance of level sensors, leading to inaccuracies, especially in harsh industrial or agricultural environments.

[0005] CN111749922A discloses a molecular pump fault diagnosis and prediction system. The molecular pump fault diagnosis and prediction system comprises a fault simulation system, a vacuum cavity, a vacuum pumping system and a molecular pump diagnosis system which are connected in sequence. The fault simulation system comprises a needle valve, a gauge tube, a VDE valve and a VDE valve controller. The fault simulation system is used for simulating the situation that a molecular pump breaks down due to the emergency situation that the vacuum cavity leaks and foreign matter enters. One end of the vacuum pumping system is connected with the vacuum cavity through a gate valve, and the other end of the vacuum pumping system is connected with a mechanical pump. The molecular pump diagnosis system comprises a multi-state monitoring sensor, a data acquisition device, a data calculation device and a fault diagnosis and prediction result output device. The multi-state monitoring sensor obtains real molecular pump fault state data and provides data guarantee for online real-time analysis of the molecular pump diagnosis system. The molecular pump fault diagnosis and prediction system is a fast, economical and efficient solution, and the problem that a molecular pump diagnosis and prediction system cannot be effectively established due to insufficient molecular pump fault data is solved.

[0006] CN114200273A relates to the technical field of electric submersible pumps, and particularly discloses a fault prediction system for on-line insulation monitoring of an electric submersible pump. The electric submersible pump insulation performance prediction system is used for solving the problems that an existing electric submersible pump insulation performance prediction mode is single, great inaccuracy exists, an insulation fault of an electric submersible pump is difficult to accurately predict, and safe operation of the electric submersible pump cannot be ensured. A server is arranged in the fault analysis and prediction platform, and the server is in communication connection with a data acquisition unit, a cloud storage unit, a load positioning unit, a first-level pre-judgment unit, a second-level pre-judgment unit, a comprehensive prediction unit, a fault early warning unit and a display terminal. According to the invention, the insulation condition of each power cable in the electric submersible pump can be accurately predicted and analyzed, so that the insulation fault of the electric submersible pump can be predicted more efficiently and accurately, and the operation safety and stability of the electric submersible pump can be ensured.

[0007] Conventionally, many devices and systems are employed in industries for monitoring performance of installed pumps for predicting faults in the pumps by utilizing external flow meters, sensors and devices. These flow meters, sensor and external devices proved to be unreliable, costly, and difficult to adapt to varying fluids. Additionally, maintenance and recalibration of the sensors and external devices needs significant downtime and operational expense, making the system less efficient over time, particularly in applications where precise flow monitoring is critical. Though these sensors and external devices somehow works for predicting the faults in the pump setup, however does not work to mitigate the fault or prevent the pump failure.

[0008] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop or improve existing state-of-the art for mitigating issues or faults predicted in electric pumps during operational time by increasing shift towards more advanced inbuilt technologies and pumping systems with better integration, real-time monitoring, and predictive maintenance capabilities. This helps improve the accuracy, efficiency, and longevity of the system, reducing downtime and operational costs.

OBJECTS OF THE INVENTION

[0009] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0010] An object of the present invention is to develop a system that is capable of monitoring real time running parameters of an electric pump while dispensing a liquid and accordingly predicts any malfunctioning of the pump or dry running condition of the pump on real time basis in view of preventing failure of the pump.

[0011] Another object of the present invention is to develop a system that eliminates usage of external sensors and flow meters for detecting real time running condition of an electric pump and employs an internal feedback and failsafe mechanism for adjusting running condition of the pump which minimizes error values or inaccuracies in the real time readings of the monitored parameters while ensuring precise and reliable monitoring of the running conditions of the pump.

[0012] Another object of the present invention is to develop a system that significantly reduces costing of the pump setup by eliminating any requirement for calibration of external sensors and flowmeter.

[0013] Yet another object of the present invention is to provide a system that is capable of estimating remaining liquid level in a tank configured with the pump which aids an operator in managing running condition of the pump along with preventing chances of dry running condition of the pump which enhances longevity of the pump.

[0014] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0015] The present invention relates to a real-time pump failure prediction and prevention system that pertains to employ internal set-up for monitoring real time data of running condition of an electric pump while dispensing a liquid in view of predicting dry running condition or malfunction the pump and accordingly triggers a failsafe mechanism in the set-up to adjust the real time running condition of the pump in order to prevent pump failure.

[0016] According to an embodiment of the present invention, a real-time pump failure prediction and prevention system, comprises of an electric pump having an impeller, deriving power from a power source and coupled with a liquid tank for pumping liquid at a regulated flow rates, characterized in that, a RPM (revolution per minute) sensor arranged with the pump for monitoring real time rotational speed of the impeller, a current sense amplifier integrated with an ESC (electronic speed controller) circuit connecting the pump with the power source for measuring real time current passed through the circuit, wherein a voltage divider is integrated with the circuit for monitoring real time voltage supplied to the pump which are calculated for evaluating a power supplied to the pump at the monitored RPM, an analyzer module operated by one of processors and linked with the microcontroller for comparing the monitored real time parameters with ideal parameters as per a database linked with an inbuilt microcontroller in view of predicting any chances of dry running or malfunctioning of the pump, wherein the parameters are also evaluated for measuring remaining liquid in the tank with the current flow rate.

[0017] According to another embodiment of the present invention, a method for real-time pump failure prediction and prevention includes steps of, a) collecting real time data including RPM, current and voltage while the system is operational for generating the database, b) comparing real time RPM and power consumption of the pump with ideal RPM and power consumption as per the database, wherein in case an increase in RPM is monitored with a decrease in power consumption, a dry-running condition or emptying of the tank is predicted, and c) triggering a failsafe mechanism for ceasing rotation of the impeller or sending an alert to the operator for adjusting flow rate.

[0018] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates a graphical representation depicting a pattern of power and rotational speed (RPM) trend as followed in a running cycle of an electric pump associated with a real-time pump failure prediction and prevention system;
Figure 2 illustrates a flow chart depicting flow of information processed in a method associated with the proposed system; and
Figure 3 illustrated another flow chart of the proposed system in continuation with Figure 2.

DETAILED DESCRIPTION OF THE INVENTION

[0020] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0021] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0022] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0023] The present invention relates to a real-time pump failure prediction and prevention system that pertains to prevent any chances of malfunctioning or failure of an electric pump while dispensing a liquid from a tank by internally setting up a calibrated set-up for monitoring real time parameters of the pump to predict an empty tank condition to prevent dry running condition of the pump which leads to pump failure.

[0024] Referring to Figure 1, a graphical representation depicting a pattern of power and rotational speed (RPM) trend as followed in a running cycle of an electric pump is illustrated, wherein red line denotes rotational speed (RPM) while green line denotes power.

[0025] The proposed system relates to an electric pump coupled with a liquid tank for dispensing liquid from the tank at different rates for varying purposes. The electric pump referred herein incudes different variants of electric pump facilitating an impellers such as a centrifugal pump, diaphragm pump, submersible pump, vortex pump, jet pumps, hose pump and many alike, wherein the electric pump are to be compatible with various ESC (electronic speed controller) configurations.

[0026] During operational state, the configuration of the electric pump set-up includes a power source for supplying a continuous power to the pump for rotating the impeller to pump liquid stored in a tank configured with the pump at varying flow rates. The system includes an RPM (revolution per minute) sensor integrated with the impeller of the pump, a current sense amplifier and a voltage divider assembled with an ESC (electronic speed controller) circuit connecting the pump with the power source for monitoring real time parameters including rotational speed of the impeller along with current and voltage passed through the circuit, respectively to evaluate the power supplied to the pump on real time basis.

[0027] Prior initiating observation of real time parameters during operational state of the pump, an initial calibration is performed by establishing a baseline RPM and power consumption data for the pump at different flow rates of the liquid without utilizing any external flow meter, level sensor, current or voltage sensor. All the calibrated data is stored in a database linked with an inbuilt microcontroller associated with the system. The database provides accurate data related to ideal power consumed by the pump for rotating at a corresponding RPM, wherein RPM, i.e. revolution per minute, used herein is taken as a standard value for measuring different rotational speed of the impeller.

[0028] After attaining a calibrated data stored in the database, the system starts to monitor real time rotational speed of the impeller during operational state of the pump while dispensing liquid from the tank. The RMP (revolution per minute) sensor is installed on the impeller’s shaft and coupled with a tachometer that works by using a small generator or a rotating magnet to produce electrical signals proportional to the speed of the shaft resulting in measurement of the rotational speed of the impeller on real time basis.

[0029] The monitored rotational speed is compared with the ideal speed as stored in the database and referred to a baseline generated as per the database for determining an ideal power to be supplied to the pump while performing the monitored rotational speed. The current sense amplifier, preferably INA 240A1, is installed in series with the ESC (electronic speed controller) circuit connecting the power source with the pump. The current sense amplifier includes a small-value shunt resistor, either positioned externally or within the sensor and is positioned in the current path of the circuit.

[0030] As the current flows through a motor coupled with the pump, a voltage drop develops across the shunt resistor which is proportional to the current. Since the voltage drop is very small, the current sense amplifier amplifies the signal to a higher level which is easily measured by the microcontroller. The current sense amplifier utilizes an internal operational amplifier integrated within the current sense amplifier to amplify the small voltage across the shunt resistor which generates an output in a digital or analog signal corresponding to the monitored current which is sent to the microcontroller.

[0031] The voltage divider, integrated in the ESC circuit is a simple circuit that works on the principle of Ohm’s law. The voltage divider is utilized for measuring voltage by scaling down high voltage signals into a voltage range that is suitable for input to an analog-to-digital converter coupled with the divider for conversion of the signal which is then electronically sent to the microcontroller.

[0032] Based on the real time monitored current and voltage passed through the ESC circuit, the microcontroller evaluates a real time power being supplied to the pump while the impeller is rotating at the monitored speed. An analyzer module is linked with the microcontroller and operated by one of processors for comparing the evaluated real time power being supplied to the pump with the ideal power corresponding to the monitored speed (RPM) as per the database, on real time basis. In case, an increase in speed (RPM) is monitored with a decrease in power supplied, the microcontroller predicts a potential issue corresponding to a potential empty tank, pump malfunction or flow disruption/leakage of the liquid filled in the tank.

[0033] Upon prediction of the above stated potential issues, the microcontroller initiates a failsafe trigger mechanism in the system which either deactivates the pump or sends an alert to an operator of the pump to adjust the settings of the pump in order to prevent dry running condition of the pump resulting in pump failure. The operator is capable of accessing controls of the pump set-up for either deactivating the pump or adjusting the power supply.

[0034] In case the operator opts for deactivation or regulation of power supply to the pump, the microcontroller generates an electronic signal to a MOSFET (Metal oxide semiconductor field effect transistors) inbuilt in the ESC circuit via a gate divider coupled with the MOSFET, regarding the adjustment to be altered. The gate driver works as a mediator in between the microcontroller and the gate of the MOSFET, wherein upon receiving a low-voltage signal from the microcontroller, the gate driver amplifies the signal and deliver a high-voltage signal to the MOSFET. As the driver has lower resistance than the microcontroller, a higher current is delivered by the driver that also amplifies the speed of the signal which allows faster switching and lower heat production.

[0035] The MOSFETs are the switches that receives the signals from the microcontroller and accordingly delivers power to the motor of the pump so that each of the coils of the motor is in one of the three phases, i.e. high voltage, low voltage or off/grounded. As the motor rotates the impeller, the signals from the MOSFETs switch the phases of the coils, so the rotor of the motor keeps spinning. As per the signals transmitted by the MOSFETs, the current sensing amplifier and the voltage divider works for delivering the regulated power or no power to the pump resulting in cease of pump or adjustment in rotational speed (RPM) of the pump. This prevents dry-running condition of the pump which results in prevention of pump failure.

[0036] Referring to Figure 2 and 3, a flow chart depicting flow of information processed in a method associated with the proposed system are illustrated, wherein the information portrayed in the flow-chart is as follows,

1. Check if the system is ARMED. - If NOT ARMED, do nothing. Explanation: Wherein ‘ARMED’ and ‘NOT ARMED’ corresponds to ‘ON’ and ‘OFF’ state of the pump-set up for dispensing liquid from the tank, respectively.
2. Check if the sprayer master and flow_ enable are both TRUE.
- If FALSE, loop back and wait for them to be TRUE.
Explanation: Wherein ‘TRUE’ and ‘FALSE’ corresponds to ‘working’ and ‘non-working’ condition of the dispensing and flowing of the liquid.
3. Access the values of ESC current, voltage, RPM, and PPM from RCOUT.
4. Check if the RPM value changes rapidly. - If TRUE, wait for 1 second for the pump to complete its full ramp-up cycle before proceeding to the next step.
5. Apply a filter to the values of voltage, RPM, PPM, and current to smooth out any irregularities.
Explanation: Precise and accurate monitoring of real time parameters of the running pump.
6. Calculate the power using voltage and current.
7. Compute the ratio of power to RPM and store it in `pow_rat`.
8. Check if `PUMP_CAL` is equal to 1 (indicating pump calibration is enabled).
- If TRUE:
a. Save the `pow_rat` value to the parameter ` FACTOR`.
b. Set and save `PUMP_CAL` to 0.
c. Display a message to the Ground Control Station (GCS) that "Pump calibration is complete and requires a reboot."
- If FALSE, proceed to the next step.
9. Calculate the flow rate based on the RPM of the pump.
10. Check if `pow_rat` is smaller than a predefined `FACTOR` value.
- If TRUE:
a. Stop the pump signal, making the flow rate 0.
b. Trigger the `TANK_EMPTY_FAILSAFE`.
• c. Initiate Return to Launch (RTL). - If FALSE, continue with the mission.
Explanation: The monitored values are compared with the ideal values as per the database and in case an increase in RPM is monitored with a decrease in power, a dry running condition, liquid leakage or pump malfunctioning is detected, in accordance to which the failsafe mechanism is triggered for shutting down the pump to prevent any chances of pump failure.

[0037] A method for real time pump failure prediction and prevention as implemented in the proposed system includes the steps of,

a) Collection of real time ESC data
Real time rotational speed of the impeller, current and voltage passed through the ESC circuit is monitored at different flow rates for generating the database consisting of a set of ideal power to be supplied to the pump for a corresponding rotational speed. The database also includes a baseline generated by plotting a graph of the ideal values of the parameters including power and rotational speed at different spray rates.
b) Comparison of real time ESC data with the database
Post generation of the database, real time rotational speed of the impeller, current and voltage are measured for evaluating a real time power supplied to the pump which is compared to the set of data saved in the database for checking operational status of the pump.
c) Triggering failsafe mechanism
In case the microcontroller monitors an increase in speed (RPM) with a decrease in power, a potential issue corresponding to an empty tank, flow disruption of the liquid stored in the tank or leakage of the liquid from the tank, is detected by the microcontroller. Upon detection of the potential issues, the microcontroller initiates a failsafe trigger mechanism which either deactivates the pump or sends an alert to the operator of the pump to initiate adjustments of the pump set-up to control the flow rate in order to prevent chances of pump failure due to dry-running condition of the pump.

[0038] The microcontroller is pre-fed with a flow rate prediction protocol that is implemented for processing the speed (RPM) data using the pre-established baseline to predict flow rate of the pumped liquid in real time. This approach allows accurate estimation of flow rate of liquid from the tank on real time basis without any requirement of an external flow meter or level sensor.

[0039] Based on the predicted flow rate, the microcontroller evaluates a volume of the liquid dispensed over time which in turn provides an estimated volume of liquid remaining in the tank. Continuously estimation of the level of liquid in the tank provides a real time insight of the operators towards the remaining level of the liquid in the tank to aid the operator in refilling the tank or regulate the flow rate of the liquid dispensed over time.

Advantages

• Increased accuracy: By taking real time data and utilizing internal ESC data, the system combats inaccuracies and errors caused due to usage of conventional flow meters, providing more precise and reliable flow rate predictions along with providing an insight into running status of the pump.
• Real time monitoring: Due to monitoring of the ESC data on real time basis, a real time monitoring and prediction capabilities are offered by the system that allows proactive intervention and measures to be taken to prevent operational failures.
• Enhanced safety and longevity: As the system works for preventing dry-running condition of the pump which leads to extending the pump’s life and maintaining consistent operation by preventing any sort of malfunctioning or pump failure along with ensuring uninterrupted flow of the liquid that makes it ideal for critical applications.
• Versatility: Adaptability of the proposed system to varying fluids and conditions makes it a versatile and valuable tool for industries seeking efficient, low-maintenance flow monitoring solutions.
• Cost efficiency: The proposed system provides a reliable, cost-effective monitoring and failure prevention system for electric pumps which is scalable across varying kinds of industries and commercial applications. As the proposed system eliminates the usage of costly external flow meters or sensors, which leads to reduction in maintenance and operational costs and enhancing overall system reliability by providing reliable flow rate prediction along with real time monitoring and prediction capabilities.

Application

[0040] The prosed system is adaptable in diverse areas for varying kind of operations, wherein some of the important applications of the proposed system in crucial fields includes,

• In Agricultural sector: The proposed system can be employed for varying operations in agricultural sector such as efficiently managing water, pesticides or fertilizer dispensing over agricultural fields during crop irrigation and spraying in inaccessible and remote areas or in large-scale environment where sensors maintenance is challenging.
• In Fuel Management sector: Tracking fuel flow and tank levels in power generation, marine and transport sectors, where reliable failsafe mechanism prevent dry runs and maintain operational integrity.

Test Results

[0041] The proposed system had undergone trial by installing the system in a drone configured with a water tank linked an electric pump for dispensing water at a defined flow rate. The drone installed with the proposed system was tested for different parameters with standardized validation steps which depicted the overall performance and behavior of the proposed system in the drone, wherein the procedures include,

1. To check occurrence of Tank, fail safe mechanism initially at 100% spray rate

[0042] The procedure followed for checking occurrence of tank fail safe mechanism initially at 100% spray rate involves connecting a battery with the calibrated pump, filling the tank at various levels and fly the drone by keeping the spray rate 100% and note data corresponding to parameters such as RTL (return to land) triggered initially, entrapment of air, mixing of air with water and if the pump got struck.

Table 1. A checklist depicting parameters checked multiple times at 100% spray rate
Sr. No. F1 F2 F3 F4 F5 F6
RTL triggered initially No No No No No No
Entrapment of air Yes Yes No Yes Yes Yes
Mixing of air with water No No No No No No
Pump got struck No No No No No No

Wherein, F1, F2, F3, F4, F5 and F6 corresponds to number of repetitions of the readings taken.

[0043] Observation: Apart from air entrapment, no issues were observed.

[0044] Inference: The pump set up was tested in drones and the performance was found to be satisfactory.

2. To check occurrence of tank fail safe mechanism at tank empty and display of remaining tank level before and after flight of the drone

[0045] The procedure followed for checking occurrence of tank fail safe mechanism at tank empty and display of remaining tank level before and after flight of the drone includes connecting the battery with the calibrated pump and filling the tank at various level while flying the drone. The parameters notes include selected chemical quantity through quick parameters, displayed chemical quantity before hardware safety implementation, displayed chemical quantity after hardware safety implementation and remaining tank level after RTL (return to land) mode activation.

Table 2. A table depicting parameters check for detecting occurrence of tank fail safe mechanism at tank empty and display of remaining tank level before and after flight of the drone

Sr. No. F1 F2 F3 F4 F5 F6 F7 F8 F9
Selected chemical quantity through quick parameter 4L 6L 8L 10L 10L 4L 6L 8L 4L at 70% spray rate
Displayed chemical quantity before hardware safety implementation 0L 0L 0L 0L 0L 0L 0L 0L 0L
Displayed chemical quantity after hardware safety implementation 4L 6L 8L 10L 10L 4L 6L 8L 4L
Remaining tank level after RTL mode activation 0L 0L 0L 0L 0L 0L gradual reduce 0L gradual reduce 0L gradual reduce 0L gradual reduce

Wherein, F1, F2, F3, F4, F5, F6, F7, F8 and F9 corresponds to number of repetition of the readings taken; and
L corresponds to standard unit in Liters.

[0046] Observation: Pressure readings in first five flights – 5.24 bar (100% spray rate), 4.90 bar (80% spray rate), 4.48 bar (75% spray rate), 3.47 bar (60% spray rate), 2.93 bar (50% spray rate), 2.26 bar (40% spray rate), 1.39 bar (35% spray rate), 0.91 bar (25% spray rate). Gradual decrease in displayed quantity was seen.
Pressure reading after flights- 4.05 bar (100% spray rate), 3.64 bar (80% spray rate), 3.36 bar (75% spray rate), 2.58 bar (60% spray rate), 2.01 bar (50% spray rate), 2.26 bar (40% spray rate), 1.25 bar (35% spray rate) and 0.96 bar (25% spray rate).

[0047] Inference: Remaining tank level test was done and no errors were observed.

[0048] These tests were performed at regular intervals of time, preferably after 24 hours, to check if the results depicted follow the same pattern. No change is pattern of the results were observed, i.e. no error was observed.

[0049] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A real-time pump failure prediction and prevention system, comprising an electric pump having an impeller, deriving power from a power source and coupled with a liquid tank for pumping liquid at a regulated flow rates, characterized in that:
i) an RPM (revolution per minute) sensor integrated with said pump for monitoring real time rotational speed of said impeller, wherein said monitored speed is compared with a set of data stored in a database linked with an inbuilt microcontroller for determining an ideal power to be supplied to said pump at said monitored speed;
ii) a current sense amplifier integrated with an ESC (electronic speed controller) circuit, connecting said pump with said power source, for measuring real time current passed through said circuit, wherein a voltage divider is assembled with said circuit for sensing voltage supplied to said pump while said pump is rotating at said monitored speed (RPM), in accordance to which said microcontroller evaluates a power supplied to said pump; and
iii) an analyzer module operated by one of processors linked with said microcontroller for comparing said evaluated power being supplied to said pump with said ideal power as per said database, wherein in case an increase in speed (RPM) is monitored with a decrease in said power supplied, a potential issue corresponding to an empty tank or flow disruption of a liquid stored in said tank is predicted, based on which said microcontroller initiates a failsafe trigger mechanism which either deactivates said pump or sends an alert to an operator of said pump in order to prevent dry running condition of said pump resulting in pump failure.

2) The system as claimed in claim 1, wherein data in said database is maintained based on initial calibration executed on said system for establishing a baseline RPM and power consumption data at different flow rates.

3) The system as claimed in claim 1, wherein said real time monitoring of parameters including rotational speed and power are utilized for estimating level of said liquid remaining in said tank.

4) The system as claimed in claim 1, wherein said operator is capable of initiating adjustment by altering power supplied to said pump for preventing any chances of pump failure.

5) A method for real time pump failure prediction and prevention as claimed in claim 1, includes steps of,
A) collecting real time data including RPM, current and voltage while said system is operational for generating said database;
B) comparing real time RPM and power consumption of said pump with ideal RPM and power consumption as per said database, wherein in case an increase in RPM is monitored with a decrease in power consumption, a dry-running condition or emptying of said tank is predicted; and
C) triggering a failsafe mechanism for ceasing rotation of said impeller or sending an alert to said operator for adjusting flow rate.

6) The method as claimed in claim 5, wherein a flow rate prediction model is inbuilt in said microcontroller that processes real time speed (RPM) data using baseline to predict flow rate of liquid pumped in real time from said tank.

7) The method as claimed in claim 5, wherein based on volume of liquid dispensed over a time period, a level of remaining liquid left in said tank is evaluated that provides an estimated liquid level insight to said operator.