CN113432863A - Valve health state detection and diagnosis device and method - Google Patents
Valve health state detection and diagnosis device and method Download PDFInfo
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- CN113432863A CN113432863A CN202110613636.3A CN202110613636A CN113432863A CN 113432863 A CN113432863 A CN 113432863A CN 202110613636 A CN202110613636 A CN 202110613636A CN 113432863 A CN113432863 A CN 113432863A
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- 238000001514 detection method Methods 0.000 title claims abstract description 70
- 238000003745 diagnosis Methods 0.000 title claims abstract description 16
- 230000036541 health Effects 0.000 title claims abstract description 13
- 238000000034 method Methods 0.000 title claims description 30
- 238000004891 communication Methods 0.000 claims abstract description 8
- 230000008569 process Effects 0.000 claims description 17
- 230000003862 health status Effects 0.000 claims description 14
- 238000013178 mathematical model Methods 0.000 claims description 10
- 239000002184 metal Substances 0.000 claims description 8
- 238000012360 testing method Methods 0.000 claims description 7
- 238000013480 data collection Methods 0.000 claims description 6
- 238000012795 verification Methods 0.000 claims description 3
- 238000012423 maintenance Methods 0.000 abstract description 9
- 230000008859 change Effects 0.000 abstract description 4
- 230000003449 preventive effect Effects 0.000 abstract description 2
- 238000004458 analytical method Methods 0.000 description 5
- 238000011217 control strategy Methods 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 238000005457 optimization Methods 0.000 description 2
- 238000013500 data storage Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 238000007726 management method Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000011158 quantitative evaluation Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
- G01M13/003—Machine valves
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- General Physics & Mathematics (AREA)
- Indication Of The Valve Opening Or Closing Status (AREA)
- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
Abstract
The invention discloses a valve health state detection and diagnosis device, which comprises: the detection platform is communicated with the plurality of data acquisition boxes through the communication module; the data acquisition box is provided with a plurality of sensor channel interfaces, and the sensor channel interfaces are connected with sensors and used for acquiring data of the valves. The valve state data is transmitted to the detection platform by the data acquisition box, and the detection platform generates fault information according to the valve state data. The data of the related sensors installed on the valve are acquired in real time through the data acquisition box and transmitted to the detection platform, the detection platform combines with the expert knowledge base to quantitatively evaluate the change degree of the characteristic data of the valve, a preventive maintenance suggestion is provided, and the safe and reliable operation of the control valve can be guaranteed.
Description
Technical Field
The present disclosure relates to valve inspection devices and methods, and particularly to a valve health status inspection and diagnosis device and method.
Background
The traditional valve maintenance concept is to make the valve work for as long as possible, once a fault is found, the factory is stopped, and the equipment is immediately maintained to restore the original state. This requires disassembly and disassembly of the valve, maintenance or replacement of worn or damaged parts. However, part damage can only be detected if the control valve operating performance degrades to the point where the control valve fails, which may make it too late to perform preventative maintenance.
Therefore, the invention aims to solve the passive maintenance, and designs a detection and diagnosis device special for a pneumatic control valve to enable the control valve to complete set movement, acquire information such as valve stroke and the like in real time through various high-precision sensors, calculate and analyze valve operation performance characteristic information, and deduce fault information and maintenance suggestions of the valve by combining with an expert knowledge base.
Disclosure of Invention
The above purpose of the invention is realized by the following technical scheme:
a valve health status detection and diagnostic apparatus, comprising: the detection platform is communicated with the plurality of data acquisition boxes through the communication module; the data acquisition box is provided with a plurality of sensor channel interfaces, and the sensor channel interfaces are connected with sensors and used for acquiring data of the valves.
The valve health status detecting and diagnosing apparatus as described above, wherein the sensor includes: pressure sensor, stroke sensor, valve rod stress sensor.
The valve health status detecting and diagnosing apparatus as described above, wherein the data collecting box further comprises a plurality of channel indicating lamps matching with the data collecting channel interface.
The valve health status detecting and diagnosing apparatus as described above, wherein a main control board is disposed in the data collecting box, and the main control board is connected to the plurality of sensor channel interfaces and the communication module.
The valve health status detecting and diagnosing apparatus as described above, wherein the data collection box comprises a metal housing, and a plurality of the sensor channel interfaces are mounted on a panel of the metal housing.
The valve health status detecting and diagnosing apparatus as described above, wherein the detecting platform further comprises: and the power interface is connected with a 220VAC power supply.
A valve health state detection and diagnosis method is characterized in that a valve positioner is controlled to act, a data acquisition box is connected with a plurality of sensors to acquire valve state data in real time, the data acquisition box transmits the valve state data to a detection platform, and the detection platform generates fault information according to the valve state data.
The method for detecting and diagnosing the health state of the valve comprises the steps that the data acquisition box preprocesses acquired sensor data and removes noise data in the sensor data.
According to the valve health state detection and diagnosis method, a fault mathematical model is established in a detection platform, and optimization is performed according to the actual verification structure multi-fault mathematical model; and importing the valve state data into a fault mathematical model to generate fault information.
The method for detecting and diagnosing the health status of the valve as described above, wherein the detection platform establishes a corresponding engineering detection data packet for each valve, and the engineering detection data packet includes: and setting parameters, process data, waveforms and detection results, selecting detection items by the detection platform to perform retesting, and verifying the detection results.
In conclusion, due to the adoption of the technical scheme, the problem that the parking maintenance is carried out after a fault occurs in the prior art is solved, the data of the relevant sensors arranged on the valve are acquired in real time through the data acquisition box and transmitted to the detection platform, the detection platform is combined with the expert knowledge base to carry out quantitative evaluation on the change degree of the characteristic data, a preventive maintenance suggestion is provided, and the safe and reliable operation of the control valve can be ensured.
Drawings
Fig. 1 is a schematic structural diagram of the valve health status detection and diagnosis device of the present invention.
Detailed Description
The invention is further described below with reference to the following figures and examples:
fig. 1 is a schematic structural diagram of a valve health status detecting and diagnosing apparatus according to the present invention, please refer to fig. 1, which is a valve health status detecting and diagnosing apparatus, including: the detection platform 3 is communicated with the plurality of data acquisition boxes 1 through the communication module; the data acquisition box 1 is provided with a plurality of sensor 2 channel interfaces, and the sensor 2 channel interfaces are connected with the sensor 2 and used for acquiring data of the valve.
The invention transmits the valve characteristic data acquired by the sensor 2 on site to the detection platform 3 in real time through the data acquisition box 1, the detection platform 3 synchronously acquires the control strategy required by the technical standard, namely the signal to the valve positioner, the synchronous real-time recording of the valve characteristic information and the real-time display of the operating process characteristic curve are realized on the detection platform 3 through the human-computer interaction interface, and the process data storage is completed at the background. On the basis of the fault mathematical model, the detection platform 3 can analyze and obtain valve control performance data such as basic errors, sliding friction force, control delay process curve, flow characteristic curve, valve seating closing force and the like through process data subdivision and curve characteristic recognition to diagnose the valve fault.
Further, the sensor 2 includes: pressure sensor, stroke sensor, valve rod stress sensor.
Further, the data acquisition box 1 further comprises a plurality of channel indicator lamps matched with the data acquisition channel interfaces.
Furthermore, a main control board is arranged in the data acquisition box 1 and is connected with the channel interfaces of the sensors 2 and the communication module.
Further, the data acquisition box 1 comprises a metal shell, and a plurality of sensor 2 channel interfaces are mounted on a panel of the metal shell.
Further, the detection platform 3 further comprises: and the power interface is connected with a 220VAC power supply.
In the specific implementation process of the invention, the portable metal shell is adopted as the case of the data acquisition box 1, and the portable metal shell is made of metal materials and is easy to process. The front panel is connected with 8-path aviation plugs and signals, and the rear panel is connected with 220V AC. Wired communication net twine interface 1 to the redundant wifi signal antenna that is equipped with. The signal channel interface adopts a universal 9-core, and meets the functions of identifying different sensors 2 and preventing the channel from being misconnected to damage a circuit. In the aspect of channel interface indication, the brightness of the light-emitting diode is adopted to represent the state information of the channel signal.
The invention also discloses a valve health state detection and diagnosis method, wherein the valve positioner is controlled to act, the data acquisition box is connected with the plurality of sensors to acquire valve state data in real time, the data acquisition box transmits the valve state data to the detection platform, and the detection platform generates fault information according to the valve state data.
In the specific operation process of the invention, a 4-20mA signal can be output to the electric valve positioner through a set control strategy, the detection platform synchronously acquires the control strategy and can acquire the data of the valve positioner in real time, a high-precision sensor is utilized to synchronously sample important information such as membrane head pressure, input/output pressure of the positioner, valve stroke, valve rod stress change and the like on a pneumatic actuating mechanism at a high speed in the valve movement process, a macroscopic and microscopic data curve change analysis is combined, the comprehensive judgment is carried out to obtain the detection conclusion of the characteristic information of the valve, such as basic error, sliding friction force, control hysteresis process curve, flow characteristic curve, valve seating force and the like, and then the valve fault information is deduced according to an expert knowledge base and rules.
Further, the data acquisition box preprocesses the acquired sensor data and removes noise data in the sensor data.
Further, a fault mathematical model is established in the detection platform, and optimization is carried out according to the actual verification structure multi-fault mathematical model; and importing the valve state data into a fault mathematical model to generate fault information.
Further, the detection platform establishes a corresponding engineering detection data packet for each valve, and the engineering detection data packet includes: and setting parameters, process data, waveforms and detection results, selecting detection items by the detection platform for retesting, and verifying the detection results.
The diagnostic protocol for the analysis of the operational characteristics of a particular valve of the present invention is shown in table 1.
TABLE 1 Intelligent detection and diagnosis scheme for regulating valve
Through the technical scheme of the invention, independent information storage of each valve is realized in an engineering management mode, data packets of all detection items in the valve motion control process are managed, and a user can browse historical engineering detection data and recheck any detection item therein. The engineering file of the system comprises configuration parameters, process data, waveforms and detection results of the system.
In the design of a system framework, the upgrading of a program version and the debugging of system functions are very conveniently realized through a software platform plus function package mode. The maintenance and the upgrade of the function program package are independent to other program packages, and the operation of other functions is not influenced even if the function program package fails.
The valve detection and diagnosis operation process is simple and convenient, and a user only needs to determine the test to be executed and then starts a single detection process. Each requested test is then executed in sequence and automatically stored as a separate test database as the basis for valve analysis.
According to the system diagnosis requirement, different types of sensors, such as a pressure sensor, a stroke sensor and a valve rod stress sensor, need to be connected.
If the accuracy and reliability of the detection result are in question, the diagnosis result may be erroneous even if the subsequent analysis method and decision system are advanced. The accuracy of the sensor and the reliability of the interface structure directly affect the detection result. The accuracy of the stroke sensor, the measuring structure thereof and the design of the valve rod strain sensor are all influencing factors needing multiple aspects.
The foregoing detailed description of the preferred embodiments of the invention has been presented. It is to be understood that modifications and variations may be resorted to without inventive faculty, or by software programming, as will be apparent to those skilled in the art. Therefore, the technical solutions available to those skilled in the art through logic analysis, reasoning and limited experiments based on the prior art according to the concept of the present invention should be within the scope of protection defined by the claims.
Claims (10)
1. A valve health status detection and diagnostic apparatus, comprising: the detection platform is communicated with the plurality of data acquisition boxes through the communication module; the data acquisition box is provided with a plurality of sensor channel interfaces, and the sensor channel interfaces are connected with sensors and used for acquiring data of the valves.
2. The valve health detection and diagnostic apparatus of claim 1, wherein the sensor comprises: pressure sensor, stroke sensor, valve rod stress sensor.
3. The valve health detection and diagnostic apparatus of claim 1, wherein the data collection pod further comprises a plurality of channel indicator lights mated to the data collection channel interface.
4. The valve health status detecting and diagnosing apparatus of claim 1, wherein a main control board is disposed in the data collection box, and the main control board is connected to the plurality of sensor channel interfaces and the communication module.
5. The valve health detection and diagnostic apparatus of claim 1, wherein the data collection pod comprises a metal housing, and wherein the plurality of sensor channel interfaces are mounted on a face plate of the metal housing.
6. The valve health status detection and diagnostic apparatus of claim 4, wherein the test platform further comprises: and the power interface is connected with a 220VAC power supply.
7. A valve health state detection and diagnosis method is characterized in that a valve positioner is controlled to act, a data acquisition box is connected with a plurality of sensors to acquire valve state data in real time, the data acquisition box transmits the valve state data to a detection platform, and the detection platform generates fault information according to the valve state data.
8. The valve health detection and diagnosis method of claim 7, wherein the data collection box pre-processes the acquired sensor data to remove noise data from the sensor data.
9. The valve state of health detection and diagnosis method of claim 7, wherein a fault mathematical model is established in the detection platform, optimized according to the actual verification structure multiple fault mathematical model; and importing the valve state data into a fault mathematical model to generate fault information.
10. The method of claim 7, wherein the testing platform establishes a corresponding engineering test data packet for each valve, the engineering test data packet comprising: and setting parameters, process data, waveforms and detection results, selecting detection items by the detection platform to perform retesting, and verifying the detection results.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202110613636.3A CN113432863A (en) | 2021-06-02 | 2021-06-02 | Valve health state detection and diagnosis device and method |
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| CN202110613636.3A CN113432863A (en) | 2021-06-02 | 2021-06-02 | Valve health state detection and diagnosis device and method |
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| CN113432863A true CN113432863A (en) | 2021-09-24 |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113915405A (en) * | 2021-11-10 | 2022-01-11 | 山东中烟工业有限责任公司 | Self-checking system and method for pneumatic ball valve of flavoring and feeding pipeline |
| CN116224975A (en) * | 2023-05-08 | 2023-06-06 | 天津卡尔斯阀门股份有限公司 | Analysis system based on valve usage data |
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| CN107367379A (en) * | 2017-07-28 | 2017-11-21 | 深圳市南海核电技术有限公司 | A kind of valve debugging, diagnosis comprehensive instrument and analysis method |
| CN110221558A (en) * | 2019-06-05 | 2019-09-10 | 镇江四联机电科技有限公司 | A kind of electrohydraulic servo valve on-line fault diagnosis gateway based on edge calculations technology |
| CN111350859A (en) * | 2018-12-21 | 2020-06-30 | 核动力运行研究所 | Device and method for detecting state of electric regulating valve |
| CN112728417A (en) * | 2020-12-25 | 2021-04-30 | 中核武汉核电运行技术股份有限公司 | Online diagnosis device and method for main steam isolation valve of nuclear power plant |
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2021
- 2021-06-02 CN CN202110613636.3A patent/CN113432863A/en active Pending
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105551226A (en) * | 2015-12-04 | 2016-05-04 | 江西飞尚科技有限公司 | Low-power consumption intelligent data acquisition box |
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| CN111350859A (en) * | 2018-12-21 | 2020-06-30 | 核动力运行研究所 | Device and method for detecting state of electric regulating valve |
| CN110221558A (en) * | 2019-06-05 | 2019-09-10 | 镇江四联机电科技有限公司 | A kind of electrohydraulic servo valve on-line fault diagnosis gateway based on edge calculations technology |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113915405A (en) * | 2021-11-10 | 2022-01-11 | 山东中烟工业有限责任公司 | Self-checking system and method for pneumatic ball valve of flavoring and feeding pipeline |
| CN116224975A (en) * | 2023-05-08 | 2023-06-06 | 天津卡尔斯阀门股份有限公司 | Analysis system based on valve usage data |
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