Variable working condition dynamic torque test device and method under long-term service state of valve

Abstract

The invention discloses a variable-working-condition dynamic torque testing device and method for a valve in a long-term service state, and belongs to the field of valve performance testing. Comprising a valve torque measuring and driving device, a water pump pressurizing system and an actuator hydraulic control system. A valve is connected with a first connecting flange and a second connecting flange, a valve rod shaft of the valve is coaxially connected with a first coupler, a torque sensor, a second coupler, an actuator output shaft, a third coupler and a rotary encoder, an actuator is installed at the upper end of the valve through an actuator support, and the torque sensor and a one-way Hall sensor are connected to the two ends of the actuator support. And a sensing element of the one-way Hall sensor is adsorbed on an output shaft of the actuator. The water pump pressurization system provides media with different pressures, different flow speeds and different temperatures for the valve; an actuator hydraulic control system pipeline is connected with an actuator oil port, and the valve is driven to be opened and closed at different rotating speeds by outputting oil at different flow speeds to the actuator. The device can be used for variable-working-condition dynamic torque testing of the valve in a long-term service state and design, manufacturing and optimization of the valve.

Description

Technical Field

[0001] The present invention belongs to the field of valve performance testing, and in particular relates to a device and method for testing dynamic torque of a valve under variable working conditions in a long-term service state. Background Art

[0002] Valves are key control components in hydraulic systems, and their dynamic torque is a key technical indicator of their overall performance. During valve design, the actuator's output torque must be determined based on the valve's dynamic torque parameters. Excessive actuator output torque can result in excessive output torque, while insufficient actuator output torque can cause valve opening and closing difficulties and even lead to valve sticking. Currently, there is no readily available data on valve dynamic torque for valve performance testing, making it difficult to determine valve dynamic torque and select valve actuators.

[0003] During the use of the valve, the flow rate, pressure and temperature of the medium flowing through the valve are not constant, and the dynamic torque of the valve will also be affected by the above parameters. Currently, there is no relevant valve torque testing device that can take the flow rate, pressure and temperature of the medium into consideration at the same time.

[0004] During the long-term service of the valve, the dynamic torque parameters of the valve will change significantly after a large number of continuous and frequent opening and closing. The valve opening and closing speed will also have a significant impact on the dynamic torque parameters. The current existing valve torque testing devices are all manually operated and reversed, that is, manually closing the valve to test the dynamic torque during the closing process, and then manually opening the valve to test the dynamic torque during the opening process. It is impossible to obtain the relationship between the valve angle and torque during the valve opening and closing process, and it is even more impossible to accurately change the valve opening and closing speed, making the testing process cumbersome and the test data inaccurate.

[0005] At present, the opening and closing life of most industrial valves is tens of thousands or even hundreds of thousands of times. In order to test the torque performance of the valve within its effective life, the valve needs to be subjected to long-term continuous opening and closing tests. The existing valve torque testing devices are all manually controlled, and it is difficult to achieve continuous opening and closing tests of tens of thousands or even hundreds of thousands of times, making it difficult to measure the dynamic torque parameters of the valve under long-term service. Summary of the Invention

[0006] In response to the problems existing in the prior art, the present invention provides a device and method for testing dynamic torque of valves under variable working conditions under long-term service conditions, which can test the dynamic torque of valves under variable working conditions under long-term service conditions. Specifically, the technical problems it can solve are:

[0007] (1) By adjusting the control elements of the water pump pressurization system, media with different pressures, flow rates and temperatures can be applied to the valve, which can simulate the medium state of the valve in actual operation;

[0008] (2) By adjusting the output flow of the actuator hydraulic control system, the actuator execution speed can be controlled, thereby changing the opening and closing speed of the valve, and simulating the working state of the valve at different opening and closing speeds;

[0009] (3) The output signal of the rotary encoder is used to perform feedback adjustment on the electromagnetic reversing valve. When the valve is fully closed or fully open, the industrial computer sends a reversing signal to the electromagnetic reversing valve, causing the electromagnetic reversing valve to automatically reverse, thereby achieving automatic reversal and automatic continuous opening and closing of the valve. The torque sensor can be used to measure the dynamic torque parameters of the valve during the opening and closing process. The shaft of the rotary encoder and the shaft of the torque sensor are coaxially connected, and the relationship between the valve angle and torque during the opening and closing process can be obtained. The test process is all automatic and does not require manual operation.

[0010] (4) The number of times the valve is opened and closed can be recorded by a unidirectional Hall sensor. When the set number of times is reached, the industrial computer can automatically shut down the test device, and the dynamic torque of the valve under different opening and closing times can be tested, which greatly reduces the manpower input and can realize automatic measurement. It provides technical support for the dynamic torque measurement of the valve under long-term service status and has high engineering application value.

[0011] To achieve the above object, the technical solution adopted by the present invention is:

[0012] A variable working condition dynamic torque test device for valves in long-term service can be used for dynamic torque testing of valves in variable working conditions during long-term service, as well as for the design, manufacture, and optimization of valves. The test device mainly consists of three parts: the first part is a valve torque measurement and drive device, the second part is a water pump pressurization system, and the third part is an actuator hydraulic control system. In the valve torque measurement and drive device, the valve is connected to a first connecting flange 20 and a second connecting flange 23 and is located between them. The first connecting flange 20, the first ferrule flange 21, and the first fixing bracket 22 are connected and fixed. The second connecting flange 23, the second ferrule flange 24, and the second fixing bracket 25 are connected and fixed. The valve stem shaft is coaxially connected to a first coupling 3, a torque sensor 4, a second coupling 6, an actuator output shaft 7, a third coupling 10, and a rotary encoder 9. The upper end of the valve is connected to an actuator bracket, and the actuator 8 is mounted on the upper end of the actuator bracket. The torque sensor 4 and a one-way Hall effect sensor 14 are connected to both ends of the actuator bracket, and the one-way Hall effect sensor sensing element 13 is adsorbed in the groove of the actuator output shaft. In the water pump pressurizing system: the water pump pressurizing system pipeline is connected to the pipelines of the first ferrule flange 21 and the second ferrule flange 24, providing the valve with media of different pressures, different flow rates and different temperatures. In the actuator hydraulic control system: the actuator hydraulic control system pipeline is connected to the oil port of the actuator 8, and the valve is driven to open and close at different speeds by outputting oil of different flow rates to the actuator 8. The torque sensor 4 can be used to continuously record the dynamic torque parameters during the valve opening and closing process, and the rotary encoder 9 can be used to obtain the valve angle parameters, and further obtain the relationship between the valve angle and torque. The valve angle feedback can also be used to control the electromagnetic reversing valve 55 to achieve automatic reversing, thereby changing the valve rotation direction and realizing automatic continuous opening and closing of the valve. The one-way Hall sensor 14 is used to record the number of times the valve is opened and closed, and the required number of openings and closings can be set in the industrial computer. After the number of openings and closings is reached, the industrial computer automatically shuts down the test device. The specific structure of each department is described as follows:

[0013] (1) The valve dynamic torque measurement and driving device is described as follows:

[0014] The valve dynamic torque measurement and driving device mainly includes a first connecting flange 20, a second connecting flange 23, a first ferrule flange 21, a second ferrule flange 24, a first pressure gauge 18 and a second pressure gauge 19, a first fixed bracket 22, a second fixed bracket 25, an actuator bracket 16, a torque sensor 4, a one-way Hall sensor 14, an actuator 8, a first coupling 3, a second coupling 6, a third coupling 10, an actuator output shaft 7, a rotary encoder 9, a one-way Hall sensor sensing element 13, and an industrial computer 27.

[0015] The valve to be tested 1 is connected to the first connecting flange 20 and the second connecting flange 23 via a second stud 60. The first connecting flange 20 and the second connecting flange 23 are respectively provided with a first pressure gauge 18 and a second pressure gauge 19. The second fixing bracket 25, the second connecting flange 23, and the second ferrule flange 24 are connected via a first stud 59. The first fixing bracket 22, the first connecting flange 20, and the first ferrule flange 21 are connected via a third stud 61. The first fixing bracket 22 and the second fixing bracket 25 serve to secure the entire device. The pipelines outside the second ferrule flange 24 and the first ferrule flange 21 are both connected to the water pump pressurization system.

[0016] The valve under test 1 has an actuator bracket 16 at its upper end. One side of the actuator bracket 16 has a slot for securing the torque sensor bracket 5, and the other side has a slot for securing the unidirectional Hall effect sensor bracket 15. The upper end has an opening for passing the thin end 11 of the actuator output shaft 7. Eight openings are evenly distributed across the upper end of the actuator bracket 16 for mounting the actuator 8. The lower end of the actuator bracket 16 has an opening for passing the valve stem shaft 2 of the valve under test 1. Four openings are evenly distributed across the lower end of the actuator bracket 16 for connecting the valve under test 1. Specifically, the valve under test 1 and the actuator bracket 16 are bolted together. The actuator 8 is mounted on the upper end of the actuator bracket 16, also bolted together. The valve stem shaft 2 of the valve under test 1 is connected to the torque sensor 4 via a first coupling 3, and the actuator output shaft 7 is connected to the torque sensor 4 via a second coupling 6. The torque sensor bracket 5 is provided with multiple openings. The torque sensor bracket 5 is connected to the slot on one side of the actuator bracket 16 by bolts. It can be moved up and down to adjust the appropriate position during installation. The torque sensor 4 is fixed to the opening of the torque sensor bracket 5 by bolts, and the unidirectional Hall sensor 14 is installed on the unidirectional Hall sensor bracket 15.

[0017] The thin end 11 of the actuator output shaft 7 is connected to the rotary encoder 9 via a third coupling 10. The upper end of the rotary encoder bracket 12 has four openings, one of which is for passing the rotary encoder output shaft 7, and the other three openings are bolted to the rotary encoder 9. The lower end of the rotary encoder bracket 12 has multiple openings, one of which is for passing the actuator output shaft 7, a second opening is bolted to the rotary encoder 9, and a third opening is bolted to the actuator 8. A unidirectional Hall effect sensor element 13 is mounted on the actuator output shaft 7. This unidirectional Hall effect sensor element 13 is a magnet that attaches to a groove in the actuator output shaft 7. A unidirectional Hall effect sensor 14 is secured to a unidirectional Hall effect sensor bracket 15. This bracket 15 has four openings, which are bolted to slots in the actuator bracket 16 and can be moved up and down to adjust the proper position during installation.

[0018] The actuator 8 drives the actuator output shaft 7 to rotate. The actuator output shaft 7 transmits torque to the valve stem shaft 2 of the valve under test 1 through the second coupling 6, the torque sensor 4, and the first coupling 3, causing the valve under test 1 to open or close. The torque sensor 4 measures the dynamic torque parameters of the valve under test 1 during the opening or closing process. The dynamic torque parameters are transmitted to the industrial computer 27 via the data acquisition card 26, and the dynamic torque parameters can be observed on the industrial computer 27. The rotary encoder 9 rotates coaxially with the actuator output shaft 7 and the valve stem shaft 2, and outputs the valve angle parameters to the industrial computer 27 via the data acquisition card 26. The industrial computer 27 can obtain the relationship between the angle and torque of the valve under test 1.

[0019] Furthermore, the unidirectional Hall effect sensor element 13 is a magnet that is attracted to the groove 701 of the actuator output shaft 7 and rotates along with the actuator output shaft 7 from 0° to 90°. Each time the unidirectional Hall effect sensor element 13 passes the unidirectional Hall effect sensor 14, the output value of the unidirectional Hall effect sensor increases by 1. This means that the unidirectional Hall effect sensor 14 records the number of rotations of the actuator output shaft 7 within the range of 0° to 90°, which represents the number of times the valve 1 under test has opened and closed. The unidirectional Hall effect sensor 14 transmits the recorded data to a counter display 17, where the number of times the valve 1 under test has opened and closed can be viewed. Furthermore, the unidirectional Hall effect sensor 14 transmits the recorded data to an industrial computer 27 via a data acquisition card 26.

[0020] (2) The description of the water pump pressurizing system is as follows:

[0021] The water pump pressurization system provides a flow medium for the valve 1 to be tested, simulating the actual medium flow under the actual working conditions of the valve. The water pump pressurization system designed by the present invention fully considers the medium pressure, temperature, and flow rate fluctuations encountered during the actual operation of the valve, and can achieve the regulation of the medium pressure, temperature, and flow rate. The water pump pressurization system mainly includes a first motor 29, a hydraulic pump 30, a water tank 44, a water filter 31, a pressure reducing valve 32, a first throttle stop valve 36, a second throttle stop valve 39, a flow meter 40, a third pressure gauge 33, a fourth pressure gauge 35, a first pressure sensor 37, a second pressure sensor 38, a liquid level and temperature gauge 28, a temperature sensor 34, a thermometer 43, and a first overflow valve 41.

[0022] The first motor 29 of the water pump pressurization system drives the first hydraulic pump 30, which pumps fluid from a water tank 44. The fluid then passes through a water filter 31, a pressure reducing valve 32, a first throttle stop valve 36, a second ferrule flange 24, and a second connecting flange 23 before acting on the valve under test 1. When the valve under test 1 is not fully closed, the fluid flowing through the valve 1 returns to the water tank 44 via the first connecting flange 20, the first ferrule flange 21, the second throttle stop valve 39, and the flowmeter 40. A first relief valve 41, installed between the pressure reducing valve 32 and the water tank 44, provides overload protection.

[0023] By adjusting the pressure reducing valve 32, different medium pressures can be achieved. A heater 42, mounted on a water tank 44, can also be adjusted to achieve different medium temperatures. By adjusting the first throttle stop valve 36 and the second throttle stop valve 39, different medium flow rates can be achieved, and the medium flow can also be cut off, thereby simulating the operating conditions of the valve under test 1 under different medium pressures, flow rates, and temperatures. A third pressure gauge 33 is mounted in front of the pressure reducing valve 32, a fourth pressure gauge 35 is mounted in back of the pressure reducing valve 32, a first pressure sensor 37 is mounted on the output pipeline of the water pump pressurization system, and a second pressure sensor 38 is mounted on the input pipeline of the water pump pressurization system. The actual pressure value of the water pump pressurization system can be obtained through the third pressure gauge 33, the fourth pressure gauge 35, the first pressure sensor 37, and the second pressure sensor 38, while the actual flow value of the water pump pressurization system can be obtained through the flowmeter 40. A liquid level and temperature gauge 28 is mounted in the water tank 44, a temperature sensor 34 is mounted in front of the first throttle stop valve 36, and a thermometer 43 is mounted in the water tank 44. The actual medium temperature value of the water pump pressurization system can be obtained through the liquid level and liquid temperature gauge 28, the temperature sensor 34 and the thermometer 43.

[0024] (3) The description of the actuator hydraulic control system is as follows:

[0025] The actuator hydraulic control system provides power to actuator 8, driving the reciprocating motion of the piston within actuator 8 and, in turn, opening and closing the valve 1 under test. The actuator hydraulic control system proposed in this invention enables actuator 8 to open and close at varying speeds, and can also achieve continuous reciprocating opening and closing over extended periods. The actuator hydraulic control system primarily includes a second motor 46, a second hydraulic pump 47, a one-way valve 52, a solenoid reversing valve 55, a first speed regulating valve 56, a second speed regulating valve 57, a filter 50, an oil tank 51, and an air cooler 54.

[0026] The second motor 46 of the actuator hydraulic control system drives the second hydraulic pump 47 to pump oil. The oil then flows through the check valve 52, the solenoid reversing valve 55, and the first or second speed control valve 56, 57 before entering the actuator 8. This reciprocating motion of the piston within the actuator 8 drives the actuator output shaft 7, which in turn drives the valve 1 under test. The oil flowing out of the actuator 8 flows through the first or second speed control valve 56, 57, the solenoid reversing valve 55, and the filter 50 before flowing into the oil tank 51. The return oil is cooled by the air cooler 54. A temperature relay 49 is located on the oil tank 51 to provide overheating protection. An air filter 48 is installed in front of the temperature relay 49 to filter air. A second relief valve 53 is installed behind the check valve 52 to provide overload protection. A level gauge 58 is installed on the oil tank 51 to indicate the oil level.

[0027] A variable working condition dynamic torque test method for a valve under long-term service is implemented based on the above-mentioned test device, comprising the following steps:

[0028] First, the actuator hydraulic control system drives the piston of actuator 8 to reciprocate, causing the actuator output shaft 7 to rotate. This in turn drives the shaft of rotary encoder 9 to rotate via the third coupling 10. Rotary encoder 9 transmits the rotation signal to industrial computer 27 via data acquisition card 26. The industrial computer 7 can then calculate the current rotation angle and speed information of actuator output shaft 7.

[0029] Next, industrial computer 7 outputs reversing signals to electromagnetic reversing valve 55 at rotation angles of 0° (fully open position of valve 1 under test) and 90° (fully closed position of valve 1 under test), thereby implementing the reversing function of actuator 8. This causes the piston of actuator 8 to reciprocate, driving valve stem shaft 2 to rotate between 0° and 90°, thereby driving valve 1 under test to repeatedly open and close, achieving dynamic torque measurement under repeated opening and closing. By adjusting first and second speed control valves 56 and 57, different flow rates of oil can be input to actuator 8, thereby opening and closing valve 1 under test at different speeds.

[0030] Finally, the required number of valve opening and closing times is set on the industrial computer 27. When the number of valve opening and closing times recorded by the unidirectional Hall sensor 14 reaches the set number of times of the industrial computer 27, the industrial computer 27 outputs a power-off signal to the electrical control box 45. The electrical control box 45 can cut off the power supply to the second motor 46 and the first motor 29, thereby achieving the effect of shutting down the test device. In this way, the set number of opening and closing times can be achieved, and the test device runs automatically. When the number of valve opening and closing times reaches the set value, the test device is automatically shut down, which greatly reduces the manpower and time costs of long-term tests.

[0031] The beneficial effects of the present invention are:

[0032] (1) The test device provided by the present invention can simulate the medium state of the valve in actual operation by adjusting the setting values ​​of the pressure reducing valve, throttling stop valve and heater of the water pump pressurization system to apply media of different pressures, flow rates and temperatures to the valve to be tested; and can control the opening and closing speed of the valve by adjusting the output flow of the actuator hydraulic control system, and can simulate the working state of the valve at different opening and closing speeds;

[0033] (2) The test device provided by the present invention can automatically reverse the electromagnetic reversing valve at the fully closed and fully open positions of the valve, and can realize automatic reversal and automatic continuous opening and closing of the valve; it can measure the dynamic torque parameters of the valve during the opening and closing process, and can obtain the relationship between the valve angle and torque during the opening and closing process. The test process is all automatic and does not require manual operation; after setting the required number of valve opening and closing times, the test device can automatically perform the test, and can automatically close the test device after reaching the set number of opening and closing times. It can test the dynamic torque of the valve under different opening and closing times, greatly reducing manpower investment, and can realize automatic measurement, providing technical support for the dynamic torque measurement of the valve under long-term service status, and has high engineering application value. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 The variable working condition dynamic torque test device for the valve under long-term service provided by the present invention;

[0035] Figure 2 The valve dynamic torque measurement and drive device, (a) is a three-dimensional diagram of the valve dynamic torque measurement and drive device, (b) is a front view of the valve dynamic torque measurement and drive device, (c) is a left view of the valve dynamic torque measurement and drive device, (d) is a right view of the valve dynamic torque measurement and drive device, and (e) is a top view of the valve dynamic torque measurement and drive device;

[0036] Figure 3 For the actuator bracket;

[0037] Figure 4 For sensor bracket;

[0038] Figure 5 For fixing the bracket;

[0039] Figure 6 It is a bracket for the rotary encoder;

[0040] Figure 7 It is a unidirectional Hall sensor and bracket;

[0041] Figure 8 is the actuator output shaft;

[0042] Figure 9 For connecting flange;

[0043] Figure 10 It is a ferrule flange;

[0044] Figure 11 It is a unidirectional Hall sensor sensing element;

[0045] Figure 12 for the first and second couplings (both identical);

[0046] Figure 13 is the third coupling;

[0047] Figure 14 is a torque sensor;

[0048] Figure 15 pressurizing the system for the water pump;

[0049] Figure 16 It is the hydraulic control system of the actuator;

[0050] In the figure: 1 valve body to be tested, 2 valve stem shaft, 3 first coupling, 4 torque sensor, 5 torque sensor bracket, 6 second coupling, 7 actuator output shaft, 8 actuator, 9 rotary encoder, 10 third coupling, 11 thin end of actuator output shaft 7, 12 rotary encoder bracket, 13 one-way Hall sensor sensing element, 14 one-way Hall sensor, 15 one-way Hall sensor bracket, 16 actuator bracket, 17 counting display, 18 first pressure gauge, 19 second pressure gauge, 20 first connecting flange, 21 first ferrule flange, 22 first fixing bracket, 23 second connecting flange, 24 second ferrule flange, 25 second fixing bracket, 26 data acquisition card, 27 industrial computer, 28 liquid level and temperature gauge, 29 first Motor, 30 first hydraulic pump, 31 water filter, 32 pressure reducing valve, 33 third pressure gauge, 34 temperature sensor, 35 fourth pressure gauge, 36 first throttle stop valve, 37 first pressure sensor, 38 second pressure sensor, 39 second throttle stop valve, 40 flow meter, 41 first relief valve, 42 heater, 43 thermometer, 44 water tank, 45 electric control box, 46 second motor, 47 second hydraulic pump, 48 air filter, 49 temperature relay, 50 filter, 51 oil tank, 52 check valve, 53 second relief valve, 54 air cooler, 55 solenoid reversing valve, 56 first speed regulating valve, 57 second speed regulating valve, 58 level gauge, 59 first stud, 60 second stud, 61 third stud. DETAILED DESCRIPTION

[0051] The present invention is described below with reference to specific embodiments.

[0052] Figure 1This is a schematic diagram of a variable-condition dynamic torque test apparatus for valves in long-term service. The valve 1 under test is connected to the first and second connecting flanges 20, 23 via a second stud 60. The first and second connecting flanges 20, 23 are equipped with a first pressure gauge 18, 19, respectively. The second fixing bracket 25, the second connecting flange 23, and the second ferrule flange 24 are connected via a first stud 59. The first fixing bracket 22, the first connecting flange 20, and the first ferrule flange 21 are connected via a third stud 61. The first and second fixing brackets 22, 25 secure the entire apparatus. Pipelines outside the second ferrule flange 24 and the first ferrule flange 21 are connected to the water pump pressurization system.

[0053] The valve under test 1 has an actuator bracket 16 at its upper end. One side of the actuator bracket 16 has a slot for securing the torque sensor bracket 5, and the other side has a slot for securing the unidirectional Hall effect sensor bracket 15. The upper end of the actuator bracket 16 has an opening for passing the thin end 11 of the actuator output shaft 7. Eight openings are evenly distributed along the upper end of the actuator bracket 16 for connecting to the actuator 8. The lower end of the actuator bracket 16 has an opening for passing the valve stem shaft 2 of the valve under test 1. Four openings are evenly distributed along the lower end of the actuator bracket 16 for connecting to the valve under test 1. The valve under test 1 and the actuator bracket 16 are connected by bolts. The actuator 8 is mounted on the upper end of the actuator bracket 16 and also bolted together. The valve stem shaft 2 of the valve under test 1 is connected to the torque sensor 4 via a first coupling 3, and the actuator output shaft 7 is connected to the torque sensor 4 via a second coupling 6. The torque sensor bracket 5 has multiple openings and is bolted to a slot on one side of the actuator bracket 16. During installation, the torque sensor bracket 5 can be moved up and down to adjust the position. The torque sensor 4 is fixed to the opening of the torque sensor bracket by bolts. The unidirectional Hall sensor 14 is installed on the unidirectional Hall sensor bracket 15.

[0054] The thin end 11 of the actuator output shaft 7 is connected to the rotary encoder 9 via a third coupling 10. The upper end of the rotary encoder bracket 12 has four openings, one of which is for passing the rotary encoder output shaft 7, and the other three openings are bolted to the rotary encoder 9. The lower end of the rotary encoder bracket 12 has multiple openings, one of which is for passing the actuator output shaft 7, a second opening is bolted to the rotary encoder 9, and a third opening is bolted to the actuator 8. A unidirectional Hall sensor sensing element 13 is mounted on the actuator output shaft 7. This unidirectional Hall sensor sensing element 13 is a magnet that is attracted to the groove 7 of the actuator output shaft 7. A unidirectional Hall sensor 14 is fixed to a unidirectional Hall sensor bracket 15. This unidirectional Hall sensor bracket 15 has four openings that are bolted to the slots of the actuator bracket 16 and can be moved up and down to adjust the proper position during installation.

[0055] The actuator 8 drives the actuator output shaft 7 to rotate. The actuator output shaft 7 transmits torque to the valve stem shaft 2 of the valve under test 1 through the second coupling 6, the torque sensor 4, and the first coupling 3, causing the valve under test 1 to open or close. The torque sensor 4 measures the dynamic torque parameters of the valve under test 1 during the opening or closing process. The dynamic torque parameters are transmitted to the industrial computer 27 via the data acquisition card 26, and the dynamic torque parameters can be observed on the industrial computer 27. The rotary encoder 9 rotates coaxially with the actuator output shaft 7 and the valve stem shaft 2, and outputs the valve angle parameters to the industrial computer 27 via the data acquisition card 26. The relationship between the valve angle and torque can be obtained on the industrial computer.

[0056] The unidirectional Hall effect sensor 13 is a magnet that attaches to the groove of the actuator output shaft 7 and rotates along with the actuator output shaft 7 between 0° and 90°. Each time the unidirectional Hall effect sensor 13 passes the unidirectional Hall effect sensor 14, the output value of the unidirectional Hall effect sensor increases by 1. This means that the unidirectional Hall effect sensor 14 records the number of rotations of the actuator output shaft 7 between 0° and 90°, which represents the number of times the valve 1 under test has opened and closed. The unidirectional Hall effect sensor 14 transmits this recorded data to a counter display 17, where the number of times the valve 1 under test has opened and closed is visually displayed. Furthermore, the unidirectional Hall effect sensor 14 transmits this recorded data to an industrial computer 27 via a data acquisition card 26.

[0057] The first motor 29 of the water pump pressurization system drives the first hydraulic pump 30, which pumps fluid from a water tank 44. The fluid then passes through a water filter 31, a pressure reducing valve 32, a first throttle stop valve 36, a second ferrule flange 24, and a second connecting flange 23 before acting on the valve under test 1. When the valve under test 1 is not fully closed, the fluid flowing through the valve 1 returns to the water tank 44 via the first connecting flange 20, the first ferrule flange 21, the second throttle stop valve 39, and the flowmeter 40. A first relief valve 41, installed between the pressure reducing valve 32 and the water tank 44, provides overload protection.

[0058] By adjusting the pressure reducing valve 32, different medium pressures can be achieved. A heater 42, mounted on the water tank 44, can also be adjusted to achieve different medium temperatures. By adjusting the first throttle stop valve 36 and the second throttle stop valve 39, different medium flow rates can be achieved, and the medium flow can also be shut off, thereby simulating the operating conditions of the valve under test 1 under different medium pressures, flow rates, and temperatures. A third pressure gauge 33 is mounted in front of the pressure reducing valve 32, a fourth pressure gauge 35 is mounted in back of the pressure reducing valve 32, a first pressure sensor 37 is mounted on the output pipeline of the water pump pressurization system, and a second pressure sensor 38 is mounted on the input pipeline of the water pump pressurization system. The third pressure gauge 33, the fourth pressure gauge 35, the first pressure sensor 37, and the second pressure sensor 38 are used to obtain the actual pressure value of the water pump pressurization system, while the flow meter 40 can obtain the actual flow value of the water pump pressurization system. A liquid level and temperature gauge 28 is mounted on the water tank 44, a temperature sensor 34 is mounted in front of the first throttle stop valve 36, and a thermometer 43 is mounted on the water tank 44. The actual medium temperature value of the water pump pressurization system can be obtained through the liquid level and liquid temperature gauge 28, the temperature sensor 34 and the thermometer 43.

[0059] The second motor 46 of the actuator hydraulic control system drives the second hydraulic pump 47 to pump oil. The oil then flows through the check valve 52, the solenoid reversing valve 55, and the first or second speed control valve 56, 57 before entering the actuator 8. This reciprocating motion of the piston within the actuator 8 drives the actuator output shaft 7, which in turn drives the valve 1 under test. The oil flowing out of the actuator 8 flows through the first or second speed control valve 56, 57, the solenoid reversing valve 55, and the filter 50 before flowing into the oil tank 51. The return oil is cooled by the air cooler 54. A temperature relay 49 is located on the oil tank 51 to provide overheating protection. An air filter 48 is installed in front of the temperature relay 49 to filter air. A second relief valve 53 is installed behind the check valve 52 to provide overload protection. A level gauge 58 is installed on the oil tank 51 to indicate the oil level.

[0060] A variable working condition dynamic torque test method for a valve under long-term service is implemented based on the above-mentioned test device, comprising the following steps:

[0061] During actual testing, first connect and secure the valve under test 1, first connecting flange 20, second connecting flange 23, first pressure gauge 18, second pressure gauge 19, second ferrule flange 24, first ferrule flange 21, first fixing bracket 22, and second fixing bracket 25. Then, secure the actuator bracket 16 to the valve under test 1. Install the torque sensor bracket 5 to the actuator bracket 16, then sequentially install the first coupling 3, torque sensor 4, second coupling 6, and actuator output shaft 7. Finally, install the actuator 8 to the actuator bracket 16. Install the rotary encoder bracket 12 to the actuator 8, followed by the third coupling 10 and rotary encoder 9. Install the one-way Hall sensor sensing element 13, one-way Hall sensor 14, and one-way Hall sensor bracket 15. Place the counter display 17 on the actuator bracket 16.

[0062] Connect the water pump pressurization system pipeline to the second clamping flange 24 and the first clamping flange 21. Connect the actuator hydraulic control system pipeline to the oil port of the actuator 8. Connect the torque sensor 4, one-way Hall sensor 14, and rotary encoder 9 to the data acquisition card 26. Connect the one-way Hall sensor 14 to the counter display 17. Connect the output port of the data acquisition card 26 to the industrial computer 27. Connect the output port of the industrial computer 27 to the electrical control box 45 and the electromagnetic reversing valve 55. Connect the electrical control box 45 to the water pump pressurization system motor 29. Connect the electrical control box 45 to the motor 46 of the actuator hydraulic control system.

[0063] Before the test begins, the number of opening and closing operations of the valve 1 to be tested that needs to be executed is set on the industrial computer 27, the valve 1 to be tested is manually adjusted to the fully open position, and the output angle value of the rotary encoder 9 at this position is set to 0°, and the output angle value of the rotary encoder 9 after rotating 90° is set to 90°.

[0064] Turn on the electrical control box 45, start and adjust the heater 42 so that the temperature displayed by the temperature sensor 34 and the thermometer 43 reaches the test temperature. Open the first throttle stop valve 36 and the second throttle stop valve 39, start the first motor 29 of the water pump pressurization system, and adjust the pressure reducing valve 32 and the first throttle stop valve 36 and the second throttle stop valve 39 so that the medium pressure, flow rate, and temperature all meet the test requirements.

[0065] Adjusting the solenoid directional control valve 55 to the right position activates the second motor 46 of the actuator hydraulic control system. Driven by the actuator hydraulic control system, the piston of actuator 8 moves leftward, driving the actuator output shaft 7, valve stem shaft 2, and the shaft of rotary encoder 9 counterclockwise. This results in the valve 1 under test rotating toward the closing direction. The torque sensor 4 transmits the torque parameters during this rotation process to the industrial computer 27 via the data acquisition card 26. When the shaft of rotary encoder 9 rotates 90 degrees counterclockwise, indicating that the valve 1 under test is in the fully closed position, the industrial computer 27 sends a reversing signal to the solenoid directional control valve 55, switching it to the left position. This changes the direction of the output oil from the actuator hydraulic control system, causing the piston of actuator 8 to move rightward. This in turn drives the actuator output shaft 7, valve stem shaft 2, and the shaft of rotary encoder 9 clockwise, resulting in the valve 1 under test rotating toward the opening direction. The torque sensor 4 transmits the torque parameters during this rotation process to the industrial computer 27 via the data acquisition card 26. When the shaft of the rotary encoder 9 rotates 90 degrees clockwise, that is, when it is at the 0 degree position, the valve 1 to be tested is in the fully open position, and the industrial computer 27 sends a reversing signal to the electromagnetic reversing valve 55. The electromagnetic reversing valve 55 switches to the right position, and the output oil direction of the actuator hydraulic control system changes, driving the valve 1 to be tested to move in the closing direction. And so on, the above actions are repeated. By adjusting the first speed regulating valve 56 and the second speed regulating valve 57, the output flow rate can be changed, so that the valve 1 to be tested can be opened and closed at different speeds.

[0066] During the repeated execution process, the torque sensor 4 transmits the torque value to the industrial computer 27 through the data acquisition card 26 in real time, and the rotary encoder 9 transmits the valve angle value to the industrial computer 27 through the acquisition card 26 in real time. The relationship between the angle and torque of the valve 1 to be tested can be obtained on the industrial computer 27. The unidirectional Hall sensor 14 records the number of opening and closing times and transmits this parameter to the counting display 17 and the industrial computer 27. When the number of opening and closing times reaches the set number, the industrial computer 27 outputs a power-off signal to the electrical control box 45, and the electrical control box 45 can cut off the power supply to the second motor 46 and the first motor 29, thereby achieving the effect of shutting down the test device and completing the test.

[0067] The above-described embodiments merely express the implementation methods of the present invention, but should not be understood as limiting the scope of the patent of the present invention. It should be pointed out that for those skilled in the art, several variations and improvements can be made without departing from the concept of the present invention, and these all fall within the scope of protection of the present invention.

Claims

1. A variable working condition dynamic torque test device for valves under long-term service, used for dynamic torque testing of valves under long-term service and design, manufacture and optimization of valves. It is characterized in that The test device comprises the following three parts: the first part is a valve torque measurement and driving device, the second part is a water pump pressurization system, and the third part is an actuator hydraulic control system; In the valve torque measurement and drive device: the valve is connected to the first connecting flange (20) and the second connecting flange (23) and is located between the two; the first connecting flange (20), the first ferrule flange (21) and the first fixed bracket (22) are fixedly connected; the second connecting flange (23), the second ferrule flange (24) and the second fixed bracket (25) are fixedly connected; the valve stem shaft is coaxially connected to the first coupling (3), the torque sensor (4), the second coupling (6), the actuator output shaft (7), the third coupling (10) and the rotary encoder (9); the upper end of the valve is connected to the actuator bracket; the actuator (8) is installed on the upper end of the actuator bracket; the torque sensor (4) and the unidirectional Hall sensor (14) are connected to both ends of the actuator bracket; the unidirectional Hall sensor sensing element (13) is adsorbed on the actuator output shaft (7); In the water pump pressurizing system: the water pump pressurizing system pipeline is connected to the pipelines of the first clamping flange (21) and the second clamping flange (24), providing the valve with media of different pressures, different flow rates and different temperatures; In the actuator hydraulic control system: the actuator hydraulic control system pipeline is connected to the actuator (8) oil port, and the valve is driven to open and close at different rotation speeds by outputting oil with different flow rates to the actuator (8); the torque sensor (4) is used to continuously record the dynamic torque parameters during the valve opening and closing process; the valve angle parameters are obtained by using a rotary encoder (9), and then the relationship between the valve angle and the torque is obtained. The valve angle feedback can also be used to control the electromagnetic reversing valve (55) to achieve automatic reversing, thereby changing the valve rotation direction and achieving automatic continuous opening and closing of the valve; and the unidirectional Hall sensor (14) is used to record the number of times the valve is opened and closed.

2. According to claim 1, a variable working condition dynamic torque test device for valves in long-term service state, It is characterized in that The valve dynamic torque measuring and driving device comprises a first connecting flange (20), a second connecting flange (23), a first ferrule flange (21), a second ferrule flange (24), a first pressure gauge (18), a second pressure gauge (19), a first fixed bracket (22), a second fixed bracket (25), an actuator bracket (16), a torque sensor (4), a one-way Hall sensor (14), an actuator (8), a first coupling (3), a second coupling (6), a third coupling (10), an actuator output shaft (7), a rotary encoder (9), a one-way Hall sensor sensing element (13), a rotary encoder bracket (12), and an industrial computer (27); the details are as follows: The valve to be tested (1) is connected to a first connecting flange (20) and a second connecting flange (23), and a first pressure gauge (18) and a second pressure gauge (19) are respectively provided on the first connecting flange (20) and the second connecting flange (23); the second fixing bracket (25), the second connecting flange (23) and the second ferrule flange (24) are connected via a first stud 59, and the first fixing bracket (22), the first connecting flange (20) and the first ferrule flange (21) are connected via a third stud 61. The first fixing bracket (22) and the second fixing bracket (25) play a role in fixing the entire device, and the pipelines outside the second ferrule flange (24) and the first ferrule flange (21) are connected to the water pump pressurization system; An actuator bracket (16) is installed at the upper end of the valve to be tested (1), and an actuator (8) is installed at the upper end of the actuator bracket (16); a torque sensor bracket (5) is installed on one side of the actuator bracket (16), and the position can be adjusted up and down during installation, and the torque sensor (4) is fixed on the torque sensor bracket (5); the other side is used to fix a one-way Hall sensor bracket (15), and the one-way Hall sensor (14) is installed on the one-way Hall sensor bracket (15); a hole is opened at the upper end of the actuator bracket (16) for passing the thin end (11) of the actuator output shaft (7); the valve stem shaft (2) of the valve to be tested (1) is connected to the torque sensor (4) through a first coupling (3), and the actuator output shaft (7) is connected to the torque sensor (4) through a second coupling (6); The thin end (11) of the actuator output shaft (7) is connected to the rotary encoder (9) via a third coupling (10); the upper end of the rotary encoder bracket (12) has a hole for passing the rotary encoder output shaft, and the upper end of the rotary encoder bracket (12) is connected to the rotary encoder (9); the lower end of the rotary encoder bracket (12) has a hole for passing the actuator output shaft (7), and the lower end of the rotary encoder bracket (12) is installed with the rotary encoder (9) and the actuator (8); the unidirectional Hall sensor sensing element (13) is a magnet, which is adsorbed on the groove of the actuator output shaft (7).

3. According to claim 2, a variable working condition dynamic torque test device for valves in long-term service state, It is characterized in that The actuator (8) drives the actuator output shaft (7) to rotate, and the actuator output shaft (7) transmits torque to the valve stem shaft (2) of the valve to be tested (1) through the second coupling (6), the torque sensor (4) and the first coupling (3), so that the valve to be tested (1) is opened or closed, and the torque sensor (4) measures the dynamic torque parameters during the opening or closing process of the valve to be tested (1), and the dynamic torque parameters are transmitted to the industrial computer (27), and the dynamic torque parameters are observed on the industrial computer (27); the rotary encoder (9) rotates coaxially with the actuator output shaft (7) and the valve stem shaft (2), and the industrial computer (27) outputs the valve rotation angle parameters, and the relationship between the rotation angle and torque of the valve to be tested (1) is obtained on the industrial computer (27).

4. According to claim 2, a variable working condition dynamic torque test device for valves in long-term service state, It is characterized in that The one-way Hall sensor sensing element (13) is a magnet, which is adsorbed on the groove 701 of the actuator output shaft (7) and rotates 0°-90° along with the actuator output shaft (7). The one-way Hall sensor (14) records the number of rotations of the actuator output shaft (7) within 0°-90°, which is the number of opening and closing times of the valve (1) to be tested.

5. According to claim 1, a variable working condition dynamic torque test device for valves in long-term service state, It is characterized in that The water pump pressurizing system provides a flow medium for the valve to be tested (1) to simulate the flow of real medium under the real working conditions of the valve, and comprises a first motor (29), a hydraulic pump (30), a water tank (44), a water filter (31), a pressure reducing valve (32), a first throttling stop valve (36), a second throttling stop valve (39), a flow meter (40), a third pressure gauge (33), a fourth pressure gauge (35), a first pressure sensor (37), a second pressure sensor (38), a liquid level and temperature gauge (28), a temperature sensor (34), a thermometer (43), and a first overflow valve (41); the details are as follows: The first motor (29) drives the first hydraulic pump (30) to pump out a medium in the water tank (44), and the medium acts on the valve to be tested (1) after passing through the water filter (31), the pressure reducing valve (32), the first throttling stop valve (36), the second ferrule flange (24) and the second connecting flange (23); when the valve to be tested (1) is in an incompletely closed position, the medium flowing through the valve to be tested (1) returns to the water tank (44) through the first connecting flange (20), the first ferrule flange (21), the second throttling stop valve (39) and the flow meter (40); the first overflow valve (41) is installed between the pressure reducing valve (32) and the water tank (44) to play an overload protection role; The third pressure gauge (33) is installed in front of the pressure reducing valve (32), and the fourth pressure gauge (35) is installed in the rear of the pressure reducing valve (32). Different medium pressures can be obtained by adjusting the pressure reducing valve (32). The heater (42) is installed on the water tank (44). Mediums with different temperatures can be obtained by adjusting the heater (42). Mediums with different flow rates can be obtained by adjusting the first throttling stop valve (36) and the second throttling stop valve (39), and the flow of the medium can also be cut off. The valve to be tested (1) is placed in working conditions with different medium pressures, different medium flow rates, and different medium temperatures. The fourth pressure gauge (35), the first pressure sensor (37) and the second pressure sensor (38) obtain the actual pressure value of the water pump pressurization system, the actual flow value of the water pump pressurization system is obtained through the flow meter (40), and the actual medium temperature value of the water pump pressurization system is obtained through the liquid level and liquid temperature meter (28), the temperature sensor (34) and the thermometer (43).

6. According to claim 1, a variable working condition dynamic torque test device for valves in long-term service state, It is characterized in that The actuator hydraulic control system is used to provide power to the actuator (8), so as to enable the actuator (8) to open and close at different speeds, and to achieve continuous reciprocating opening and closing for a long time; the actuator hydraulic control system mainly comprises a second motor (46), a second hydraulic pump (47), a one-way valve (52), an electromagnetic reversing valve (55), a first speed regulating valve (56), a second speed regulating valve (57), a filter (50), an oil tank (51), and an air cooler (54); the details are as follows: The second motor (46) drives the second hydraulic pump (47) to pump oil, and the oil enters the actuator (8) after passing through the one-way valve (52), the electromagnetic reversing valve (55) and the first speed regulating valve (56) or the second speed regulating valve (57), drives the piston in the actuator (8) to reciprocate, drives the actuator output shaft (7) to rotate, and then drives the valve to be tested (1) to open and close; the oil flowing out of the actuator (8) passes through the first speed regulating valve (56) or the second speed regulating valve (57), the electromagnetic reversing valve (55) and the first speed regulating valve (56) or the second speed regulating valve (57). The oil flows into the oil tank (51) after passing through the valve (55) and the filter (50), and the return oil is cooled by the air cooler (54); the temperature relay (49) is installed on the oil tank (51) to play an overheat protection role; the air filter (48) is installed in front of the temperature relay (49) to filter the air; the second overflow valve 53 is installed at the rear of the check valve (52) to play an overload protection role; the liquid level meter (58) is installed on the oil tank (51) to display the oil height.

7. A method for testing the dynamic torque of a valve under variable working conditions under long-term service conditions based on the test device described in any one of claims 1 to 6, It is characterized in that The following steps are involved: First, the actuator hydraulic control system drives the piston of the actuator (8) to reciprocate, and the actuator output shaft (7) rotates, which drives the shaft of the rotary encoder (9) to rotate through the third coupling (10). The rotary encoder (9) transmits the rotation signal to the industrial computer (27), and calculates the current rotation angle and speed information of the actuator output shaft (7); Secondly, the industrial computer (27) outputs a reversing signal to the electromagnetic reversing valve (55) when the rotation angle is 0° and 90° respectively, so as to realize the reversing function of the actuator (8), so as to make the piston of the actuator (8) reciprocate, drive the valve stem shaft (2) to rotate within the range of 0° to 90°, and then drive the valve to be tested (1) to open and close repeatedly, so as to realize dynamic torque measurement under repeated opening and closing; by adjusting the first speed regulating valve (56) and the second speed regulating valve (57), oil with different flow rates is input to the actuator (8), so that the valve to be tested (1) is opened and closed at different speeds; wherein 0° is the fully open position of the valve to be tested (1), and 90° is the fully closed position of the valve to be tested (1); Finally, the required number of valve opening and closing times is set on the industrial computer (27). When the number of valve opening and closing times recorded by the unidirectional Hall sensor (14) reaches the number set by the industrial computer (27), the industrial computer (27) outputs a power-off signal to the electric control box 45, and the electric control box 45 cuts off the power supply to the second motor (46) and the first motor (29), thereby achieving the effect of shutting down the test device and realizing the set number of opening and closing times.

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