Pilot valve control method and device based on data detection and automatic pressure regulation

Abstract

The invention discloses a pilot valve control method and device based on data detection and automatic pressure regulation, and relates to the technical field of pilot valves. The method comprises the steps that the medium pressure of a piston containing cavity is obtained in real time through a pressure sensor, and the displacement amount of a piston shaft is obtained in real time through a displacement sensor; querying a pre-stored pressure-displacement correlation curve based on the medium pressure to determine a target displacement amount; generating an adjusting signal according to the deviation data of the real-time displacement and the target displacement; and the pressure regulating component is controlled to dynamically regulate the pretightening force of the spring to realize pressure closed-loop control. The device comprises a mechanical execution unit, a data detection unit and a control processing unit, all the units work cooperatively, closed-loop control over pressure adjustment is achieved by detecting medium pressure and piston shaft displacement in real time and dynamically adjusting spring pre-tightening force, and the device has the advantages of automatic calibration, manual intervention reduction and control precision improvement.

Description

Technical Field

[0001] This application relates to the field of pilot valve technology, specifically to a pilot valve control method and device based on data detection and automatic pressure regulation. Background Art In fluid pressure control systems in industrial fields such as petrochemicals, pilot valves, as core components for achieving precise control of medium pressure, are widely used in key scenarios such as high-pressure oil and gas pipeline transportation and reactor pressure stabilization. Traditional pilot valves rely on mechanical spring preload to set the pressure threshold. However, during long-term operation, the spring preload will decay due to mechanical fatigue, medium erosion, or temperature changes, causing the actual control pressure to deviate from the set value. At this time, it is necessary to calibrate the spring preload by shutting down the valve body and manually tightening the adjustment bolts. This process is not only time-consuming and labor-intensive, and interrupts the production process, but the adjustment accuracy is significantly affected by the operator's experience. Especially in high-pressure, flammable and explosive oil and gas environments, delayed manual intervention can easily lead to the risk of overpressure leakage.

[0002] These problems seriously restrict the application effect of pilot valves in precision fluid control systems. Therefore, there is an urgent need to provide a pilot valve control method and equipment that automatically adjusts the spring preload based on real-time data detection, so as to achieve adaptive calibration and dynamic balance of industrial pipeline system pressure and improve the automation level and operation reliability of the fluid control system. Summary of the Invention

[0003] The purpose of this application is to provide a pilot valve control method and device with automatic pressure regulation based on data detection, which has the advantages of automatically adjusting the spring preload in real time, avoiding manual intervention, and improving pressure control accuracy.

[0004] This application provides a pilot valve control method based on data detection and automatic pressure regulation. The technical solution is as follows: The pilot valve includes a valve body, a pressure regulating assembly, a spring assembly, a pressure sensor, and a displacement sensor; the pressure regulating assembly includes a piston and a piston shaft; the spring assembly includes a spring acting on the piston and a pressure regulating component for adjusting the spring preload; the pressure sensor is used to obtain the real-time medium pressure in the valve body, and the displacement sensor is used to detect the real-time displacement of the piston shaft; the method includes: Obtain the real-time medium pressure of the valve body through the pressure sensor; The real-time displacement of the piston shaft is obtained in real time through the displacement sensor; Determine the target displacement of the piston shaft based on the real-time medium pressure; Determine displacement deviation data based on the real-time displacement and the target displacement; When it is determined according to the displacement deviation data that the pressure regulating component needs to be adjusted, determining the adjustment data based on the displacement deviation data; The pressure regulating component is controlled to adjust the preload force of the spring based on the regulating data. Furthermore, the present application also proposes to query the stored pressure-displacement correlation curve and use the piston shaft displacement corresponding to the real-time medium pressure mapping as the target displacement; wherein the pressure-displacement correlation curve is determined by experimental calibration or theoretical calculation, and is used to characterize the correspondence between the steady-state pressure and the equilibrium position of the piston shaft. Furthermore, the present application also proposes obtaining a displacement deviation value based on the difference between the real-time displacement and the target displacement; and performing low-pass filtering on the displacement deviation value to obtain displacement deviation data. Furthermore, the present application also proposes to determine whether the absolute value of the displacement deviation data is greater than the set adjustment threshold; if it is greater than the adjustment threshold, the adjustment direction is determined according to the positive or negative sign of the displacement deviation data, and the adjustment amplitude is determined according to the absolute value of the displacement deviation data. Furthermore, the present application also proposes generating a pulse width control signal according to the adjustment data to drive the pressure regulating component, thereby adjusting the preload force of the spring. Furthermore, the present application also proposes to compare the collected real-time medium pressure and real-time displacement with the set pressure-displacement correlation curve threshold range; if the detection data deviates from the threshold range for more than a set time or number of times, an alarm signal is triggered, and the pressure regulating component is controlled to drive the piston shaft to move to a safe position. Furthermore, the present application also proposes a pilot valve device, comprising a mechanical execution unit, a data detection unit, and a control processing unit; the mechanical execution unit comprises: The valve body has an inner cavity provided with a piston accommodating cavity and a modulation cavity which are interconnected through a piston shaft hole; The pressure regulating assembly is used to regulate the medium pressure in the valve body, comprising: a piston slidably disposed in the piston accommodating chamber, a pressure stabilizing chamber assembly disposed in the modulation chamber, and a piston shaft axially movably disposed in the valve body cavity; one end of the piston shaft is connected to the piston, and the other end extends into the pressure stabilizing chamber in the pressure stabilizing chamber assembly; and The spring assembly includes a spring and a pressure-adjusting component; the spring is clamped between the piston and the pressure-adjusting component to provide a preload force for the piston, and the pressure-adjusting component is used to adjust the spring preload force.

[0005] A sealing assembly is installed at the bottom of the piston accommodating chamber and is provided with a through hole for the piston shaft to pass through; The data detection unit includes a pressure sensor and a displacement sensor. The pressure sensor is arranged at the piston accommodating chamber to obtain the real-time medium pressure in the valve body. The displacement sensor is arranged at the corresponding piston shaft end position in the pressure stabilizing chamber of the pressure stabilizing chamber assembly to detect the real-time displacement of the piston shaft. The control processing unit is connected to the data detection unit and the voltage regulating component by signal, and includes a memory, a processor, and a computer program stored in the memory and executable on the processor. The above method is implemented when the processor executes the computer program. Furthermore, the present application also proposes that the pressure regulating component includes an adjusting bolt and a micro-stepping motor, and the micro-stepping motor drives the adjusting bolt to rotate through a transmission mechanism to change the compression amount of the spring. Furthermore, the present application also proposes that the piston shaft includes a cutoff section and a flow section, which passes through the piston shaft hole; the outer diameter of the piston shaft at each location is smaller than the aperture of the piston shaft hole to form a medium flow channel; and the cutoff section has a variable diameter structure, which cooperates with the through hole of the sealing assembly, and is used to adjust the cross-sectional area of the medium flow channel through the change of the axial movement of the piston shaft to form an adjustable medium flow channel: when the piston shaft is in a safe position, the maximum diameter part of the cutoff section cooperates with the through hole seal to block the flow of the medium; when the piston shaft is in a working position, an annular flow gap is formed between the cutoff section and the through hole, and the cross-sectional area of the annular flow gap changes with the displacement of the piston shaft. The beneficial effect of the present application is that it provides a pilot valve control method and device with automatic pressure regulation based on data detection, which dynamically adjusts the spring preload force by real-time detection of medium pressure and piston shaft displacement to achieve closed-loop control of pressure deviation, and has the advantages of automatic calibration, reduced manual intervention, and improved control accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the embodiments or descriptions of the prior art.

[0007] Figure 1 This is a schematic diagram of the control method steps of the application embodiment; Figure 2 A schematic diagram of the device structure of an embodiment of the application; Figure 3 Schematic diagram of the cross-section structure of the valve body; Figure 4 Schematic diagram of the piston shaft structure.

[0008] Among them, the reference numerals in the figures are: 10. Valve body; 11. Piston accommodating chamber; 12. Modulating chamber; 13. Piston shaft hole; 20. Piston; 30. Pressure-stabilizing chamber assembly; 40. Piston shaft; 41. Cut-off section; 411. Thin shaft section; 412. Thick shaft section; 423. Conical surface; 42. Flow section; 44. Medium flow channel; 50. Sealing assembly; 60. Spring; 70. Pressure regulating component; 71. Micro stepping motor; 72. Adjusting bolt; 80. Data detection unit; 81. Pressure sensor; 82. Displacement sensor; 90. Control processing unit. DETAILED DESCRIPTION

[0009] The technical solutions in this application will be clearly and completely described below in conjunction with the drawings in this application. Obviously, the described embodiments are only a part of the embodiments of this application, rather than all of the embodiments. The components of the present application generally described and shown in the drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the application for which protection is claimed, but merely represents selected embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without making creative work are within the scope of protection of this application.

[0010] It should be noted that similar reference numerals and letters represent similar items in the following drawings. Therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings. At the same time, in the description of this application, the terms "first", "second", etc. are only used to distinguish the description and should not be understood as indicating or implying relative importance.

[0011] In traditional fluid pressure control systems, the pilot valve relies on a mechanical spring preload to set the pressure threshold. However, due to the attenuation of the spring preload over long-term operation, the actual control pressure deviates from the set value. Manual calibration requires interrupting the production process, and adjustment accuracy is limited by operating experience, posing a safety risk in high-pressure, flammable environments. Existing technologies lack a dual-parameter closed-loop control model for pressure and piston shaft displacement, making it impossible to establish a dynamic compensation mechanism for spring preload. This results in the system's inability to respond to medium pressure fluctuations in real time, leading to adjustment lag and pressure oscillations.

[0012] The spring preload of traditional pilot valves is fixed, and the displacement of the piston shaft cannot be dynamically adjusted to follow the pressure changes. When the medium pressure rises suddenly, the piston shaft is restricted by the spring reaction force and cannot move quickly to the equilibrium position, resulting in overshoot of the pressure inside the valve body. At this time, the sealing component is subjected to abnormal stress, the cross-sectional area of the annular flow gap is misadjusted, and the medium flow rate exceeds the design range, causing the pipeline pressure to continue to fluctuate. Under such operating conditions, the safety valve is frequently triggered by mistake, and the system is forced to enter a protective shutdown state. If the above problems are not solved, the pressure control deviation will cause the pipeline system to start and stop frequently, shortening the service life of key components. Under extreme conditions, the pressure regulation lag may exceed the response threshold of the safety valve, directly leading to structural damage to the pressure-bearing components of the pipeline.

[0013] When faced with the above problems, this application first considers how to achieve dynamic compensation of spring preload to eliminate pressure control deviation. Traditional solutions rely solely on pressure feedback for alarms or simple adjustments, but there is a lag between pressure changes and piston shaft displacement, and a single parameter cannot accurately reflect the dynamic equilibrium state of the system. If the spring preload is adjusted based solely on pressure deviation, the adjustment action may be frequently triggered due to pressure fluctuations, resulting in excessive wear of the actuator. If only a displacement sensor is introduced to monitor the piston shaft position, although it can directly reflect the spring deformation, it cannot correlate the dynamic impact of medium pressure changes on displacement requirements.

[0014] In this regard, the present application proposes to fuse pressure and displacement data to form a closed-loop control logic. By mapping the target displacement through real-time medium pressure, a steady-state correspondence between pressure and displacement is established, and then the preload adjustment requirements are judged in combination with the real-time displacement deviation. Among them, pressure data is used to set the displacement reference, and displacement data is used to feedback the actual adjustment effect. The combination of the two can avoid the limitations of single parameter control. For example, when the medium pressure rises suddenly, the target displacement is dynamically adjusted with the pressure change. The system quickly identifies insufficient spring preload through displacement deviation, and then drives the pressure regulating component to compensate for the preload, so that the piston shaft moves to a new equilibrium position, avoiding pressure oscillation and adjustment lag.

[0015] In this regard, Figure 1 and Figure 2 As shown, the present application proposes a pilot valve control method based on data detection and automatic pressure regulation. The pilot valve includes a valve body 10, a pressure regulating assembly, a spring assembly, a pressure sensor 81 and a displacement sensor 82; the pressure regulating assembly includes a piston 20 and a piston shaft 40; the spring assembly includes a spring 60 acting on the piston 20 and a pressure regulating component 70 for adjusting the spring preload; the pressure sensor 81 is used to obtain the real-time medium pressure in the valve body 10, and the displacement sensor 82 is used to detect the real-time displacement of the piston shaft 40; Figure 1 A schematic flow chart of a pilot valve control method for automatic pressure regulation based on data detection provided by the present application is shown, and the method includes: The real-time medium pressure of the valve body 10 is obtained in real time through the pressure sensor 81; The real-time displacement of the piston shaft 40 is obtained in real time through the displacement sensor 82; Determine the target displacement of the piston shaft 40 based on the real-time medium pressure; Determine displacement deviation data based on the real-time displacement and the target displacement; When it is determined according to the displacement deviation data that the pressure regulating component 70 needs to be adjusted, the adjustment data is determined based on the displacement deviation data; The pressure regulating component 70 is controlled to adjust the preload force of the spring 60 based on the adjustment data.

[0016] It is understood that the pressure regulating assembly includes a piston 20 and a piston shaft 40, which means that the cross-sectional area of the medium flow channel 44 is changed by the axial movement of the piston 20 within the valve body 10, thereby adjusting the medium pressure. Specifically, this can be achieved by using a hydraulic cylinder structure or a pneumatic actuator. The piston shaft 40 is rigidly connected to the piston 20 and transmits the movement of the piston 20 to the pressure regulating component 70. The spring assembly includes a spring 60 acting on the piston 20 and a pressure regulating component 70 for adjusting the spring preload. This means that the initial force acting on the piston 20 is adjusted by changing the compression of the spring 60. Specifically, this can be achieved by using a coil spring 60 in conjunction with a threaded adjustment mechanism or an electric push rod structure. The pressure regulating component 70 changes the spring compression through mechanical transmission or electrical signal drive. The pressure sensor 81 is used to obtain the real-time medium pressure within the valve body 10. This means that the physical pressure signal is converted into an electrical signal through a pressure sensitive element. Specifically, this can be achieved by using a piezoelectric sensor. The medium pressure changes are monitored in real time and transmitted to the control processing unit 90. The displacement sensor 82 is used to detect the real-time displacement of the piston shaft 40, which means obtaining the position information of the piston shaft 40 through non-contact measurement technology. Specifically, it can be achieved by using a magnetostrictive displacement sensor 82 or a grating encoder to provide real-time feedback of the movement state of the piston shaft 40 to the control processing unit 90.

[0017] It can be understood that S3 determines the target displacement of the piston shaft 40 based on the real-time medium pressure, which means calculating the ideal displacement value corresponding to the current pressure based on the mapping relationship between the preset pressure and displacement. Specifically, it can be implemented by using a table lookup method or an interpolation algorithm to establish a steady-state equilibrium model of pressure and displacement.

[0018] Among them, S4 determines the displacement deviation data based on the real-time displacement and the target displacement, which means generating an error signal by comparing the difference between the actual displacement and the target displacement. Specifically, it can be implemented by a digital signal processing algorithm to quantify the position deviation of the piston shaft 40.

[0019] Among them, S5 determines the adjustment data based on the displacement deviation data, which means generating a control instruction for the pressure regulating component 70 according to the error size and direction. Specifically, it can be implemented by using a proportional integral differential algorithm or a fuzzy control algorithm to dynamically adjust the spring preload to eliminate the displacement deviation.

[0020] Among them, S6, controlling the pressure regulating component 70 to adjust the preload force of the spring 60 based on the adjustment data refers to converting the control instruction into the mechanical action of the pressure regulating component 70, which can be specifically achieved by using a stepper motor 71 to drive the thread pair to rotate or a servo motor to drive the linear push rod to move, so as to achieve precise adjustment of the spring compression amount. The working process and principle of the present application are as follows: the control method first obtains the medium pressure in the valve body 10 in real time through the pressure sensor 81, and at the same time obtains the displacement of the piston shaft 40 in real time through the displacement sensor 82. Based on the obtained real-time medium pressure, the target displacement of the piston shaft 40 is determined. Then, the actual displacement is compared with the target displacement to determine the displacement deviation data. Based on the displacement deviation data, it is determined whether the pressure regulating component 70 needs to be adjusted. If adjustment is required, the specific adjustment data is determined based on the displacement deviation data. Finally, the pressure regulating component 70 is controlled according to the adjustment data to adjust the preload force of the spring 60.

[0021] This dual-parameter closed-loop control logic integrates pressure and displacement data, using pressure data to set the displacement baseline and displacement data to provide feedback on the actual adjustment effect. When the medium pressure changes, the system quickly determines whether the spring preload is sufficient and activates the pressure-regulating component 70 to compensate, moving the piston shaft 40 to a new equilibrium position. This approach avoids the limitations of single-parameter control and enables more precise response to system pressure changes.

[0022] As a preferred embodiment, the solution of this application is specifically implemented as follows: The pilot valve assembly includes a valve body 10, a pressure-regulating assembly, a spring assembly, a pressure sensor 81, and a displacement sensor 82. The valve body 10 includes a piston-accommodating chamber 11 and a modulation chamber 12, which are connected via a piston shaft hole 13. The pressure-regulating assembly includes a piston 20 slidably disposed within the piston-accommodating chamber 11 and an axially movable piston shaft 40. One end of the piston shaft 40 is connected to the piston 20, and the other end extends into the pressure-regulating chamber. The spring assembly includes a spring 60 and a pressure-regulating component 70. The spring 60 is sandwiched between the piston 20 and the pressure-regulating component 70 to provide preload for the piston 20.

[0023] A pressure sensor 81 is mounted within the piston accommodating chamber 11 and is used to obtain the real-time medium pressure within the valve body 10. A displacement sensor 82 is located within the pressure-stabilizing chamber, corresponding to the distal end of the piston shaft 40, and is used to detect the real-time displacement of the piston shaft 40. The control processing unit 90 is signal-connected to the data detection unit 80 and the pressure regulating component 70 and includes a memory, a processor, and a computer program executable on the processor.

[0024] The specific steps of the control method are as follows: First, the pressure sensor 81 collects the medium pressure data in the valve body 10 in real time, and the displacement sensor 82 simultaneously collects the displacement data of the piston shaft 40. These data are transmitted to the control processing unit 90 for processing.

[0025] The control processing unit 90 determines the target displacement of the piston shaft 40 based on the real-time medium pressure. Specifically, the real-time pressure can be mapped to the corresponding target displacement by querying a pre-stored pressure-displacement correlation curve.

[0026] Next, the control processing unit 90 compares the real-time displacement with the target displacement and calculates the displacement deviation. To eliminate the influence of instantaneous fluctuations, the displacement deviation can be low-pass filtered to obtain stable displacement deviation data.

[0027] Based on the displacement deviation data, the control processing unit 90 determines whether the pressure regulating component 70 needs to be adjusted. This determination can be done by setting an adjustment threshold, triggering an adjustment when the absolute value of the displacement deviation exceeds the threshold. The adjustment data includes the adjustment direction and adjustment amplitude, which are determined by the sign and absolute value of the displacement deviation, respectively.

[0028] Finally, the control processing unit 90 generates a control signal based on the adjustment data to drive the pressure regulating component 70 to adjust the spring preload. The pressure regulating component 70 can achieve precise adjustment by using a micro stepping motor 71 to drive the adjustment bolt 72.

[0029] Through the above scheme, the present application realizes dynamic compensation of the pilot valve spring preload force and effectively eliminates the pressure control deviation. Through the closed-loop control logic that integrates pressure and displacement data, the system can quickly respond to medium pressure fluctuations, avoiding the adjustment lag and pressure oscillation problems in traditional schemes. In application scenarios such as high-pressure long-distance oil and gas pipelines, this solution can effectively deal with pressure fluctuations caused by factors such as compressor start and stop and ambient temperature changes, and maintain stable operation of the system. In addition, the automatic adjustment mechanism reduces the need for manual intervention and reduces safety risks in high-pressure flammable environments. Overall, this application improves the application effect of pilot valves in precision fluid control systems and improves the automation level and operational reliability of pressure control in industrial pipeline systems.

[0030] Furthermore, the present application proposes to query the stored pressure-displacement correlation curve, and use the displacement of the piston shaft 40 corresponding to the real-time medium pressure mapping as the target displacement; the pressure-displacement correlation curve is determined through experimental calibration or theoretical calculation, and is used to characterize the correspondence between the steady-state pressure and the equilibrium position of the piston shaft 40.

[0031] Among them, the generation method of the pressure-displacement correlation curve includes two ways: experimental calibration and theoretical calculation. Experimental calibration records the actual equilibrium position of the piston shaft 40 under different steady-state pressures and fits to form a continuous curve of discrete data points; for example, a step pressure loading method is used to apply steady-state pressure at intervals of 1 MPa in the range of 0-10 MPa, and the equilibrium position of the piston shaft is recorded at each pressure point and fitted with a cubic polynomial curve. Theoretical calculation is based on the mechanical model of the mechanical system, and the mathematical relationship between pressure and displacement is derived to construct a curve. For example, the theoretical calculation of the pressure-displacement correlation curve is based on the piston force balance equation: Where, Pis the medium pressure (Pa), A is the effective area of the piston (m²), k is the spring stiffness coefficient (N / m), x 0 is the initial compression of the spring (mm), x is the displacement of the piston shaft (mm). The mapping relationship between pressure and displacement can be obtained through deformation: This equation characterizes the equilibrium position of the piston shaft under steady-state pressure, and is used to generate a pressure-displacement correlation curve. During the query process, the real-time medium pressure is input into the stored curve database, and the corresponding target displacement is matched through interpolation or table lookup.

[0032] Specifically, after the real-time medium pressure is collected by the pressure sensor 81, the control processing unit 90 calls the pre-stored pressure-displacement correlation curve, uses the current pressure value as the input parameter, locates the corresponding point along the horizontal axis of the curve, and the vertical axis output is the target displacement. For example, in the experimental calibration scenario, a step-by-step steady-state pressure is applied to the pilot valve on the pressure test bench in advance, and the static position of the piston shaft 40 when the force balance is achieved under each pressure step is recorded, and a smooth curve is generated by polynomial fitting; in the theoretical calculation scenario, according to the stiffness coefficient of the spring 60, the effective area of the piston 20 and the medium pressure balance equation, an analytical expression of pressure and displacement is established to generate a curve. The target displacement determined in the above manner can accurately reflect the theoretical equilibrium position of the piston shaft 40 under a specific pressure, provide a reliable benchmark for subsequent deviation calculations, and eliminate mapping errors caused by empirical estimation or dynamic interference.

[0033] As a preferred embodiment, the solution of this application is specifically implemented as follows: The pressure-displacement correlation curve, determined through experimental calibration or theoretical calculation, represents the correspondence between steady-state pressure and the equilibrium position of piston shaft 40. Specifically, a high-precision pressure sensor 81 and displacement sensor 82 can be installed on the pilot valve assembly to record the equilibrium position of piston shaft 40 at different steady-state pressures. Multiple tests are performed to obtain a series of corresponding pressure and displacement data points, which are then fitted using the least squares method to create a pressure-displacement correlation curve.

[0034] For example, five different steady-state pressure points can be selected for testing, namely 1 MPa, 3 MPa, 5 MPa, 7 MPa, and 9 MPa. The test is repeated three times for each pressure point, and the equilibrium position of the piston shaft 40 is recorded. The 15 sets of data points obtained are input into the computer, and the curve fitting toolbox of the MATLAB software is used for data processing and curve fitting. The pressure-displacement correlation curve obtained by fitting can be expressed by a quadratic polynomial: y = ax^2 + bx + c, where y represents the displacement of the piston shaft 40, x represents the steady-state pressure, and a, b, and c are fitting coefficients.

[0035] Furthermore, the fitted pressure-displacement correlation curve is stored in the memory of the control processing unit 90. During actual operation, after the real-time medium pressure of the valve body 10 is obtained in real time by the pressure sensor 81, this pressure value is substituted into the stored correlation curve equation to calculate the corresponding displacement of the piston shaft 40, which is the target displacement.

[0036] Therefore, based on the pressure-displacement correlation curve determined by experimental calibration or theoretical calculation, the real-time medium pressure can be accurately mapped to the target displacement of the piston shaft 40, providing a reliable reference benchmark for subsequent displacement deviation calculation and pressure regulation control.

[0037] Through the above technical solution, the present application realizes the precise mapping between the real-time medium pressure and the target displacement of the piston shaft 40. Specifically, through the pre-established pressure-displacement correlation curve, the ideal equilibrium position of the piston shaft 40 under the current pressure can be quickly and accurately determined. This data-driven method avoids complex theoretical calculations and improves the efficiency and accuracy of determining the target displacement. At the same time, since the correlation curve is established based on the experimental data of the actual device or an accurate theoretical model, it can better reflect the actual working characteristics of the specific pilot valve and improve the adaptability and reliability of the control system. This provides a reliable reference benchmark for subsequent displacement deviation calculations and pressure regulation control, which helps to achieve more accurate pressure regulation and system stability control.

[0038] Furthermore, the present application proposes determining displacement deviation data based on the real-time displacement and the target displacement, including obtaining a displacement deviation value according to the difference between the real-time displacement and the target displacement, and performing low-pass filtering on the displacement deviation value to obtain the displacement deviation data.

[0039] Among them, the displacement deviation value e ( t ) is defined as: , where is the real-time displacement, The low-pass filter is realized by configuring a Butterworth filter with a cutoff frequency lower than the natural frequency of the system. The order of the filter is set to second order, and the cutoff frequency is set to the range of 10Hz to 50Hz according to the motion response speed of the piston shaft 40. The low-pass filter transfer function expression is: , cutoff angular frequency , f is the cut-off frequency (Hz), and the displacement deviation data is transmitted to the control processing unit 90 through the analog-to-digital converter.

[0040] Specifically, the analog signal of the piston shaft 40 position collected by the displacement sensor 82 is amplified by the signal conditioning circuit and then input into the subtractor together with the analog signal output by the digital-to-analog converter of the target displacement digital signal to generate an original displacement deviation signal containing high-frequency noise. This signal is input into a second-order Butterworth low-pass filter composed of an operational amplifier and an RC element to filter out noise components with frequencies higher than the cutoff frequency. For example, in a scenario where the pressure of a high-pressure pipeline fluctuates frequently, setting the cutoff frequency to 20Hz can effectively suppress the high-frequency micro-vibration noise of the piston shaft 40 caused by fluid pulsation, and retain the low-frequency effective signal reflecting the true displacement deviation. The filtered displacement deviation data is input into the control algorithm module after analog-to-digital conversion as an input parameter for subsequent adjustment decisions to avoid misadjustment of the pressure regulating component 70 due to noise interference and ensure stable operation of the system.

[0041] As a preferred embodiment, the solution of this application is specifically implemented as follows: When determining displacement deviation data based on the real-time displacement and the target displacement, the displacement deviation value is first determined based on the difference between the real-time and target displacements. For example, when the real-time displacement is 5 mm and the target displacement is 6 mm, the displacement deviation value is -1 mm. Furthermore, the displacement deviation value is low-pass filtered to obtain displacement deviation data. Specifically, a Butterworth low-pass filter can be used to process the displacement deviation value to remove high-frequency noise. This results in smoother displacement deviation data, reducing the impact of transient interference on the control system.

[0042] Through the above-mentioned technical solution, the present application can effectively filter out high-frequency noise in the displacement deviation value, obtaining more stable and reliable displacement deviation data. This improves the anti-interference capability and control accuracy of the pilot valve control system, avoids misadjustments caused by transient interference, and ensures the stable operation of the pilot valve. Furthermore, through low-pass filtering, the frequent adjustment of the control system is reduced, the service life of the pressure regulating component 70 is extended, and the reliability and durability of the entire pilot valve system are improved.

[0043] Furthermore, the present application proposes to determine whether the absolute value of the displacement deviation data is greater than the set adjustment threshold; if it is greater than the adjustment threshold, the adjustment direction is determined according to the positive or negative sign of the displacement deviation data, and the adjustment amplitude is determined according to the absolute value of the displacement deviation data. Among them, the setting of the adjustment threshold is used to filter out small deviations or instantaneous fluctuations to avoid invalid adjustment actions; the adjustment direction is determined by the positive and negative signs of the displacement deviation data, a positive deviation corresponds to an adjustment direction that increases the preload force, and a negative deviation corresponds to an adjustment direction that reduces the preload force; the adjustment amplitude is positively correlated with the absolute value of the displacement deviation, the larger the deviation, the larger the adjustment amplitude, and the smaller the deviation, the smaller the adjustment amplitude. Specifically, after the displacement deviation data is processed by low-pass filtering, its absolute value is compared with the preset adjustment threshold. When the absolute value exceeds the adjustment threshold, it is determined that an adjustment action needs to be performed. At this time, the rotation direction of the pressure regulating component 70 is determined according to the positive and negative signs of the deviation value. For example, a positive deviation drives the pressure regulating component 70 to move in the direction of the compression spring 60, and a negative deviation drives the pressure regulating component 70 to move in the direction of the release spring 60. The adjustment amplitude is determined according to the difference ratio between the absolute value of the deviation and the threshold or the preset segmented interval. For example, when the absolute value of the deviation exceeds the threshold but is less than twice the threshold, a first-level adjustment amplitude is used, and when it exceeds twice the threshold, a second-level adjustment amplitude is used. Through the joint control of threshold judgment and direction amplitude, it is ensured that the adjustment action is only triggered under necessary conditions, and the adjustment amount accurately matches the actual needs, thereby reducing the number of adjustments and improving control accuracy.

[0044] As a preferred embodiment, the solution of this application is specifically implemented as follows: Determine whether the absolute value of the displacement deviation data is greater than the set adjustment threshold. If it is greater than the adjustment threshold, determine the adjustment direction based on the sign of the displacement deviation data and determine the adjustment amplitude based on the absolute value of the displacement deviation data.

[0045] Specifically, the adjustment threshold can be set to 0.1mm. When the absolute value of the displacement deviation data is detected to be greater than 0.1mm, the adjustment operation is triggered. If the displacement deviation data is a positive value, it indicates that the actual displacement is greater than the target displacement, and the spring preload needs to be increased; if it is a negative value, the spring preload needs to be reduced. The adjustment amplitude can be graded according to the absolute value of the displacement deviation data, for example, 0.1-0.3mm corresponds to level 1 adjustment, 0.3-0.5mm corresponds to level 2 adjustment, and 0.5mm and above correspond to level 3 adjustment. Each level of adjustment corresponds to different drive parameters of the pressure regulating component 70.

[0046] Through the above technical solution, the present application can flexibly adjust the spring preload based on the size and positive / negative value of the displacement deviation data, avoiding system fluctuations caused by frequent small adjustments while ensuring rapid response to large deviations. This hierarchical adjustment strategy can improve system stability while maintaining adjustment accuracy, effectively solving problems such as hysteresis and pressure oscillation in traditional pilot valves.

[0047] Furthermore, the present application proposes controlling the pressure regulating component 70 to adjust the preload force of the spring 60 based on the adjustment data, including: generating a control signal of a pulse width according to the adjustment data to drive the pressure regulating component 70, thereby adjusting the preload force of the spring 60.

[0048] The pulse width control signal establishes a linear mapping relationship with the adjustment amplitude through a preset pulse step size, and the pulse width is positively correlated with the absolute value of the displacement deviation data. Specifically, the relationship between the adjustment data and the pulse signal is: Where, is the number of pulses, Δ x is the spring compression adjustment amount (m), p To adjust the bolt pitch (m), i is the reduction ratio of the transmission mechanism.

[0049] The duty cycle D of the pulse width modulation signal is related to the regulation direction: Where, D 0 is the basic duty cycle (typical value is 0.5), k is the duty cycle adjustment coefficient (unit: 1 / mm), |Δ x ∣ is the absolute value of the displacement deviation (mm). The adjustment direction is determined by the sign of the displacement deviation data: a positive deviation corresponds to an increase in spring compression, driving the pressure regulating component in the screw-in direction; a negative deviation corresponds to a decrease in spring compression, driving the pressure regulating component in the screw-out direction.

[0050] The pressure regulating component 70 comprises a transmission assembly consisting of a micro-stepping motor 71 and an adjusting bolt 72. Upon receiving a pulse signal, the micro-stepping motor 71 drives the adjusting bolt 72 to rotate via a reduction gear train. Each pulse corresponds to a fixed rotation angle of the adjusting bolt 72. The number of pulses determines the axial displacement of the adjusting bolt 72, which in turn changes the spring compression. For example, when the absolute value of the displacement deviation data reaches twice the adjustment threshold, a control signal consisting of 20 pulses is generated, rotating the adjusting bolt 72 five degrees, increasing the spring preload by three Newtons.

[0051] Specifically, the control processing unit 90 converts the displacement deviation data into a pulse width modulation signal, and the number of pulses in the signal is proportional to the adjustment amplitude. After receiving the pulse signal, the micro-stepping motor 71 converts the rotational motion into the axial linear motion of the adjustment bolt 72 through the transmission mechanism. Every time the adjustment bolt 72 rotates a fixed angle, its end pushes the spring 60 seat to produce a corresponding displacement increment, and the spring compression changes accordingly. This method achieves precise fine-tuning of mechanical components through discrete pulse control, avoiding the inertia accumulation error caused by continuous drive. For example, when a positive displacement deviation is detected, the control signal drives the adjustment bolt 72 to screw in to increase the spring compression; when a negative deviation is detected, the control signal drives the adjustment bolt 72 to screw out to reduce the compression. The correspondence between the pulse width and the adjustment amplitude is calibrated through experiments to ensure that the change in preload force corresponding to each pulse does not exceed the error threshold allowed by the system.

[0052] As a preferred embodiment, the solution of this application is specifically implemented as follows: When controlling the pressure regulating component 70 to adjust the preload of the spring 60 based on the adjustment data, a pulse width control signal is first generated based on the adjustment data. Specifically, the processor in the control processing unit 90 executes a computer program to convert the adjustment data into a corresponding pulse width modulation signal. For example, a positive adjustment data value generates a forward-rotating pulse signal, while a negative adjustment data value generates a reverse-rotating pulse signal. The larger the absolute value of the adjustment data, the larger the generated pulse width.

[0053] The generated pulse-width modulated signal is then sent to the micro-stepping motor 71 in the voltage regulator 70. This micro-stepping motor 71 then rotates the adjustment screw 72 based on the received pulse signal. Specifically, the stepping motor 71 drives the adjustment screw 72 forward or reverse through a gear transmission mechanism, with the rotation angle determined by the width of the pulse signal.

[0054] The rotational motion of adjustment bolt 72 is converted into axial displacement, thereby changing the compression of spring 60. For example, clockwise rotation of adjustment bolt 72 moves the bolt downward, increasing spring compression; counterclockwise rotation moves the bolt upward, decreasing spring compression. In a preferred embodiment, the thread pitch of adjustment bolt 72 is 1 mm, and the step angle of stepper motor 71 is 1.8°. This is transmitted to adjustment bolt 72 via a 200:1 reduction ratio, achieving a minimum adjustment accuracy of 0.025 μm.

[0055] Through the above-mentioned technical solution, the present application achieves precise automatic adjustment of the pilot valve spring preload. This avoids the inefficiency and inaccuracy of traditional manual adjustment methods and improves the pressure control accuracy and response speed of the pilot valve. Furthermore, the automated adjustment process does not require downtime or disassembly, reducing production interruption time and improving the continuity and reliability of system operation. Furthermore, closed-loop control enables real-time compensation of the spring preload, effectively resolving the pressure deviation problem caused by spring fatigue during long-term operation and ensuring the stable performance of the pilot valve under various operating conditions.

[0056] Furthermore, the present application proposes to compare the collected real-time medium pressure and real-time displacement with the set pressure-displacement correlation curve threshold range; if the detection data deviates from the threshold range for more than a set time or number of times, an alarm signal is triggered, and the pressure regulating component 70 is controlled to drive the piston shaft 40 to move to a safe position.

[0057] The threshold range of the pressure-displacement correlation curve is determined through experimental calibration and includes upper and lower pressure limits and the corresponding allowable fluctuation range of displacement. During the comparison process, the real-time medium pressure and displacement must meet both the pressure threshold and the displacement threshold. If either parameter exceeds the range, it is considered a deviation.

[0058] The judgment condition for the detection data to deviate from the threshold range is: in, P ( t ), x ( t ) is the real-time detection value, P ref ( t ), x ref ( t ) is the theoretical value of the pressure-displacement correlation curve, Δ P , Δ x To set the threshold (such as Δ P =0.5MPa, Δ x = 0.1mm). If the above conditions last t > t thr or consecutive occurrences n > n thr , the safety mechanism is triggered.

[0059] Set time t thr or times n thr Pre-configured according to system response speed and process safety requirements, such as setting time tthr 5 seconds, times n thr If the deviation is detected three times in a row, an alarm signal is issued through an audible and visual device or a remote monitoring system. The safe position is defined as the position where the maximum diameter portion of the intercepting section 41 is fully matched with the through hole of the sealing component 50.

[0060] Specifically, the pressure sensor 81 continuously monitors the medium pressure in the valve body 10, the displacement sensor 82 collects the displacement of the piston shaft 40 in real time, and the control processing unit 90 synchronizes the two sets of data with the stored pressure-displacement correlation curve threshold range. When the medium pressure exceeds the set pressure threshold or the displacement deviates from the corresponding displacement threshold, the system starts a timer or counter. If the deviation state is not eliminated within the set time or the cumulative number reaches the set number, it is determined to be an irreversible abnormality and an alarm signal is immediately triggered. At the same time, the control processing unit 90 sends an emergency control instruction to the pressure regulating component 70, driving the piston shaft 40 to move to a safe position, so that the maximum diameter part of the cut-off section 41 forms a seal with the through hole of the sealing assembly 50, completely blocking the medium flow channel 44, and avoiding equipment overload or medium leakage due to continuous pressure abnormality. During this process, the micro stepping motor 71 quickly rotates the adjustment bolt 72 through the transmission mechanism, changes the spring compression, and forces the piston shaft 40 to reset to a safe position.

[0061] As a preferred embodiment, the solution of this application is specifically implemented as follows: The collected real-time medium pressure and displacement are compared with the set pressure-displacement correlation curve threshold range. If the detection data deviates from the threshold range for more than a set time or number of times, an alarm signal is triggered and the pressure regulating component 70 is controlled to drive the piston shaft 40 to move to a safe position.

[0062] Specifically, you can set upper and lower thresholds for the pressure-displacement correlation curve to create a range of acceptable fluctuations. For example, for a certain pilot valve model, the threshold range could be set to ±5% of the pressure-displacement correlation curve. Real-time pressure and displacement data are then compared against this threshold range.

[0063] Furthermore, a duration threshold, such as 10 seconds, or a consecutive deviation threshold, such as 5, can be set. When it is detected that the actual data deviates from the threshold range for more than 10 seconds, or if 5 consecutive samples deviate from the threshold range, the system will determine that an anomaly has occurred.

[0064] This triggers an alarm signal, which can be in the form of an audible or visual alarm or remote notification, to alert the operator to the system status. Simultaneously, the pressure regulating component 70 is controlled to drive the piston shaft 40 to a predetermined safe position, such as completely sealing the flow channel to prevent potential pressure runaway risks.

[0065] Through the above technical solution, this application realizes real-time monitoring of the operating status of the pilot valve and timely response to abnormal situations. By setting a reasonable threshold range and trigger conditions, false alarms caused by instantaneous fluctuations are avoided and the reliability of the system is improved. When persistent abnormalities are detected, safety measures can be automatically taken to effectively prevent the risk of pressure loss due to valve failure. This active early warning and automatic protection mechanism greatly improves the safety performance of the pilot valve in high-pressure, flammable and explosive environments, providing more reliable pressure control guarantees for industrial production processes.

[0066] It should be understood that the size of the serial numbers of the above steps does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.

[0067] Corresponding to the control method described in the above embodiment, the embodiment of the present application further provides a pilot valve device, and each module of the device can implement each step of the control method.

[0068] Please refer to Figure 2 The present application proposes a pilot valve device including a mechanical execution unit, a data detection unit 80 and a control processing unit 90. The mechanical actuator unit comprises a valve body 10, a pressure-regulating assembly, a spring assembly, and a sealing assembly 50. The valve body 10 has a piston-accommodating chamber 11 and a modulation chamber 12 connected by a piston shaft hole 13. The pressure-regulating assembly comprises a piston 20 slidably mounted in the piston-accommodating chamber 11, a pressure-stabilizing chamber assembly 30 mounted in the modulation chamber 12, and an axially movable piston shaft 40. One end of the piston shaft 40 is connected to the piston 20 and the other end extends into the pressure-stabilizing chamber. The spring assembly comprises a spring 60 and a pressure-regulating component 70. The spring 60 is sandwiched between the piston 20 and the pressure-regulating component 70, which is used to adjust the spring preload. The sealing assembly 50 is mounted at the bottom of the piston-accommodating chamber 11 and has a through-hole for the piston shaft 40 to pass through. The data detection unit 80 comprises a pressure sensor 81 mounted in the piston-accommodating chamber 11 and a displacement sensor 82 mounted in the pressure-stabilizing chamber. The control processing unit 90 is signal-connected to the data detection unit 80 and the pressure-regulating component 70 and includes a memory for storing data and a processor for executing control programs. Specifically, the pressure sensor 81 detects the medium pressure in the valve body 10 in real time, the displacement sensor 82 detects the displacement of the end of the piston shaft 40, and the control processing unit 90 maps the real-time pressure to the target displacement, calculates the displacement deviation and generates an adjustment instruction. The pressure regulating component 70 receives the instruction to adjust the spring compression, change the axial position of the piston shaft 40, and then adjusts the cross-sectional area of the medium flow channel 44 by changing the gap between the cut-off section 41 and the through hole. When the piston shaft 40 moves to the safe position, the maximum diameter part of the cut-off section 41 cooperates with the through hole seal to block the flow of the medium; when in the working position, the cross-sectional area of the annular flow gap is dynamically adjusted with the displacement of the piston shaft 40, forming a closed-loop control of pressure and displacement. This structure realizes real-time calibration of the spring preload and adaptive adjustment of the medium pressure by integrating mechanical execution, data detection and control processing unit 90, avoiding adjustment lag and safety hazards caused by manual intervention.

[0069] As a preferred embodiment, the solution of this application is specifically implemented as follows: The pilot valve device includes a mechanical execution unit, a data detection unit 80 and a control processing unit 90. The mechanical execution unit includes a valve body 10, a pressure regulating assembly, a spring assembly and a sealing assembly 50.

[0070] Please refer to Figure 2 and Figure 3 The valve body 10 has a piston accommodating chamber 11 and a modulation chamber 12 interconnected through a piston shaft hole 13. The valve body's outer wall is also provided with a medium inlet 14, a medium outlet 16, and a pressure relief port 17. The medium inlet is connected to the medium inlet 11, the medium outlet 16 is connected to the piston shaft hole 13, and the pressure relief port is connected to the modulation chamber 12. The pressure regulating assembly is used to regulate the medium pressure within the valve body 10 and includes a piston 20 slidably disposed within the piston accommodating chamber 11, a pressure stabilizing chamber assembly 30 disposed within the modulation chamber 12, and a piston shaft 40 axially movably disposed within the valve body 10. One end of the piston shaft 40 is connected to the piston 20, and the other end extends into the pressure stabilizing chamber 321 within the pressure stabilizing chamber assembly 30.

[0071] The spring assembly includes a spring 60 and a pressure-regulating component 70. Spring 60 is sandwiched between piston 20 and pressure-regulating component 70, providing a preload for piston 20. Pressure-regulating component 70 is used to adjust the spring preload. A sealing assembly 50 is mounted at the bottom of piston accommodating chamber 11 and includes a through-hole for piston shaft 40 to pass through.

[0072] The data detection unit 80 includes a pressure sensor 81 and a displacement sensor 82. The pressure sensor 81 is disposed in the piston accommodating chamber 11 to obtain the real-time medium pressure in the valve body 10. The displacement sensor 82 is disposed in the pressure stabilizing chamber of the pressure stabilizing chamber assembly 30 at the corresponding end position of the piston shaft 40 to detect the real-time displacement of the piston shaft 40.

[0073] The control processing unit 90 is signal-connected to the data detection unit 80 and the voltage regulating component 70, and includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, the following method is implemented: The real-time medium pressure of the valve body 10 is obtained in real time through the pressure sensor 81; the real-time displacement of the piston shaft 40 is obtained in real time through the displacement sensor 82; the target displacement of the piston shaft 40 is determined based on the real-time medium pressure; the displacement deviation data is determined based on the real-time displacement and the target displacement; when it is determined according to the displacement deviation data that the pressure regulating component 70 needs to be adjusted, the adjustment data is determined based on the displacement deviation data; the pressure regulating component 70 is controlled based on the adjustment data to adjust the preload force of the spring 60.

[0074] Through the above technical solution, the present application realizes the automatic adjustment of the pilot valve device. Since the pressure sensor 81 and the displacement sensor 82 are used to monitor the medium pressure in the valve body 10 and the displacement of the piston shaft 40 in real time, and the control processing unit 90 analyzes the data and generates adjustment instructions, the pressure regulating component 70 is automatically controlled to adjust the spring preload, avoiding the inconvenience and risk of manual intervention. This control method can respond to changes in system pressure in a timely manner, maintain the stability of the position of the piston shaft 40, and improve the pressure regulation accuracy and reliability of the pilot valve. At the same time, the automatic adjustment mechanism reduces the need for downtime maintenance and improves the operating efficiency of the equipment. In addition, the real-time data monitoring and automatic adjustment functions enhance the safety of the system, can quickly respond to abnormal situations, and reduce the risks of overpressure or leakage.

[0075] Furthermore, the present application proposes that the pressure regulating component 70 includes an adjusting bolt 72 and a micro-stepping motor 71 , and the micro-stepping motor 71 drives the adjusting bolt 72 to rotate through a transmission mechanism to change the compression amount of the spring 60 .

[0076] It will be appreciated that the micro-stepping motor 71 and the adjusting bolt 72 can be connected via a transmission mechanism, whereby the rotational motion of the stepping motor 71 is converted via the transmission mechanism into the axial displacement of the adjusting bolt 72. The threads of the adjusting bolt 72 engage the threaded hole of the valve cover, and its end abuts the spring 60. As the adjusting bolt 72 is screwed in or out, the compression of the spring 60 changes accordingly.

[0077] Specifically, when the control processing unit 90 outputs a pulse signal to drive the micro-stepping motor 71, the rotational motion of the motor is transmitted to the adjustment bolt 72 through the transmission mechanism. The rotation of the adjustment bolt 72 causes it to move axially, pushing the end of the spring 60 to produce displacement, thereby changing the preload force of the spring 60. When it is detected that the displacement deviation data needs to be adjusted, the processor calculates the required number of pulses based on the adjustment amplitude, drives the stepping motor 71 to rotate the corresponding angle, and moves the adjustment bolt 72 to the target position. For example, a fine thread with a lead of 1 mm is used in conjunction with a stepping motor 71 with 200 steps / turn, and an axial displacement accuracy of 5 μm per step can be achieved. This axial displacement directly changes the distance between the spring 60 seat and the piston 20, causing a corresponding change in the spring compression amount, thereby accurately adjusting the preload force.

[0078] Through the above technical solution, this application converts rotational motion into linear displacement through mechanical transmission, achieving precise control of spring compression and avoiding the errors and risks associated with manual operation. Furthermore, the high resolution of the micro-stepping motor 71 and the deceleration design of the transmission mechanism enable micron-level adjustment of the spring preload, ensuring stable pressure control.

[0079] Further, if Figure 4 As shown, the present application proposes that the piston shaft 40 includes a cut-off section 41 and a flow section 42. The piston shaft 40 passes through the piston shaft hole 13, and its outer diameter at each location is smaller than the aperture of the piston shaft hole 13 to form a medium flow channel 44; the cut-off section 41 has a variable diameter structure, which cooperates with the through hole of the sealing assembly 50, and is used to adjust the cross-sectional area of the medium flow channel 44 through the change of the axial movement of the piston shaft 40, thereby forming an adjustable medium flow channel 44: when the piston shaft 40 is in a safe position, the maximum diameter part of the cut-off section 41 cooperates with the through hole seal to block the flow of the medium; when the piston shaft 40 is in a working position, an annular flow gap is formed between the cut-off section 41 and the through hole, and the cross-sectional area of the annular flow gap changes with the displacement of the piston shaft 40.

[0080] The cutoff section 41's variable diameter structure adopts a conical or stepped design, with its diameter gradually varying along the axial direction. The flow section 42 maintains a constant outer diameter, forming a fixed flow cross-section with the piston shaft hole 13. The cutoff section 41 and the through-hole of the sealing assembly 50 utilize hard or elastic sealing materials to ensure complete blockage in the safe position. As the piston shaft 40 moves, the relative position of the variable diameter portion of the cutoff section 41 and the through-hole changes, causing the width of the annular flow gap to change synchronously with the axial coverage length, achieving continuous adjustment of the cross-sectional area.

[0081] Specifically, when the piston shaft 40 is controlled to move toward the safe position, the largest diameter portion of the shutoff section 41 gradually embeds into the through-hole until a complete sealing contact is achieved. At this point, the medium flow channel 44 is completely blocked, and the system enters a safe state. In the operating position, an annular gap is formed between the shutoff section 41 of the piston shaft 40 and the through-hole. The flow rate of the medium through this gap is determined by the gap width and the axial coverage length. As the displacement of the piston shaft 40 changes, the relative position of the reduced diameter portion of the shutoff section 41 and the through-hole changes linearly or nonlinearly, and the equivalent cross-sectional area of the annular gap is adjusted accordingly, thereby precisely controlling the medium flow rate. For example, when the piston shaft 40 moves 1 mm toward the pressure regulating component 70, the tapered surface of the shutoff section 41 increases the annular gap width by 0.2 mm and reduces the axial coverage length by 2 mm. The combined effect expands the flow cross-sectional area to 1.5 times its original value. This structure, through the direct relationship between displacement and cross-sectional area, achieves linear regulation of the medium pressure while avoiding the pressure shock caused by the step-like opening and closing of traditional valves.

[0082] As a preferred embodiment, please refer to Figure 4 The specific implementation of this application is as follows: the piston shaft 40 is composed of an alternating cut-off section 41 and a flow section 42. The outer surface of the cut-off section 41 has a stepped diameter-reducing structure. Specifically, the cut-off section 41 includes a thin shaft section 411 and a thick shaft section 412, which are transitionally connected by a conical surface 423. The outer diameter of the flow section 42 is uniform and smaller than the aperture of the piston shaft hole 13. When the piston shaft 40 is in a safe position, the thick shaft section 412 of the cut-off section 41 forms an interference fit with the elastic sealing ring on the inner wall of the through hole of the sealing assembly 50 to achieve sealing; when the piston shaft 40 moves axially to the working position, the stepped diameter-reducing section of the cut-off section 41 forms an annular gap with the inner wall of the through hole, and the medium is transmitted through the composite flow channel formed by the flow section 42, the shaft hole gap and the annular gap. The displacement of the piston shaft 40 is monitored in real time by the displacement sensor 82. When a pressure anomaly is detected, the control processing unit 90 drives the pressure regulating component 70 to reset the piston shaft 40 to a safe position. At this time, the maximum diameter section of the cut-off section 41 is completely in contact with the through hole, thereby quickly blocking the medium flow channel 44. Through the above technical solution, the present application can realize automatic opening and closing control of the medium flow channel according to the system pressure state, and achieve physical blocking of the flow channel through precise control of the axial displacement of the piston shaft under emergency conditions, thereby avoiding the risk of medium leakage caused by spring failure or actuator delay in traditional valves. The coordinated design of the stepped variable diameter structure and the sealing assembly not only ensures the linearity of the flow regulation under normal working conditions, but also forms a double sealing structure in a safe position, effectively improving the blocking reliability of high-pressure media.

[0083] The above description is merely an embodiment of the present application and is not intended to limit the scope of protection of the present application. For those skilled in the art, various modifications and variations of the present application are possible. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present application shall be included in the scope of protection of the present application.

Claims

1. A pilot valve control method based on data detection and automatic pressure regulation, characterized in that: The pilot valve includes a valve body, a pressure regulating assembly, a spring assembly, a pressure sensor, and a displacement sensor; the pressure regulating assembly includes a piston and a piston shaft; the spring assembly includes a spring acting on the piston and a pressure regulating component for adjusting the spring preload; the pressure sensor is used to obtain the real-time medium pressure in the valve body, and the displacement sensor is used to detect the real-time displacement of the piston shaft; the method includes: Acquire the real-time medium pressure of the valve body in real time through the pressure sensor; The real-time displacement of the piston shaft is obtained in real time by the displacement sensor; determining a target displacement of the piston shaft based on the real-time medium pressure; determining displacement deviation data based on the real-time displacement and the target displacement; When it is determined according to the displacement deviation data that the pressure regulating component needs to be adjusted, determining adjustment data based on the displacement deviation data; The pressure regulating component is controlled to regulate the preload force of the spring based on the regulating data.

2. The control method according to claim 1, characterized in that: Determining the target displacement of the piston shaft based on the real-time medium pressure includes: querying a stored pressure-displacement correlation curve, and mapping the corresponding piston shaft displacement according to the real-time medium pressure as the target displacement; wherein the pressure-displacement correlation curve is determined by experimental calibration or theoretical calculation to characterize the corresponding relationship between pressure and piston shaft equilibrium position.

3. The control method according to claim 1, wherein: The determining of the displacement deviation data based on the real-time displacement and the target displacement includes: obtaining a displacement deviation value according to a difference between the real-time displacement and the target displacement; and performing low-pass filtering on the displacement deviation value to obtain the displacement deviation data.

4. The control method according to claim 1, wherein: When it is determined according to the displacement deviation data that the pressure regulating component needs to be adjusted, the adjustment data is determined based on the displacement deviation data, including: judging whether the absolute value of the displacement deviation data is greater than the set adjustment threshold; if it is greater than the adjustment threshold, determining the adjustment direction according to the positive or negative sign of the displacement deviation data, and determining the adjustment amplitude according to the absolute value of the displacement deviation data.

5. The control method according to claim 1, characterized in that: Controlling the pressure regulating component to regulate the preload force of the spring based on the regulation data includes: generating a control signal with a pulse width according to the regulation data to drive the pressure regulating component, thereby regulating the preload force of the spring.

6. The control method according to claim 1, characterized in that: The method further comprises: The collected real-time medium pressure and real-time displacement are compared with the set threshold range of the pressure-displacement correlation curve; if the detection data deviates from the threshold range for more than a set time or number of times, an alarm signal is triggered, and the pressure regulating component is controlled to drive the piston shaft to a safe position.

7. A pilot valve device, characterized in that: It includes a mechanical execution unit, a data detection unit and a control processing unit; the mechanical execution unit includes: The valve body has an inner cavity provided with a piston accommodating cavity and a modulation cavity which are interconnected through a piston shaft hole; The pressure regulating assembly is used to regulate the medium pressure in the valve body, and includes: a piston slidably arranged in the piston accommodating chamber, a pressure stabilizing chamber assembly arranged in the modulation chamber, and a piston shaft axially movably arranged in the valve body cavity; one end of the piston shaft is connected to the piston, and the other end extends into the pressure stabilizing chamber in the pressure stabilizing chamber assembly; and The spring assembly comprises the spring and the pressure-adjusting component; the spring is sandwiched between the piston and the pressure-adjusting component to provide a preload force for the piston, and the pressure-adjusting component is used to adjust the spring preload force; A sealing assembly is installed at the bottom of the piston accommodating chamber and is provided with a through hole for the piston shaft to pass through; The data detection unit includes the pressure sensor and the displacement sensor, wherein the pressure sensor is arranged at the piston accommodating chamber to obtain the real-time medium pressure in the valve body, and the displacement sensor is arranged at the corresponding piston shaft end position in the pressure stabilizing chamber of the pressure stabilizing chamber assembly to detect the real-time displacement of the piston shaft; The control processing unit is signal-connected to the data detection unit and the voltage regulating component, and includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, the method according to any one of claims 1 to 6 is implemented.

8. The pilot valve device according to claim 7, characterized in that: The pressure regulating component includes an adjusting bolt and a micro stepping motor. The micro stepping motor drives the adjusting bolt to rotate through a transmission mechanism to change the compression amount of the spring.

9. The pilot valve device according to claim 7, characterized in that: The piston shaft includes a cutoff section and a flow section, which passes through the piston shaft hole; the outer diameter of the piston shaft at each location is smaller than the aperture of the piston shaft hole to form a medium flow channel; and the cutoff section has a variable diameter structure, which cooperates with the through hole of the sealing assembly, and is used to adjust the cross-sectional area of the medium flow channel through the change of the axial movement of the piston shaft to form an adjustable medium flow channel: when the piston shaft is in the safety position, the maximum diameter part of the cutoff section seals with the through hole to block the flow of the medium; when the piston shaft is in the working position, an annular flow gap is formed between the cutoff section and the through hole, and the cross-sectional area of the annular flow gap changes with the displacement of the piston shaft.

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