Rapid fault diagnosis device for pulse valve of dust removal system
By combining a PLC with a multi-signal acquisition unit and a logic judgment module, the problem of real-time and accuracy in pulse valve fault diagnosis was solved, and the stable operation and production continuity of the dust removal system were achieved.
Patent Information
- Application Number
- CN202511726876.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-24
- Publication Date
- 2026-01-23
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
In existing technologies, pulse valve fault diagnosis relies on manual inspection, which is inefficient and cannot be monitored in real time. Automated systems are prone to misjudgment and cannot accurately locate the fault, leading to a decrease in dust removal efficiency and production interruption.
The system employs a PLC combined with a booster valve signal acquisition unit, a pulse valve signal acquisition unit, a pressure detection unit, an analog-to-analog converter, a fault signal output unit, and a logic judgment module to achieve multi-dimensional signal acquisition and comprehensive judgment of the pulse valves in the dust removal system. The logic judgment module determines the fault and drives the alarm device.
It enables timely and accurate diagnosis of pulse valve malfunctions, reduces manual inspection costs, improves equipment stability and production continuity, and reduces environmental pollution and economic losses.
Smart Images
Figure CN121371813A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the field of industrial automation control technology of cloth bag dust removal system in environmental protection equipment, and particularly relates to a dust removal system pulse valve fault rapid diagnosis device. BACKGROUND
[0002] Currently, there are two main problems in the industry for judging the pulse valve fault: first, most of them rely on manual inspection, which is not only low in efficiency, but also cannot monitor the working state of the pulse valve in real time, and often the problem cannot be found until the pulse valve fault causes the dust removal effect to decrease significantly, thereby causing environmental pollution and even production interruption; second, some systems with slightly higher automation degree can only detect the opening and closing signals of the pulse valve, and cannot make comprehensive judgments combined with multi-dimensional data such as pressure, which is prone to misjudgment, that is, it cannot accurately distinguish whether the fault is from the pulse valve itself or other factors causing abnormality, and cannot quickly locate the specific pulse valve with fault, thereby affecting the normal maintenance of the equipment and reducing the operation efficiency. SUMMARY
[0003] The present application provides a dust removal system pulse valve fault rapid diagnosis device to solve the problems in the background art.
[0004] The specific technical solutions are as follows:
[0005] A dust removal system pulse valve fault rapid diagnosis device, comprising: a PLC, a lift valve signal acquisition unit, a pulse valve signal acquisition unit, a pressure detection unit, an analog quantity conversion unit, a fault signal output unit, a logic judgment module and an alarm driving unit, wherein:
[0006] The output end of the poppet valve signal acquisition unit is connected with the first digital quantity input end of the PLC, for collecting the working state signal of the poppet valve in the dust removal system and transmitting to the PLC; the output end of the pulse valve signal acquisition unit is connected with the second digital quantity input end of the PLC, for collecting the working state signal of the pulse valve in the dust removal system and transmitting to the PLC; the pressure detection unit is correspondingly arranged with the pulse valve in the dust removal system, for collecting the pressure data when the pulse valve works, and the output end of the pressure detection unit is connected with the input end of the analog quantity conversion unit; the output end of the analog quantity conversion unit is connected with the analog quantity input end of the PLC, for converting the analog quantity pressure signal output by the pressure detection unit into the digital quantity pressure signal recognizable by the PLC and transmitting to the PLC; the logic judgment module is integrated in the PLC, for receiving the signals transmitted by the poppet valve signal acquisition unit, the pulse valve signal acquisition unit and the analog quantity conversion unit, and performing logic judgment on the working state of the pulse valve; the input end of the fault signal output unit is connected with the digital quantity output end of the PLC, for receiving the fault signal output by the logic judgment module; and the input end of the alarm driving unit is connected with the output end of the fault signal output unit, for receiving the fault signal and driving the external alarm device to act.
[0007] As a preferred scheme of the present application, the poppet valve signal acquisition unit is provided with a group of signal acquisition interfaces corresponding to each group of poppet valves in the dust removal system, each group of signal acquisition interfaces is connected with a group of first digital quantity input points of the PLC in one-to-one correspondence, and each poppet valve of each group of poppet valves is connected with a corresponding first digital quantity input point through a signal acquisition interface.
[0008] As a preferred scheme of the present application, the pulse valve signal acquisition unit is provided with a group of signal acquisition interfaces corresponding to each group of pulse valves in the dust removal system, each group of signal acquisition interfaces is connected with a group of second digital quantity input points of the PLC in one-to-one correspondence, each pulse valve of each group of pulse valves is connected with a corresponding second digital quantity input point through a signal acquisition interface, and the second digital quantity input points and the first digital quantity input points are different input point groups on the PLC.
[0009] As a preferred scheme of the present application, the number of the pressure detection units corresponds to the number of the pulse valves in the dust removal system in one-to-one correspondence, each pulse valve of each group of pulse valves in the dust removal system is provided with an independent pressure detection unit, and each pressure detection unit is only used for collecting the pressure data of a corresponding pulse valve.
[0010] As a preferred scheme of the present application, the analog quantity conversion unit is provided with a plurality of analog quantity input channels, the output end of each pressure detection unit is connected to one analog quantity input channel in one-to-one correspondence, and the output end of each analog quantity input channel is connected to one analog quantity input point of the PLC, so that the pressure signal collected by each pressure detection unit is transmitted to the PLC through an independent analog quantity input channel.
[0011] As a preferred scheme of the present application, the judgment logic of the logic judgment module is that when the received lifting valve working state signal is an open state and the received pulse valve working state signal is an action state, the logic judgment module acquires the digital quantity pressure signal corresponding to the pulse valve, and if the pressure value corresponding to the digital quantity pressure signal is not within the preset normal pressure range or the pressure change trend corresponding to the digital quantity pressure signal does not match the action trend of the pulse valve working state signal, the logic judgment module determines that the pulse valve has a fault and outputs a fault determination signal to the digital quantity output end of the PLC.
[0012] As a preferred scheme of the present application, when the logic judgment module determines that the pressure value is not within the preset normal pressure range, the logic judgment module also needs to continuously monitor the time when the pressure value is in the abnormal range, and only when the duration exceeds a preset time threshold, the logic judgment module outputs the fault determination signal. The preset time threshold can be adjusted according to the actual operation parameters of the dust removal system.
[0013] As a preferred scheme of the present application, the fault signal output unit is provided with a group of signal output interfaces corresponding to each group of pulse valves in the dust removal system, each group of signal output interfaces is connected to one group of digital quantity output points of the PLC in one-to-one correspondence, and the fault signal of each pulse valve in each group of pulse valves is output to the alarm driving unit through an independent signal output interface.
[0014] As a preferred scheme of the present application, the output end of the alarm driving unit is used for connecting an external alarm device, the external alarm device includes at least one of an audible and light alarm, a fault indicating lamp and a main control alarm terminal of the dust removal system, and the alarm driving unit drives the corresponding external alarm device to issue an alarm prompt after receiving the fault signal.
[0015] As a preferred scheme of the present application, the logic judgment module also integrates a port initialization function, before starting the device and starting signal collection, the logic judgment module first performs initialization detection on the first digital quantity input end, the second digital quantity input end, the analog quantity input end and the digital quantity output end of the PLC, and after ensuring that the data collection and signal transmission functions of each port are normal, the signal collection and logic judgment flow are started.
[0016] The present application has the following beneficial effects:
[0017] 1. Improve the timeliness of fault finding: Compared with artificial inspection, the device can continuously collect and analyze signals through PLC, determine and trigger alarms in the first time when the pulse valve fails, and avoid problems such as dust removal effect decline and environmental pollution caused by late fault discovery.
[0018] 2. Improve fault judgment accuracy: In view of the defect that some automatic systems only rely on single signal and are easy to misjudge, the device integrates the lift valve signal, pulse valve signal and pressure data. Only when the three types of signals meet the logical relationship of "lift valve open + pulse valve action + pressure anomaly" can the fault be determined, effectively eliminating the misjudgment caused by non-pulse valve itself factors (such as temporary air flow fluctuation), and accurately positioning the fault pulse valve through the corresponding input port.
[0019] 3. Reduce maintenance cost and ensure system stability: The automatic fault diagnosis process reduces the labor cost of artificial inspection, and the fault can be quickly located and timely processed to avoid equipment damage caused by fault accumulation, ensure the stable operation of the bag dust removal system, and thus ensure the continuity of industrial production, reduce the economic loss caused by production interruption, and improve the environmental protection benefit of the enterprise. BRIEF DESCRIPTION OF DRAWINGS
[0020] Figure 1 The structure diagram of the dust removal system pulse valve fault rapid diagnosis device provided by the embodiment of the application is shown. DETAILED DESCRIPTION
[0021] The technical solutions of the application will be further described below in combination with the drawings and specific embodiments.
[0022] Among them, the drawings are only used for example description, and the representation is only a schematic diagram, not a real object diagram, and cannot be understood as a limitation of the application; in order to better illustrate the embodiments of the application, some components of the drawings will be omitted, enlarged or reduced, and the size of the actual product is not represented; for those skilled in the art, it is understandable that some known structures and their descriptions in the drawings can be omitted.
[0023] The same or similar reference numerals in the drawings of the embodiments of the application correspond to the same or similar components; in the description of the application, it should be understood that if the terms "upper", "lower", "left", "right", "inner", "outer" and the like indicate the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, therefore the terms describing the positional relationship in the drawings are only used for example description, and cannot be understood as a limitation of the application, and for those skilled in the art, the specific meaning of the above terms can be understood according to the specific situation.
[0024] In the description of the present application, unless otherwise explicitly specified and limited, if the term "connection" or the like appears to indicate the connection relationship between components, the term should be understood broadly, for example, it can be fixedly connected, or detachably connected, or integrated; it can be mechanically connected, or electrically connected; it can be directly connected, or indirectly connected through an intermediate medium; it can be the internal communication of two components or the interaction relationship between two components. For those skilled in the art, the specific meaning of the above-mentioned terms in the present application can be understood according to the specific circumstances.
[0025] Embodiment
[0026] The dust removal system pulse valve fault rapid diagnosis device provided by the embodiment comprises a PLC, a poppet valve signal acquisition unit, a pulse valve signal acquisition unit, a pressure detection unit, an analog quantity conversion unit, a fault signal output unit, a logic judgment module, and an alarm driving unit. Figure 1 The output end of the poppet valve signal acquisition unit is connected with the first digital quantity input end of the PLC, for acquiring the working state signal of the poppet valve in the dust removal system and transmitting the signal to the PLC; the output end of the pulse valve signal acquisition unit is connected with the second digital quantity input end of the PLC, for acquiring the working state signal of the pulse valve in the dust removal system and transmitting the signal to the PLC; the pressure detection unit is arranged correspondingly with the pulse valve in the dust removal system, for acquiring the pressure data when the pulse valve works, and the output end of the pressure detection unit is connected with the input end of the analog quantity conversion unit; the output end of the analog quantity conversion unit is connected with the analog quantity input end of the PLC, for converting the analog pressure signal output by the pressure detection unit into a digital pressure signal recognizable by the PLC and transmitting the signal to the PLC; the logic judgment module is integrated in the PLC, for receiving the signals transmitted by the poppet valve signal acquisition unit, the pulse valve signal acquisition unit, and the analog quantity conversion unit, and performing logic judgment on the working state of the pulse valve; the input end of the fault signal output unit is connected with the digital quantity output end of the PLC, for receiving the fault signal output by the logic judgment module; and the input end of the alarm driving unit is connected with the output end of the fault signal output unit, for receiving the fault signal and driving the external alarm device to act.
[0027] The scheme realizes the multi-source signal cooperative collection and analysis of the lifting valve state, the pulse valve state and the pulse valve pressure data in the dust removal system by integrating the programmable logic controller (PLC), the multi-type signal collection unit, the pressure detection unit, the analog quantity conversion unit and the alarm driving unit, and clearly connecting the relationship between the units. Compared with the low efficiency of manual inspection and the misjudgment problem of single signal judgment in the prior art, the scheme relies on the internal logic judgment module of the PLC to comprehensively judge the multi-source signals, can automatically complete the identification of the pulse valve fault, and simultaneously links the fault signal output unit and the alarm driving unit to the external alarm device, realizes the timely early warning of the fault, effectively guarantees the stable operation of the bag dust removal system, and reduces the risk of environmental pollution and production interruption caused by failure to discover the fault in time.
[0028] Specifically, in the embodiment, the lifting valve signal collection unit is provided with a group of signal collection interfaces corresponding to each group of lifting valves in the dust removal system, each group of signal collection interfaces is connected to a group of first digital quantity input points of the PLC one by one, and each lifting valve of each group of lifting valves is connected to a corresponding first digital quantity input point through a signal collection interface.
[0029] The scheme ensures that the working state signals of each lifting valve of each group can be accurately and independently collected and transmitted to the PLC by configuring a corresponding signal collection interface for each group of lifting valves and making the interface correspond to the first digital quantity input point of the PLC one by one. This design avoids the situation of signal confusion or omission during lifting valve signal collection, provides accurate lifting valve state basis for subsequent PLC judgment of pulse valve fault, and further consolidates the accuracy basis of fault judgment.
[0030] Specifically, in the embodiment, the pulse valve signal collection unit is provided with a group of signal collection interfaces corresponding to each group of pulse valves in the dust removal system, each group of signal collection interfaces is connected to a group of second digital quantity input points of the PLC one by one, each pulse valve of each group of pulse valves is connected to a corresponding second digital quantity input point through a signal collection interface, and the second digital quantity input point and the first digital quantity input point are different input point groups on the PLC. The scheme clearly configures an interface for each group of pulse valves in the pulse valve signal collection unit, and corresponds to the second digital quantity input point (different from the lifting valve signal input point) of the PLC one by one, realizes the independent collection and transmission of the pulse valve signal and the lifting valve signal. This signal collection separation design can avoid mutual interference of the two types of signals in the PLC input link, ensure that the PLC can accurately obtain the working state of the pulse valve and the lifting valve, provide clear and independent data sources for the subsequent logic judgment module to judge the pulse valve fault according to the two types of signals, and reduce the fault judgment error caused by signal aliasing.
[0031] Specifically, in the embodiment, the number of pressure detection units corresponds to the number of pulse valves in the dust removal system, and each pulse valve in each group of pulse valves in the dust removal system is provided with an independent pressure detection unit, and each pressure detection unit is only used to collect pressure data of the corresponding pulse valve. The scheme realizes accurate monitoring of the pressure state of a single pulse valve by making the pressure detection unit correspond to each pulse valve one by one, and each pressure detection unit only collects pressure data of the corresponding pulse valve. In the prior art, if the pressure detection does not correspond to a single pulse valve, only the existence of an abnormal pulse valve in a group can be determined, but the specific fault valve cannot be located. The scheme can make the PLC accurately obtain the pressure data of each pulse valve, directly lock the corresponding fault pulse valve when the pressure is abnormal, solve the problem of difficult positioning of the fault pulse valve in the prior art, greatly shorten the troubleshooting time, and improve the equipment maintenance efficiency.
[0032] Specifically, in the embodiment, the analog quantity conversion unit is provided with a plurality of analog quantity input channels, the output end of each pressure detection unit is connected to one analog quantity input channel one by one, and the output end of each analog quantity input channel is connected to one analog quantity input point of the PLC one by one, so that the pressure signal collected by each pressure detection unit is transmitted to the PLC through an independent analog quantity input channel. The scheme configures the analog quantity conversion unit with a plurality of independent analog quantity input channels, so that the signal of each pressure detection unit is transmitted to the PLC through an independent channel, avoiding the signal crosstalk or data distortion problem that may occur when a plurality of pressure signals share a channel. The pressure signal is the key data for judging the fault of the pulse valve, and its accuracy directly affects the fault judgment result. The independent channel design can ensure that the pressure signal of each pulse valve remains accurate during the analog quantity to digital quantity conversion, so that the pressure data of each pulse valve received by the PLC can truly reflect its working state, further improving the accuracy of fault judgment.
[0033] Specifically, in the embodiment, the judgment logic of the logic judgment module is: when the received lift valve working state signal is in the open state and the received pulse valve working state signal is in the action state, the logic judgment module acquires the digital pressure signal corresponding to the pulse valve, and if the pressure value corresponding to the digital pressure signal is not in the preset normal pressure range, or the pressure change trend corresponding to the digital pressure signal does not match the action trend of the pulse valve working state signal, the logic judgment module determines that the pulse valve has a fault, and outputs a fault determination signal to the digital output end of the PLC. The scheme clearly defines the core judgment logic of the logic judgment module - to determine the fault by combining the open state of the lift valve, the action state of the pulse valve, and the pressure data (pressure range or change trend), instead of relying on a single signal. In the prior art, only detecting the pulse valve switch signal is easy to misjudge (such as when the pulse valve signal is normal but the pressure is abnormal, the fault cannot be identified), and this logic can exclude abnormalities caused by factors other than the pulse valve itself (such as pressure fluctuations when the lift valve is not open): only when the lift valve is open, the pulse valve is in action, and the pressure is abnormal (the range is inconsistent or the trend is not matched), the pulse valve is determined to be faulty, effectively avoiding the limitations of single signal judgment, significantly improving the accuracy of fault judgment, and reducing unnecessary maintenance or fault omission caused by misjudgment.
[0034] Specifically, in the embodiment, when the logic judgment module determines that the pressure value is not in the preset normal pressure range, it also needs to continuously monitor the time when the pressure value is in the abnormal range, and only when the duration exceeds the preset time threshold, the logic judgment module outputs the fault determination signal. The preset time threshold can be adjusted according to the actual running parameters of the dust removal system. On the basis of claim 6, the scheme adds the logic of "determining fault only when the pressure abnormality duration exceeds the preset threshold". This design can filter out the transient pressure fluctuations that may occur during system operation (such as short-term pressure abnormalities caused by temporary air flow disturbances, which are not real pulse valve faults), and avoid false alarms caused by transient fluctuations. By setting the duration judgment, it is ensured that only when the pressure abnormality exists stably, the fault is determined, unnecessary alarm and maintenance operation are reduced, the reliability of the device fault judgment is improved, and the production continuity is ensured by preventing the dust removal system from being affected by the shutdown caused by false alarm.
[0035] Specifically, in the embodiment, the fault signal output unit is provided with a set of signal output interfaces corresponding to each group of pulse valves in the dust removal system, each group of signal output interfaces is connected to a group of digital output points of the PLC one by one, and the fault signal of each pulse valve in each group of pulse valves is output to the alarm driving unit through an independent signal output interface. The scheme realizes accurate output of the fault signal by configuring corresponding fault signal output interfaces for each group of pulse valves and one-to-one correspondence with the digital output points of the PLC. When a pulse valve is determined to be faulty, the corresponding fault signal can be output through an independent interface, and maintenance personnel can directly locate the faulty pulse valve according to the pulse valve group and position corresponding to the output interface, without checking each pulse valve in multiple groups. The design solves the problem of fuzzy fault location in the prior art, greatly shortens the fault finding and maintenance time, improves the equipment maintenance efficiency, and reduces the system operation risk caused by untimely maintenance.
[0036] Specifically, in the embodiment, the output end of the alarm driving unit is used to connect external alarm devices, the external alarm devices include at least one of an audible and light alarm, a fault indicator lamp and a main control alarm terminal of the dust removal system, and the alarm driving unit drives the corresponding external alarm device to issue an alarm prompt after receiving the fault signal. The scheme connects the alarm driving unit to various external alarm devices such as audible and light alarms, fault indicator lamps and main control alarm terminals, thereby widening the transmission path of the fault warning. In the prior art, if the alarm mode is single, the maintenance personnel may not notice the fault in time (such as when there is only audible and light alarm and the personnel are not on site), and the linkage of multiple alarm devices can ensure that the fault information can be transmitted through on-site prompt (audible and light, indicator lamp) and remote prompt (main control terminal), so that the maintenance personnel can know the fault in time whether they are on site or in the control room, and respond quickly, thereby avoiding the continuous expansion of the fault, which leads to the decline of the dust removal effect or the damage of the equipment.
[0037] Specifically, in the embodiment, the logic judgment module is also integrated with a port initialization function. Before the device starts and begins to collect signals, the logic judgment module first performs initialization detection on the first digital quantity input end, the second digital quantity input end, the analog quantity input end and the digital quantity output end of the PLC, and after ensuring that the data collection and signal transmission functions of each port are normal, the signal collection and logic judgment process is started. The scheme detects each input and output port of the PLC before the device starts by adding a port initialization function to the logic judgment module, and ensures that the data collection and signal transmission functions of each port are normal. If there is a port failure (such as an input port that cannot collect signals or an output port that cannot output signals), direct starting without detection may cause two problems: one is that the real pulse valve failure is missed due to the failure of signal transmission, and the other is that the signal anomaly caused by the port failure is misjudged as a pulse valve failure. The port initialization detection can exclude the port's own problems before the device works, ensure that the subsequent signal collection and failure judgment are based on a normal hardware basis, improve the reliability of the entire device operation, and avoid judgment errors or alarm failures caused by port failures.
[0038] In summary, the dust removal system pulse valve failure rapid diagnosis device provided in the embodiment takes a programmable logic controller (PLC) as the core, and realizes pulse valve failure diagnosis through multi-unit cooperation. The specific principle includes two parts of hardware connection logic and software judgment logic.
[0039] (I) Hardware connection logic
[0040] 1. Signal input end: The working state signal of the lift valve is connected to the first group of digital quantity input ports of the PLC, which is used to transmit the opening and closing state of the lift valve to the PLC; the working state signal of the pulse valve is connected to the second group of digital quantity input ports of the PLC, which is used to transmit the action state of the pulse valve; each pulse valve is equipped with an independent pressure detection device, and the analog quantity pressure signal collected by the pressure detection device is connected to the analog quantity input channel of the PLC to provide the pressure data of the pulse valve during work for the PLC.
[0041] 2. Signal output end: The digital quantity output port of the PLC is connected to the fault signal output module, which is used to transmit the fault signal to the external equipment; the fault signal output module is further connected to the alarm driving device to ensure that the external alarm can be triggered when a fault occurs.
[0042] (II) Software judgment logic
[0043] The PLC program first initializes each input and output port to ensure normal data collection and transmission; then continuously collects the lift valve signal, pulse valve signal and pressure detection signal; through the preset logical judgment rule, when the lift valve is in the open state and the pulse valve has an action signal, if the pressure detection value is not in the normal range or the pulse valve action signal does not match the actual pressure change (such as the pulse valve showing open but the pressure has no obvious change), it is determined that the pulse valve has a fault; after fault determination, the PLC immediately sends a fault signal through the corresponding output port to drive the external alarm device to act.
[0044] Method of use
[0045] (1) Hardware installation steps
[0046] 1. According to the grouping of the pulse valve, the state signal of each group of lift valves is connected to the designated digital input port of the PLC (such as the I0.0 to I0.6 ports of the PLC for a certain group of lift valve signals), ensuring that the state signal of each lift valve can be independently transmitted to the PLC.
[0047] 2. Similarly, the state signal of each group of pulse valves is connected to another group of digital input ports of the PLC (such as the I1.0 to I1.6 ports of the PLC for a certain group of pulse valve signals), ensuring that the input channels of the pulse valve action signal and the lift valve signal are not confused.
[0048] 3. Install an independent pressure detection device for each pulse valve in each group, and connect the analog output signal of each pressure detection device to the analog input channel of the PLC (such as the AIW0 to AIW6 channels of the PLC for the pressure signal of a certain group of pulse valves), ensuring that the pressure data of each pulse valve can be collected independently.
[0049] 4. Connect the fault signal output module to the designated digital output port of the PLC (such as the Q0.0 to Q0.6 ports of the PLC for a certain group of pulse valve fault outputs), and connect the fault signal output module to the external alarm device (such as an audible and visual alarm).
[0050] (2) Software setup and running steps
[0051] 1. Write an initialization program in the PLC to perform function detection on the connected input and output ports, and confirm that the data collection and signal transmission functions of each port are normal.
[0052] 2. Write a logical judgment program to preset judgment parameters such as pressure normal range and signal matching rules (such as the correspondence between pulse valve action and pressure change).
[0053] 3. Start the device, and the PLC starts to continuously collect lift valve, pulse valve and pressure signals, and judges the working state of the pulse valve in real time according to the preset logic.
[0054] 4. When a pulse valve fault is detected, the PLC sends a fault signal through the corresponding output port to trigger an external alarm device; maintenance personnel locate and repair the faulty pulse valve according to the alarm prompt and the fault port displayed by the PLC.
[0055] Overall technical effects:
[0056] The device realizes multi-faceted improvement by the scheme of "multi-signal acquisition + PLC logical judgment" in view of the deficiencies of the prior art, and the specific technical effects are as follows:
[0057] 1. Improve the timeliness of fault discovery: Compared with manual inspection that cannot monitor in real time, the device can determine and trigger an alarm at the first time when the pulse valve fails by continuously collecting and analyzing signals through the PLC, avoiding problems such as reduced dust removal effect, environmental pollution, etc. caused by late fault discovery.
[0058] 2. Improve fault judgment accuracy: In view of the defect that some automatic systems rely on a single signal and are prone to misjudgment, the device integrates the lift valve signal, pulse valve signal and pressure data. Only when the three types of signals satisfy the logical relationship of "lift valve open + pulse valve action + pressure anomaly" can the fault be determined, effectively eliminating misjudgment caused by non-pulse valve itself factors (such as temporary air flow fluctuations), and accurately locating the faulty pulse valve through the corresponding input port.
[0059] 3. Reduce maintenance costs and ensure system stability: The automatic fault diagnosis process reduces the labor input of manual inspection and reduces labor costs; and the fault can be quickly located and timely processed, avoiding equipment damage caused by accumulated faults, ensuring the stable operation of the bag dust removal system, thereby ensuring the continuity of industrial production, reducing economic losses caused by production interruptions, and improving the environmental benefits of enterprises.
[0060] The above is only the preferred embodiment of the present application, and does not limit the implementation and protection scope of the present application. For those skilled in the art, it should be realized that any equivalent replacement and obvious change made by applying the contents of the present application should be included in the protection scope of the present application.
Claims
1. A dust removal system pulse valve fault rapid diagnosis device, characterized in that, The application relates to a PLC, a poppet valve signal acquisition unit, a pulse valve signal acquisition unit, a pressure detection unit, an analog quantity conversion unit, a fault signal output unit, a logic judgment module and an alarm driving unit, wherein: The output end of the poppet valve signal acquisition unit is connected with the first digital quantity input end of the PLC, and is used for acquiring the working state signal of the poppet valve in the dust removal system and transmitting the working state signal to the PLC; the output end of the pulse valve signal acquisition unit is connected with the second digital quantity input end of the PLC, and is used for acquiring the working state signal of the pulse valve in the dust removal system and transmitting the working state signal to the PLC; the pressure detection unit is correspondingly arranged with the pulse valve in the dust removal system, and is used for acquiring the pressure data when the pulse valve works; the output end of the pressure detection unit is connected with the input end of the analog quantity conversion unit; the output end of the analog quantity conversion unit is connected with the analog quantity input end of the PLC, and is used for converting the analog quantity pressure signal output by the pressure detection unit into a digital quantity pressure signal recognizable by the PLC and transmitting the digital quantity pressure signal to the PLC; the logic judgment module is integrated in the PLC, and is used for receiving the signals transmitted by the poppet valve signal acquisition unit, the pulse valve signal acquisition unit and the analog quantity conversion unit, and logically judging the working state of the pulse valve; the input end of the fault signal output unit is connected with the digital quantity output end of the PLC, and is used for receiving the fault signal output by the logic judgment module; and the input end of the alarm driving unit is connected with the output end of the fault signal output unit, and is used for receiving the fault signal and driving the external alarm device to act. The poppet valve signal acquisition unit is provided with a group of signal acquisition interfaces corresponding to each group of poppet valves in the dust removal system, each group of signal acquisition interfaces is connected with a group of first digital quantity input points of the PLC in one-to-one correspondence, and each poppet valve of each group of poppet valves is connected with a corresponding first digital quantity input point through a signal acquisition interface.
2. The device according to claim 1, characterized in that, The pulse valve signal acquisition unit is provided with a group of signal acquisition interfaces corresponding to each group of pulse valves in the dust removal system, each group of signal acquisition interfaces is connected with a group of second digital quantity input points of the PLC in one-to-one correspondence, each pulse valve of each group of pulse valves is connected with a corresponding second digital quantity input point through a signal acquisition interface, and the second digital quantity input points and the first digital quantity input points are different input point groups on the PLC.
3. The device according to claim 1, wherein The number of the pressure detection units corresponds to the number of the pulse valves in the dust removal system in one-to-one correspondence, each pulse valve of each group of pulse valves in the dust removal system is provided with an independent pressure detection unit, and each pressure detection unit is only used for acquiring pressure data of a corresponding pulse valve.
4. The device according to claim 1, wherein The analog quantity conversion unit is provided with a plurality of analog quantity input channels, the output end of each pressure detection unit is connected with an analog quantity input channel in one-to-one correspondence, and the output end of each analog quantity input channel is connected with an analog quantity input point of the PLC in one-to-one correspondence, so that the pressure signals acquired by each pressure detection unit are transmitted to the PLC through independent analog quantity input channels.
5. The dust system pulse valve fault quick diagnosis device according to claim 1, characterized in that, 6. The device according to claim 1, wherein The judgment logic of the logic judgment module is: when the received lift valve working state signal is in an open state and the received pulse valve working state signal is in a motion state, the logic judgment module acquires the digital pressure signal corresponding to the pulse valve, if the pressure value corresponding to the digital pressure signal is not in the preset normal pressure range, or the pressure change trend corresponding to the digital pressure signal does not match the motion trend of the pulse valve working state signal, then the logic judgment module determines that the pulse valve has a fault, and outputs a fault determination signal to the digital output end of the PLC.
7. The device according to claim 6, characterized in that, When the logic judgment module determines that the pressure value is not in the preset normal pressure range, it also needs to continuously monitor the time when the pressure value is in the abnormal range, and only when the duration exceeds the preset time threshold, the logic judgment module outputs the fault determination signal. The preset time threshold can be adjusted according to the actual operation parameters of the dust removal system.
8. The device according to claim 1, wherein The fault signal output unit is provided with a group of signal output interfaces corresponding to each group of pulse valves in the dust removal system, each group of signal output interfaces is connected one by one with a group of digital output points of the PLC, and the fault signal of each pulse valve in each group of pulse valves is output to the alarm driving unit through an independent signal output interface.
9. The device according to claim 1, wherein The output end of the alarm driving unit is used for connecting an external alarm device, and the external alarm device includes at least one of an audible and visual alarm, a fault indicator light and a main control alarm terminal of the dust removal system. After receiving the fault signal, the alarm driving unit drives the corresponding external alarm device to issue an alarm prompt.
10. The device according to any one of claims 1 to 9, characterized in that, The logic judgment module also integrates a port initialization function. Before starting the device and starting signal acquisition, the logic judgment module first initializes and detects the first digital input end, the second digital input end, the analog input end and the digital output end of the PLC, ensures that the data acquisition and signal transmission functions of each port are normal, and then starts the signal acquisition and logic judgment process.