An intelligent measurement and control system and method for hydraulic pressure test of hydraulic penstock

Abstract

The present invention discloses an intelligent measurement and control system and method for water pressure test of hydraulic penstock, comprising a water pressure loading and unloading control device and a measurement and control device; a controllable and stable water pressure is provided for the penstock through servo control of an air-liquid pump; under the action of different water pressures, the measurement and control device collects and records the stress, deformation, water pressure, water flow, water temperature, etc. and the action time of the penstock in real time; the present invention realizes pressure servo control of water pressure test of penstock, and realizes real-time collection of a plurality of different types of sensors collected in one acquisition instrument, realizes intelligent monitoring of the whole process of water pressure test through a computer and special software, and displays the relationship curve between any parameters in real time, with high precision, small fluctuation, accurate and controllable stabilization time, and convenient operation, and can be widely used in water pressure test of pressure vessels.

Description

Technical Field

[0001] The invention relates to the technical field of metal pressure vessel testing equipment, and in particular to an intelligent measurement and control system and method for hydraulic pressure testing of hydraulic penstocks. Background Art

[0002] Penstocks (including bifurcated pipes, connecting pipes, special-shaped pipes, etc.) are mostly used in water supply and transportation of large and medium-sized water conservancy and hydropower projects. For high-head and large-diameter penstocks, hydraulic pressure tests must be carried out after manufacturing and installation. The stress state and deformation characteristics of each part of the penstock under different pressure conditions are comprehensively tested to see whether the working state of the penstock meets the design requirements. During the hydraulic pressure test, the deformation, stress, water pressure, flow, temperature and duration of the penstock need to be monitored in real time. The current hydraulic pressure test and monitoring methods are a combination of multiple methods and are independent of each other. They cannot well and intuitively reflect the stress state of each part of the steel pipe under different pressure conditions. It is not only time-consuming and laborious to make preliminary judgments based on the data collected by various instruments, but also easy to cause misjudgment. The loading and unloading equipment mainly uses high-pressure water pumps and mechanical pressure gauges, which cannot accurately control the loading and unloading rate and record the pressure curve of the entire process. The acquisition time of the monitoring parameters cannot be accurately synchronized with the pressure duration.

[0003] In summary, the problems existing in the prior art are: 1. Ordinary high-pressure water pumps are used for pressure and pressure relief, and the work efficiency and precision of manually controlling pressure and time are low; 2. There is no intelligent control and recording device, and the whole process of pressure cannot be recorded by computer; 3. The strain, deformation, pressure, flow and temperature monitoring equipment of the pressure steel pipe are independent of each other, and it is difficult to form the relationship curve between various monitoring parameters and time in real time in the same set of equipment, which is not conducive to timely judgment of the changes of various parameters in each pressure stage. Summary of the invention

[0004] The purpose of the present invention is to provide an intelligent measurement and control system and method for hydraulic pressure testing of hydraulic penstocks in order to solve the above-mentioned problems.

[0005] The present invention achieves the above-mentioned purpose through the following technical solutions:

[0006] An intelligent measurement and control system for hydraulic pressure test of hydraulic penstock, comprising a loading and unloading control device for hydraulic penstock, and a measurement and control device for detecting the stress state of the hydraulic penstock during loading and unloading; the hydraulic pressure loading and unloading control device comprises a servo controller, the servo controller is connected to an air source filter, an air pressure valve, an air pressure sensor, an air-liquid pump, an air-liquid servo valve, and a hydraulic control sensor through a data line, the hydraulic control sensor is connected to the air-liquid servo valve through a pipeline, the air-liquid servo valve input end is connected to the air-liquid pump, and the air-liquid pump input end is connected to a water A filter and an air pressure sensor, wherein the water filter is connected to a water valve through a pipeline, the water valve input end is connected to a water tank, the air pressure sensor input end is connected to an air pressure valve, the air pressure valve input end is connected to an air source filter, and the air source filter input end is connected to an air pump; the measurement and control device includes a data acquisition instrument, the data acquisition instrument input end is connected to a conversion module, the conversion module is respectively connected to a stress sensor group, a deformation sensor group, a temperature sensor group, a pressure sensor, and a flow meter through data lines, and the servo controller output end and the data acquisition instrument output end are connected to a computer.

[0007] Further configuration: the servo controller, the computer and the data acquisition instrument are connected to an uninterruptible power supply via a power line, and the output pipeline of the gas-liquid servo valve is connected to the pressure sensor and the flow meter.

[0008] It is further configured that the gas-liquid pump is connected to the gas-liquid servo valve via an air pipe and a water pipe, and the servo controller is connected to the computer via a data line.

[0009] It is further configured that the air pump is connected to the air source filter via threads, and the air source filter is connected to the air pressure valve via an air pipe.

[0010] A method for using an intelligent measurement and control system for hydraulic pressure test of hydraulic penstocks. After starting the system, the special software in the computer automatically searches to see whether the status of all electrical connection devices is normal. If normal, the human-computer dialogue menu is exited, and the control target value (0-20MPa), pressure increase and reduction rate (0.01-50.00L / min), duration (0.1-50h), sampling interval (0.001-20min), display mode (full display or single display), file name, pilot number, sensor number, etc. are set respectively. After the setting is completed and confirmed to be correct, click "Send", the system automatically enters the working state, and the screen dynamically displays the relationship curves of each monitoring parameter (temperature, flow, pressure, strain, deformation) and time.

[0011] The temperature sensor group is placed on the inner wall of the penstock, the water tank and the air respectively, the deformation sensor group is placed on the penstock and the outer wall of the bulkhead, the stress sensor group is placed on the inner and outer walls of the penstock, and the pressure sensor and the flow meter are placed on the high-pressure water pipe of the penstock;

[0012] During the test, you can operate from the interface. For example, if you need to modify the parameters of a channel, click "Stop" to keep the pressure of the corresponding channel at the current state. After the modification is completed, click Send to continue to execute according to the set target.

[0013] After the test is completed, you need to uninstall. First, click "Stop", set the pressure relief target value and other parameters, and then click "Pressure Relief". After the entire test process is completed, click "Stop" and the program will automatically save to the specified document location. Then click "Exit" to close the program and copy the data through the USB flash drive.

[0014] The dedicated software realizes the execution control of the servo controller and the data acquisition instrument, and the instruction execution process is as follows:

[0015] The hydraulic control sensor outputs 0-5V DC voltage (corresponding to hydraulic pressure 0-20MPa). The proportional relationship between water pressure and voltage is obtained through calibration in the program. The computer generates a water pressure adjustment electrical signal (such as ±δ) and a duration signal to the servo controller at any time according to the water pressure and loading and unloading rate of the current system. The servo controller converts the electrical signal into an air pressure adjustment signal, and adjusts the output water pressure according to a certain ratio through the air-liquid servo valve. This cycle is repeated to achieve servo control of water pressure.

[0016] The stress sensor group, pressure sensor, deformation sensor group, flow meter, and temperature sensor group on the pressure steel pipe output 0-5V DC voltage. The proportional relationship between the relevant parameters and the voltage is obtained through calibration within the program, and the electrical signals are uniformly output to the data acquisition instrument. The data acquisition instrument saves and displays the converted values ​​in real time according to the type and size of the electrical signals; during the loading and unloading process, the relationship curves between any parameters and time and the relationship curves between any parameters can be displayed in real time as needed.

[0017] When the water pressure cannot be increased or decreased at the prescribed rate or fails to reach the target value for a long time, the program will sound an alarm to prompt the operator to deal with it in time; when the stress or deformation of any part of the pipe wall of the pressure steel pipe under the action of water pressure approaches and reaches the limit value, the water pressure cannot be loaded automatically, the current pressure is maintained and a warning menu pops up for the operator to deal with.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] 1. The air pressure and air control components are used to realize the servo control of high water pressure. The output water pressure has high precision and small fluctuation. The maximum fluctuation range is less than ±20kPa. The flow rate is adjustable and the stability is good.

[0020] 2. Convert different types of sensors into electrical signals through conversion modules, and use the same system for control and acquisition, which solves the problem of independent monitoring of water pressure, water flow, water temperature, stress (strain) and deformation of inner and outer walls of steel pipes in water pressure test. It significantly improves the consistency and coordination of pressure pipe pressure state monitoring, improves the quality of results and work efficiency, and saves 3 to 5 times the labor cost compared with conventional test methods;

[0021] 3. It has the function of automatically retrieving and identifying the stress and deformation state of the pressure steel pipe wall to prevent overpressure from damaging the pressure steel pipe;

[0022] 4. Simple and light structure, easy to operate, and can adapt well to the outdoor environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0024] Figure 1 It is a structural schematic diagram of an intelligent measurement and control system for hydraulic pressure test of hydraulic penstocks according to the present invention;

[0025] Figure 2 The present invention is a schematic diagram of the structure of the sensor connection state of the intelligent measurement and control system for hydraulic pressure test of hydraulic penstock on the test penstock.

[0026] The following are the descriptions of the reference numerals:

[0027] 1. Air pump; 2. Air source filter; 3. Air pressure valve; 4. Air pressure sensor; 5. Water tank; 6. Water valve; 7. Water filter; 8. Air-liquid pump; 9. Air-liquid servo valve; 10. Hydraulic control sensor; 11. Servo controller; 12. Computer; 13. Uninterruptible power supply; 14. Data acquisition instrument; 15. Conversion module; 16. Stress sensor group; 17. Deformation sensor group; 18. Temperature sensor group; 19. Pressure sensor; 20. Flow meter; 21. Pressure steel pipe; 16-1. First stress sensor; 16-2. Second stress sensor; 18-1. First temperature sensor; 18-2. Second temperature sensor; 18-3. Third temperature sensor; 22-1. First bulkhead; 22-2. Second bulkhead; 22-3. Third bulkhead. DETAILED DESCRIPTION

[0028] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", and the like are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, features defined as "first", "second", and the like may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0029] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood by specific circumstances.

[0030] The present invention will be further described below in conjunction with the accompanying drawings:

[0031] like Figure 1-Figure 2As shown, an intelligent measurement and control system for hydraulic pressure test of hydraulic penstock includes a control device for loading and unloading water pressure of hydraulic penstock, and a measurement and control device for stress detection of hydraulic penstock; the water pressure loading and unloading control device includes a servo controller 11, the servo controller 11 is connected with an air source filter 2, an air pressure valve 3, an air pressure sensor 4, an air-liquid pump 8, an air-liquid servo valve 9, and a hydraulic control sensor 10 through a data line, the hydraulic control sensor 10 is connected with the air-liquid servo valve 9 through a pipeline, the air-liquid servo valve 9 adjusts the water pressure through air pressure according to the size and direction of the electrical signal and keeps it within a certain range, the hydraulic control sensor 10 transmits the pressure fluctuation to the servo controller 11 in real time, so as to realize closed-loop control of the water pressure, the air-liquid servo valve 9 input end is connected with an air-liquid pump 8, the air-liquid pump 8 input end is connected with a water filter 7 and an air pressure sensor 4, the water filter 7 is connected with a water valve 6 through a pipeline, and the water valve 6 input end is connected with a water tank 5, The input end of the air pressure sensor 4 is connected to the air pressure valve 3, the input end of the air pressure valve 3 is connected to the air source filter 2, the input end of the air source filter 2 is connected to the air pump 1, the air pump 1, the air source filter 2, and the air pressure sensor 4 provide a constant air pressure for the test, the water tank 5, the water filter 7, the air-liquid pump 8, the air-liquid servo valve 9 and the hydraulic control sensor 10 provide a constant water pressure for the test, and the high-pressure water pipe injects the water pressure into the pressure steel pipe 21 through the bulkhead 22-1; the measurement and control device includes a data acquisition instrument 14, the input end of the data acquisition instrument 14 is connected to a conversion module 15, and the conversion module 15 is respectively connected to a stress sensor group 16, a deformation sensor group 17, a temperature sensor group 18, a pressure sensor 19, and a flow meter 20 through data lines. The conversion module 15 automatically and cyclically collects the sensor information of each channel of the terminal, automatically saves the data and displays the numerical value and curve on the screen, and the output end of the servo controller 11 and the output end of the data acquisition instrument 14 are connected to a computer 12.

[0032] Preferably: the servo controller 11, the computer 12, and the data acquisition instrument 14 are connected to an uninterruptible power supply 13 through a power cord, and the uninterruptible power supply 13 is used to ensure the continuity of the system power supply. The output pipeline of the gas-liquid servo valve 9 is connected to the pressure sensor 19 and the flow meter 20; the gas-liquid pump 8 is connected to the gas-liquid servo valve 9 through an air pipe and a water pipe, and the servo controller 11 is connected to the computer 12 through a data line; the air pump 1 is connected to the air source filter 2 through a threaded connection, and the air source filter 2 is connected to the air pressure valve 3 through an air pipe.

[0033] A method for using an intelligent measurement and control system for hydraulic pressure test of hydraulic penstocks. After starting the system, the special software in a computer 12 is used to automatically retrieve whether the status of all electrical connection devices is normal. If normal, the human-computer dialogue menu is exited, and the control target value (0-20MPa), pressure increase and reduction rate (0.01-50.00L / min), duration (0.1-50h), sampling interval (0.001-20min), display mode (full display or single display), file name, pilot number, sensor number, etc. are set respectively. After the setting is completed and confirmed to be correct, click "Send", the system automatically enters the working state, and the screen dynamically displays the relationship curves between each monitoring parameter (temperature, flow, pressure, strain, deformation) and time.

[0034] The first temperature sensor 18-1 is placed in the water tank 5, the second temperature sensor 18-2 is placed in the air outside the pressure steel pipe 21, and the third temperature sensor 18-3 is placed inside the pressure steel pipe 21; the first stress sensor 16-1 is placed on the inner wall of the pressure steel pipe 21, and the second stress sensor 16-2 is placed on the outer wall of the pressure steel pipe 21, and the first stress sensor 16-1 and the second stress sensor 16-2 are arranged at the corresponding positions of the inner and outer walls; the first stress sensor 16-1 and the second stress sensor 16-2 are unidirectional, bidirectional or tridirectional strain gauges, for pressure The wall thickness of the steel pipe 21, the stress state of important welds and reinforcing ribs are selected, and a number of measuring points are arranged according to the resistance limit requirements of the pressure steel pipe 21; the deformation sensor in the deformation sensor group 17 adopts a grating displacement sensor, which is arranged outside the pressure steel pipe 21, and can also be arranged outside the first bulkhead 22-1, the second bulkhead 22-2, and the third bulkhead 22-3 as needed. The position and number of measuring points are also reasonably arranged according to the deformation characteristics of the pressure steel pipe and the bulkhead. The reference point and reference beam of the deformation sensor group 17 should have sufficient rigidity to minimize the influence of temperature;

[0035] During the test, you can operate from the interface. For example, if you need to modify the parameters of a channel, click "Stop" to keep the pressure of the corresponding channel at the current state. After the modification is completed, click Send to continue to execute according to the set target.

[0036] After the test is completed, you need to uninstall. First, click "Stop", set the pressure relief target value and other parameters, and then click "Pressure Relief". After the entire test process is completed, click "Stop" and the program will automatically save to the specified document location. Then click "Exit" to close the program and copy the data through the USB flash drive.

[0037] The dedicated software realizes the execution control of the servo controller 11 and the data acquisition device 14, and the instruction execution process is as follows:

[0038] The hydraulic control sensor 10 outputs a 0-5V DC voltage (corresponding to a hydraulic pressure of 0-20MPa). The proportional relationship between the water pressure and the voltage is obtained through calibration in the program. The computer 12 generates a water pressure regulating electrical signal (such as ±δ) and a duration signal to the servo controller 11 at any time according to the water pressure and loading and unloading rate of the current system. The servo controller 11 converts the electrical signal into an air pressure regulating signal, and adjusts the water pressure at the output end according to a certain ratio through the air-liquid servo valve 9. In this way, the servo control of the water pressure is realized in a reciprocating cycle.

[0039] The stress sensor group 16, pressure sensor 19, deformation sensor group 17, flow meter 20 and temperature sensor group 18 on the pressure steel pipe output 0-5V DC voltage. The proportional relationship between relevant parameters and voltage is obtained through calibration in the program, and the electrical signals are uniformly output to the data acquisition instrument 14. The data acquisition instrument 14 saves and displays the converted values ​​in real time according to the type and size of the electrical signals. During the loading and unloading process, the relationship curves between any parameters and time and the relationship curves between any parameters can be displayed in real time as needed.

[0040] When the water pressure cannot be increased or decreased at the prescribed rate or fails to reach the target value for a long time, the program will sound an alarm to prompt the operator to deal with it in time; when the stress or deformation of any part of the pipe wall of the pressure steel pipe under the action of water pressure approaches and reaches the limit value, the water pressure cannot be loaded automatically, the current pressure is maintained and a warning menu pops up for the operator to deal with.

[0041] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements all fall within the scope of the present invention to be protected.

Claims

1. An intelligent measurement and control system for hydraulic pressure test of hydraulic penstock, characterized by: The invention comprises a control device for loading and unloading water pressure on a hydraulic penstock, and a measurement and control device for detecting the force on the hydraulic penstock; the water pressure loading and unloading control device comprises a servo controller (11), the servo controller (11) is connected to an air source filter (2), an air pressure valve (3), an air pressure sensor (4), an air-liquid pump (8), an air-liquid servo valve (9), and a hydraulic control sensor (10) via a data line, the hydraulic control sensor (10) is connected to the air-liquid servo valve (9) via a pipeline, the air-liquid servo valve (9) is connected to an input end thereof, the air-liquid pump (8) is connected to an input end thereof, the water filter (7) and the air pressure sensor (4) are connected to an input end thereof, the water filter (7) is connected to an air source filter (2), an air pressure valve (3), an air pressure sensor (4), an air-liquid pump (8), an air-liquid servo valve (9), and a hydraulic control sensor (10) via a pipeline, The measuring and controlling device comprises a data acquisition device (14), the input end of the data acquisition device (14) is connected to a conversion module (15), the conversion module (15) is respectively connected to a stress sensor group (16), a deformation sensor group (17), a temperature sensor group (18), a pressure sensor (19), and a flow meter (20) through data lines, and the output end of the servo controller (11) and the output end of the data acquisition device (14) are connected to a computer (12).

2. According to claim 1, the intelligent measurement and control system for hydraulic pressure test of hydraulic penstock is characterized by: The servo controller (11), the computer (12), and the data acquisition device (14) are connected to an uninterruptible power supply (13) via a power line, and the output pipeline of the gas-liquid servo valve (9) is connected to the pressure sensor (19) and the flow meter (20).

3. According to claim 2, the intelligent measurement and control system for hydraulic pressure test of hydraulic penstock is characterized by: The gas-liquid pump (8) is connected to the gas-liquid servo valve (9) via an air pipe and a water pipe, and the servo controller (11) is connected to the computer (12) via a data line.

4. The intelligent measurement and control system for hydraulic pressure test of hydraulic penstock according to claim 3 is characterized by: The air pump (1) is connected to the air source filter (2) via threads, and the air source filter (2) is connected to the air pressure valve (3) via an air pipe.

5. The method for using the intelligent measurement and control system for hydraulic pressure test of hydraulic penstock according to claim 4 is characterized by: Start the uninterruptible power supply (13) and the computer (12) and open the dedicated software. First, the software automatically detects the current state of the system, then pops up the human-computer dialogue interface, sets the corresponding control parameters, and then sends instructions to the servo controller (11) and the data acquisition instrument (14), and the system enters the working state; The temperature sensor group (18) is placed on the inner wall of the pressure steel pipe (21), the deformation sensor group (17) is placed on the outer wall of the pressure steel pipe (21), the stress sensor group (16) is placed on the inner and outer walls of the pressure steel pipe (21), and the pressure sensor (19) and the flow meter (20) are placed on the water pipe of the pressure steel pipe (21); When the air pressure and water pressure reach the rated value, the air-liquid servo valve (9) provides water pressure to the output end at a set rate, and at the same time the hydraulic control sensor (10) feeds back the water pressure at the output end, controls the output water pressure in real time within the specified error range, and displays it in real time in a graph. When the output water pressure reaches the target value, the output pressure is automatically stabilized; After the loading and stabilizing process is completed, an unloading instruction is issued through the software, and the gas-liquid servo valve (9) unloads the water pressure at the output end to zero at a set rate.

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