Solenoid valve failure monitoring system and method

Abstract

The application provides an electromagnetic valve fault monitoring system and method, and relates to the technical field of fault monitoring.The electromagnetic valve fault monitoring system comprises a medium source, an electromagnetic valve assembly connected with the medium source through a pipeline, a medium flow meter arranged on the pipeline, and a control device connected with the electromagnetic valve assembly and the medium flow meter respectively.During the electromagnetic valve fault monitoring, the control device can acquire the opening and closing state data of the electromagnetic valve assembly within a preset time period and the medium flow data collected by the medium flow meter within the preset time period, and automatically determines the fault monitoring result of the electromagnetic valve assembly according to the opening and closing state data and the medium flow data.Thus, the medium flow data collected by the medium flow meter can be used to monitor whether the electromagnetic valve assembly has a fault electromagnetic valve during the working process of the electromagnetic valve assembly, the online test of the electromagnetic valve during the working process is realized, the test method is simple, the test process does not need manual participation, and the test efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of fault monitoring technology, and in particular to a solenoid valve fault monitoring system and method. Background Technology

[0002] Solenoid valves are electromagnetically controlled industrial devices and fundamental components for fluid control in automation systems. They can be used with various circuits to achieve desired control, ensuring both precision and flexibility. However, solenoid valves are prone to failure in harsh operating environments, and existing fault monitoring methods cannot perform online testing during operation, resulting in low testing efficiency. Summary of the Invention

[0003] The purpose of this invention is to provide a solenoid valve fault monitoring system and method to realize online testing during the operation of solenoid valves and improve testing efficiency.

[0004] In a first aspect, embodiments of the present invention provide a solenoid valve fault monitoring system, comprising:

[0005] Media source;

[0006] The solenoid valve assembly is connected to the medium source via a pipeline, and a medium flow meter is installed on the pipeline.

[0007] The control device is connected to the solenoid valve assembly and the medium flow meter respectively. The control device is used to acquire the on / off status data of the solenoid valve assembly within a preset time period and the medium flow data collected by the medium flow meter within a preset time period, and to determine the fault monitoring results of the solenoid valve assembly based on the on / off status data and the medium flow data.

[0008] Furthermore, the above medium flow rate data are actual medium volume values;

[0009] The aforementioned control equipment is specifically used to: calculate the lower limit and upper limit of the medium volume consumed within a preset time period based on the switch status data; and determine the fault monitoring results of the solenoid valve assembly based on the relationship between the actual medium volume and the lower and upper limits of the medium volume.

[0010] Furthermore, the aforementioned solenoid valve assembly includes multiple solenoid valves, each of which has the same opening duration each time it is opened; the switch status data includes the number of times each solenoid valve is opened within a preset time period.

[0011] The aforementioned control device is also used to: calculate the lower limit and upper limit of the medium volume consumed within a preset time period based on the preset medium volume consumption range for each solenoid valve opening once and the number of times each solenoid valve opens within a preset time period.

[0012] Furthermore, the aforementioned control device is also used to: determine that the solenoid valve assembly is operating normally when the actual medium volume value is between the lower limit and the upper limit of the medium volume; determine that there is a solenoid valve in the solenoid valve assembly that cannot be opened when the actual medium volume value is less than the lower limit of the medium volume; and determine that there is a solenoid valve in the solenoid valve assembly that is continuously spraying when the actual medium volume value is greater than the upper limit of the medium volume.

[0013] Furthermore, the aforementioned control device is also used to: when there is a faulty solenoid valve in the solenoid valve assembly, sequentially control each solenoid valve in the solenoid valve assembly to open a preset number of times, and obtain the corresponding medium volume value collected by the medium flow meter; and determine whether the solenoid valve has malfunctioned based on the corresponding medium volume value of each solenoid valve and the medium volume consumption range when it is opened a preset number of times.

[0014] Furthermore, the aforementioned solenoid valve assembly includes an air solenoid valve, and the medium flow meter is a compressed air flow meter.

[0015] Secondly, embodiments of the present invention also provide a method for monitoring solenoid valve faults, applied to a control device in the solenoid valve fault monitoring system of the first aspect; the method for monitoring solenoid valve faults includes:

[0016] Acquire the on / off status data of the solenoid valve assembly within a preset time period and the medium flow data collected by the medium flow meter within a preset time period;

[0017] Based on the switch status data and medium flow data, the fault monitoring results of the solenoid valve assembly are determined.

[0018] Furthermore, the aforementioned medium flow rate data is the actual medium volume value; the steps for determining the fault monitoring results of the solenoid valve assembly based on the switch status data and medium flow rate data include:

[0019] Based on the switch status data, the lower limit and upper limit of the media volume consumed within the preset time period are calculated.

[0020] The fault monitoring results of the solenoid valve assembly are determined based on the relationship between the actual medium volume value and the lower and upper limits of the medium volume.

[0021] Furthermore, the aforementioned solenoid valve assembly includes multiple solenoid valves, each solenoid valve having the same opening duration each time it is opened; the switch status data includes the number of times each solenoid valve is opened within a preset time period; the step of calculating the lower limit and upper limit of the medium volume consumed within the preset time period based on the switch status data includes:

[0022] Based on the preset range of media volume consumption for each solenoid valve opening once and the preset number of times each solenoid valve opens within a preset time period, the lower limit and upper limit of media volume consumption within the preset time period are calculated.

[0023] Furthermore, the above-mentioned solenoid valve fault monitoring method also includes:

[0024] When there is a faulty solenoid valve in the solenoid valve assembly, each solenoid valve in the solenoid valve assembly is opened a preset number of times in sequence, and the corresponding medium volume value collected by the medium flow meter is obtained.

[0025] Based on the corresponding medium volume value for each solenoid valve and the medium volume consumption range when it is opened a preset number of times, determine whether the solenoid valve has malfunctioned.

[0026] The solenoid valve fault monitoring system and method provided in this invention include: a medium source; a solenoid valve assembly connected to the medium source via a pipeline, on which a medium flow meter is installed; and a control device connected to both the solenoid valve assembly and the medium flow meter. During solenoid valve fault monitoring, the control device acquires the on / off status data of the solenoid valve assembly within a preset time period and the medium flow data collected by the medium flow meter within the same preset time period. Based on the on / off status data and the medium flow data, the control device automatically determines the fault monitoring result of the solenoid valve assembly. This allows for monitoring of whether the solenoid valve assembly is malfunctioning during operation, using the medium flow data collected by the medium flow meter. This achieves online testing during solenoid valve operation, and the testing method is simple, requiring no manual intervention, thus improving testing efficiency. Attached Figure Description

[0027] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the structure of a solenoid valve fault monitoring system provided in an embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram of the electrical connection of a solenoid valve fault monitoring system provided in an embodiment of the present invention;

[0030] Figure 3 A flowchart illustrating a method for monitoring solenoid valve faults according to an embodiment of the present invention;

[0031] Figure 4 This is a flowchart illustrating another method for monitoring solenoid valve faults provided in an embodiment of the present invention.

[0032] Icons: 100 - Medium source; 200 - Solenoid valve assembly; 300 - Piping; 400 - Medium flow meter; 500 - Control equipment. Detailed Implementation

[0033] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] The TDS (Telligent Dry Separator) is equipped with numerous air solenoid valves, which separate different types of materials by blowing compressed air. Because the TDS operates in a harsh environment, and the quality of compressed air on-site often fails to meet the requirements of the solenoid valves, the failure rate of these valves is relatively high.

[0035] Currently, when detecting solenoid valve faults, a pressure sensor is typically installed at the outlet of the solenoid valve. The pressure signal collected by the sensor is processed to obtain the solenoid valve's response characteristics, and the final detection result is then determined manually. However, this solenoid valve fault testing system is complex, cannot perform online testing while the solenoid valve is operating, requires manual intervention, demands a high level of expertise from the operators, and has low testing efficiency. Therefore, this invention provides a solenoid valve fault monitoring system and method. By monitoring the consumption of the medium flowing through the pipeline during solenoid valve operation, it can automatically and promptly detect whether a solenoid valve fault has occurred, achieving online testing during solenoid valve operation and improving testing efficiency.

[0036] It should be noted that the embodiments of the present invention are not limited to the testing of air solenoid valves in TDS, but can also be applied to other types of solenoid valves in other devices, such as gas solenoid valves, liquid solenoid valves, etc.

[0037] To facilitate understanding of this embodiment, a detailed description of a solenoid valve fault monitoring system disclosed in this embodiment of the invention will be provided first.

[0038] See Figure 1 The diagram shows a structural schematic of a solenoid valve fault monitoring system. The solenoid valve fault monitoring system provided in this embodiment of the invention includes:

[0039] Medium source 100;

[0040] The solenoid valve assembly 200 is connected to the medium source 100 through the pipeline 300, and the medium flow meter 400 is installed on the pipeline 300.

[0041] The control device 500 is connected to the solenoid valve assembly 200 and the medium flow meter 400 respectively. The control device 500 is used to acquire the on / off status data of the solenoid valve assembly 200 within a preset time period and the medium flow data collected by the medium flow meter 400 within a preset time period, and to determine the fault monitoring result of the solenoid valve assembly 200 based on the on / off status data and the medium flow data.

[0042] The preset time period can be set in advance according to actual needs. For example, the working time of the solenoid valve fault monitoring system is 8:00-18:00, and the preset time period is the first minute after each hour, including 8:00-8:01, 9:00-9:01, etc.

[0043] The solenoid valve fault monitoring system provided in this embodiment of the invention allows the control device 500 to acquire the on / off status data of the solenoid valve assembly 200 within a preset time period and the medium flow data collected by the medium flow meter 400 within the same preset time period during solenoid valve fault monitoring. Based on the on / off status data and the medium flow data, the system automatically determines the fault monitoring result of the solenoid valve assembly 200. This enables monitoring of whether a solenoid valve assembly has malfunctioned during operation using the medium flow data collected by the medium flow meter, achieving online testing of the solenoid valve during operation. Furthermore, the testing method is simple, the testing process requires no manual intervention, and thus improves testing efficiency.

[0044] In some possible embodiments, considering that the volume of medium consumed by each solenoid valve during a certain period of time is usually within a certain range, the above-mentioned medium flow data is the actual medium volume value. The control device 500 is specifically used to: calculate the lower limit value and the upper limit value of the medium volume consumed within a preset time period based on the switch status data; and determine the fault monitoring result of the solenoid valve assembly 200 based on the relationship between the actual medium volume value and the lower limit value and the upper limit value.

[0045] In specific implementation, the control device 500 can determine the fault monitoring results of the solenoid valve assembly 200 in the following ways: when the actual medium volume value is between the lower limit and the upper limit of the medium volume, the solenoid valve assembly 200 is determined to be operating normally; when the actual medium volume value is less than the lower limit of the medium volume, it is determined that there is a solenoid valve in the solenoid valve assembly 200 that cannot be opened; when the actual medium volume value is greater than the upper limit of the medium volume, it is determined that there is a solenoid valve in the solenoid valve assembly 200 that is continuously spraying (i.e., a solenoid valve that cannot be closed). Both the solenoid valve that cannot be opened and the solenoid valve that cannot be closed are faulty solenoid valves.

[0046] The aforementioned solenoid valve assembly 200 may include one or more solenoid valves, which may be, but are not limited to, air solenoid valves. An air solenoid valve is a valve driven by compressed air. During operation, the air solenoid valve provides compressed air within a certain pressure range; that is, compressed air flows through pipeline 300. When an air solenoid valve is used, the medium flow meter 400 is a compressed air flow meter.

[0047] See Figure 2 The diagram shows the electrical connection of a solenoid valve fault monitoring system. The solenoid valve assembly 200 may include multiple solenoid valves. During operation, the control device 500 can control the opening duration of each solenoid valve by a given pulse signal.

[0048] Considering that devices such as TDS require multiple solenoid valves, the opening duration of the solenoid valves at fixed positions on each device is fixed, meaning that the opening duration of each solenoid valve is the same each time it is opened. Therefore, it is only necessary to count the number of times each solenoid valve is opened within a preset time period. Based on this, the control device 500 can also sum the counts within the preset time period based on the recorded on / off states of different solenoid valves at different times to obtain the number of times each solenoid valve is opened within the preset time period. That is, the aforementioned on / off state data can include the number of times each solenoid valve is opened within the preset time period. In this case, the control device 500 is also used to: calculate the lower limit and upper limit of the media volume consumed within the preset time period based on the preset media volume consumption range for each solenoid valve opening once and the number of times each solenoid valve is opened within the preset time period. The media volume consumption range for each solenoid valve opening once can be obtained through actual testing; the media volume consumption range for different solenoid valves opening once may be the same or different.

[0049] Furthermore, the solenoid valve fault monitoring system provided in this embodiment of the invention can also identify solenoid valves that are abnormal or faulty (i.e., faulty solenoid valves) during solenoid valve troubleshooting and periodic inspection. Specifically, the control device 500 is also used to: when there is a faulty solenoid valve in the solenoid valve assembly 200, sequentially control each solenoid valve in the solenoid valve assembly 200 to open a preset number of times, and obtain the corresponding medium volume value collected by the medium flow meter 400; based on the corresponding medium volume value of each solenoid valve and the medium volume consumption range when it is opened a preset number of times, determine whether the solenoid valve has malfunctioned. The preset number can be set according to actual needs and is not limited here.

[0050] To facilitate understanding, the following example of testing an air solenoid valve in a TDS system will be used to illustrate the specific workflow of the aforementioned solenoid valve fault monitoring system:

[0051] The opening duration of a single solenoid valve in the solenoid valve assembly 200 is defined as T. iA single solenoid valve opens T i Over a given period of time, the amount (volume) of compressed air consumed is affected by the compressed air pressure. The range of compressed air volume consumption is defined as V. i1 ~V i2 (Under standard conditions). In actual operation, the number of solenoid valves opened at any given time varies. The control device 500 obtains the number of times N different solenoid valves are opened within time period j. j i This allows us to calculate the total gas consumption range of n solenoid valves within time period j: That is, the lower limit and upper limit of the media volume consumed within time period j are respectively

[0052] A compressed air flow meter is installed on pipeline 300 to collect the actual volume of compressed air consumed within time period j, which is V. j ,contrast and V j The size, if This indicates that all solenoid valves in the solenoid valve assembly 200 are operating normally; if... This indicates that there is a non-opening solenoid valve in the solenoid valve assembly 200; if this occurs... This indicates that there is a continuous injection solenoid valve in the solenoid valve assembly 200.

[0053] During the troubleshooting process, each solenoid valve in the solenoid valve assembly 200 was blown out sequentially. Each solenoid valve was opened k times. The amount of compressed air consumed by opening a single solenoid valve k times is: kV i1 ~kV i2 The compressed air consumption collected by the compressed air flow meter is V. n测 Comparison of kV i1 ~kV i2 and V n测 The size, if kV i1 ≤V n测 ≤kV i2 If V appears, it indicates that the solenoid valve is operating normally; if V appears... n测 <kV i1 If V appears, it means the solenoid valve cannot be opened; n测 >kV i2 If this is the case, it indicates that the solenoid valve is continuously spraying. This allows you to locate all faulty solenoid valves.

[0054] In this embodiment of the invention, by monitoring compressed air consumption, it is possible to promptly detect whether a solenoid valve is malfunctioning. Furthermore, during troubleshooting and periodic inspections of the solenoid valve, the faulty solenoid valve can be located. This solenoid valve fault monitoring system can monitor for faulty solenoid valves during operation and can also perform troubleshooting procedures.

[0055] This invention also provides a method for monitoring solenoid valve faults. This method is applied to the control equipment in the aforementioned solenoid valve fault monitoring system. See [link to relevant documentation]. Figure 3 The diagram shows a flowchart of a solenoid valve fault monitoring method, which mainly includes the following steps:

[0056] Step S302: Obtain the on / off status data of the solenoid valve assembly within a preset time period and the medium flow data collected by the medium flow meter within a preset time period.

[0057] Step S304: Determine the fault monitoring results of the solenoid valve assembly based on the switch status data and medium flow data.

[0058] The solenoid valve fault monitoring method provided in this invention allows the control device to acquire the on / off status data of the solenoid valve assembly within a preset time period and the medium flow data collected by the medium flow meter within the same preset time period during solenoid valve fault monitoring. Based on the on / off status data and the medium flow data, the fault monitoring result of the solenoid valve assembly is automatically determined. This enables online testing of the solenoid valve during operation, using the medium flow data collected by the medium flow meter to monitor whether a fault has occurred in the solenoid valve assembly. The testing method is simple, requires no manual intervention, and improves testing efficiency.

[0059] Furthermore, the aforementioned medium flow rate data can be the actual medium volume value. The solenoid valve assembly includes multiple solenoid valves, see [link to documentation]. Figure 4 The diagram shows another method for monitoring solenoid valve faults, which includes the following steps:

[0060] Step S402: Obtain the on / off status data of the solenoid valve assembly within a preset time period and the actual medium volume value collected by the medium flow meter within the preset time period.

[0061] Step S404: Based on the switch status data, calculate the lower limit and upper limit of the medium volume consumed within the preset time period.

[0062] In some possible embodiments, the opening duration of each solenoid valve is the same each time it is opened, and the switch status data includes the number of times each solenoid valve is opened within a preset time period; based on this, step S404 can be implemented by the following process: according to the preset medium volume consumption range for each solenoid valve opening once and the number of times each solenoid valve is opened within the preset time period, the lower limit value and the upper limit value of the medium volume consumed within the preset time period are calculated.

[0063] Step S406: Determine the fault monitoring result of the solenoid valve assembly based on the relationship between the actual medium volume value and the lower and upper limits of the medium volume.

[0064] Step S408: When there is a faulty solenoid valve in the solenoid valve assembly, each solenoid valve in the solenoid valve assembly is opened a preset number of times in sequence, and the corresponding medium volume value collected by the medium flow meter is obtained.

[0065] Step S410: Based on the corresponding medium volume value for each solenoid valve and the medium volume consumption range when it is opened a preset number of times, determine whether the solenoid valve has malfunctioned.

[0066] The solenoid valve fault monitoring method provided in this embodiment has the same implementation principle and technical effect as the aforementioned solenoid valve fault monitoring system embodiment. For the sake of brevity, any parts not mentioned in the embodiment of the solenoid valve fault monitoring method can be referred to the corresponding content in the aforementioned embodiment of the solenoid valve fault monitoring system.

[0067] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0068] Furthermore, in the description of the embodiments of the present invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention based on the specific circumstances.

[0069] In the description of this invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0070] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A solenoid valve fault monitoring system, characterized in that, include: Media source; The solenoid valve assembly is connected to the medium source via a pipeline, and a medium flow meter is installed on the pipeline. A control device is connected to the solenoid valve assembly and the medium flow meter respectively. The control device is used to acquire the on / off status data of the solenoid valve assembly within a preset time period and the medium flow data collected by the medium flow meter within the preset time period during the normal operation of the solenoid valve assembly, and to determine the fault monitoring result of the solenoid valve assembly based on the on / off status data and the medium flow data. The medium flow rate data is the actual medium volume value; the solenoid valve assembly includes multiple solenoid valves, and each solenoid valve has the same opening duration each time it is opened; the switch status data includes the number of times each solenoid valve is opened within the preset time period; The control device is specifically used to: calculate the lower limit and upper limit of the medium volume consumed in the preset time period based on the preset medium volume consumption range for each solenoid valve opening once and the number of times each solenoid valve is opened in the preset time period. The fault monitoring result of the solenoid valve assembly is determined based on the relationship between the actual medium volume value and the lower and upper limits of the medium volume.

2. The solenoid valve fault monitoring system according to claim 1, characterized in that, The control device is also used to: determine that the solenoid valve assembly is operating normally when the actual medium volume value is between the lower limit value of the medium volume and the upper limit value of the medium volume; When the actual medium volume value is less than the lower limit value of the medium volume, it is determined that there is a solenoid valve in the solenoid valve assembly that cannot be opened; When the actual medium volume value is greater than the upper limit value of the medium volume, it is determined that the solenoid valve assembly has a solenoid valve that continuously sprays.

3. The solenoid valve fault monitoring system according to claim 1, characterized in that, The control device is further configured to: when there is a faulty solenoid valve in the solenoid valve assembly, sequentially control each solenoid valve in the solenoid valve assembly to open a preset number of times, and obtain the corresponding medium volume value collected by the medium flow meter; and determine whether the solenoid valve has malfunctioned based on the corresponding medium volume value of each solenoid valve and the medium volume consumption range when it is opened the preset number of times.

4. The solenoid valve fault monitoring system according to any one of claims 1-3, characterized in that, The solenoid valve assembly includes an air solenoid valve, and the medium flow meter is a compressed air flow meter.

5. A method for monitoring solenoid valve faults, characterized in that, A control device applied to the solenoid valve fault monitoring system according to any one of claims 1-4; The solenoid valve fault monitoring method includes: During the normal operation of the solenoid valve assembly, the on / off status data of the solenoid valve assembly within a preset time period and the medium flow data collected by the medium flow meter within the preset time period are acquired. Based on the switch status data and the medium flow data, determine the fault monitoring results of the solenoid valve assembly; The medium flow rate data is the actual medium volume value; the solenoid valve assembly includes multiple solenoid valves, each solenoid valve having the same opening duration each time it is opened; the switch status data includes the number of times each solenoid valve is opened within the preset time period; the step of determining the fault monitoring result of the solenoid valve assembly based on the switch status data and the medium flow rate data includes: Based on the preset range of medium volume consumption for each solenoid valve opening once and the number of times each solenoid valve opens within the preset time period, the lower limit and upper limit of the medium volume consumed within the preset time period are calculated. The fault monitoring result of the solenoid valve assembly is determined based on the relationship between the actual medium volume value and the lower and upper limits of the medium volume.

6. The solenoid valve fault monitoring method according to claim 5, characterized in that, The solenoid valve fault monitoring method also includes: When a faulty solenoid valve exists in the solenoid valve assembly, each solenoid valve in the solenoid valve assembly is sequentially controlled to open a preset number of times, and the corresponding medium volume value collected by the medium flow meter is obtained. Based on the corresponding medium volume value for each solenoid valve and the medium volume consumption range when it is opened a preset number of times, it is determined whether the solenoid valve has malfunctioned.

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