Low pressure loss electro-hydraulic proportional flow detection and control integrated unit

Abstract

The present application relates to a kind of hydraulic control valves, specifically, a kind of low pressure loss electro-hydraulic proportional flow detection and control integrated unit, comprising: main valve, flow sensor, energy recovery unit, multifunctional valve controller, cloud storage, import cavity pressure sensor, outlet cavity pressure sensor, temperature sensor;The present application is based on pilot flow closed-loop control, combined with main valve flow amplification principle, is not influenced by load variation and continuously controls main valve flow.In the basis of low pressure loss, wide flow range flow control valve, detect real-time information such as pressure, flow, power and energy, the above data can be uploaded to cloud by Ethernet interface, realize big data accumulation.Fault prediction module can use system key parameters to carry out fault diagnosis and residual life prediction, and optimize hydraulic system control method.The present application has the advantages of flow detection and control integration, small valve port pressure loss, real-time display and storage hydraulic system parameters, fault diagnosis and residual life prediction.

Description

Technical Field

[0001] This invention relates to a hydraulic control valve, specifically to a low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit that integrates flow detection and control, and can perform real-time status monitoring, fault diagnosis, and remaining life prediction. Background Technology

[0002] Flow valves are core control components in hydraulic transmission and are widely used in various types of critical equipment. They are crucial for achieving automation and intelligence in such equipment, and their core function is high-precision flow control at the valve orifice. Current flow valves control flow by installing a differential pressure compensator in the main flow channel of a proportional throttle valve to maintain a relatively constant pressure difference between the inlet and outlet of the main valve. The oil undergoes secondary throttling through the main valve and the differential pressure compensator, increasing the valve's throttling losses and reducing its flow capacity. Furthermore, the compensator's accuracy is affected by steady-state hydrodynamic forces. This type of valve suffers from large differential pressure losses and significant dynamic flow overshoot.

[0003] Reducing energy consumption in hydraulic systems and achieving closed-loop flow control are inseparable from flow measurement. Theoretically, if a sensor similar to a pressure sensor existed—easy to install and capable of high-precision, high-dynamic flow detection—high-precision closed-loop flow control could be achieved, unaffected by load pressure changes. However, existing flow sensors struggle to accurately measure flow and can only measure static flow, not real-time flow. Furthermore, flow sensors require series connection in the pipeline, resulting in significant losses, high costs, and operational difficulties. In closed-loop flow control, if any sensor fails, the entire system will cease operation.

[0004] Existing electro-hydraulic proportional valves have low levels of intelligence, lacking the ability to learn and adapt to changes in load, environment, and their own characteristics. Furthermore, they cannot predict valve health or diagnose faults, relying solely on post-accident repairs, leading to safety incidents and economic losses. In addition, the failure to utilize historical data for analysis, calculation, comparison, and decision-making results in resource waste and low valve control accuracy. Summary of the Invention

[0005] The purpose of this invention is to provide a low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit. It uses an active flow sensor and a proportional pilot valve together as the pilot stage. The pilot flow is amplified by the principle of main valve flow amplification. It does not require a differential pressure compensator to be installed on the main valve and can continuously control the main valve flow regardless of load changes. It can monitor the pressure, flow, power, energy and other data of various parts of the valve in real time. All of the above data can be uploaded to the cloud via Ethernet interface to achieve big data accumulation. It can also use valve status parameters for fault diagnosis and remaining life prediction.

[0006] To achieve the above objectives, the present invention provides a low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit, including: a main valve 1, and additionally equipped with a flow sensor 12, an energy recovery unit 13, a multi-functional valve controller 21, a cloud storage 30, an inlet pressure sensor 31, an outlet pressure sensor 32, and a temperature sensor 33.

[0007] The main valve 1 includes a main valve sleeve 2, a main valve core 3, a main valve spring 4, a main valve inlet A, a main valve outlet B, and a main valve control chamber X; the inlet pressure sensor 31 is connected to the main valve inlet A and outputs the main valve inlet pressure signal. p A The outlet pressure sensor 32 is connected to the main valve outlet port B and outputs the main valve outlet pressure signal. p B Temperature sensor 33 is connected to the main valve outlet port B and outputs the main valve outlet temperature signal. T ;

[0008] The flow sensor inlet C is connected to the main valve control chamber X, and the flow sensor outlet D is connected to the main valve outlet B; the flow sensor 12 outputs a flow sensor signal. q b Connect to the input terminal of signal processing module 22;

[0009] The energy recovery unit 13 includes a coupling 14, a motor / generator 15, a speed sensor 16, a motor speed controller 17, a power supply 18, a DC-DC converter 19, and a supercapacitor bank 20. One end of the coupling 14 is connected to the output shaft of the motor / generator 15, and the other end is connected to the flow sensor 12. The speed sensor 16 is connected to the motor / generator 15 and outputs a motor speed signal. n The output of power supply 18 is connected to motor speed controller 17, and the output of motor speed controller 17 is connected to the input of motor / generator 15 to control motor speed; the input of DC-DC converter 19 is connected to motor speed controller 17, and the output of DC-DC converter 19 is connected to supercapacitor bank 20.

[0010] The multi-functional valve controller 21 includes a signal processing module 22, a parameter calculation module 23, an integration module 24, a data storage module 25, a control module 26, a display module 27, a fault prediction module 28, and a communication interaction module 29; inlet pressure signal p A Oral pressure signal p B Flow sensor signal q b Speed ​​sensor signal n Temperature sensor signal TThe signal processing module 22 is connected to its input terminal, and its output terminal is connected to the input terminal of the parameter calculation module 23 and the data storage module 25. The parameter calculation module 23 calculates the main valve flow rate. q Δ pressure difference between main valve inlet and outlet p Main valve input power P 1. Main valve output power P 2. Power loss due to throttling of the main valve P 3. Inputs are sent to the integration module 24 input terminal and the data storage module 25;

[0011] The integrator module 24 calculates the input energy of the main valve. E 1. Main valve output energy E 2. Energy consumption due to throttling of the main valve E 3. Main valve efficiency or The data is input to the data storage module 25, which is connected to the input terminals of the control module 26, display module 27, fault prediction module 28, and communication interaction module 29 via a bidirectional data bus.

[0012] The control module 26 calculates the speed setting signal. n s The speed setting signal is connected to the motor speed controller 17;

[0013] The output of the communication interaction module 29 is connected to the cloud storage 30.

[0014] The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit is characterized in that it further includes a proportional pilot valve 5, which includes a pilot valve spring 6, a pilot valve core 7, a proportional electromagnet 8, a proportional amplifier 9, a displacement sensor 10, a flow controller 11, a pilot valve inlet G, and a pilot valve outlet F; the flow controller receives a flow setting signal. q s and flow feedback signal q f The output of the flow controller is connected to the input of the proportional amplifier 9. The displacement sensor 10 detects the displacement of the pilot valve core 7 and outputs a pilot valve displacement signal. y The output of proportional amplifier 9 is connected to the feedback terminal of proportional amplifier 9 and the output terminal of proportional amplifier 9 is connected to proportional electromagnet 8.

[0015] The flow sensor inlet C is connected to the main valve control chamber X, and the flow sensor outlet D is connected to the pilot valve inlet G. The pilot valve outlet F is connected to the main valve outlet B. The flow sensor 12 outputs a flow sensor signal. q b Connect to the input terminal of signal processing module 22.

[0016] The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit is characterized in that the flow sensor 12 is a gear flow meter, or a miniature plunger pump / motor, or other form of volumetric flow meter.

[0017] The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit is characterized in that the flow sensor 12 is connected between the main valve control chamber X and the proportional pilot valve inlet G, or between the proportional pilot valve outlet F and the main valve outlet B; when the flow sensor 12 is connected between the proportional pilot valve outlet F and the main valve outlet B, the main valve control chamber X is connected to the pilot valve inlet G, the pilot valve outlet F is connected to the flow sensor inlet C, and the flow sensor outlet D is connected to the main valve outlet B.

[0018] The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit is characterized in that the electric motor / generator 15 operates in torque control mode or speed control mode.

[0019] The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit is characterized in that the parameter calculation module 23 calculates the following parameters according to the calculation formulas (1), (2), (3), (4), and (5):

[0020] Main valve flow (1)

[0021] Pressure difference between main valve inlet and outlet (2)

[0022] Main valve input power (3)

[0023] Main valve output power (4)

[0024] Main valve throttling loss power (5);

[0025] In the formula, g (x) is the flow amplification factor.

[0026] The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit is characterized in that the parameter calculation module 23 calculates the following parameters according to the calculation formulas (1), (2), (3), (4), (5), and (6):

[0027] Main valve flow (1)

[0028] Pressure difference between main valve inlet and outlet (2)

[0029] Main valve input power (3)

[0030] Main valve output power (4)

[0031] Main valve throttling loss power (5)

[0032] Flow feedback signal (6);

[0033] In the formula, g (x) is the flow amplification factor.

[0034] The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit is characterized in that the integral module calculates the following parameters by integrating formulas (7), (8), (9), and (10):

[0035] Main valve input energy (7)

[0036] Main valve output energy (8)

[0037] Main valve throttling energy loss (9)

[0038] Main valve efficiency (10).

[0039] The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit is characterized in that the fault prediction module 28 predicts the main valve input power based on the stored data. P 1. Main valve input energy E 1. Main valve inlet pressure p A Main valve outlet pressure p B Signals enable proactive maintenance and fault diagnosis of the integrated unit; once the accumulated energy reaches the fault alarm threshold... g y The system will proactively perform detection and maintenance, utilizing expert knowledge and an expert database to identify fault characteristics and causes, accurately locate faults, analyze fault diagnosis results, and predict valve lifespan.

[0040] The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit is characterized in that its working process includes the following steps:

[0041] Step 1: If the present invention has an energy recovery unit and a proportional pilot valve, then the inlet pressure signal is collected by each sensor. p A Oral pressure signal p B Flow sensor signalq b Displacement sensor signal y Speed ​​sensor signal n Temperature sensor signal T If the present invention has an energy recovery unit but no proportional pilot valve, then the inlet pressure signal is collected by each sensor. p A Oral pressure signal p B Flow sensor signal q b Speed ​​sensor signal n Temperature sensor signal T If the present invention does not have an energy recovery unit but has a proportional pilot valve, then the inlet pressure signal is collected by each sensor. p A Oral pressure signal p B Flow sensor signal q b Displacement sensor signal y Temperature sensor signal T Each signal is input to the signal processing module;

[0042] Step 2: After signal processing, the signal is input into the parameter calculation module to obtain the main valve flow rate according to formula (1). q The pressure difference between the inlet and outlet of the main valve is obtained according to formula (2). ∆p The main valve input power is obtained according to formula (3). P 1. Obtain the main valve output power according to formula (4) P 2. Obtain the main valve throttling loss power according to formula (5). P 3. Obtain the flow feedback signal according to formula (6) q f If the present invention includes a proportional pilot valve, the flow feedback signal... q f Input is sent to the feedback terminal of the flow controller;

[0043] Step 3: The main valve input power calculated in Step 2 P 1. Main valve output power P 2. Power loss due to throttling of the main valve P 3. The input energy is fed into the integration module, and the main valve input energy is obtained according to formula (7). E 1. Obtain the valve output energy according to formula (8) E 2. Obtain the throttling loss energy consumption according to formula (9) E 3. Obtain the valve efficiency according to formula (10) or ;

[0044] Step 4: All signals obtained in Steps 1, 2, and 3 are input into the data storage module for storage;

[0045] Step 5: The data storage module is connected to the input terminals of the control module, display module, fault prediction module, and communication interaction module via a bidirectional data bus; if the present invention has a proportional pilot valve, the control module outputs a flow setting signal. q s The signal is sent to the input terminal of the flow controller; if the invention includes an energy recovery unit, the control module outputs a speed setting signal. n s Connected to the motor speed controller; the display module visualizes the information in the data storage module, displaying various status curves in real time; the fault prediction module detects faults exceeding the alarm threshold. g y The system generates alarms based on parameter signals, performs proactive maintenance and fault location, and predicts valve lifespan. The communication and interaction module receives data output from the data storage module and uploads the data to the cloud storage via Ethernet, Industrial Internet, or Bluetooth.

[0046] Compared with the prior art, the present invention has the following beneficial effects:

[0047] (1) This invention can detect and control the actuator flow with high precision without installing a flow sensor in the main oil circuit of the hydraulic system. It solves the problems of existing flow sensors being unable to control flow in a closed loop, high cost, difficult installation, and large pressure loss. The flow control valve also has the function of a flow sensor, realizing the integration of flow detection and control.

[0048] (2) This invention does not require a pressure compensator. By controlling the pilot valve flow through closed-loop control and amplifying it through the main valve, the main valve flow can be continuously controlled without being affected by load changes. It has high control accuracy and low pressure loss.

[0049] (3) The present invention can monitor the flow rate, power, energy, efficiency and other information of each part of the hydraulic system in real time, and can store and upload them to the cloud in real time. In contrast, it is not convenient to obtain power and energy information in the existing hydraulic system, which lays the foundation for further optimization of system energy efficiency.

[0050] (4) By real-time monitoring and analysis of power and energy information, the present invention can perform proactive maintenance and fault diagnosis on the life cycle of the control valve, and realize the status monitoring, life prediction and fault location of key components of the control valve. Attached Figure Description

[0051] Figure 1 A schematic diagram of the structural principle of an embodiment of a low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit;

[0052] Figure 2Structural principle diagram of Embodiment 2 of the low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit;

[0053] Figure 3 This is a flowchart of the workflow of the present invention.

[0054] In the diagram: 1—Main valve, 2—Main valve sleeve, 3—Main valve core, 4—Main valve spring, 5—Proportional pilot valve, 6—Pilot valve spring, 7—Pilot valve core, 8—Proportional electromagnet, 9—Proportional amplifier, 10—Displacement sensor, 11—Flow controller, 12—Flow sensor, 13—Energy recovery unit, 14—Coupling, 15—Electric motor / generator, 16—Speed ​​sensor, 17—Motor speed controller, 18—Power supply, 19—DC-DC converter, 20—Supercapacitor bank, 21—Multi-functional valve controller, 22—Signal processing module, 23—Parameter calculation module, 24—Integration module, 25—Data storage module, 26—Control module, 27—Display module, 28—Fault prediction module, 29—Communication interaction module, 30—Cloud storage, 31—Inlet pressure sensor, 32—Outlet pressure sensor, 33—Temperature sensor.

[0055] A—Main valve inlet, B—Main valve outlet, X—Main valve control chamber, C—Flow sensor inlet, D—Flow sensor outlet, G—Pilot valve inlet, F—Pilot valve outlet. Detailed Implementation

[0056] The meanings of the parameters in the instruction manual are as follows:

[0057] p A —In-oral pressure signal, p B —Out-of-mouth pressure signal, q b —Flow sensor signal, T— Valve outlet mouth temperature, q s —Flow setting signal, q f —Flow feedback signal, y— Pilot valve displacement signal n s —Speed ​​setting signal n— Motor speed signal, g (x) — Flow amplification factor, q —Main valve flow rate, ∆ p —Pressure difference between inlet and outlet of main valve, P 1—Main valve input power, P 2—Main valve output power, P 3—Main valve throttling loss power, E 1—Main valve input energy,E 2—Main valve output energy, E 3—Main valve throttling loss and energy consumption or —Main valve efficiency, g y —Fault alarm threshold, k —Flow feedback gain.

[0058] Example 1:

[0059] like Figure 1 As shown, a low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit is adopted, which uses a proportional pilot valve and an active flow sensor for redundant control. The proportional pilot valve and the active flow sensor together serve as the pilot stage to control the pilot stage flow.

[0060] The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit includes: a main valve 1, a proportional pilot valve 5, and further adds a flow sensor 12, an energy recovery unit 13, a multi-functional valve controller 21, an inlet pressure sensor 31, an outlet pressure sensor 32, and a temperature sensor 33.

[0061] The main valve 1 includes a main valve sleeve 2, a main valve core 3, a main valve spring 4, a main valve inlet A, a main valve outlet B, and a main valve control chamber X; the inlet pressure sensor 31 is connected to the main valve inlet A and outputs the main valve inlet pressure signal. p A The outlet pressure sensor 32 is connected to the main valve outlet port B and outputs the main valve outlet pressure signal. p B Temperature sensor 33 is connected to the main valve outlet port B and outputs the main valve outlet temperature signal. T .

[0062] The proportional pilot valve 5 includes a pilot valve spring 6, a pilot valve core 7, a proportional electromagnet 8, a proportional amplifier 9, a displacement sensor 10, a flow controller 11, a pilot valve inlet G, and a pilot valve outlet F; the flow controller 11 receives the flow setting signal. q s and flow feedback signal q f The output of the flow controller is connected to the input of the proportional amplifier 9. The displacement sensor 10 detects the displacement of the pilot valve core 7 and outputs a pilot valve displacement signal. y The signal is directed to the feedback terminal of proportional amplifier 9, and the output terminal of proportional amplifier 9 is connected to proportional electromagnet 8.

[0063] The flow sensor inlet C is connected to the main valve control chamber X, the flow sensor outlet D is connected to the pilot valve inlet G, and the pilot valve outlet F is connected to the main valve outlet B; the flow sensor 12 outputs a flow sensor signal. q bConnect to the input terminal of signal processing module 22.

[0064] Energy recovery unit 13 includes a coupling 14, an electric motor / generator 15, a speed sensor 16, a motor speed controller 17, a power supply 18, a DC-DC converter 19, and a supercapacitor bank 20; one end of the coupling 14 is connected to the output shaft of the electric motor / generator 15, and the other end is connected to the flow sensor 12; the speed sensor 16 is connected to the electric motor / generator 15 and outputs a motor speed signal. n The output of power supply 18 is connected to motor speed controller 17, and the output of motor speed controller 17 is connected to the input of motor / generator 15 to control motor speed; the input of DC-DC converter 19 is connected to motor speed controller 17, and the output of DC-DC converter 19 is connected to supercapacitor bank 20.

[0065] The multi-functional valve controller 21 includes a signal processing module 22, a parameter calculation module 23, an integration module 24, a data storage module 25, a control module 26, a display module 27, a fault prediction module 28, and a communication interaction module 29; inlet pressure signal p A Oral pressure signal p B Flow sensor signal q b Displacement sensor signal y Speed ​​sensor signal n Temperature sensor signal T The signal processing module 22 is connected to its input terminal, and its output terminal is connected to the input terminal of the parameter calculation module 23 and the data storage module 25. The parameter calculation module 23 calculates the main valve flow rate. q Flow feedback signal q f Δ pressure difference between main valve inlet and outlet p Main valve input power P 1. Main valve output power P 2. Power loss due to throttling of the main valve P 3. The input is fed into the integration module 24 and the data storage module 25. The parameter calculation module 23 then feeds back the calculated flow rate signal. q f The input is sent to the feedback terminal of flow controller 11.

[0066] Integrator module 24 calculates the input energy of the main valve. E 1. Main valve output energy E 2. Energy consumption due to throttling of the main valve E 3. Main valve efficiency orThe data is input to the data storage module 25, which is connected to the input terminals of the control module 26, display module 27, fault prediction module 28, and communication interaction module 29 via a bidirectional data bus.

[0067] Control module 26 calculates the flow rate setting signal q s and speed setting signal n s The flow setting signal is connected to the input terminal of the flow controller 11, and the speed setting signal is connected to the motor speed controller 17.

[0068] The output of the communication interaction module 29 is connected to the cloud storage 30.

[0069] The flow sensor 12 is a gear flow meter, or a miniature plunger pump / motor, or other form of positive displacement flow meter.

[0070] Flow sensor 12 except Figure 1 In addition to the connection shown, it can also be connected between the proportional pilot valve outlet F and the main valve outlet B. When the flow sensor 12 is connected between the proportional pilot valve outlet F and the main valve outlet B, the main valve control chamber X is connected to the pilot valve inlet G, the pilot valve outlet F is connected to the flow sensor inlet C, and the flow sensor outlet D is connected to the main valve outlet B.

[0071] The electric motor / generator 15 operates in torque control mode or speed control mode.

[0072] The parameter calculation module 23 calculates the following parameters based on the calculation formulas (1), (2), (3), (4), (5), and (6):

[0073] Main valve flow (1)

[0074] Pressure difference between main valve inlet and outlet (2)

[0075] Main valve input power (3)

[0076] Main valve output power (4)

[0077] Main valve throttling loss power (5)

[0078] Flow feedback signal (6).

[0079] The integration module calculates the following parameters by integrating using formulas (7), (8), (9), and (10):

[0080] Main valve input energy (7)

[0081] Main valve output energy (8)

[0082] Main valve throttling energy loss (9)

[0083] Main valve efficiency (10).

[0084] The display module 27 can display information stored in the data storage module 25 via a program, including real-time display of valve inlet pressure. p A Valve outlet pressure p B Pilot valve displacement signal y Motor speed n Valve outlet temperature T Main valve flow rate q Main valve input power P 1. Main valve output power P 2. Power loss due to throttling of the main valve P 3. Main valve input energy E 1. Main valve output energy E 2. Energy consumption due to throttling of the main valve E 3. Main valve efficiency or Dynamic signal curves with equal state parameters.

[0085] The fault prediction module 28 predicts the main valve input power based on the stored power. P 1. Main valve input energy E 1. Main valve inlet pressure p A Main valve outlet pressure p B Signals enable proactive maintenance and fault diagnosis of the integrated unit; once the accumulated energy reaches the fault alarm threshold... g y The system will proactively perform detection and maintenance, utilizing expert knowledge and an expert database to identify fault characteristics and causes, accurately locate faults, analyze fault diagnosis results, and predict valve lifespan.

[0086] The communication interaction module 29 is Ethernet, Industrial Internet or Bluetooth, and transmits the data stored in the data storage module 25 to the cloud storage 30.

[0087] The working process of this invention includes the following steps:

[0088] Step 1: Each sensor collects the pressure signal entering the oral cavity. pA Oral pressure signal p B Flow sensor signal q b Displacement sensor signal y Speed ​​sensor signal n Temperature sensor signal T The signal is input to the signal processing module.

[0089] Step 2: After signal processing, the signal is input into the parameter calculation module to obtain the main valve flow rate according to formula (1). q The pressure difference between the inlet and outlet of the main valve is obtained according to formula (2). ∆p The main valve input power is obtained according to formula (3). P 1. Obtain the main valve output power according to formula (4) P 2. Obtain the main valve throttling loss power according to formula (5). P 3. Obtain the flow feedback signal according to formula (6) q f Flow feedback signal q f The input is sent to the feedback terminal of the flow controller.

[0090] Step 3: The main valve input power calculated in Step 2 P 1. Main valve output power P 2. Power loss due to throttling of the main valve P 3. The input energy is fed into the integration module, and the main valve input energy is obtained according to formula (7). E 1. Obtain the valve output energy according to formula (8) E 2. Obtain the throttling loss energy consumption according to formula (9) E 3. Obtain the valve efficiency according to formula (10) or .

[0091] Step 4: All signals obtained in Steps 1, 2, and 3 are input into the data storage module for storage.

[0092] Step 5: The data storage module is connected to the input terminals of the control module, display module, fault prediction module, and communication interaction module via a bidirectional data bus; the control module outputs a flow rate setting signal. q s The speed setting signal is output from the input terminal of the flow controller. n s Connected to the motor speed controller. The display module visualizes the information in the data storage module, displaying various status curves in real time. The fault prediction module detects faults exceeding alarm thresholds. g yThe system generates alarms based on parameter signals, enabling proactive maintenance, fault location, and valve life prediction. The communication module receives data from the data storage module and uploads it to cloud storage via Ethernet, Industrial Internet, or Bluetooth.

[0093] Example 2:

[0094] like Figure 2 As shown, the difference between this embodiment and Embodiment 1 is that the low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit adopts a separate control structure for the flow sensor 12, with the active flow sensor acting as a separate pilot stage to control the pilot stage flow. It includes: a main valve 1, a proportional pilot valve 5, and further adds a flow sensor 12, an energy recovery unit 13, a multi-functional valve controller 21, a cloud storage 30, an inlet pressure sensor 31, an outlet pressure sensor 32, and a temperature sensor 33.

[0095] The main valve 1 includes a main valve sleeve 2, a main valve core 3, a main valve spring 4, a main valve inlet A, a main valve outlet B, and a main valve control chamber X; the inlet pressure sensor 31 is connected to the main valve inlet A and outputs the main valve inlet pressure signal. p A The outlet pressure sensor 32 is connected to the main valve outlet port B and outputs the main valve outlet pressure signal. p B Temperature sensor 33 is connected to the main valve outlet port B and outputs the main valve outlet temperature signal. T .

[0096] The flow sensor inlet C is connected to the main valve control chamber X, and the flow sensor outlet D is connected to the main valve outlet B; the flow sensor 12 outputs a flow sensor signal. q b Connect to the input terminal of signal processing module 22.

[0097] Energy recovery unit 13 includes a coupling 14, an electric motor / generator 15, a speed sensor 16, a motor speed controller 17, a power supply 18, a DC-DC converter 19, and a supercapacitor bank 20; one end of the coupling 14 is connected to the output shaft of the electric motor / generator 15, and the other end is connected to the flow sensor 12; the speed sensor 16 is connected to the electric motor / generator 15 and outputs a motor speed signal. n The output of power supply 18 is connected to motor speed controller 17, and the output of motor speed controller 17 is connected to the input of motor / generator 15 to control motor speed; the input of DC-DC converter 19 is connected to motor speed controller 17, and the output of DC-DC converter 19 is connected to supercapacitor bank 20.

[0098] The multi-functional valve controller 21 includes a signal processing module 22, a parameter calculation module 23, an integration module 24, a data storage module 25, a control module 26, a display module 27, a fault prediction module 28, and a communication interaction module 29; inlet pressure signal p A Oral pressure signal p B Flow sensor signal q b Speed ​​sensor signal n Temperature sensor signal T The signal processing module 22 is connected to its input terminal, and its output terminal is connected to the input terminal of the parameter calculation module 23 and the data storage module 25. The parameter calculation module 23 calculates the main valve flow rate. q Δ pressure difference between main valve inlet and outlet p Main valve input power P 1. Main valve output power P 2. Power loss due to throttling of the main valve P 3. Input to the integration module 24 and the data storage module 25.

[0099] Integrator module 24 calculates the input energy of the main valve. E 1. Main valve output energy E 2. Energy consumption due to throttling of the main valve E 3. Main valve efficiency or The data is input to the data storage module 25, which is connected to the input terminals of the control module 26, display module 27, fault prediction module 28, and communication interaction module 29 via a bidirectional data bus.

[0100] Control module 26 calculates the speed setting signal n s The speed setting signal is connected to the motor speed controller 17.

[0101] The output of the communication interaction module 29 is connected to the cloud storage 30.

[0102] The flow sensor 12 can be a gear flow meter, a miniature plunger pump / motor, or other types of positive displacement flow meter.

[0103] The electric motor / generator 15 can operate in either torque control mode or speed control mode.

[0104] The parameter calculation module 23 calculates the following parameters based on the calculation formulas (1), (2), (3), (4), and (5):

[0105] Main valve flow (1)

[0106] Pressure difference between main valve inlet and outlet (2)

[0107] Main valve input power (3)

[0108] Main valve output power (4)

[0109] Main valve throttling loss power (5).

[0110] The integration module calculates the following parameters by integrating using formulas (7), (8), (9), and (10):

[0111] Main valve input energy (7)

[0112] Main valve output energy (8)

[0113] Main valve throttling energy loss (9)

[0114] Main valve efficiency (10).

[0115] The display module 27 can display information stored in the data storage module 25 via a program, including real-time display of valve inlet pressure. p A Valve outlet pressure p B Motor speed n Valve outlet temperature T Main valve flow rate q Main valve input power P 1. Main valve output power P 2. Power loss due to throttling of the main valve P 3. Main valve input energy E 1. Main valve output energy E 2. Energy consumption due to throttling of the main valve E 3. Main valve efficiency or Dynamic signal curves with equal state parameters.

[0116] The fault prediction module 28 predicts the main valve input power based on the stored data. P 1. Main valve input energy E 1. Main valve inlet pressure p A Main valve outlet pressure p B Signals enable proactive maintenance and fault diagnosis of the integrated unit; once the accumulated energy reaches the fault alarm threshold... g yThe system will proactively perform detection and maintenance, utilizing expert knowledge and an expert database to identify fault characteristics and causes, accurately locate faults, analyze fault diagnosis results, and predict valve lifespan.

[0117] The communication interaction module 29 uses Ethernet, Industrial Internet, or Bluetooth to transmit the data stored in the data storage module 25 to the cloud storage 30.

[0118] The working process of this invention includes the following steps:

[0119] Step 1: Each sensor collects the pressure signal entering the oral cavity. p A Oral pressure signal p B Flow sensor signal q b Speed ​​sensor signal n Temperature sensor signal T The signal is input to the signal processing module.

[0120] Step 2: After signal processing, the signal is input into the parameter calculation module to obtain the main valve flow rate according to formula (1). q The pressure difference between the inlet and outlet of the main valve is obtained according to formula (2). ∆p The main valve input power is obtained according to formula (3). P 1. Obtain the main valve output power according to formula (4) P 2. Obtain the main valve throttling loss power according to formula (5). P 3.

[0121] Step 3: The main valve input power calculated in Step 2 P 1. Main valve output power P 2. Power loss due to throttling of the main valve P 3. The input energy is fed into the integration module, and the main valve input energy is obtained according to formula (7). E 1. Obtain the valve output energy according to formula (8) E 2. Obtain the throttling loss energy consumption according to formula (9) E 3. Obtain the valve efficiency according to formula (10) or .

[0122] Step 4: All signals obtained in Steps 1, 2, and 3 are input into the data storage module for storage.

[0123] Step 5: The data storage module is connected to the input terminals of the control module, display module, fault prediction module, and communication interaction module via a bidirectional data bus; the control module outputs the speed setting signal. n sConnected to the motor speed controller. The display module visualizes the information in the data storage module, displaying various status curves in real time. The fault prediction module detects faults exceeding alarm thresholds. g y The system generates alarms based on parameter signals, enabling proactive maintenance, fault location, and valve life prediction. The communication module receives data from the data storage module and uploads it to cloud storage via Ethernet, Industrial Internet, or Bluetooth.

Claims

1. A low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit, comprising a main valve (1), characterized in that, Add a flow sensor (12), an energy recovery unit (13), a multi-functional valve controller (21), a cloud storage (30), an inlet oral pressure sensor (31), an outlet oral pressure sensor (32), and a temperature sensor (33). The main valve (1) includes a main valve sleeve (2), a main valve core (3), a main valve spring (4), a main valve inlet (A), a main valve outlet (B), and a main valve control chamber (X); the inlet pressure sensor (31) is connected to the main valve inlet (A) and outputs the main valve inlet pressure signal. p A The outlet pressure sensor (32) is connected to the main valve outlet (B) and outputs the main valve outlet pressure signal. p B The temperature sensor (33) is connected to the oil outlet (B) of the main valve and outputs the temperature signal of the main valve outlet. T ; The flow sensor inlet (C) is connected to the main valve control chamber (X), and the flow sensor outlet (D) is connected to the main valve outlet (B); the flow sensor (12) outputs a flow sensor signal. q b Connect to the input terminal of the signal processing module (22); The energy recovery unit (13) includes a coupling (14), an electric motor / generator (15), a speed sensor (16), a motor speed controller (17), a power supply (18), a DC-DC converter (19), and a supercapacitor bank (20). One end of the coupling (14) is connected to the output shaft of the electric motor / generator (15), and the other end is connected to the flow sensor (12). The speed sensor (16) is connected to the electric motor / generator (15) and outputs a motor speed signal. n The output of the power supply (18) is connected to the motor speed controller (17), and the output of the motor speed controller (17) is connected to the input of the electric motor / generator (15) to control the motor speed. The input terminal of the DC-DC converter (19) is connected to the motor speed controller (17), and the output terminal of the DC-DC converter (19) is connected to the supercapacitor bank (20). The multi-functional valve controller (21) includes a signal processing module (22), a parameter calculation module (23), an integration module (24), a data storage module (25), a control module (26), a display module (27), a fault prediction module (28), and a communication interaction module (29); inlet pressure signal p A Oral pressure signal p B Flow sensor signal q b Speed ​​sensor signal n Temperature sensor signal T The signal processing module (22) is connected to the input terminal of the signal processing module (22), and the output terminal of the signal processing module (22) is connected to the input terminal of the parameter calculation module (23) and the data storage module (25). The parameter calculation module (23) calculates the main valve flow rate. q Δ pressure difference between main valve inlet and outlet p Main valve input power P 1. Main valve output power P 2. Power loss due to throttling of the main valve P 3. Input to the integration module (24) input terminal and data storage module (25); The integrator module (24) calculates the main valve input energy. E 1. Main valve output energy E 2. Energy consumption due to throttling of the main valve E 3. Main valve efficiency η The data is input to the data storage module (25), which is connected to the input terminals of the control module (26), display module (27), fault prediction module (28), and communication interaction module (29) via a bidirectional data bus. The control module (26) calculates the speed setting signal. n s The speed setting signal is connected to the motor speed controller (17). The output of the communication interaction module (29) is connected to the cloud storage (30). The parameter calculation module (23) calculates the following parameters according to the calculation formulas (1), (2), (3), (4), (5), and (6): Main valve flow (1) Pressure difference between main valve inlet and outlet (2) Main valve input power (3) Main valve output power (4) Main valve throttling loss power (5) Flow feedback signal (6); In the formula, g (x) is the flow amplification factor; The integration module calculates the following parameters by integrating using formulas (7), (8), (9), and (10): Main valve input energy (7) Main valve output energy (8) Main valve throttling energy loss (9) Main valve efficiency (10).

2. The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit as described in claim 1, characterized in that, It also includes a proportional pilot valve (5), which comprises a pilot valve spring (6), a pilot valve core (7), a proportional electromagnet (8), a proportional amplifier (9), a displacement sensor (10), a flow controller (11), a pilot valve inlet (G), and a pilot valve outlet (F); the flow controller receives a flow setting signal. q s and flow feedback signal q f The output of the flow controller is connected to the input of the proportional amplifier (9), and the displacement sensor (10) detects the displacement of the pilot valve core (7) and outputs the pilot valve displacement signal. y The output of the proportional amplifier (9) is connected to the proportional electromagnet (8). The flow sensor inlet (C) is connected to the main valve control chamber (X), the flow sensor outlet (D) is connected to the pilot valve inlet (G), and the pilot valve outlet (F) is connected to the main valve outlet (B); the flow sensor (12) outputs a flow sensor signal. q b Connect to the input terminal of the signal processing module (22).

3. The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit as described in claim 1 or 2, characterized in that, The flow sensor (12) is a gear flow meter, or a miniature plunger pump / motor, or other form of volumetric flow meter.

4. The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit as described in claim 2, characterized in that, The flow sensor (12) is connected between the main valve control chamber (X) and the proportional pilot valve inlet (G), or between the proportional pilot valve outlet (F) and the main valve outlet (B). When the flow sensor (12) is connected between the proportional pilot valve outlet (F) and the main valve outlet (B), the main valve control chamber (X) is connected to the pilot valve inlet (G), the pilot valve outlet (F) is connected to the flow sensor inlet (C), and the flow sensor outlet (D) is connected to the main valve outlet (B).

5. The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit as described in claim 1 or 2, characterized in that: The electric motor / generator (15) operates in torque control mode or speed control mode.

6. The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit as described in claim 1 or 2, characterized in that: The fault prediction module (28) is based on the stored main valve input power. P 1. Main valve input energy E 1. Main valve inlet pressure p A Main valve outlet pressure p B Signals enable proactive maintenance and fault diagnosis of the integrated unit; once the accumulated energy reaches the fault alarm threshold... g y The system will proactively perform detection and maintenance, utilizing expert knowledge and an expert database to identify fault characteristics and causes, accurately locate faults, analyze fault diagnosis results, and predict valve lifespan.

7. The low-pressure-loss electro-hydraulic proportional flow detection and control integrated unit as described in claim 2, characterized in that, The work process includes the following steps: Step 1: If there is an energy recovery unit and a proportional pilot valve, the inlet pressure signal is collected by each sensor. p A Oral pressure signal p B Flow sensor signal q b Displacement sensor signal y Speed ​​sensor signal n Temperature sensor signal T If there is an energy recovery unit but no proportional pilot valve, the inlet pressure signal is collected by each sensor. p A Oral pressure signal p B Flow sensor signal q b Speed ​​sensor signal n Temperature sensor signal T If there is no energy recovery unit but a proportional pilot valve, the inlet pressure signal is collected by each sensor. p A Oral pressure signal p B Flow sensor signal q b Displacement sensor signal y Temperature sensor signal T Each signal is input to the signal processing module; Step 2: After signal processing, the signal is input into the parameter calculation module to obtain the main valve flow rate according to formula (1). q The pressure difference between the inlet and outlet of the main valve is obtained according to formula (2). ∆p The main valve input power is obtained according to formula (3). P 1. Obtain the main valve output power according to formula (4) P 2. Obtain the main valve throttling loss power according to formula (5). P 3. Obtain the flow feedback signal according to formula (6) q f ; If a proportional pilot valve is present, the flow feedback signal q f Input is sent to the feedback terminal of the flow controller; Step 3: The main valve input power calculated in Step 2 P 1. Main valve output power P 2. Power loss due to throttling of the main valve P 3. The input energy is fed into the integration module, and the main valve input energy is obtained according to formula (7). E 1. Obtain the valve output energy according to formula (8) E 2. Obtain the throttling loss energy consumption according to formula (9) E 3. Obtain the valve efficiency according to formula (10) η ; Step 4: All signals obtained in Steps 1, 2, and 3 are input into the data storage module for storage; Step 5: The data storage module is connected to the input terminals of the control module, display module, fault prediction module, and communication interaction module via a bidirectional data bus; if a proportional pilot valve is present, the control module outputs a flow setting signal. q s The signal is sent to the input terminal of the flow controller; if an energy recovery unit is present, the control module outputs a speed setting signal. n s Connected to the motor speed controller; the display module visualizes the information in the data storage module, displaying various status curves in real time; the fault prediction module detects faults exceeding the alarm threshold. g y The system generates alarms based on parameter signals, performs proactive maintenance and fault location, and predicts valve lifespan. The communication and interaction module receives data output from the data storage module and uploads the data to the cloud storage via Ethernet, Industrial Internet, or Bluetooth.

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