A portable intelligent terminal for electrically operated valves

Abstract

A portable intelligent terminal of an electric valve is connected with a driver of the electric valve in wired or wireless mode to remotely operate and control the electric valve, comprising a shell and a main controller, a memory, a communication module and an input / output module arranged in the shell, the memory, the communication module and the input / output module are connected with the main controller, the main controller divides a control process of the electric valve into multiple control units, sets operation conditions, inflection points and parameters of each control unit according to different types of the electric valve and corresponding control decision items, generates a general control mode for full-process control of the electric valve under multiple types and multiple working conditions; when a trigger condition is met, an adaptive optimal control method and / or a control curve are generated according to different application requirements of the electric valve, and are bound with the corresponding electric valve, the general control mode is converted into a special matching mode for the specific electric valve, and is used for full-process control of the specific electric valve.

Description

Technical Field

[0001] This invention relates to valve actuation technology, and in particular to a portable intelligent terminal for electric valves that is simple in structure, reliable in function, and highly adaptable to the environment. Background Technology

[0002] Currently, many valve actuators use AC asynchronous motors that are directly started by a power source. The motor drives a mechanical transmission mechanism to operate the valve, thus opening or closing it. However, existing technologies lack remote control devices that can perform equipment data management functions such as equipment status recording and storage, preventative maintenance reminders, data communication, fault diagnosis, and human-machine interface, while also being highly adaptable to various environments. Furthermore, they fail to provide a more user-friendly human-machine interface and lack corresponding expansion capabilities, resulting in low equipment management efficiency, high operating costs, and an inability to meet the requirements of digital factories. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a portable intelligent terminal for electric valves, addressing the above-mentioned deficiencies of the prior art.

[0004] To achieve the above objectives, the present invention provides a portable intelligent terminal for an electric valve, wherein the terminal is wired or wirelessly connected to the actuator of the electric valve for remote operation and control of the electric valve. The portable intelligent terminal includes:

[0005] case;

[0006] The main controller, located inside the housing, is used for remote control of the electric valves. It establishes control decision items for the electric valves according to the different types and working requirements of various electric valves.

[0007] The memory, located inside the housing and connected to the main controller, contains a database of various electric valves and is classified and stored according to the different structural characteristics, operating conditions and usage requirements of the various electric valves.

[0008] A communication module, located inside the housing and connected to the main controller, is used to connect the actuator of the electric valve via wired or wireless means and to exchange data.

[0009] An input / output module is disposed inside the housing and connected to the main controller, and is used for human-machine interaction and remote control operation;

[0010] The main controller divides the control process of the electric valve into multiple control units. Based on the type of each electric valve and the corresponding control decision items, it sets the operating conditions, inflection points, and parameters of each control unit and generates a general control mode for electric valve control with full-process control requirements for multiple types and multiple working conditions. When the triggering conditions are met, it generates the best control method and / or control curve corresponding to different electric valve application requirements and binds it to the corresponding electric valve. The general control mode is converted into a special matching mode for the specific electric valve and used for the full-process control of that specific electric valve.

[0011] The portable smart terminal for the aforementioned electric valve includes a memory that is also used to record operating data during connection with the actuator of the electric valve, and stores it locally in the form of a data file containing time nodes for querying by local or remote network sites.

[0012] The aforementioned portable intelligent terminal for electric valves includes a database of multiple electric valves, which summarizes and establishes an electric valve execution process data structure covering the multiple electric valves based on valve control principles and in combination with their structural characteristics, operating conditions, and working strategies.

[0013] The aforementioned portable intelligent terminal for electric valves further includes an LCD screen and / or a keyboard disposed on the surface of the housing, which are respectively connected to the input / output module. The LCD screen is used for visual monitoring of the control process, and the monitoring information is displayed in the human-machine interface of the LCD screen as a real-time curve or bar chart. The keyboard enables remote control operation of the electric valve through physical or virtual buttons.

[0014] The aforementioned portable intelligent terminal for electric valves includes operating conditions such as switching and / or throttling; the multiple control units include a starting unit, an acceleration unit, a constant speed unit, a deceleration unit, an approximation unit, a torque control unit, and / or a stopping unit; and the control decision items include a precision priority strategy, a safety priority strategy, and / or an efficiency priority strategy.

[0015] The portable intelligent terminal for the aforementioned electric valve includes operating conditions for the starting unit, acceleration unit, constant speed unit, deceleration unit, and approximation unit, respectively, including direction and position judgment. If the movement direction is the valve opening direction and the current position of the valve plate has exceeded the valve opening limit position, operation is stopped directly; if the movement direction is the valve closing direction and the current position of the valve plate has exceeded the valve closing limit position, operation is switched to the torque control unit; and / or, both the approximation unit and the torque control unit have a disable judgment in their operating conditions; if so, operation is switched directly to the next control unit; and / or Alternatively, the starting unit, acceleration unit, constant speed unit, and deceleration unit may each be equipped with a stop judgment in their operating conditions. If the starting unit times out, it will directly jump to the stop unit; if the motor torque exceeds the acceleration torque limit or the acceleration times out in the acceleration unit, it will directly jump to the stop unit; if the valve plate position exceeds the constant speed limit or the motor torque exceeds the constant speed torque limit in the constant speed unit, it will directly jump to the stop unit; if the motor torque exceeds the deceleration torque limit or the deceleration times out in the deceleration unit, it will directly jump to the stop unit.

[0016] The portable intelligent terminal for the aforementioned electric valve includes control units with inflection points such as start-up inflection points, acceleration inflection points, constant speed inflection points, deceleration inflection points, approach inflection points, torque control inflection points, and / or stop inflection points set for each control unit. When an inflection point is determined to be true, the system moves from the current control unit to the next control unit. Control ends when the stop inflection point occurs.

[0017] The aforementioned portable intelligent terminal for electric valves, wherein the main controller takes the set parameters and inflection points of each stage of the bound electric valve as input, and correspondingly takes the real-time speed, valve stroke and / or real-time torque of the bound electric valve as feedback, and uses a PID control algorithm to make real-time corrections to the speed, torque and / or position parameters of the corresponding control unit to meet the response speed and control accuracy requirements of each stage of the valve control process.

[0018] The aforementioned portable intelligent terminal for electric valves uses a torque sensor or a vector transformation method combined with an output current detection circuit to obtain the real-time torque, thereby making immediate corrections to the output torque and improving torque accuracy through parameter identification and torque calibration.

[0019] The portable intelligent terminal for the aforementioned electric valve includes a central controller that is also used to detect sudden changes in the stroke of the electric valve, abnormal operating torque, and / or loss of sensor signals, and to provide preventative maintenance prompts after determining the conditions according to the preset criteria, so as to avoid damage to the electric valve; at the same time, it synchronously records the actuator fault information of the electric valve and provides diagnostic information prompts to assist in confirming and troubleshooting the fault.

[0020] The technical advantages of this invention are as follows:

[0021] This invention features a simple structure, reliable function, and strong environmental adaptability. In addition to basic functions such as parameter setting, torque calibration, and operational status monitoring, it also enables equipment data management functions including equipment status recording and storage, preventative maintenance reminders, data communication, fault diagnosis, and a human-machine interface, providing a more user-friendly interface and enhanced scalability. A single portable intelligent terminal can support multiple electric valve actuators, facilitating convenient and quick data communication between the field and the actuators. It adapts to the requirements of digital factories, improving equipment management efficiency and reducing operating costs.

[0022] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the present invention. Attached Figure Description

[0023] Figure 1 This is a structural block diagram of an embodiment of the present invention;

[0024] Figure 2 This is a schematic diagram of a human-computer interaction interface according to an embodiment of the present invention;

[0025] Figure 3 This is a schematic diagram of the valve closing parameter setting interface according to an embodiment of the present invention;

[0026] Figure 4 This is a schematic diagram of the valve opening parameter setting interface according to an embodiment of the present invention;

[0027] Figure 5 This is a schematic diagram of a real-time curve according to an embodiment of the present invention;

[0028] Figure 6 This is a schematic diagram of a real-time curve according to another embodiment of the present invention.

[0029] Among them, the attached figures are labeled

[0030] 1. Motor speed line

[0031] 2 Valve Plate Position Line

[0032] 3 Motor Torque Line Detailed Implementation

[0033] The structural and working principles of the present invention will be described in detail below with reference to the accompanying drawings:

[0034] The portable intelligent terminal for electric valves of the present invention is used for valve control of various types and requirements. It can perform system parameter setting, status monitoring, information storage, and alarm prompts. It has functions such as equipment operation, parameter setting, torque calibration, operating status monitoring, curve display, and historical query. It is suitable for on / off and / or throttling conditions. It can be used for valve intermediate position positioning in throttling conditions and for valve on / off control in on / off conditions. The portable intelligent terminal is wired or wirelessly connected to the driver or actuator of the electric valve. The electric valve can be remotely controlled by physical or virtual buttons set on the portable intelligent terminal.

[0035] See Figure 1 , Figure 1 This is a structural block diagram of an embodiment of the present invention. The portable smart terminal includes:

[0036] case;

[0037] The main controller, located inside the housing, is used for remote control of the electric valves. It establishes corresponding control decision items for various electric valves based on their different types and operating requirements. As the control core, it connects and schedules modules such as display, sound, keyboard, storage, communication, and external interfaces to complete data acquisition, processing, display, and sending of operation commands.

[0038] A memory, housed within the housing and connected to the main controller, contains a database of various electric valves. These valves are categorized and stored according to their structural characteristics, operating conditions, and usage requirements. This database includes a data structure summarizing and covering the execution process of various electric valves based on valve control principles, their structural characteristics, operating conditions, and working strategies. The data hierarchy can be divided according to valve type, execution strategy, execution stage, and stage parameters. Differences in valve type and applied execution strategies are also reflected in this data structure. For example, if there is no torque control stage during intermediate position control, the "effective" parameter setting for the torque control unit should be "no." The difference between the precision-priority strategy and the safety-priority strategy for gate valves is that the execution rate of each stage in the safety-priority strategy is slower, and the protective torque is reduced; therefore, their corresponding parameters are different. The various electric valves in this embodiment include gate valves, globe valves, butterfly valves, ball valves, plug valves, knife gate valves, and / or dampers.

[0039] The memory is also used to record operating data during connection with the actuator of the electric valve, and store it locally in the form of a data file containing time nodes for querying by local or remote network sites;

[0040] A communication module, housed within the housing and connected to the main controller, is used for wired or wireless connection to the actuator of the electric valve and for data exchange. This module may include Bluetooth, infrared, serial, and near-field communication modules, etc.

[0041] An input / output module is housed within the casing and connected to the main controller, used for human-machine interaction and remote control operation;

[0042] The main controller divides the control process of the electric valve into multiple control units. Based on the type of electric valve and the corresponding control decision items, it sets the operating conditions, inflection points, and parameters for each control unit. It then generates a general control mode encompassing communication, display, I / O connection, and drive control, for controlling electric valves with diverse types and operating conditions requiring full-process control. When trigger conditions are met, it generates an optimal control method and / or control curve tailored to different electric valve application requirements, and binds it to the corresponding electric valve. The general control mode is then converted into a dedicated matching mode for the specific electric valve, used for its full-process control. In other words, the portable intelligent terminal has a general control mode and a dedicated matching mode. A general control mode is pre-modeled and generated, applicable to multiple types and requirements of valve control. Then, based on different valve types and usage requirements, it is converted into a specific dedicated matching mode according to set conditions and bound to that specific valve for its dedicated control.

[0043] See Figures 2-4 , Figure 2 This is a schematic diagram of a human-computer interaction interface according to an embodiment of the present invention. Figure 3 This is a schematic diagram of the valve closing parameter setting interface according to an embodiment of the present invention. Figure 4 This is a schematic diagram of the valve opening parameter setting interface according to an embodiment of the present invention. In this embodiment, it also includes a liquid crystal display screen and / or a keyboard (including a touch keyboard and a physical keyboard) disposed on the surface of the housing, respectively connected to the input / output module. The liquid crystal display screen is used for visual monitoring of the control process; monitoring information is displayed in the human-machine interface of the liquid crystal display screen in the form of real-time curves or bar charts, providing a more user-friendly and convenient data display. The keyboard enables remote control operation of the electric valve through physical or virtual buttons. It may also include a graphic code recognition module, a power management module, and a built-in battery. The speed and torque-related parameters in the interface parameters are divided into two sets for selection: "valve actuator-oriented" and "motor-oriented." Switching between the two sets of parameters is controlled by the "parameter switching" button on the "main interface," and is automatically calculated based on parameters such as the "reduction ratio," "transmission efficiency," and "pitch" of the transmission device. For example: the jamming torque of the electric valve actuator = motor jamming torque × reduction ratio × transmission efficiency.

[0044] The operating conditions include switching operating conditions and / or throttling operating conditions; the multiple control units include a starting unit, an acceleration unit, a constant speed unit, a deceleration unit, an approximation unit, a torque control unit, and / or a stopping unit; the control decision items include a precision priority strategy, a safety priority strategy, and / or an efficiency priority strategy. In this embodiment, the operating conditions of the starting unit, acceleration unit, constant speed unit, deceleration unit, and approximation unit respectively include direction and position judgment. If the movement direction is the valve opening direction and the current position of the valve plate has exceeded the valve opening limit position, the operation is stopped directly. If the movement direction is the valve closing direction and the current position of the valve plate has exceeded the valve closing limit position, the operation jumps to the torque control unit. And / or, the operating conditions of the approximation unit and the torque control unit are both equipped with a disable judgment. If so, the operation jumps directly to the next control unit. And / or, the operating conditions of the starting unit, acceleration unit, constant speed unit, and deceleration unit are respectively equipped with a stop judgment. If the starting unit times out, the operation jumps directly to the stop unit. If the motor torque in the acceleration unit exceeds the acceleration torque limit value or the acceleration times out, the operation jumps directly to the stop unit. If the valve plate position in the constant speed unit exceeds the constant speed limit position or the motor torque exceeds the constant speed torque limit value, the operation jumps directly to the stop unit. If the motor torque in the deceleration unit exceeds the deceleration torque limit value or the deceleration times out, the operation jumps directly to the stop unit.

[0045] The inflection points of the control unit include start-up inflection points, acceleration inflection points, constant speed inflection points, deceleration inflection points, approach inflection points, torque control inflection points, and / or stop inflection points set for each control unit. When an inflection point is determined, the system moves from the current control unit to the next control unit. Control ends when a stop inflection point occurs. The start-up inflection point occurs when the current speed of the electric valve's drive motor is greater than or equal to the set start-up speed; the acceleration inflection point occurs when the current speed of the drive motor is greater than or equal to a set percentage of the set constant speed; the constant speed inflection point occurs when the current stroke of the electric valve is greater than or equal to the set stroke; the deceleration inflection point occurs when the current speed of the drive motor is less than or equal to the set approach speed; the approach inflection point occurs when the current torque of the electric valve's drive motor is greater than or equal to the set torque; the torque control inflection point occurs when the torque holding time of the electric valve is greater than or equal to the set holding time; and the stop inflection point occurs when the current speed of the electric valve is 0, ending the intermediate position positioning control of the electric valve.

[0046] In throttling operations, taking a gate valve as an example, before the command is executed for intermediate position positioning, information including valve type, execution strategy, execution stages, and parameters for each stage is read and applied to the intermediate position positioning process. This generates and binds the optimal control method and / or control curve suitable for the gate valve's throttling condition, which is then used for the intermediate position positioning control of that gate valve. This can also be applied to the intermediate position positioning process of gate valves under similar conditions in the future. Specifically, this can include: a starting stage, where high torque is used to overcome static friction to initiate the intermediate position positioning; this stage ends after the actual speed reaches the starting speed, and the acceleration stage begins; in the acceleration stage, high torque, high speed, and uniform acceleration are used to quickly and accurately bring the valve plate to the set speed, after which the constant speed stage begins; in the constant speed stage, high speed is used to achieve efficient positioning, and a reasonable protective torque is used to monitor for blockages; in the deceleration stage, high torque and uniform deceleration are used to quickly and accurately bring the valve plate down to the approach speed; in the approach stage, the valve plate moves at low speed and searches for the stopping position. After accurately reaching the stopping position, the electric valve's actuator stops outputting, and the intermediate position positioning process ends. The valve intermediate position positioning control process can also be used for valve opening and closing processes.

[0047] See Figure 5 , Figure 5 This is a schematic diagram of real-time curves according to an embodiment of the present invention. The diagram shows the motor speed line 1, valve plate position line 2, and motor torque line 3 during the gate valve opening control process. In the opening and closing operation, taking a gate valve as an example, before the valve opening command is executed, data including valve type, execution strategy, each execution stage, control unit, and corresponding parameter data for each stage are read. The valve opening control method and / or control curve are generated and bound, and used for the valve opening control of this specific valve. It can also be applied to the valve opening process of electric valves of the same type and under the same operating conditions in the future. Figure 5 In the starting phase, a large torque is used to overcome static friction to start the valve opening. This phase ends after the actual speed reaches the starting speed, and the acceleration phase begins. In the acceleration phase, a large torque, high speed, and uniform acceleration are used to make the valve plate quickly and accurately reach the set speed. In the uniform speed phase, a high speed is used to achieve efficient valve opening, and a reasonable protective torque is used to monitor for blockage. In the deceleration phase, a large torque and uniform deceleration are used to make the valve plate quickly and accurately descend to the approach speed. In the approach phase, the valve plate moves at a low speed until it accurately reaches the fully open position of the valve, and the valve opening process ends.

[0048] See Figure 6 , Figure 6 This is a schematic diagram of real-time curves according to another embodiment of the present invention. The diagram shows the motor speed line 1, valve plate position line 2, and motor torque line 3 during the gate valve closing control process in real time. Figure 6As shown, before executing the valve closing command, the system reads data including valve type, execution strategy, execution stages, control unit, and corresponding parameter data for each stage, generates and binds the optimal closing control method and / or control curve suitable for the gate valve, and uses it for the closing control of the gate valve. It can also be applied to the valve closing process of gate valves of the same type and under the same working conditions in the future. Figure 6 In the starting phase, a large torque is used to overcome static friction to initiate valve closure. This phase ends once the actual speed reaches the starting speed, and the acceleration phase begins. During the acceleration phase, a large torque, high speed, and uniform acceleration are used to quickly and accurately bring the valve plate to the set speed. In the constant speed phase, high speed is used to achieve efficient shut-off, and a reasonable protective torque is used to monitor for blockages. In the deceleration phase, a large torque and uniform deceleration enable the valve plate to quickly and accurately descend to the approach speed. In the approach phase, the valve plate moves at a low speed and searches for the contact position between the valve plate and the sealing surface. After the torque reaches the limit value, the torque control phase begins. During the torque control phase, the valve plate maintains the set torque to accurately establish the sealing pressure. In the stopping phase, the sealing pressure has been established, the electric valve actuator stops outputting, and the valve closing process ends.

[0049] In this embodiment, the main controller also takes the set parameters and inflection points of each stage of the bound electric valve as input (which may include the starting stage, acceleration stage, constant speed stage, deceleration stage, approach stage, torque control stage, and / or stopping stage, setting specific parameters and inflection points for acceleration time, deceleration time, torque, speed, and / or stroke for each stage, such as setting starting speed, constant speed, stroke, approach speed, torque, and / or holding time, etc.), and correspondingly uses the real-time speed, valve stroke, and / or real-time torque of the bound electric valve as feedback. A PID control algorithm is used to instantly correct the speed, torque, and / or position parameters of the corresponding control unit to meet the response speed and control accuracy requirements of each stage of the valve control process. Preferably, a torque sensor is used or the real-time torque is obtained through an output current detection circuit combined with a vector transformation method to instantly correct the output torque, and parameter identification and torque calibration are used to improve torque accuracy.

[0050] The central controller in this embodiment is also used to detect sudden changes in the stroke of the electric valve, abnormal working torque, and / or loss of sensor signals, and after determining the condition according to the set condition logic, to provide preventive maintenance prompts through its own alarm or information reminders from a portable smart terminal, so as to avoid more serious damage to the electric valve; at the same time, it synchronously records the actuator fault information of the electric valve, and provides necessary diagnostic information prompts according to the set logic to assist in confirming and eliminating the fault.

[0051] This invention allows for control strategy switching by adjusting the priority and ratio of parameters such as torque, acceleration, speed, start and end positions at each stage of the operation logic. This multi-mode control strategy switching reduces the power requirements of AC asynchronous motors for valves of the same specifications, thereby reducing the size, weight, energy consumption, noise, heat generation, and electromagnetic interference of the electric valve actuator. In use, with the appropriate setting permissions, a portable smart terminal is connected to the corresponding electric valve actuator. After inputting the corresponding parameters through the human-machine interface, these settings are written to the corresponding storage area of ​​the electric valve actuator's logic control module or vector frequency converter control module via wireless or wired communication.

[0052] When selecting a precision-priority strategy, options include prioritizing positional accuracy and torque accuracy. The key is to avoid mechanical shocks, ensure precise switching positions for each control unit, and maintain smooth transitions between stages. Prioritizing positional accuracy ensures accurate valve opening / closing positions and intermediate positions during throttling. Besides reducing the approach speed to improve positional accuracy, a position closed loop can be used to correct the stop position. Prioritizing torque accuracy primarily aims to achieve precise sealing pressure at valve closure by increasing the accuracy of the closing torque, ensuring no valve leakage. In addition to reducing the approach speed to improve torque accuracy, a torque closed loop and torque calibration are used to correct the stop torque. This embodiment preferably employs a three-loop control system (torque, speed, and position closed-loop control; if hardware limitations exist, torque and speed two-loop control can also be used) throughout the entire process to ensure position accuracy and real-time performance. The acceleration and deceleration times are appropriately extended, or the acceleration and deceleration curves are optimized (e.g., changing from linear acceleration / deceleration to curved acceleration / deceleration, with options including S-curves, sine curves, or exponential curves) to avoid mechanical shock. Torque vector control is used, supplemented by parameter identification and torque calibration methods to improve torque accuracy, ensuring accurate control of the stopping position. Speed, torque, and position parameters are set according to actual needs, and upper limits are set to ensure system safety. Preferably, the acceleration, deceleration, and stopping units use three-loop control and S-shaped acceleration / deceleration curves to improve stopping position accuracy and reduce mechanical shock.

[0053] When selecting a safety-first strategy, priorities may include valve safety, pipeline safety, and pipeline system stability. For example, if pipeline safety is prioritized, water hammer must be controlled / eliminated to ensure pipeline safety. Based on the characteristics of the pipeline network, the stroke of the deceleration and approximation units can be increased, and the speed of the approximation unit can be reduced to control / eliminate water hammer and prevent pipeline damage. This can be achieved by analyzing and identifying pipeline characteristics and water hammer fluctuation patterns to obtain boundary conditions for water hammer control, and by controlling / eliminating water hammer through parameters such as the start time and deceleration of the deceleration and approximation units. Valve and pipeline safety can be effectively controlled by matching the operating parameters of the AC asynchronous motor, effectively controlling the movement speed and acceleration of the valve plate or gate to avoid impact damage caused by dynamic loads. It also controls the fluid medium velocity changes to prevent water hammer impact damage to valves and pipelines. This can be achieved by reducing the acceleration and speed setpoints at each stage of the AC asynchronous motor's full stroke; reducing the maximum torque setpoint of the AC asynchronous motor; and increasing the distance between the deceleration inflection point and the valve closing / opening stop point.

[0054] Prioritizing pipeline system stability requires avoiding mechanical shocks during execution, ensuring precise inflection point switching positions for each control unit, and smooth transitions between stages. Simultaneously, effective fault prediction is crucial to extend the pipeline system's lifespan and ensure safe operation. Therefore, a three-loop control system (torque, speed, and position) can be employed throughout the control process or at a preferred stopping unit. If hardware limitations exist, a two-loop control system (torque and speed) can be used to ensure accurate valve stopping positions. Appropriately extending acceleration / deceleration times or optimizing acceleration / deceleration curves, such as changing from linear to curvilinear acceleration / deceleration (selectable curves include S-curves, sine curves, or exponential curves), can mitigate mechanical shocks. Using torque vector control, supplemented by parameter identification and torque calibration methods, improves torque accuracy to ensure precise stopping position control. Continuous monitoring effectively identifies faults such as overcurrent, overvoltage, undervoltage, phase loss, overtorque, overtemperature, and jamming, effectively predicting or detecting valve and pipeline damage caused by these factors and extending the pipeline system's lifespan. By setting acceleration and deceleration parameters or applying acceleration / deceleration curves, the smoothness of the speed change process in the acceleration and deceleration units can be improved, avoiding mechanical shock. During monitoring, the jamming torque detection value is reduced, accurately identifying and displaying the jamming location, thus extending the valve's service life. For gate valves, the valve can also be controlled to quickly pass through the cavitation-prone area (such as an opening angle of less than 30°) based on cavitation-prone conditions (such as cavitation coefficient curves), preventing vibration, noise, and other damage to the valve or pipeline system caused by cavitation.

[0055] For scenarios requiring rapid positioning, an efficiency-first strategy can be selected to execute rapid valve opening and closing, and ensure rapid attainment of the throttling position. For scenarios requiring rapid opening, rapid closing, and rapid check valve operation, rapid valve opening and closing can be achieved; ensuring effective opening, including full valve opening to avoid erosion damage; ensuring effective closing, which can be achieved through precise torque control to maintain sealing pressure and prevent erosion caused by internal leakage. A three-loop control system (torque, speed, and position) is preferred; however, a two-loop control system (torque and speed) can be used if hardware limitations exist. Using maximum torque, maximum speed (generally 1.5 times or more of the rated speed), and the shortest acceleration / deceleration time achieves rapid valve opening and closing and accurate attainment of the positioning position. Alternatively, using maximum torque, maximum speed, and a shorter acceleration / deceleration time can increase speed. During valve closing, the speed is reduced to an approximate speed using torque vector control, supplemented by parameter identification and torque calibration methods to improve torque accuracy and ensure sealing pressure. In the efficiency-first mode, the execution speed of each process of the valve is maximized, and the acceleration time and torque control stage duration are reduced without causing overflow and oscillation.

[0056] The dedicated matching mode is fully integrated with the electric valve. After the electric valve is installed and wired, it can also include valve initialization settings, automatically searching for and setting the initial open / closed valve position. Upon receiving the initialization setting command, it performs a slow and low-torque valve closing action until the valve drive motor torque rises to the set valve closing sealing torque and stops, setting the current position as the valve closed position. Then, it performs a slow and low-torque valve opening action until the set valve maximum stroke decelerates and stops, setting the current position as the valve open position. The valve initialization setting process requires no manual measurement or intervention. After the valve initialization setting is completed, normal valve control operations can be performed, improving accuracy while reducing the workload of operators.

[0057] In this embodiment, the drive motor of the electric valve is preferably an AC asynchronous motor, which can perform multi-mode control of the valve's opening, closing, and intermediate position processes based on vector control of a common AC asynchronous motor. Simultaneously, the set torque and output torque of the AC asynchronous motor can be tested and corrected using appropriate devices for torque calibration. Real-time torque is preferably obtained through an output current detection circuit combined with a vector transformation method. The output current detection circuit detects the physical parameters of the AC asynchronous motor and transmits them to a real-time torque detection unit. This real-time torque detection unit calculates the real-time torque and transmits it to a torque correction unit. The physical parameters may include stator resistance, rotor resistance, stator-rotor mutual inductance, stator-rotor leakage inductance, and no-load current, etc. The three-phase AC signal of the AC asynchronous motor can be converted into the torque component i of the stator current through coordinate transformation. sT The excitation component i of the stator current sMThe real-time torque is calculated using different methods depending on the magnetic field orientation: rotor magnetic field orientation vector control, direct torque control, slip frequency vector control, stator magnetic field orientation vector control, or air gap magnetic field orientation vector control. In other words, vector torque control is used as the output method, with the detection result of the torque detection circuit (preferably the output current detection circuit in this embodiment) as the feedback signal. The output torque is adjusted through a PID closed-loop control to ensure that the actual output torque driving the electric valve operates within the set torque, i.e., the desired value.

[0058] To achieve more precise vector control, this embodiment can also perform parameter identification on the physical parameters of the AC asynchronous motor first. This involves collecting parameters such as stator resistance, rotor resistance, stator-rotor mutual inductance, and stator-rotor leakage inductance to ensure the accuracy of the basic parameters in torque vector control. A physical parameter identification unit can then acquire the physical parameters of the AC asynchronous motor for more accurate torque vector control. AC and DC excitation signals can be input to the AC asynchronous motor, and stator current feedback can be monitored in real time. The aforementioned relevant parameters are calculated based on the voltage and current values ​​and phase relationships. The no-load current is used to estimate the torque consumption during AC asynchronous motor operation (such as friction, ventilation, core loss, etc.) and to compensate for its output torque. This no-load current is preferably 20% to 50% of the motor's rated current.

[0059] In this embodiment, an output current detection circuit is preferably used for parameter detection. Real-time torque (which can be calculated from the rotor's equivalent self-inductance, rotor's equivalent mutual inductance, rotor flux linkage, and stator current torque components) is collected as feedback. A PID control principle is then used to perform closed-loop control and correction of the output torque, ultimately achieving torque vector control. This ensures the torque response speed and control accuracy during the operation of the electric valve. A torque calibration device can also be used to calibrate the AC asynchronous motor to correct its output torque.

[0060] This invention enables real-time monitoring of parameters such as position, speed, torque, and current of electric valves to assess valve status and optimize their operation. A portable intelligent terminal can communicate with the electric valve's actuator to collect, analyze, and display this information for reference. The control employs a nested control mode, from the inside out, consisting of a torque loop, a speed loop, and a position loop, or a nested torque loop and speed loop. The torque loop directly affects the torque, offering fast response and high accuracy, meeting the requirements for real-time motor output torque control. The speed loop operates on top of the torque loop, acquiring the current speed feedback from the electric valve through vector control principles and influencing it through the torque loop to meet speed requirements at different stages. The position loop, as an optional and supplementary element, operates on top of the speed and torque loops, serving as the outermost adjustment layer. It judges and adjusts the output based on the electric valve's feedback to meet the requirements of control logic and stop position accuracy.

[0061] This invention provides precise control of valve displacement through a phased combination of the starting, acceleration, constant speed, deceleration, approach, torque control, and stopping processes. It ensures that the starting process has sufficient torque to overcome the residual torque and static friction resistance during valve closure, the constant speed process has an efficient execution rate to achieve rapid valve closure, the approach process has a low approach speed and torque to avoid collisions and improve position accuracy, the torque control process has a stable torque output to accurately control the stopping position, and the entire process is monitored to predict or detect defects in the valve's mechanical system.

[0062] During startup and acceleration, vector control mode can be used to control the operation of a common AC asynchronous motor. The torque limit is generally 1.5 to 2 times the rated torque of the common AC asynchronous motor, and the speed is the maximum speed of the common AC asynchronous motor (generally 1.5 to 2 times the rated speed). This allows the electric valve's actuator to start with high torque to overcome static friction resistance and accelerate quickly to overcome system inertia and dynamic friction resistance. During the constant speed process, a maintenance control mode and set speed are used, automatically reducing the torque limit to the blocking torque (30% to 80% of the rated torque), while simultaneously monitoring the motor torque. If the output torque abnormally increases to the blocking torque, operation can be stopped immediately and an alarm message can be issued to avoid valve damage. After inspection and confirmation, operation can continue. After the valve displacement reaches the deceleration point, the deceleration process begins, with the control mode and torque limit remaining unchanged, gradually reducing the operating speed to the approximate speed. When used for valve closing control, after approaching the position limit, an approximation process begins. The electric valve actuator maintains the control mode and torque limit unchanged, running at the approximation speed to the torque control position. Then, the torque control stage begins, further reducing the speed and setting the torque limit to 50%–100% of the rated torque. This continues until the actual torque reaches the desired torque, and after maintaining the set holding time, the output stops. This stage is based on torque vector control, using the torque calibration results of a common AC asynchronous motor to reduce torque deviation. It can be combined with superimposed torque closed-loop control to ensure the sealing pressure.

[0063] The above methods are applicable to drives or valve actuators controlled by encoders that measure the full stroke, and are also compatible with solutions using limit switches as the measuring device. If a limit switch is used as the measuring device, the maximum operating speed can be appropriately reduced and the torque limit adjusted to ensure safe operation. Under the premise that the limit switch position is properly adjusted, a stable valve closing sealing pressure can still be ensured.

[0064] This invention, based on an analysis of all current electric valves, focuses on identifying seven representative commonly used electric valves. These seven valves are categorized into three types according to their structural characteristics, operating conditions, and working strategies. A method for controlling these seven types of electric valves is then developed. This method involves establishing a database with valve characteristics, operating conditions, and working strategies as its main framework and content. Combined with encapsulated, inheritable, instantiable, and reusable core control logic, and considering the on / off and throttling conditions of the electric valves, three workflows are defined: opening process control, closing process control, and intermediate position positioning process. This ultimately generates a universal control mode adaptable to various operating conditions and processes, applicable to multiple types and requirements of valve control, particularly suitable for the aforementioned seven types of electric valves. For various operating conditions of different valve types, the method can automatically convert the data into an optimal control method / curve suitable for a specific valve, and bind this optimal control method to that specific valve. Finally, optimal control of the valve is achieved through communication, display, I / O connection, and drive control.

[0065] The relevant features of operating conditions (on / off / throttling), workflow (valve opening / closing / intermediate position positioning), and execution strategies (precision priority / safety priority / fast opening / fast closing) are all set in the data layer. That is, the data layer is a "data string" containing relevant feature information transmitted by the user or host computer to the electric valve actuator before the valve operates. A structured, somewhat common subroutines representing seven different execution stages form a unified, reconfigurable logic layer. After the valve is installed, the user modifies the "data string" according to its features and transmits it to the electric valve actuator. By recombining the corresponding subroutines in the logic layer according to the information in the "data string," various types and requirements of valve control can be achieved.

[0066] This portable smart terminal interacts with the actuators or drivers of electric valves via wired or wireless communication, monitoring and controlling the actuators. Using data structures as an example, program logic as the core, and hardware devices as the implementation method, a "universal valve actuator" can be used. After matching the corresponding valve control and / or control curves through this invention, it can be used for specific valve control without needing to match a dedicated valve actuator for each type of valve. Adaptive control methods can be generated based on the usage scenario and requirements, easily converting general-purpose equipment into dedicated equipment. This significantly reduces the number of equipment series and models, simplifies configuration and use, enables large-scale production, and greatly reduces production, use, and maintenance costs.

[0067] This invention is applicable to the control of most electric valves. One intelligent handheld terminal can support multiple electric valve actuators, facilitating convenient and quick data communication between the field and the electric valve actuators. It adapts to the requirements of digital factories, improving equipment management efficiency and reducing equipment operating costs. The functional modules have been optimized, resulting in a simple structure, reliable function, and strong environmental adaptability. It possesses greater data processing capabilities, and in addition to completing basic functions such as parameter setting, torque calibration, and operating status monitoring, it can also realize equipment status recording and storage, preventative maintenance reminders, data communication, fault diagnosis, and human-machine interface functions, providing a more user-friendly interface and stronger expandability. This portable intelligent terminal can also be used with a common PDA (Personal Digital Assistant), smartphone, tablet, or laptop computer for parameter setting, torque calibration, visual monitoring, remote control operation, and equipment data management of electric valve actuators.

[0068] Of course, the present invention may have other various embodiments. Without departing from the spirit and essence of the present invention, those skilled in the art can make various corresponding changes and modifications according to the present invention, but these corresponding changes and modifications should all fall within the protection scope of the appended claims.

Claims

1. A portable intelligent terminal for an electric valve, characterized in that, The portable smart terminal is wired or wirelessly connected to the actuator of the electric valve for remote operation and control of the electric valve, and includes: case; The main controller, located inside the housing, is used for remote control of the electric valves. It establishes control decision items for the electric valves according to the different types and working requirements of various electric valves. The memory, located inside the housing and connected to the main controller, contains a database of various electric valves and is classified and stored according to the different structural characteristics, operating conditions and usage requirements of the various electric valves. A communication module, located inside the housing and connected to the main controller, is used to connect the actuator of the electric valve via wired or wireless means and to exchange data. An input / output module is disposed inside the housing and connected to the main controller, and is used for human-machine interaction and remote control operation; The main controller divides the control process of the electric valve into multiple control units. Based on the type of each electric valve and the corresponding control decision items, it sets the operating conditions, inflection points, and parameters of each control unit and generates a general control mode for electric valve control with full-process control requirements for multiple types and multiple working conditions. When the triggering conditions are met, it generates the best control method and / or control curve corresponding to different electric valve application requirements and binds it to the corresponding electric valve. The general control mode is converted into a special matching mode for the specific electric valve and used for the full-process control of that specific electric valve.

2. The portable intelligent terminal for the electric valve as described in claim 1, characterized in that, The memory is also used to record operating data during connection with the actuator of the electric valve, and store it locally in the form of a data file containing time nodes for querying by local or remote network sites.

3. The portable intelligent terminal for the electric valve as described in claim 1 or 2, characterized in that, The database of various electric valves includes a data structure for the electric valve execution process that is summarized and established based on valve control principles, combined with the structural characteristics, operating conditions and working strategies of the various electric valves.

4. The portable intelligent terminal for the electric valve as described in claim 1 or 2, characterized in that, It also includes a liquid crystal display screen and / or keyboard disposed on the surface of the housing, which are respectively connected to the input / output module. The liquid crystal display screen is used for visual monitoring of the control process, and the monitoring information is displayed in the human-machine interface of the liquid crystal display screen as a real-time curve or bar chart. The keyboard realizes remote control operation of the electric valve through physical or virtual keys.

5. The portable intelligent terminal for the electric valve as described in claim 1 or 2, characterized in that, The operating conditions include switching operating conditions and / or throttling operating conditions; the multiple control units include a starting unit, an acceleration unit, a constant speed unit, a deceleration unit, an approximation unit, a torque control unit, and / or a stopping unit; the control decision items include a precision priority strategy, a safety priority strategy, and / or an efficiency priority strategy.

6. The portable intelligent terminal for the electric valve as described in claim 5, characterized in that, The operating conditions of the starting unit, acceleration unit, constant speed unit, deceleration unit, and approximation unit include direction and position judgments. If the movement direction is the valve opening direction and the current position of the valve plate has exceeded the valve opening limit position, the operation stops directly. If the movement direction is the valve closing direction and the current position of the valve plate has exceeded the valve closing limit position, the operation jumps to the torque control unit. The operating conditions of the approximation unit and the torque control unit are both equipped with a disable judgment. If the disable judgment is enabled, the operation jumps directly to the next control unit. The operating conditions of the starting unit, acceleration unit, constant speed unit, and deceleration unit are each equipped with a stop judgment. If the starting timeout occurs in the starting unit, the operation jumps directly to the stop unit. If the motor torque exceeds the acceleration torque limit or the acceleration timeout occurs in the acceleration unit, the operation jumps directly to the stop unit. If the valve plate position exceeds the constant speed limit position or the motor torque exceeds the constant speed torque limit in the constant speed unit, the operation jumps directly to the stop unit. If the motor torque exceeds the deceleration torque limit or the deceleration timeout occurs in the deceleration unit, the operation jumps directly to the stop unit.

7. The portable intelligent terminal for the electric valve as described in claim 5, characterized in that, The inflection points of the control unit include start-up inflection points, acceleration inflection points, constant speed inflection points, deceleration inflection points, approach inflection points, torque control inflection points, and / or stop inflection points set for each control unit. When an inflection point is determined to be true, the operation proceeds from the current control unit to the next control unit. Control ends when the stop inflection point occurs.

8. The portable intelligent terminal for the electric valve as described in claim 5, characterized in that, The main controller takes the set parameters and inflection points of each stage of the bound electric valve as input, and takes the real-time speed, valve stroke and / or real-time torque of the bound electric valve as feedback. It uses a PID control algorithm to make real-time corrections to the speed, torque and / or position parameters of the corresponding control unit to meet the response speed and control accuracy requirements of each stage of the valve control process.

9. The portable intelligent terminal for the electric valve as described in claim 8, characterized in that, The real-time torque is obtained by using a torque sensor or by combining an output current detection circuit with a vector transformation method, so as to make immediate corrections to the output torque, and improve torque accuracy by combining parameter identification and torque calibration.

10. The portable intelligent terminal for the electric valve as described in claim 1 or 2, characterized in that, The main controller is also used to detect sudden changes in the stroke of the electric valve, abnormal operating torque, and / or loss of sensor signals, and to provide preventive maintenance prompts after determining the conditions according to the set criteria, so as to avoid damage to the electric valve. Simultaneously, the fault information of the electric valve's actuator is recorded, and diagnostic information prompts are provided to assist in confirming and troubleshooting the fault.

Images