A control method and device of an electric valve, a storage medium and an electronic device

Abstract

A control method and device of an electric valve, a storage medium and an electronic device, the method comprising: establishing a plurality of electric valve databases, and storing them according to different structural characteristics, working conditions and use requirements of the plurality of electric valves; establishing control decision items of corresponding electric valves according to different types and working requirements of the plurality of electric valves; dividing a control process into a plurality of control units, and setting operating conditions, inflection points and parameters of each control unit according to different types and corresponding control decision items of each electric valve; generating a general control mode with communication, display, IO connection and driving control as contents, for full-process control of the electric valve in multiple types and multiple working conditions; and when a trigger condition is met, generating and binding an adapted optimal control method according to different application requirements of the electric valve, and converting the general control mode into a special matching mode. The application further discloses a control device of an electric valve, a storage medium and an electronic device.

Description

Technical Field

[0001] This invention relates to valve actuation and control technology, and in particular to a control method, device, storage medium and electronic equipment for electric valves that meet the full-process control requirements of various types and operating conditions. 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. While AC asynchronous motors offer advantages such as simple structure, reliable operation, light weight, low cost, and high starting torque, the following problems exist during their use:

[0003] During valve operation, the AC asynchronous motor operates at a fixed speed, resulting in a constant valve opening / closing speed. When the valve reaches its stop point, it is prone to dynamic load overload on the valve seat, leading to a problem where the valve cannot be opened after being fully closed. Simultaneously, dynamic load overload accelerates wear on the valve sealing surface, reducing the valve's service life. The valve opening / closing stop method uses point-to-point triggering, meaning a limit switch (or reed switch) is installed at each of the valve body's opening / closing stop points, stopping the valve based on the limit switch's (or reed switch's) signal. However, due to the inherent mechanical clearance of the limit switch (or reed switch) and its relatively large error in repeatability control accuracy, the valve may not stop fully or may fail to stop after being fully closed, leading to internal leakage or the AC asynchronous motor failing to stop and burning out. Furthermore, through… The point-to-point triggering stop method implemented by complex mechanical transmission systems (counters and torque protection devices) not only fails to achieve high-precision position control throughout the entire stroke, but also significantly increases manufacturing costs; it cannot control the force on the valve seat when the valve is fully closed, and cannot establish the specific pressure required for sealing, which can easily cause the valve to not close tightly, resulting in internal leakage; the torque control accuracy of the AC asynchronous motors for valve closing and opening is low, and coupled with the influence of factors such as medium temperature, foreign objects, and corrosion, the driving torque during valve opening cannot overcome all resistance torques, causing the valve to fail to open; a fixed speed cannot meet the needs of rapid valve opening / closing in emergency situations, nor can it meet the speed adjustment operation of valves prone to "water hammer" conditions; and it cannot achieve highly reliable, anti-interference, and networked centralized remote control. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to address the above-mentioned deficiencies of the prior art by providing a control method, device, storage medium and electronic equipment for electric valves that meet the full-process control needs of multiple types and multiple working conditions.

[0005] To achieve the above objectives, the present invention provides a control method for an electric valve, comprising the following steps:

[0006] S100. Construct a data layer, establish a database of various electric valves, and classify and store them according to the different structural characteristics, working conditions and usage requirements of the various electric valves.

[0007] S200. Establish a logic layer and set up corresponding control decision items for the electric valves according to the different types and working requirements of the various electric valves; divide the control process of the electric valves into multiple control units, and set the operating conditions, inflection points and parameters of each control unit according to the different types of electric valves and corresponding control decision items.

[0008] S300: Establish a device layer to generate a general control mode encompassing communication, display, I / O connections, and drive control, for electric valve control requiring full-process control across multiple types and operating conditions; and

[0009] S400. When the triggering conditions are met, the optimal control method and / or control curve are generated to match the different electric valve application requirements, and bound 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 the specific electric valve.

[0010] The above-mentioned control method for electric valves includes a database of multiple electric valves, which is a data structure for the electric valve execution process that is summarized and established based on the valve control principle and combined with the structural characteristics, operating conditions and working strategies of the multiple electric valves.

[0011] The above-mentioned control method for electric valves includes the following operating conditions: 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; and the control decision items include a precision priority strategy, a safety priority strategy, and / or an efficiency priority strategy.

[0012] The above-described control method for electric valves includes the following operating conditions for the starting unit, acceleration unit, constant speed unit, deceleration unit, and approximation unit: direction and position judgment are included respectively. 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 The starting unit, acceleration unit, constant speed unit, and deceleration unit are each equipped with a stop judgment function in their operating conditions. If the starting unit times out, it will directly jump to the stop unit. If the motor torque in the acceleration unit exceeds the acceleration torque limit or the acceleration times out, it will directly jump to the stop unit. If the valve plate position in the constant speed unit exceeds the constant speed limit or the motor torque exceeds the constant speed torque limit, it will directly jump to the stop unit. If the motor torque in the deceleration unit exceeds the deceleration torque limit or the deceleration times out, it will directly jump to the stop unit.

[0013] In the above-mentioned control method for electric valves, the inflection points of the control unit include starting inflection points, acceleration inflection points, constant speed inflection points, deceleration inflection points, approach inflection points, torque control inflection points, and / or stopping inflection points set for each control unit. When the inflection point is determined to be true, the operation proceeds from the current control unit to the next control unit; control ends when the stopping inflection point occurs.

[0014] The above-mentioned control method for electric valves further includes:

[0015] S500: Taking the set parameters and inflection points of each stage of the bound electric valve as input, and the real-time speed, valve stroke and / or real-time torque of the bound electric valve as feedback, the PID control algorithm is used 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.

[0016] The above-mentioned control method 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, so as to correct the output torque in real time, and to improve torque accuracy by combining parameter identification and torque calibration.

[0017] The above-mentioned control method for electric valves includes various electric valves such as gate valves, globe valves, butterfly valves, ball valves, plug valves, knife gate valves, and / or dampers.

[0018] To better achieve the above objectives, the present invention also provides a control device for an electric valve, which includes a controller and uses the above-described control method for the electric valve to control the electric valve.

[0019] To better achieve the above objectives, the present invention also provides a storage medium storing a computer program configured to execute the above-described control method for an electric valve during runtime.

[0020] To better achieve the above objectives, the present invention also provides an electronic device, comprising:

[0021] Processor; and

[0022] Memory for storing the executable instructions of the processor;

[0023] The processor is configured to execute the above-described control method for the electric valve by executing the executable instructions.

[0024] The technical advantages of this invention are as follows:

[0025] This invention is applicable to the control of most electric valves. Taking data structures as an example, program logic as the core, and hardware devices as the implementation method, it sets the relevant characteristics of valve operating conditions (on / off / throttling), workflow (opening / closing / intermediate position positioning), and execution strategies (precision priority / safety priority / fast opening / fast closing) in the data layer. This data string, containing relevant characteristic information, is transmitted to the valve actuator by the user or host computer before the valve operates. The structured, common subroutines representing different execution stages are combined into a unified, reconfigurable logic layer. After the valve is installed, the user selects the matching data string according to the valve type and usage requirements and transmits it to the valve actuator. The corresponding subroutines in the logic layer are reassembled according to the information in the data string, converting the valve control from a "general control mode" to a "dedicated matching mode" for a specific valve, thus completing valve control for various types and requirements.

[0026] This invention features a universal data and logic structure, simpler configuration and usage methods; universal hardware components, fewer device series and models, making it easy to select and use; and a structured software and hardware organization method suitable for mass production, significantly reducing production, usage, and maintenance costs. It also supports the design and use of universal valve actuators.

[0027] 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

[0028] Figure 1 This is a data structure diagram of the electric valve execution process according to an embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram of the valve intermediate position positioning control principle according to an embodiment of the present invention;

[0030] Figure 3 This is a gate valve opening control curve diagram according to an embodiment of the present invention;

[0031] Figure 4 This is a schematic diagram of the gate valve closing control principle according to an embodiment of the present invention;

[0032] Figure 5 This is a gate valve closing control curve diagram according to an embodiment of the present invention;

[0033] Figure 6 This is a shut-off valve control curve diagram according to an embodiment of the present invention;

[0034] Figure 7 This is a control curve diagram of a ball valve closing according to an embodiment of the present invention;

[0035] Figure 8 This is an acceleration / deceleration curve diagram according to an embodiment of the present invention.

[0036] Among them, the attached reference numerals

[0037] 1. Motor speed line

[0038] 2 Valve Plate Position Line

[0039] 3 Motor Torque Line Detailed Implementation

[0040] The structural and working principles of the present invention will be described in detail below with reference to the accompanying drawings:

[0041] The electric valve control method of the present invention is used for valve control of various types and requirements, applicable to on / off and / or throttling conditions. It can be used for valve positioning in throttling conditions and for valve on / off control in on / off conditions. It has a general control mode and a dedicated matching mode. A general control mode is pre-modeled and generated for valve control of various types and requirements. Then, based on different valve types and usage needs, it is converted into a specific dedicated matching mode according to set conditions and bound to the specific valve for dedicated control. The electric valve control method of the present invention includes the following steps:

[0042] Step S100: Construct a data layer, establish a database of various electric valves, and classify and store them according to their structural characteristics, operating conditions, and usage requirements. The database of various electric valves includes a data structure summarizing and establishing the electric valve execution process of the various electric valves based on valve control principles and their structural characteristics, operating conditions, and working strategies. (See [link to relevant documentation]). Figure 1 , Figure 1This is a data structure diagram of the electric valve execution process according to an embodiment of the present invention; the data hierarchy can be divided according to valve type, execution strategy, execution stage, and stage parameters. Figure 1 The diagram illustrates an example of the parameter structure for a gate valve's precision-priority strategy during the startup phase. The instantiation of the data structure involves setting the parameters for each stage of valve operation. Differences in valve type and applied execution strategies are also reflected in this data structure. For instance, 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 and safety-priority strategies for gate valves is that the execution rate of each stage in the safety-priority strategy is slower, and the protection torque is reduced, resulting in different corresponding parameters. The various electric valves described in this embodiment include gate valves, globe valves, butterfly valves, ball valves, plug valves, knife gate valves, and / or dampers. The operating conditions include switching conditions and / or throttling conditions.

[0043] Step S200: Establish a logic layer, and establish corresponding control decision items for the various electric valves according to their different types and working requirements; divide the control process of the electric valves into multiple control units, and set the operating conditions, inflection points and parameters of each control unit according to the type of each electric valve and the corresponding control decision items; the control decision items in this embodiment include accuracy priority strategy, safety priority strategy and / or efficiency priority strategy to adapt to different valves, different usage environments and different operating requirements; 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;

[0044] Step S300: Establish a device layer, generating a general control mode encompassing communication, display, I / O connection, and drive control, for electric valve control requiring full-process control across multiple types and operating conditions; and

[0045] Step S400: When the triggering conditions are met, generate the best control method and / or control curve to match the different electric valve application requirements, and bind 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 control of the specific electric valve.

[0046] See Figure 2 , Figure 2This is a schematic diagram of the valve intermediate position positioning control principle according to an embodiment of the present invention. In this embodiment, the operating conditions of the starting unit, acceleration unit, constant speed unit, deceleration unit, and approximation unit all 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, then 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, then the process jumps to the torque control unit. The operating conditions of the approximation unit and the torque control unit both include a disable judgment; if this is enabled, the process jumps directly to the next control unit. The starting unit, acceleration unit, constant speed unit, and deceleration unit are all equipped with stop judgment in their operating conditions. If the starting unit times out, it will directly jump to the stop unit. If the motor torque in the acceleration unit exceeds the acceleration torque limit or the acceleration timeout occurs, it will directly jump 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, it will directly jump to the stop unit. If the motor torque in the deceleration unit exceeds the deceleration torque limit or the deceleration timeout occurs, it will directly jump to the stop unit.

[0047] In this embodiment, 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 the inflection point is determined to be true, the control unit moves from the current control unit to the next control unit. Control ends when the stop inflection point occurs.

[0048] In this embodiment, the starting inflection point is when the current speed of the drive motor of the electric valve is greater than or equal to the set starting speed; the acceleration inflection point is when the current speed of the drive motor is greater than or equal to a set percentage of the set uniform speed; the uniform speed inflection point is when the current stroke of the electric valve is greater than or equal to the set stroke; the deceleration inflection point is when the current speed of the drive motor is less than or equal to the set approximation speed; the approximation inflection point is when the current torque of the drive motor of the electric valve is greater than or equal to the set torque; the torque control inflection point is when the torque holding time of the electric valve is greater than or equal to the set holding time; and the stop inflection point is when the current speed of the electric valve is 0, thus ending the intermediate position positioning control of the electric valve.

[0049] In throttling operations, taking a gate valve as an example, before the command is executed for valve intermediate position positioning, the equipment reads information including valve type, execution strategy, various execution stages, and parameters for each stage, and applies this information to the valve intermediate position positioning process. This generates and binds the optimal control method and / or control curve suitable for the gate valve's throttling operation, and uses it for the gate valve's intermediate position positioning control. It can also be applied to the intermediate position positioning process of gate valves under the same conditions in the future. Specifically, this can include: a starting stage, where high torque is used to overcome static friction to initiate the valve 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 valve plate's stopping position. After accurately reaching the stopping position, the valve 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. That is, the valve intermediate positioning is applicable to the execution strategies, opening and closing conditions and throttling conditions of the aforementioned 7 types of valves. It includes 7 stages of control and the application of corresponding parameters for each stage.

[0050] In the switching operation, taking a gate valve as an example, see [link / reference]. Figure 3 , Figure 3 This is a gate valve opening control curve diagram according to an embodiment of the present invention. The three curves in the diagram are the motor speed line 1, the valve plate position line 2, and the motor torque line 3, respectively. Before the valve opening command is executed, the device reads data including valve type, execution strategy, each execution stage, control unit, and corresponding parameter data for each stage, generates and binds the valve opening control method and / or control curve, and uses it 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 working conditions in the future. Figure 3 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.

[0051] See Figure 4 and Figure 5 , Figure 4 This is a schematic diagram of the gate valve closing control principle according to an embodiment of the present invention. Figure 5This is a gate valve closing control curve diagram according to an embodiment of the present invention. The gate valve closing process of the precision-priority strategy is as follows: Figure 4 As shown, the control curve for this process is as follows: Figure 5 As shown, the three curves are the motor speed line 1, the valve plate position line 2, and the motor torque line 3, respectively. Figure 5 As shown, before executing the valve closing command, the equipment reads data including valve type, execution strategy, each execution stage, 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 5 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 valve actuator stops outputting, and the valve closing process ends.

[0052] See Figure 6 , Figure 6 This is a shut-off valve closing control curve according to an embodiment of the present invention, wherein the three curves are motor speed line 1, valve plate position line 2, and motor torque line 3. The main difference between the shut-off valve closing control curve and the gate valve closing control curve lies in the torque change trend during the approximation phase. During the closing process, the valve disc of the shut-off valve (equivalent to the valve plate of the gate valve) gradually approaches the sealing seat. At this time, the reverse force of the medium pressure inside the valve on the valve disc slowly increases, resulting in a slow increase in the control torque during the approximation phase of the shut-off valve closing process. Figure 6 The motor torque curve is shown in the diagram. The medium pressure varies depending on the operating conditions; this diagram only illustrates a general pattern. At the instant the valve disc contacts the sealing seat, the reverse force caused by the medium pressure decreases, causing the motor torque curve to jump. This is the reason for the torque decrease at the end of the approach phase.

[0053] See Figure 7 , Figure 7This is a ball valve closing control curve according to an embodiment of the present invention, wherein the three curves are motor speed line 1, valve plate position line 2, and motor torque line 3, respectively. The main difference between the ball valve closing control curve and the gate valve closing control curve lies in the approximation stage and torque control stage. Ball valves do not require torque control or the establishment of sealing pressure, therefore their closing does not have a torque control stage, and an approximation stage is not required if the stop position requirement is not high. The control of plug valves, knife valves, or dampers is the same as or similar to that of ball valves. In this case, the control unit includes a starting unit, an acceleration unit, a constant speed unit, a deceleration unit, an approximation unit, and a stopping unit. When the current speed of the drive motor is greater than or equal to the set starting speed of the ball valve, plug valve, knife valve, or damper, the drive motor is controlled to enter the acceleration unit from the starting unit; when the current speed of the drive motor is greater than or equal to a set proportion of the set constant speed of the ball valve, plug valve, knife valve, or damper, the drive motor is controlled to enter the constant speed unit from the acceleration unit; the ball valve, plug valve, knife valve, and damper... When the current stroke of the knife valve or damper is greater than or equal to the set stroke, the drive motor is controlled to enter the deceleration unit from the constant speed unit; when the current speed of the drive motor is less than or equal to the set approximation speed of the ball valve, plug valve, knife valve, or damper, the drive motor is controlled to enter the approximation unit from the deceleration unit; when the current torque of the drive motor is greater than or equal to the set torque of the ball valve, plug valve, knife valve, or damper, the drive motor is controlled to enter the stop unit from the approximation unit; when the current speed is 0, the closing control of the ball valve, plug valve, knife valve, or damper ends. Some dampers have the function of closing by their own gravity after power failure or loss of power. In this case, the closing process does not need to be controlled, only monitored.

[0054] 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 can reduce 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 valve actuator.

[0055] When selecting a precision-priority strategy, it can include prioritizing position accuracy or torque accuracy. The key is to avoid mechanical shocks, ensure precise switching positions of each control unit, and ensure smooth transitions between stages. Prioritizing position accuracy ensures accurate valve opening / closing positions and intermediate positions during throttling. Besides reducing the approach speed to improve position 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 precision of the valve's closing torque, ensuring no leakage. Besides 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 throughout the entire process (torque, speed, and position three-loop control; if hardware limitations exist, torque and speed two-loop control can also be used) to ensure position accuracy and real-time performance; appropriately extending acceleration and deceleration times or optimizing acceleration and deceleration curves (see...) Figure 8 The acceleration and deceleration system can be changed from linear acceleration / deceleration to curvilinear acceleration / deceleration (selectable curves include 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 and ensure precise control of the stopping position. Parameters such as speed, torque, and position are set according to actual needs, and upper limits are set to ensure system safety. The acceleration, deceleration, and stopping units preferably use three-loop control and S-shaped acceleration / deceleration curves to improve stopping position accuracy and reduce mechanical shock.

[0056] 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.

[0057] 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.

[0058] 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 the torque control stage duration are reduced without causing overflow and oscillation.

[0059] In this embodiment, the operation of the electric valve may also include:

[0060] Step S500: Using 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 the acceleration time, deceleration time, torque, speed, and / or stroke of each stage, such as setting the starting speed, constant speed, stroke, approach speed, torque, and / or holding time, etc.), and correspondingly using 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.

[0061] The dedicated matching mode is paired with the electric valve. After the electric valve is installed and wired, the process includes valve initialization settings, automatically searching for and setting the initial open / closed valve position. Upon receiving the initialization setting command, the valve closes slowly and with low torque until the valve drive motor torque reaches the set valve closing sealing torque, at which point the current position is set to the closed position. Then, the valve opens slowly and with low torque until the set maximum valve stroke is reached, at which point the current position is set to the open position. The valve initialization setting process requires no manual measurement or intervention. After the initialization setting is complete, normal valve control operations can be performed, improving accuracy while reducing operator workload.

[0062] 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. 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.

[0063] 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.

[0064] 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.

[0065] This invention enables real-time monitoring of the position, speed, and torque of an electric valve. It employs a nested control mode, from the inside out, using torque loops, speed loops, and position loops, or a nested control mode of torque loops and speed loops. The torque loop directly affects the torque, offering fast response and high accuracy, meeting the requirements for real-time control of the motor's output torque. The speed loop operates on top of the torque loop, acquiring the current speed feedback from the electric valve through the basic principles of vector control 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 feedback from the electric valve to meet the requirements of the control logic and stop position accuracy.

[0066] Furthermore, the present invention also provides a control device for an electric valve, including a controller, and uses the aforementioned control method for the electric valve to control the electric valve. It should be noted that this device is used for actuation, and its function can be implemented by several modules or units. In fact, according to embodiments of the present invention, the features and functions of two or more modules or units can be embodied in one module or unit. Conversely, the features and functions of one module or unit can be further divided and embodied by multiple modules or units.

[0067] 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.

[0068] 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 valve 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 a set speed are used, automatically reducing the torque limit to the jamming torque (30% to 80% of the rated torque), while simultaneously monitoring the motor torque. If the output torque abnormally increases to the jamming 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, a deceleration process begins. The control mode and torque limit remain unchanged, and the operating speed is gradually reduced to the approximate speed. When used for valve closing control, after approaching the position limit, an approximation process begins. The valve actuator maintains the control mode and torque limit unchanged, running at the approximation speed to the torque control position, and then enters the torque control stage. The speed is further reduced, and the torque limit is set to 50%–100% of the rated torque. This continues until the actual torque reaches the desired torque, and the output stops after maintaining the set holding time. 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 specific pressure.

[0069] The above method is applicable to valve actuator control where the encoder is the full-stroke measuring device, and is also compatible with schemes 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.

[0070] This invention, based on an analysis of all current electric valves, identifies seven representative commonly used electric valves. These seven valves are then categorized into three types according to their structural characteristics, operating conditions, and working strategies. Finally, a method for controlling these seven types of electric valves is 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. Ultimately, a universal control mode adaptable to various operating conditions and processes is generated, 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 to the optimal control method / curve adapted to 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.

[0071] 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 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 valve actuator. By reassembling 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.

[0072] This invention is applicable to the control of most electric valves. Its essence is to use data structures as examples, program logic as the core, and hardware devices as the implementation method. It can realize the use of a "general valve driver". After matching the corresponding valve control method through the method of this invention, it can be used for specific valve control without matching a dedicated valve driver for each type of valve. It can generate an appropriate control method according to the usage scenario and requirements. It can easily and conveniently bind general equipment to convert it into special equipment, which can significantly reduce the number of equipment series and models, simplify configuration and use, realize large-scale production, and greatly reduce production, use and maintenance costs.

[0073] Accordingly, based on the same inventive concept, the present invention also provides a storage medium storing a computer program configured to execute the above-described control method for an electric valve during runtime. Through the above description of the embodiments, those skilled in the art will readily understand that the exemplary embodiments described herein can be implemented by software or by combining software with necessary hardware. Therefore, the technical solution according to the embodiments of the present invention can be embodied in the form of a software product, which can be stored in a non-volatile storage medium (e.g., a CD-ROM, USB flash drive, portable hard drive, etc.) or on a network, including several instructions to cause a computing device (which may be a personal computer, server, mobile terminal, or network device, etc.) to execute the method according to the embodiments of the present invention.

[0074] In some possible implementations, various aspects of the present invention can also be implemented as a program product, comprising program code that, when run on a terminal device, causes the terminal device to execute the steps described in the "Exemplary Methods" section of this specification according to various exemplary embodiments of the present invention. In specific programming, a combination of "data strings" and "subroutines" can be used. The "data string" contains specific execution parameters and entry (or path) information for subroutine calls (or selections). During remote control, the corresponding "data string" is sent to the actuator via the bus, thereby setting (or changing) the actuator's execution parameters and execution logic. Structured data organization and program decomposition methods can be used to reorganize mutually independent stages using user-defined data strings with a certain order and logic, according to actual needs, ultimately achieving universal gate machine control for various valves. For example, the relevant characteristics of operating conditions, workflows, and execution strategies are all implicit in the data layer (i.e., "data string instructions" containing relevant characteristic information transmitted by the user or host computer to the valve actuator before valve operation); structured, common subroutines representing different execution stages form a unified, reconfigurable logic layer. After the valve is installed, the user selects the corresponding "data string instruction" based on its characteristics and passes it to the valve actuator. The actuator then reassembles the corresponding subroutine of the logic layer according to the information in the "data string instruction," thus completing various types and requirements of valve control. Optionally, in this embodiment, the aforementioned storage medium may include, but is not limited to, various media capable of storing computer programs, such as USB flash drives, read-only memory (ROM), random access memory (RAM), portable hard drives, magnetic disks, or optical disks.

[0075] According to embodiments of the present invention, a program product for implementing the above-described method may employ a portable compact disc read-only memory (CD-ROM) and include program code, and may run on a terminal device, such as a host computer, a central controller, or a mobile smart terminal. However, the program product of the present invention is not limited thereto; the readable storage medium may be any tangible medium containing or storing a program, which may be used by or in conjunction with an instruction execution system, apparatus, or device.

[0076] The program product may employ any combination of one or more readable media. The readable media may be a readable signal medium or a readable storage medium. The readable storage medium may be, for example, but not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination thereof. Examples of readable storage media may include: an electrical connection having one or more wires, a portable disk, a hard disk, a random access memory, a read-only memory, an erasable programmable read-only memory (EPROM or flash memory), an optical fiber, a portable compact disk read-only memory, an optical storage device, a magnetic storage device, or any suitable combination thereof.

[0077] Computer-readable signal media may include data signals propagated in baseband or as part of a carrier wave, carrying readable program code. Such propagated data signals may take various forms, including but not limited to electromagnetic signals, optical signals, or any suitable combination thereof. A readable signal medium may also be any readable medium other than a readable storage medium, capable of sending, propagating, or transmitting programs for use by or in conjunction with an instruction execution system, apparatus, or device.

[0078] The program code contained on the readable medium may be transmitted using any suitable medium, including but not limited to wireless, wired, optical fiber, RF, etc., or any suitable combination thereof.

[0079] Program code for performing the operations of this invention can be written in any combination of one or more programming languages, including object-oriented programming languages ​​such as Java and C++, and conventional procedural programming languages ​​such as C or similar languages. The program code can execute entirely on the user's computing device, partially on the user's computing device, as a standalone software package, partially on the user's computing device and partially on a remote computing device, or entirely on a remote computing device or server. In cases involving remote computing devices, the remote computing device can be connected to the user's computing device via any type of network, including a local area network (LAN) or a wide area network (WAN), or it can be connected to an external computing device.

[0080] Accordingly, based on the same inventive concept, the present invention also provides an electronic device, comprising: a processor; and a memory for storing executable instructions of the processor; wherein the processor is configured to perform the above-described control method for an electric valve by executing the executable instructions.

[0081] Those skilled in the art will understand that the present invention can be implemented as a system, method, or program product. Therefore, various aspects of the present invention can be specifically implemented in the following forms: a completely hardware implementation, a completely software implementation (including firmware, microcode, etc.), or a combination of hardware and software aspects, collectively referred to herein as a "circuit," "module," or "system." The electronic device of this embodiment is manifested in the form of a general-purpose computing device. Components of the electronic device may include, but are not limited to: at least one processor described above, at least one memory described above, and a bus connecting different system components (including the memory and the processor). The memory is used to store executable instructions of the processor; the processor is configured to execute the above-described control method for an electric valve by executing the executable instructions. The memory stores program code that can be executed by the processor, causing the processor to perform the steps of the various exemplary embodiments of the present invention described in the "Exemplary Methods" section above.

[0082] The memory may include readable media in the form of volatile memory cells, such as random access memory (RAM) and / or cache memory cells, and may further include read-only memory (ROM). The memory may also include programs / utilities having a set (at least one) of program modules, including but not limited to: an operating system, one or more application programs, other program modules, and program data, each or some combination of these examples may include an implementation of a network environment.

[0083] A bus can represent one or more of several types of bus structures, including a memory cell bus or memory cell controller, a peripheral bus, a graphics acceleration port, a processing unit, or a local bus that uses any of the various bus structures.

[0084] The electronic device can also communicate with one or more external devices (e.g., keyboards, pointing devices, Bluetooth devices, etc.), one or more devices that enable user interaction with the electronic device, and / or any device that enables the electronic device to communicate with one or more other computing devices (e.g., routers, modems, etc.). This communication can be performed through input / output (I / O) interfaces. Furthermore, the electronic device can communicate with one or more networks (e.g., local area networks (LANs), wide area networks (WANs), and / or public networks such as the Internet) via a network adapter. The network adapter communicates with other modules of the electronic device via a bus. Other hardware and / or software modules can be used in conjunction with the electronic device, including but not limited to: microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, tape drives, and data backup storage systems.

[0085] From the above description of the embodiments, those skilled in the art will readily understand that the exemplary embodiments described herein can be implemented by software or by combining software with necessary hardware. Therefore, the technical solutions according to the embodiments of the present invention can be embodied in the form of a software product, which can be stored in a non-volatile storage medium (such as a CD-ROM, USB flash drive, portable hard drive, etc.) or on a network, including several instructions to cause a computing device (such as a personal computer, server, terminal device, or network device, etc.) to execute the method according to the embodiments of the present invention.

[0086] 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 control method for an electric valve, characterized in that, Includes the following steps: S100. Construct a data layer, establish a database of various electric valves, and classify and store them according to the different structural characteristics, working conditions and usage requirements of the various electric valves. S200. Establish a logic layer and set up corresponding control decision items for the electric valves according to the different types and working requirements of the various electric valves; divide the control process of the electric valves into multiple control units, and set the operating conditions, inflection points and parameters of each control unit according to the different types of electric valves and corresponding control decision items. S300: Establish a device layer to generate a general control mode encompassing communication, display, I / O connections, and drive control, for electric valve control requiring full-process control across multiple types and operating conditions; and S400. When the triggering conditions are met, the optimal control method and / or control curve are generated to match the different electric valve application requirements, and bound 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 the specific electric valve.

2. The control method for the electric valve as described in claim 1, 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.

3. The control method 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.

4. The control method for the electric valve as described in claim 3, 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.

5. The control method for the electric valve as described in claim 3, 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.

6. The control method for the electric valve as described in claim 1, 2, 4 or 5, characterized in that, Also includes: S500: Taking the set parameters and inflection points of each stage of the bound electric valve as input, and the real-time speed, valve stroke and / or real-time torque of the bound electric valve as feedback, the PID control algorithm is used 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.

7. The control method for the electric valve as described in claim 6, 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.

8. The control method for the electric valve as described in claim 1, 2, 4 or 5, characterized in that, The various electric valves include gate valves, globe valves, butterfly valves, ball valves, plug valves, and / or dampers.

9. A control device for an electric valve, characterized in that, It includes a controller and uses the control method for the electric valve as described in any one of claims 1-8 to control the electric valve.

10. A storage medium, characterized in that, The storage medium stores a computer program configured to execute the control method for the electric valve according to any one of claims 1-8 when running.

11. An electronic device, characterized in that, include: processor; as well as Memory for storing the executable instructions of the processor; The processor is configured to execute the control method of the electric valve according to any one of claims 1-8 by executing the executable instructions.

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