Intelligent valve positioner and valve position deviation adjustment method thereof

Abstract

The application discloses an intelligent valve positioner and a valve position deviation adjusting method thereof, and belongs to the technical field of valve positioners.The technical scheme of the application is an intelligent valve positioner which comprises a device cover and a positioner base, a control circuit board, an IP preposition unit, a slide valve, a back pressure base and a main shaft are arranged in the device cover and the positioner base, and the device cover is connected with the positioner base through cover locking screws.The application solves the technical problem that a plurality of feedback signals need to be used for adjustment in the prior art debugging, and the application provides an intelligent valve positioner and a valve position deviation adjusting method thereof, after a microprocessor μC detects that an input signal deviates from a, the model is automatically brought in for calculation, and according to the existing data set, even when part of the data is missing, the deviation can be adjusted, so that when other arbitrary measurement fails, the valve does not fail.

Description

Technical Field

[0001] This invention relates to the field of valve positioner technology, specifically to an intelligent valve positioner and a method for adjusting valve position deviation. Background Technology

[0002] In industrial production systems, adjustments to environmental factors closely related to product quality, such as temperature, pressure, liquid level, and concentration, all require control of the valve opening (valve position). Whether the valve position meets production requirements directly affects the safe operation of the entire production system.

[0003] The adjustment of various control parameters of existing intelligent valve positioners must be carried out on-site, which is cumbersome and increases the difficulty of on-site operation, and is also prone to human error. Moreover, existing intelligent valve positioners have poor adaptability. For example, different models of intelligent valve positioners are required for large-stroke pneumatic valves and small-stroke pneumatic valves, or for actuators with different flow characteristics such as angular stroke and linear stroke.

[0004] Chinese patent CN101770240B discloses a control method for an intelligent valve positioner, which is simple and quick to debug. A microcontroller receives a setting signal from the controller and a feedback signal from the valve position sensor. It compares the setting signal with the feedback signal, performs adaptive PID control on the deviation, and outputs a corresponding PWM signal to drive an I / P conversion unit, which in turn drives the actuator via a pneumatic power amplifier. While this patent addresses the technical problem of poor adaptability in intelligent valve positioners to some extent, the debugging process requires adjustments using multiple feedback signals. If any feedback signal fails to transmit properly, further adjustments cannot be made. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent valve positioner and a method for adjusting valve position deviation. The microprocessor μC has a storage module for storing datasets and building a calculation model. When the microprocessor μC detects a deviation between the input signal and 'a', it automatically inputs the data into the model for calculation. Based on the existing dataset, the deviation can be adjusted even when some data is missing, thus solving the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an intelligent valve positioner, comprising a device housing and a positioner base, wherein a control circuit board, an IP pre-amplifier unit, a slide valve and a back pressure base and a spindle are disposed inside the device housing and the positioner base; the device housing is connected to the positioner base by a housing locking screw; a slide valve and a back pressure base are mounted on one side of the positioner base by studs; an IP pre-amplifier unit is mounted on the slide valve of the slide valve and the back pressure base; a pre-amplifier unit shielding cover is disposed outside the IP pre-amplifier unit; and a spindle is mounted on the other side of the positioner base, the spindle penetrating the control circuit board.

[0007] The control circuit board is connected to a communication circuit board via copper support pillars. The control circuit board is equipped with a microprocessor μC, which is used to read input signals and measurement values ​​from various sensors, detect numerical deviations, and calculate a new value based on the input signals and sensor measurement values, which is then sent to the IP front-end unit.

[0008] Preferably, the upper surface of the device casing is equipped with a local interface, which is electrically connected to the communication circuit board.

[0009] Preferably, the control circuit board is connected to the positioner base via a PCB pressure plate, and the control circuit board is provided with a circuit shielding cover, with the communication circuit board placed inside the circuit shielding cover.

[0010] Preferably, a corrugated washer is fitted onto the main shaft, the main shaft is movably connected to the circuit part shielding cover through a bushing, the main shaft passes through the circuit part shielding cover, and a valve position indicator is connected to the upper end of the main shaft. The valve position indicator is movably connected to the outer cover of the device. The main shaft is sealed to the positioner base through an O-ring. A shaft position indicator is connected near the lower end of the main shaft. A hinged connection assembly is movably connected to the lower end of the main shaft. The main shaft is connected to the positioner base through screws.

[0011] Preferably, the lower surface of the locator base is provided with an exhaust port guard plate, and an O-ring is provided at the upper end of the exhaust port of the locator base, and the O-ring is fixed by an O-ring fixing plate.

[0012] Preferably, the intelligent valve positioner further includes a position sensor, a pressure sensor, and a slide sensor. The position sensor is used to detect the valve position, the pressure sensor is used to detect the actuator pressure and the air source pressure, and the slide sensor is used to detect the displacement of the spool valve core.

[0013] Another technical problem to be solved by the present invention is to provide a method for adjusting the valve position deviation of the above-mentioned intelligent valve positioner, comprising the following steps:

[0014] S1: The microprocessor μC detects whether all measurement functions are working properly. If they are not working properly, an alarm is triggered.

[0015] S11: The microprocessor μC first detects whether the input signal and position sensor are working properly. If either the input signal or the position sensor is not working properly, the valve positioner is not working. If both the input signal and the position sensor are working properly, the valve positioner can work and proceed to the next detection step.

[0016] S12: The microprocessor μC detects the working status of other sensors. If the working status of other sensors is normal, the valve positioner is in normal working status; if the working status of other sensors is abnormal, the valve positioner is in working status, but the accuracy needs to be adjusted.

[0017] S2: When the valve positioner is in normal working condition, the microprocessor μC reads the input signal and compares the input signal with the valve position value detected by the position sensor. When the comparison is consistent, the microprocessor μC does not process it. When the comparison value deviates, the microprocessor μC calculates a new value based on the data from the input signal and the sensor respectively and enters the IP front-end unit.

[0018] S3: Under the control of the IP front unit, the slide valve and back pressure base drive the actuator and spindle to rotate. The position sensor remeasures the rotation amount and sends it to the microprocessor μC. The microprocessor μC repeats the steps of S2.

[0019] Preferably, if other sensors malfunction, the valve positioner is in a working state, but its accuracy needs adjustment, including:

[0020] When other sensors are in abnormal operating states, extract the abnormal parameter types and corresponding abnormal parameter values ​​of the sensors in abnormal operating states; wherein, the other sensors include temperature sensors, humidity sensors and / or corrosive gas concentration sensors;

[0021] Extract the range values ​​of the normal parameters corresponding to the parameter types to which the abnormal parameters of the sensor belong, and obtain the upper and lower limits of the range values;

[0022] Extract the allowable error fluctuation value corresponding to the abnormal parameter type of the sensor;

[0023] The accuracy adjustment parameter evaluation value is obtained using the abnormal parameter value, the upper and lower limits corresponding to the range value, and the error fluctuation value. The accuracy adjustment parameter evaluation value is obtained using the following formula:

[0024]

[0025] Among them, J cJ0 represents the preset precision adjustment parameter threshold; n represents the total number of abnormal parameters; F represents the evaluation value of the precision adjustment parameter. i F represents the actual parameter value corresponding to the i-th abnormal parameter; upi and F dowin These represent the upper and lower limits of the rated range value under normal operation corresponding to the i-th abnormal parameter, respectively; f i This represents the allowable error fluctuation value corresponding to the i-th abnormal parameter; abs() indicates that the value inside the parentheses is positive; m represents the number of abnormal parameters whose actual parameter value is lower than the lower limit of the range value; k represents the number of abnormal parameters whose actual parameter value is higher than the lower limit of the range value.

[0026] The accuracy adjustment range is determined by comparing the evaluation value of the accuracy adjustment parameter with the preset accuracy adjustment parameter threshold.

[0027] Preferably, the accuracy adjustment range is determined by comparing the accuracy adjustment parameter evaluation value with a preset accuracy adjustment parameter threshold, including:

[0028] When the evaluation value of the accuracy adjustment parameter is lower than the preset accuracy adjustment parameter threshold, the positioning accuracy adjustment range of the valve positioner is set by the following formula;

[0029]

[0030]

[0031] Among them, W up1 and W down1 These represent the upper and lower limits of the precision adjustment when the evaluation value of the precision adjustment parameter is lower than the preset precision adjustment parameter threshold, respectively; W0 represents the allowable error value corresponding to the rated precision of the valve positioner.

[0032] When the evaluation value of the accuracy adjustment parameter is higher than the preset accuracy adjustment parameter threshold, the positioning accuracy adjustment range of the valve positioner is set by the following formula;

[0033]

[0034]

[0035] Among them, W up2 and W down2 These represent the upper and lower limits of precision adjustment when the evaluation value of the precision adjustment parameter is higher than the preset precision adjustment parameter threshold, respectively; W0 represents the allowable error value corresponding to the rated precision of the valve positioner.

[0036] Preferably, the microprocessor μC is provided with:

[0037] The self-diagnostic module is used to check whether all measurement functions are working properly.

[0038] The detection module is used to acquire the input signal and the valve position value detected by the position sensor, and compare the acquired input signal and the valve position value to obtain the comparison result;

[0039] The calculation module is used to obtain the detection value of the pressure sensor and the detection value of the sliding valve sensor when the detection module obtains inconsistent comparison results, and calculates a new value based on the input signal and the data of each sensor.

[0040] The valve position output module is used to convert the new value calculated by the calculation module to the IP front-end unit;

[0041] The storage module is used to store datasets and build computational models. The specific steps for building a computational model using the storage module are as follows:

[0042] Through parameter self-tuning, the parameters and dataset required for intelligent control are tuned. The parameters include input signal, valve position value, actuator pressure value, air source pressure value and spool valve value. The dataset establishes a value set by comparing the input signal with the valve position value, and the corresponding pressure sensor detection value and spool valve value detected by the spool valve sensor. Different value sets are established for different input signal values, and the different value sets constitute the dataset.

[0043] Model construction is performed through neural network learning. Input and output sample sets are extracted from parameter self-tuning. Input samples include input signals, actuator pressure values, air source pressure values, and spool valve values. Output samples are the new values ​​corresponding to a specific valve position and overshoot. These historical data are then trained using neural network learning methods. The neural network structure includes an input layer, hidden layers, and an output layer. During training, the valve position, actuator pressure value, air source pressure value, and spool valve value are used as the output, along with the new values ​​corresponding to the actual valve position and overshoot. The neural network model is then obtained through neural network learning.

[0044] The beneficial effects of this invention are:

[0045] 1. The present invention includes a device housing and a positioner base. The control circuit board, IP preamplifier unit, slide valve, back pressure base and main shaft are all set inside the device housing and positioner base. Human-machine interaction is realized through a local interface. Information is received and sent by the communication circuit board. The structure is compact and easy to install.

[0046] 2. After the microprocessor μC of this invention detects a deviation between the input signal and a, it calculates a new value based on the data from the input signal and the sensor, and enters the IP pre-amplifier unit. This allows feedback on the valve opening and timely correction of the valve position deviation.

[0047] 3. The microprocessor μC of this invention is equipped with a storage module for storing datasets and building calculation models. After the microprocessor μC detects a deviation between the input signal and a, it automatically inputs the data into the model for calculation. Based on the existing dataset, even when some data is missing, the deviation can be adjusted to ensure that the valve will not malfunction when any other measurement fails. Attached Figure Description

[0048] Figure 1 This is an exploded view of the intelligent valve positioner of the present invention;

[0049] Figure 2 This is the circuit schematic diagram of the present invention;

[0050] Figure 3 This is a diagram of the μC microprocessor module of the present invention.

[0051] In the diagram: 1. Device casing; 11. Local interface; 2. Positioner base; 21. Exhaust port guard plate; 22. O-ring fixing plate; 3. Control circuit board; 31. Copper support column; 32. Communication circuit board; 33. Microprocessor μC; 331. Self-diagnostic module; 332. Detection module; 333. Calculation module; 334. Valve position output module; 335. Storage module; 34. PCB pressure plate; 35. Circuit shield; 4. IP preamplifier unit; 41. Preamplifier unit shield; 5. Slide valve and back pressure base; 6. Spindle; 61. Corrugated washer; 62. Bushing; 63. Valve position indicator; 64. Hinge connection assembly; 65. Rotary shaft position indicator; 7. Position sensor; 8. Pressure sensor; 9. Slide sensor. Detailed Implementation

[0052] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0053] To address the issue where multiple feedback signals are used for adjustment, but adjustment cannot continue if any of the feedback signals fails to transmit properly, please refer to [link to relevant documentation]. Figures 1-3 This embodiment provides the following technical solution:

[0054] An intelligent valve positioner includes a device housing 1 and a positioner base 2. A control circuit board 3, an IP pre-amplifier unit 4, a slide valve and back pressure base 5, and a spindle 6 are installed inside the device housing 1 and the positioner base 2. The device housing 1 is connected to the positioner base 2 by a housing locking screw. A slide valve and back pressure base 5 are installed on one side of the positioner base 2 by a stud. An IP pre-amplifier unit 4 is installed on the slide valve of the slide valve and back pressure base 5. A spindle 6 is installed on the other side of the positioner base 2. The spindle 6 passes through the control circuit board 3.

[0055] A communication circuit board 32 is connected to the control circuit board 3 via a copper support column 31. A microprocessor μC33 is installed on the control circuit board 3. The microprocessor μC33 is used to read the input signal and the measurement values ​​of various sensors, detect the numerical deviation, and calculate a new value based on the input signal and the measurement values ​​of the sensors, which is then sent to the IP front-end unit 4.

[0056] The upper surface of the device casing 1 is equipped with a local interface 11, which is electrically connected to the communication circuit board 32.

[0057] Specifically, human-computer interaction is achieved locally through interface 11, and information is received and sent by communication circuit board 32.

[0058] The control circuit board 3 is connected to the positioner base 2 via the PCB pressure plate 34, and the control circuit board 3 is provided with a circuit shield 35 on the outside, and the communication circuit board 32 is placed inside the circuit shield 35.

[0059] A corrugated washer 61 is fitted onto the main shaft 6. The main shaft 6 is movably connected to the circuit shield 35 through the bushing 62. The main shaft 6 passes through the circuit shield 35. A valve position indicator 63 is connected to the upper end of the main shaft 6. The valve position indicator 63 is movably connected to the outer cover 1 of the device. The main shaft 6 is sealed to the positioner base 2 through an O-ring. A shaft position indicator 65 is connected to the lower end of the main shaft 6. A hinged connection assembly 64 is movably connected to the lower end of the main shaft 6. The main shaft 6 is connected to the positioner base 2 through screws.

[0060] Specifically, when the spindle 6 rotates, the amount of valve rotation can be observed through the valve position indicator 63, and the position of the spindle 6 can be observed through the shaft position indicator 65.

[0061] The IP front-end unit 4 is externally equipped with a front-end unit shield 41. By setting the front-end unit shield 41 and the circuit part shield 35, the stability of circuit operation is improved and external interference is avoided.

[0062] The lower surface of the positioner base 2 is provided with an exhaust port guard plate 21, and an O-ring is provided at the upper end of the exhaust port of the positioner base 2, and the O-ring is fixed by the O-ring fixing plate 22.

[0063] The intelligent valve positioner also includes a position sensor 7, a pressure sensor 8, and a slide sensor 9. The position sensor 7 is used to detect the valve position, the pressure sensor 8 is used to detect the actuator pressure and the air source pressure, and the slide sensor 9 is used to detect the displacement of the spool valve core.

[0064] Specifically, the valve position value detected by position sensor 7 is denoted as a, the pressure of the actuator detected by pressure sensor 8 is denoted as P1 and P2, the air source pressure detected by pressure sensor 8 is denoted as Ps, and the spool valve value detected by sliding sensor 9 is SPS. After the microprocessor μC33 detects that the input signal deviates from a, it calculates a new value based on the data from the input signal and the sensor respectively and sends it to IP pre-amplifier unit 4. The IP pre-amplifier unit 4 is equipped with a pre-amplifier coil circuit, denoted as PR. Changing the current input to PR changes the control pressure to the spool valve accordingly.

[0065] Specifically, the microprocessor μC33 changes the current input to PR, thus correspondingly changing the control pressure to the spool valve. The reduced control pressure causes the spool valve core to displace, thereby changing the pressure of the actuator. After the spool valve opens, gas flows to the drive side of the dual-diaphragm actuator and is discharged from the other side of the actuator. The gradually increasing pressure causes the diaphragm to displace, driving the actuator and feedback rod or shaft to rotate. The position sensor 7 measures the rotation amount 'a' and sends it to the microprocessor μC33. The microprocessor μC33 then adjusts the current in PR until a new value is generated that makes the actuator state reach the state corresponding to the input signal value.

[0066] To better illustrate the valve position deviation adjustment process of an intelligent valve positioner, this embodiment proposes a valve position deviation adjustment method for an intelligent valve positioner, including the following steps:

[0067] S1: After the electrical signal connection and the air supply connection of the cylinder are completed, the microprocessor μC33 checks whether all measurement functions are working properly. If they are not working properly, an alarm is triggered.

[0068] S11: The microprocessor μC33 first detects whether the input signal and position sensor 7 are working properly. If either the input signal or the position sensor 7 is not working properly, the valve positioner is not working. If both the input signal and the position sensor 7 are working properly, the valve positioner can work and proceed to the next detection step.

[0069] S12: The microprocessor μC33 detects the working status of other sensors. If the working status of other sensors is normal, the valve positioner is in normal working status; if the working status of other sensors is abnormal, the valve positioner is in working status, but the accuracy needs to be adjusted.

[0070] S2: When the valve positioner is in normal working condition, the microprocessor μC33 reads the input signal and compares the input signal with the valve position value detected by the position sensor 7. When the comparison is consistent, the microprocessor μC33 does not perform any processing. When the comparison value deviates, the microprocessor μC33 calculates a new value based on the data from the input signal and the sensor respectively and enters the IP preamplifier unit 4.

[0071] S3: Under the control of the IP front unit 4, the slide valve and back pressure base 5 drive the actuator and spindle 6 to rotate. The position sensor 7 remeasures the rotation amount and sends it to the microprocessor μC33. The microprocessor μC33 repeats the steps of S2.

[0072] Specifically, if other sensors malfunction, the valve positioner will be considered operational but its accuracy needs adjustment. This includes:

[0073] When other sensors are in abnormal operating states, extract the abnormal parameter types and corresponding abnormal parameter values ​​of the sensors in abnormal operating states.

[0074] Extract the range values ​​of the normal parameters corresponding to the parameter types to which the abnormal parameters of the sensor belong, and obtain the upper and lower limits of the range values;

[0075] Extract the allowable error fluctuation value corresponding to the abnormal parameter type of the sensor;

[0076] The accuracy adjustment parameter evaluation value is obtained using the abnormal parameter value, the upper and lower limits corresponding to the range value, and the error fluctuation value. The accuracy adjustment parameter evaluation value is obtained using the following formula:

[0077]

[0078] Where Jc represents the evaluation value of the precision adjustment parameter; J0 represents the preset threshold of the precision adjustment parameter; n represents the total number of abnormal parameters; Fi represents the actual parameter value corresponding to the i-th abnormal parameter; Fupi and Fdowin represent the upper and lower limits of the rated range value under normal operation corresponding to the i-th abnormal parameter, respectively; fi represents the allowable error fluctuation value corresponding to the i-th abnormal parameter; abs() indicates that the value inside the parentheses is positive; m represents the number of abnormal parameters whose actual parameter value is lower than the lower limit of the range value; k represents the number of abnormal parameters whose actual parameter value is higher than the lower limit of the range value.

[0079] The accuracy adjustment range is determined by comparing the evaluation value of the accuracy adjustment parameter with the preset accuracy adjustment parameter threshold.

[0080] The determination of the precision adjustment range by comparing the evaluation value of the precision adjustment parameter with a preset precision adjustment parameter threshold includes:

[0081] When the evaluation value of the accuracy adjustment parameter is lower than the preset accuracy adjustment parameter threshold, the positioning accuracy adjustment range of the valve positioner is set by the following formula;

[0082]

[0083]

[0084] Wherein, Wup1 and Wdown1 represent the upper and lower limits of the precision adjustment when the evaluation value of the precision adjustment parameter is lower than the preset precision adjustment parameter threshold, respectively; W0 represents the allowable error value corresponding to the rated precision of the valve positioner;

[0085] When the evaluation value of the accuracy adjustment parameter is higher than the preset accuracy adjustment parameter threshold, the positioning accuracy adjustment range of the valve positioner is set by the following formula;

[0086]

[0087]

[0088] Wherein, Wup2 and Wdown2 represent the upper and lower limits of the precision adjustment when the evaluation value of the precision adjustment parameter is higher than the preset precision adjustment parameter threshold, respectively; W0 represents the allowable error value corresponding to the rated precision of the valve positioner.

[0089] The technical effect of the above solution is as follows: by comparing the evaluation value of the precision adjustment parameter with the preset precision adjustment parameter threshold, the adjustment range of the valve positioner's operating precision is determined. This can effectively improve the accuracy of the precision adjustment range setting and the matching between the precision range setting and the actual sensor operating state. At the same time, it improves the adjustment constraints for precision adjustment under different conditions, preventing the problem of unreasonable positioning precision setting of the intelligent valve positioner due to uniform precision range adjustment, which in turn leads to inaccurate positioning data acquisition.

[0090] Meanwhile, the accuracy adjustment parameter evaluation value obtained through the above formula can effectively improve the evaluation accuracy of the overall operating status of other sensors. Furthermore, the accuracy adjustment range obtained through the above formula can also effectively improve the matching between the accuracy range and the overall operating status of other sensors. Further, in the event of malfunctions in other sensors, the rationality of the valve positioner's accuracy adjustment range setting is maximized, thereby ensuring improved positioning accuracy of the valve positioner even when other sensors are malfunctioning.

[0091] This intelligent valve positioner uses a 4-20mA power supply circuit and supports a minimum input signal of 3.6mA when using HART to operate the device. The μC33 microprocessor has the following features:

[0092] Self-diagnostic module 331 is used to check whether all measurement functions are working properly;

[0093] The detection module 332 is used to acquire the input signal and the valve position value detected by the position sensor 7, and compare the acquired input signal and the valve position value to obtain the comparison result. The comparison result can be either consistent or inconsistent.

[0094] The calculation module 333 is used to obtain the detection value of the pressure sensor 8 and the detection value of the sliding valve sensor 9 when the detection module 332 obtains inconsistent comparison results, and calculates a new value based on the input signal and the data of each sensor.

[0095] Valve position output module 334 is used to convert the new value calculated by calculation module 333 to IP front-end unit 4;

[0096] Storage module 335 is used to store datasets and build computational models. The specific steps for storage module 335 to build computational models are as follows:

[0097] Through parameter self-tuning, the parameters and dataset required for intelligent control are tuned. The parameters include input signal, valve position value, actuator pressure value, air source pressure value, and spool valve value. The dataset establishes a value set by comparing the input signal with the valve position value. When they match, the corresponding values ​​detected by pressure sensor 8 and spool valve value detected by spool sensor 9 are used. Different value sets are established for different input signal values. The different value sets constitute the dataset.

[0098] Model construction is performed through neural network learning. Input and output sample sets are extracted from parameter self-tuning. Input samples include input signals, actuator pressure values, air source pressure values, and spool valve values. Output samples are the new values ​​corresponding to a specific valve position and overshoot. These historical data are then trained using neural network learning methods. The neural network structure includes an input layer, hidden layers, and an output layer. During training, the valve position, actuator pressure value, air source pressure value, and spool valve value are used as the output, along with the new values ​​corresponding to the actual valve position and overshoot. The neural network model is then obtained through neural network learning.

[0099] When the input signal detected by the microprocessor μC33 and the position sensor 7 are both in normal working condition, and the working condition of other sensors is abnormal, the valve positioner is in a working state with its accuracy to be adjusted. That is, in the calculation model, any value among the input signal, actuator pressure value, air source pressure value, and spool valve value is input. The model obtains a new value corresponding to a certain valve position or multiple valve positions and overshoot. The microprocessor μC33 selects the valve position with the smallest difference from the input signal and the smallest overshoot for adjustment, thereby ensuring that the valve will not fail if any other measurement fails.

[0100] In summary, the intelligent valve positioner and its valve position deviation adjustment method proposed in this invention include a device housing 1 and a positioner base 2, a control circuit board 3, an IP preamplifier unit 4, a slide valve and back pressure base 5, and a main shaft 6, all housed inside the device housing 1 and the positioner base 2. Human-machine interaction is achieved through a local interface 11, and information is received and sent via a communication circuit board 32. The structure is compact and easy to install. After the microprocessor μC33 detects a deviation between the input signal and 'a', it calculates a new value based on data from the input signal and the sensor, and inputs it into the IP preamplifier unit 4. This provides feedback on the valve opening, enabling timely correction of the valve position deviation. The microprocessor μC33 contains a storage module 335 for storing datasets and building a calculation model. When the microprocessor μC33 detects a deviation between the input signal and 'a', it automatically inputs the data into the model for calculation. Based on the existing dataset, even when some data is missing, the deviation can be adjusted, ensuring that valve failure will not occur if any other measurement fails.

[0101] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0102] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An intelligent valve positioner, comprising a device housing (1) and a positioner base (2), characterized in that: The device housing (1) and the positioner base (2) are equipped with a control circuit board (3), an IP pre-amplifier unit (4), a slide valve and back pressure base (5), and a spindle (6). The device housing (1) is connected to the positioner base (2) by a housing locking screw. A slide valve and back pressure base (5) are installed on one side of the positioner base (2) by a stud. An IP pre-amplifier unit (4) is installed on the slide valve of the slide valve and back pressure base (5). A pre-amplifier unit shield (41) is provided on the outside of the IP pre-amplifier unit (4). A spindle (6) is installed on the other side of the positioner base (2). The spindle (6) passes through the control circuit board (3). The control circuit board (3) is connected to the communication circuit board (32) via copper support pillars (31). The control circuit board (3) is equipped with a microprocessor uC (33). The microprocessor uC (33) is used to read the input signal and the measurement values ​​of various sensors, detect the numerical deviation, and calculate a new value based on the input signal and the measurement values ​​of the sensors and send it to the IP front-end unit (4). Among them, the various sensors include position sensor (7), pressure sensor (8), sliding sensor (9) and other sensors. Position sensor (7) is used to detect valve position, pressure sensor (8) is used to detect actuator pressure and air source pressure, sliding sensor (9) is used to detect valve core displacement, and other sensors include temperature sensor, humidity sensor and / or corrosive gas concentration sensor. The microprocessor uC (33) is equipped with: The self-diagnostic module (331) is used to check whether all measurement functions are working properly. The detection module (332) is used to acquire the input signal and the valve position value detected by the position sensor (7), and compare the acquired input signal and the valve position value to obtain the comparison result; The calculation module (333) is used to obtain the detection value of the pressure sensor (8) and the detection value of the sliding valve sensor (9) when the detection module (332) obtains inconsistent comparison results, and calculates a new value based on the input signal and the data of each sensor. The valve position output module (334) is used to convert the new value calculated by the calculation module (333) to the IP front-end unit (4); The storage module (335) is used to store the dataset and build the computational model. The specific steps for the storage module (335) to build the computational model are as follows: Through parameter self-tuning, the parameters and dataset required for intelligent control are tuned. The parameters include input signal, valve position value, actuator pressure value, air source pressure value and spool valve value. The dataset establishes a value set by comparing the input signal with the valve position value, the corresponding pressure sensor (8) detection value and the spool valve value detected by the spool sensor (9). Different value sets are established for different input signal values. Different value sets constitute the dataset. Model construction is performed through neural network learning. Input and output sample sets are extracted from parameter self-tuning. Input samples include input signals, actuator pressure values, air source pressure values, and spool valve values. Output samples are the new values ​​corresponding to a specific valve position and overshoot. Then, a neural network learning method is used to train on historical data. The neural network structure includes an input layer, hidden layers, and an output layer. During training, the valve position, actuator pressure value, air source pressure value, and spool valve value are used as the output, with the new values ​​corresponding to the actual valve position and overshoot being used as the output. The neural network model is then obtained through neural network learning. The intelligent valve positioner is configured such that when the microprocessor uC (33) detects a deviation between the input signal and the valve position value detected by the position sensor (7), and other sensors are in abnormal working condition, it uses the neural network model to calculate a new value based on the currently available sensor data and sends it to the IP front-end unit (4) to adjust the valve position.

2. The intelligent valve positioner according to claim 1, characterized in that: The upper surface of the device casing (1) is equipped with a local interface (11), which is electrically connected to the communication circuit board (32).

3. The intelligent valve positioner according to claim 2, characterized in that: The control circuit board (3) is connected to the positioner base (2) through the PCB pressure plate (34), and the control circuit board (3) is provided with a circuit part shielding cover (35) on the outside, and the communication circuit board (32) is placed inside the circuit part shielding cover (35).

4. The intelligent valve positioner according to claim 3, characterized in that: A corrugated washer (61) is fitted on the main shaft (6). The main shaft (6) is movably connected to the circuit shield (35) through the bushing (62). The main shaft (6) passes through the circuit shield (35). A valve position indicator (63) is connected to the upper end of the main shaft (6). The valve position indicator (63) is movably connected to the outer cover (1) of the device. The main shaft (6) is sealed to the positioner base (2) through an O-ring. A shaft position indicator (65) is connected to the lower end of the main shaft (6). A hinge connection assembly (64) is movably connected to the lower end of the main shaft (6). The main shaft (6) is connected to the positioner base (2) through screws.

5. The intelligent valve positioner according to claim 4, characterized in that: The lower surface of the locator base (2) is provided with an exhaust port guard plate (21), and an O-ring is provided at the upper end of the exhaust port of the locator base (2), and the O-ring is fixed by the O-ring fixing plate (22).

6. A method for adjusting the valve position deviation of an intelligent valve positioner as described in claim 5, characterized in that, Includes the following steps: S1: The microprocessor uC (33) detects whether all measurement functions are working properly. If they are not working properly, an alarm is triggered. S11: The microprocessor uC (33) first detects whether the input signal and the position sensor (7) can work normally. If either the input signal or the position sensor (7) is not working normally, the valve positioner is not working. If both the input signal and the position sensor (7) are working normally, the valve positioner can work and proceed to the next step of detection. S12: The microprocessor uC (33) detects the working status of other sensors. If the working status of other sensors is normal, the valve positioner is in normal working status; if the working status of other sensors is abnormal, the valve positioner is in working status, and the accuracy needs to be adjusted. S2: When the valve positioner is in normal working condition, the microprocessor uC (33) reads the input signal and compares the input signal with the valve position value detected by the position sensor (7). When the comparison is consistent, the microprocessor uC (33) does not process it. When the comparison value is different, the microprocessor uC (33) calculates a new value based on the data from the input signal and the position sensor respectively and enters the IP pre-amplifier unit (4). S3: The slide valve and back pressure base (5) drive the actuator and spindle (6) to rotate under the control of the IP front unit (4). The position sensor (7) remeasures the rotation amount and sends it to the microprocessor uC (33). The microprocessor uC (33) repeats the steps of S2.

7. The valve position deviation adjustment method for the intelligent valve positioner according to claim 6, characterized in that: If other sensors malfunction, the valve positioner will be considered operational but its accuracy needs adjustment. This includes: When other sensors are in abnormal operating states, extract the abnormal parameter types and corresponding abnormal parameter values ​​of the other sensors in abnormal operating states; Extract the range values ​​of normal parameters corresponding to the abnormal parameter types of the other sensors, and obtain the upper and lower limits of the range values; Extract the allowable error fluctuation values ​​corresponding to the abnormal parameter types of the other sensors; The accuracy adjustment parameter evaluation value is obtained using the abnormal parameter value, the upper and lower limits corresponding to the range value, and the error fluctuation value. The accuracy adjustment parameter evaluation value is obtained using the following formula: ； in, This indicates the evaluation value of the accuracy adjustment parameters; This indicates the preset precision adjustment parameter threshold; This indicates the total number of abnormal parameters. Indicates the first The actual parameter values ​​corresponding to each abnormal parameter; and They represent the first The upper and lower limits of the rated range values ​​under normal operating conditions corresponding to each abnormal parameter; Indicates the first The allowable error fluctuation value corresponding to each abnormal parameter; This indicates that the value inside the parentheses is positive. This indicates the number of abnormal parameters whose actual parameter values ​​are lower than the lower limit of the range. This indicates the number of abnormal parameters whose actual parameter values ​​are higher than the lower limit of the range. The accuracy adjustment range is determined by comparing the evaluation value of the accuracy adjustment parameter with the preset accuracy adjustment parameter threshold.

8. The valve position deviation adjustment method for the intelligent valve positioner according to claim 7, characterized in that: The accuracy adjustment range is determined by comparing the accuracy adjustment parameter evaluation value with the preset accuracy adjustment parameter threshold, including: When the evaluation value of the accuracy adjustment parameter is lower than the preset accuracy adjustment parameter threshold, the positioning accuracy adjustment range of the valve positioner is set by the following formula; ； in, and These represent the upper and lower limits of precision adjustment when the evaluation value of the precision adjustment parameter is lower than the preset precision adjustment parameter threshold, respectively. This indicates the allowable error value corresponding to the rated accuracy of the valve positioner; When the evaluation value of the accuracy adjustment parameter is higher than the preset accuracy adjustment parameter threshold, the positioning accuracy adjustment range of the valve positioner is set by the following formula; ； in, and These represent the upper and lower limits of precision adjustment when the evaluation value of the precision adjustment parameter is higher than the preset precision adjustment parameter threshold, respectively. This indicates the allowable error value corresponding to the rated accuracy of the valve positioner.

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