Electric valve execution process protection method and device, storage medium and electronic equipment

Abstract

The application discloses an electric valve execution process protection method and device, a storage medium and an electronic device. The electric valve execution process protection method is used for state monitoring, fault diagnosis and safety protection in an electric valve running process, and comprises the following steps: state monitoring, real-time detection of voltage, current, torque and / or stroke parameters in the electric valve running process; fault diagnosis, comparison of the detected voltage, current, torque and / or stroke parameters with corresponding set thresholds, judgment of corresponding faults according to a comparison result, and sending of corresponding alarm prompts or auxiliary decision suggestions; and real-time adjustment of corresponding control parameters or control curves of the electric valve, or deceleration or immediate shutdown according to the alarm prompts or auxiliary decision suggestions. The application further provides an electric valve execution process protection device, a storage medium and an electronic device.

Description

Technical Field

[0001] This invention relates to valve actuation technology, and in particular to a method and apparatus for protecting the operation of an electric valve, a storage medium, and an electronic device. Background Technology

[0002] In existing technologies, AC asynchronous motors are widely used in valve electric actuators due to their advantages such as simple structure, reliable operation, light weight, low price, and large starting torque. These motors are driven by actuators that control the mechanical transmission mechanism to operate the valve / gate, achieving valve opening / closing. However, during operation, the AC asynchronous motor's speed is fixed, and the valve opening / closing speed remains constant. When the valve reaches its stop point, it easily causes dynamic load overload on the valve seat, resulting in the valve being unable to open after being tightly closed. Dynamic load overload also accelerates wear on the valve sealing surface, reducing the valve's service life. Furthermore, the control accuracy error of the valve opening / closing stopping method is relatively large, causing the valve to not stop completely or to fail to stop after being tightly closed, leading to internal leakage or the AC asynchronous motor failing to stop and burning out. Moreover, it cannot achieve high-precision position control throughout the entire stroke. How to achieve high-precision control throughout the entire stroke of electric valves, and how to effectively monitor, diagnose, and protect the current status of valves and their actuators of different types, specifications, parameters, and operating environments to meet the safe, rapid, accurate, and long-term operation requirements of valves and their actuators, are urgent technical problems to be solved in this field. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a method and device, storage medium and electronic device for protecting the operation process of electric valves, in order to address the above-mentioned deficiencies of the prior art.

[0004] To achieve the above objectives, the present invention provides a method for protecting the operation of an electric valve, wherein the method for monitoring the status, diagnosing faults, and protecting the safety of the electric valve during operation includes the following steps:

[0005] S100, Status monitoring, real-time detection of voltage, current, torque and / or stroke parameters during the operation of the electric valve;

[0006] S200, Fault diagnosis: Compare the detected voltage, current, torque, and / or stroke parameters with corresponding set thresholds; determine the corresponding fault based on the comparison results; and send corresponding alarm prompts or auxiliary decision-making suggestions.

[0007] S300. Based on the alarm prompts or auxiliary decision-making suggestions, adjust the corresponding control parameters or control curves of the electric valve in real time to reduce speed or stop the machine immediately.

[0008] In the above-mentioned electric valve execution process protection method, the set threshold includes a prompt threshold and an alarm threshold, wherein the alarm threshold is greater than the prompt threshold; the prompt threshold includes a stage set current value, a warning voltage value, and a set torque value; the alarm threshold includes an alarm current value, an alarm voltage value, an alarm torque value, and a limit stroke value.

[0009] In the above-mentioned electric valve execution process protection method, in step S200, the corresponding faults are judged according to the comparison results, including overcurrent, overpressure, jamming and overtravel faults. The alarm prompts include overcurrent alarm, overpressure alarm, jamming alarm and overtravel alarm. After statistical analysis, query and analysis of valve operation history information, fault predictions of torque abnormality points, closing position error and / or starting torque error are obtained.

[0010] In the above-mentioned electric valve execution process protection method, when the real-time detected current value is greater than or equal to the stage set current value, the system continues to detect whether the current value is greater than or equal to the alarm current value. If so, an overcurrent fault is diagnosed and an overcurrent alarm is sent. When the real-time detected voltage value is greater than or equal to the warning voltage value, the system continues to detect whether the voltage value is greater than or equal to the alarm voltage value. If so, an overvoltage fault is diagnosed and an overvoltage alarm is sent. When the real-time detected torque value is greater than or equal to the set torque value, the system continues to detect whether the torque value is greater than or equal to the alarm torque value. If so, a jamming fault is diagnosed and a jamming alarm is sent. When the real-time detected stroke value is greater than or equal to the limit stroke value, an overtravel fault is diagnosed and an overtravel alarm is sent.

[0011] The above-mentioned electric valve execution process protection method further includes, in step S100, real-time detection of the electric valve's vibration, noise, flow rate, temperature, battery power and / or sensor failure parameters. If each parameter meets the set shutdown alarm conditions, a corresponding alarm message is sent.

[0012] The above-mentioned electric valve operation protection method includes automatic control of the electric valve operation through the following steps:

[0013] S001. 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.

[0014] S002. 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;

[0015] S003. Establish the equipment layer and generate a general control mode for electric valve control that meets the full-process control needs of various types and operating conditions; and

[0016] S004. When the triggering conditions are met, the optimal control method and / or control curve are generated according to 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 control of the specific electric valve.

[0017] During the full-process control or set control phase of the specific electric valve, monitoring, fault diagnosis, and protection of steps S100-S300 are performed simultaneously.

[0018] The above-mentioned electric valve execution process protection method uses 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. A PID control algorithm is used to monitor and / or correct the speed, torque and / or position parameters of the corresponding control unit in real time, so as to meet the response speed, control accuracy and safety requirements of each stage of the valve control process.

[0019] To better achieve the above objectives, the present invention also provides an electric valve execution process protection device, which includes a controller and employs the above-described electric valve execution process protection method to perform status monitoring, fault diagnosis, and safety protection during the electric valve control process.

[0020] To better achieve the above objectives, the present invention also provides a storage medium storing a computer program configured to execute the above-described electric valve execution process protection method during runtime.

[0021] To better achieve the above objectives, the present invention also provides an electronic device, comprising:

[0022] Processor; and

[0023] Memory for storing the executable instructions of the processor;

[0024] The processor is configured to execute the above-described electric valve execution process protection method by executing the executable instructions.

[0025] The technical advantages of this invention are as follows:

[0026] During the operation of electric valves, this invention can obtain the current status, corresponding causes, and development trends of valves and their actuators of different types, specifications, environments, and parameters through status monitoring and fault diagnosis. This provides support to users or helps them make decisions to ensure the safe, rapid, accurate, and long-term operation of valves and their actuators. Attached Figure Description

[0027] Figure 1 This is a flowchart of a protection method according to an embodiment of the present invention;

[0028] Figure 2 This is a flowchart of a protection method according to another embodiment of the present invention;

[0029] Figure 3 This is a valve operation curve diagram according to an embodiment of the present invention;

[0030] Figure 4 This is a valve operation curve diagram according to another embodiment of the present invention;

[0031] Figure 5 This is a schematic diagram of the output detection circuit according to an embodiment of the present invention.

[0032] Among them, the attached reference numerals

[0033] 1. Motor speed line

[0034] 2 Valve Plate Position Line

[0035] 3 Motor Torque Line Detailed Implementation

[0036] The structural and working principles of the present invention will be described in detail below with reference to the accompanying drawings:

[0037] See Figure 1 , Figure 1 This is a flowchart of a protection method according to an embodiment of the present invention. The electric valve execution process protection method of the present invention is used for status monitoring, fault diagnosis, and safety protection during the operation of the electric valve, so as to protect the valve and its pipeline system and ensure the safe and accurate execution process of valve control operation. The method includes the following steps:

[0038] Step S100: Status monitoring, which involves real-time detection of voltage, current, torque and / or stroke parameters during the operation of the electric valve; it may also include real-time detection of vibration, noise, flow, temperature, battery power and / or sensor status parameters of the electric valve, etc. If each parameter meets the set shutdown alarm conditions, a corresponding alarm message is sent.

[0039] Step S200: Fault diagnosis, comparing the detected voltage, current, torque and / or stroke parameters with corresponding set thresholds, determining the corresponding fault based on the comparison results, and sending corresponding alarm prompts or auxiliary decision-making suggestions; and

[0040] Step S300: Based on the alarm prompts or auxiliary decision-making suggestions, adjust the corresponding control parameters or control curves of the electric valve in real time, reduce speed, or stop the machine immediately.

[0041] In step S200, based on the comparison results, the corresponding faults are determined to include overcurrent, overpressure, jamming, and overtravel faults. The alarm prompts include overcurrent alarms, overpressure alarms, jamming alarms, and overtravel alarms. After statistical analysis, querying, and analyzing the valve's historical operating information, fault predictions for torque anomalies, closing position errors, and / or starting torque errors are obtained. Torque anomalies refer to the locations where peak torque and jamming alarms are concentrated during the valve's uniform speed operation phase. Through statistical analysis of peak torque locations and jamming locations, they are sorted according to frequency of occurrence and corresponding prompts are given. Closing position error refers to the deviation between the stop position and the closing position during valve initialization in each operation. If the closing position deviation frequently exceeds the allowable value (the allowable value can be set according to the valve structure and actual operating conditions), it indicates that the valve's closing result is unstable, possibly due to a fault in the position sensor or mechanical structure. If the closing position is relatively stable but the standard deviation is large, the possible reason is that the torque closed-loop control parameters are set unreasonably, resulting in inaccurate torque control. Starting torque error refers to the difference in peak torque during each starting process. Excessive starting torque and prolonged duration may be due to mechanical jamming at the starting position, while insufficient and unstable starting torque may be due to excessive acceleration time affecting execution efficiency.

[0042] All parameters, diagnostics, and alarm information can be acquired through communication between the controller or portable smart terminal and the valve actuator. After acquisition, the raw data can be directly recorded (stored in the form of a database or data table on the controller, portable smart terminal, or a remote server). Alternatively, the data can be displayed graphically on a screen or human-machine interface. Finally, some information is logically judged and processed to provide corresponding prompts for the operation process or potential valve safety hazards. This data can be displayed or prompted when parameters are set (or modified), when an alarm occurs, at the end of a single operation, during maintenance, and when status is queried.

[0043] The system can statistically analyze historical data from multiple operations of valves of different types, specifications, environments, and parameters. This data can be queried and analyzed using structured query language or data mining algorithms. Statistical parameters include inherent valve and actuator parameters, as well as data on time, mode, speed, torque, current, displacement, acceleration, deceleration, prompts, and alarms during valve opening / closing. Conclusions can be derived from assessing the valve and actuator's operating status, analyzing the causes of the current state, and predicting future operating trends. The system also allows verification of specific operation information, displayed in the desired format (trend curves, data tables, etc.) on a screen or human-machine interface. Query results can be used for valve inspection, maintenance, and operating parameter optimization.

[0044] By querying, statistically analyzing, and treating multi-source heterogeneous data, diagnostic results can be obtained regarding the current status, corresponding causes, and development trends of valves and their actuators of different types, specifications, environments, and parameters. This provides support to operators and helps them make informed decisions, ensuring the safe, rapid, accurate, and long-term operation of valves and their actuators. Analysis methods for structured operational data can include comparative analysis, grouping analysis, structural analysis, cross-analysis, matrix analysis, and comprehensive evaluation analysis. Analysis methods for large-scale multi-source heterogeneous data mainly include association analysis (using algorithms such as Apriori, FP-Growth, and Eclat), classification analysis (using algorithms such as Neural Network, KNN, Bayes, Decision Tree, and SVM), clustering analysis (using algorithms such as K-means, K-medoids, Clara, DBSCAN, and BIRCH), and predictive analysis (including algorithms such as Regression Analysis, Time Series, and Probability Estimate). For example: statistical analysis of the standard deviation of the historical stopping positions of a gate valve under the same parameter conditions can reveal the valve's closing position error; comparative analysis of this error at different times can reveal whether the mechanical structure of the valve actuator is worn or lacks lubrication; the torque error during the torque control stage of the gate valve closing process can determine whether the torque closed-loop parameter setting of the valve actuator is reasonable; denoising and feature analysis of operating data are performed using preprocessing methods such as filtering, smoothing, and wavelet analysis to extract original features; the frequency distribution and weight of interference or specific signals are confirmed through time-domain and frequency-domain analysis; and algorithm models are obtained and iteratively optimized through data annotation and algorithm training.

[0045] When parameters are set (or modified), when an alarm occurs, when a single run ends, during maintenance or inspection, or when the execution status is queried, the above analysis results can be displayed in the form of prompts or images. As the amount of basic data accumulates and the amount of analysis data increases, the number of diagnostic results that can be obtained will gradually increase, and the analysis methods can also be gradually enriched.

[0046] Decision-making relies on the query, statistics, and analysis of historical information. Suggestions are provided based on the diagnostic results, and the operator makes the final decision and execution, or the operator makes a decision directly based on data trends. Reasonable decisions ensure the safe, rapid, accurate, and long-term operation of valves and their actuators. For example: if the valve's operating torque gradually increases over a certain period, maintenance suggestions are provided, such as checking the lubrication of the mechanism and performing necessary repairs or on-site torque calibration; or if the valve's stopping position error increases during closing, maintenance suggestions are provided, such as checking for loose valve structure, deterioration of position sensor accuracy, and performing necessary repairs or initial parameter settings; or if there is concentrated jamming during a certain valve stroke, maintenance suggestions are provided, such as checking for abnormalities or wear in the mechanical structure; or if a short deceleration time causes an overpressure alarm during the valve's braking process, parameter adjustment suggestions are provided, such as adjusting the corresponding parameters or adding an external braking resistor; if a low torque limit during the constant speed operation phase leads to frequent jamming, parameter adjustment suggestions are provided, such as appropriately increasing the torque limit during this phase; furthermore, maintenance or replacement suggestions for components or the entire valve can be provided based on the valve's operating parameters throughout its lifespan, such as fault modes, fault frequency, and operating time.

[0047] See Figure 2 , Figure 2This is a flowchart of a protection method according to another embodiment of the present invention. In this embodiment, the set threshold includes a prompt threshold and an alarm threshold, wherein the alarm threshold is greater than the prompt threshold; the prompt threshold includes a stage set current value, a warning voltage value, and a set torque value; the alarm threshold includes an alarm current value, an alarm voltage value, an alarm torque value, and a limit stroke value. During operation, relevant parameters are continuously monitored. When the monitored parameter exceeds the set prompt threshold but does not reach the alarm threshold, a prompt message is issued, and monitoring and operation continue; when the monitored parameter exceeds the set alarm threshold, a prompt message is issued, and the system immediately enters a stop phase, slowing down or immediately shutting down. That is, prompts or shutdowns are issued according to the type and degree of danger of the prompt or alarm. After the alarm is cleared, the main process can be restarted, continuing operation from the breakpoint, and status monitoring and alarm diagnosis can continue. When the real-time detected current value is greater than or equal to the stage set current value, the system continues to detect whether the current value is greater than or equal to the alarm current value. If so, an overcurrent fault is diagnosed and an overcurrent alarm is sent. When the real-time detected voltage value is greater than or equal to the warning voltage value, the system continues to detect whether the voltage value is greater than or equal to the alarm voltage value. If so, an overvoltage fault is diagnosed and an overvoltage alarm is sent. When the real-time detected torque value is greater than or equal to the set torque value, the system continues to detect whether the torque value is greater than or equal to the alarm torque value. If so, a jamming fault is diagnosed and a jamming alarm is sent. When the real-time detected stroke value is greater than or equal to the limit stroke value, an overtravel fault is diagnosed and an overtravel alarm is sent.

[0048] In this embodiment, the operation of the electric valve is automatically controlled using the following steps:

[0049] Step S001: Construct a data layer, establish a database of multiple electric valves, and classify and store them according to the different structural characteristics, operating conditions, and usage requirements of the various electric valves; it can record and store valve operation history information, including parameters such as time, mode, speed, torque, current, displacement, acceleration, and deceleration during each valve opening and closing operation, as well as prompts (such as preventive maintenance, operation guidance, safety warnings, etc.) and alarms that occur during operation; wherein, the database of multiple electric valves includes an electric valve execution process data structure that is summarized and established based on the valve control principle and combined with the structural characteristics, operating conditions, and working strategies of the various electric valves; it can be classified according to valve The data structure is hierarchically divided into types, execution strategies, execution stages, and stage parameters. The instantiation process of the data structure is the process of setting the parameters for each stage of valve operation. The differences in valve types and the execution strategies applied are also reflected in this data structure. For example, if there is no torque control stage when controlling the intermediate position, the setting value of the "whether it is effective" parameter of the torque control unit should be "no". The difference between the precision priority strategy and the safety priority strategy of the gate valve is that the execution rate of each stage of the safety priority strategy is slowed down and the protection torque is reduced, so the corresponding parameters are different. The various electric valves mentioned in this embodiment may include gate valves, globe valves, butterfly valves, ball valves, plug valves, knife gate valves and / or dampers. The operating conditions include on / off operating conditions and / or throttling operating conditions.

[0050] Step S002: Establish a logic layer. Based on the different types and operational requirements of the various electric valves, establish corresponding control decision items for each electric valve. This layer can perform historical information statistics, queries, analysis, and decision-making. It can analyze torque anomalies, closing position errors, and starting torque errors, and predict faults. The control process of the electric valves is divided into multiple control units. The operating conditions, inflection points, and parameters of each control unit are set according to the type of electric valve and the corresponding control decision items. In this embodiment, the control decision items include a precision-priority strategy, a safety-priority strategy, and / or an efficiency-priority strategy to adapt to different valves, different operating environments, and different operational 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.

[0051] Step S003: Establish the 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

[0052] Step S004: When the triggering conditions are met, corresponding to different electric valve application requirements, an optimal control method and / or control curve are generated and bound to the corresponding electric valve. The general control mode is converted into a dedicated matching mode for the specific electric valve and used for the full-process control of the specific electric valve. During the full-process control or set control phase of the specific electric valve, the monitoring, fault diagnosis, and protection steps S100-S300 are performed simultaneously. That is, status monitoring and alarm diagnosis run through the entire operation of the valve actuator. Status monitoring and alarm diagnosis can be parallel "threads" with valve operation control; the electric valve execution process is a "multi-threaded" process where execution, monitoring, and diagnosis occur simultaneously.

[0053] 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 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 both include a disable judgment; if so, the operation jumps directly to the next control unit. The operating conditions of the starting unit, acceleration unit, constant speed unit, and deceleration unit all include a stop judgment. If the starting unit times out, the operation jumps directly to the stop unit. If the motor torque in the acceleration unit exceeds the acceleration torque limit or the acceleration times out, the operation jumps directly to the stop unit. If the valve plate position in the constant speed unit exceeds the constant speed limit position or the motor torque exceeds the constant speed torque limit, the operation jumps directly to the stop unit. If the motor torque in the deceleration unit exceeds the deceleration torque limit or the deceleration times out, the operation jumps directly to the stop unit.

[0054] 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.

[0055] 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.

[0056] This embodiment uses the set parameters and inflection points of each stage of the bound electric valve as input (which may include the starting stage, acceleration stage, constant speed stage, deceleration stage, approach stage, torque control stage, and / or stopping stage, setting specific parameters and inflection points for acceleration time, deceleration time, torque, speed, and / or stroke for each stage, such as setting starting speed, constant speed, stroke, approach speed, torque, and / or holding time, etc.). Correspondingly, the real-time speed, valve stroke, and / or real-time torque of the bound electric valve are used as feedback. A PID control algorithm is employed to monitor and / or instantly correct the speed, torque, and / or position parameters of the corresponding control unit to meet the response speed, control accuracy, and safety 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.

[0057] 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.

[0058] 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 sM The 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.

[0059] 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.

[0060] 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.

[0061] This invention enables real-time monitoring of the position, speed, and torque of electric valves. It employs a nested control and monitoring mode, from the inside out, using torque loops, speed loops, and position loops, or a nested torque loop and speed loop. The torque loop directly affects the torque, offering fast response and high accuracy, meeting the requirements for real-time 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 control logic, stop position accuracy, and safety.

[0062] Furthermore, this invention also provides an electric valve execution process protection device, including a controller, and employs the aforementioned electric valve execution process protection method for status monitoring, fault diagnosis, and safety protection during the electric valve control process. It should be noted that this device is used for action execution, and its functions can be implemented by several modules or units. In fact, according to embodiments of this 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.

[0063] The valve monitoring, transmission, and acquisition program runs on the controller. The program includes a quick connection method using graphic code information. By scanning the graphic code or RFID tag on the corresponding valve actuator, the controller obtains basic information such as the valve actuator's name, serial number, power, and communication address. Based on this information, it quickly establishes a connection between the valve actuator and the controller using one of three methods: serial bus, Bluetooth, or infrared. The controller can record and store historical valve operating information and has functions for historical information statistics, querying, analysis, and decision-making. It can analyze and predict faults related to torque anomalies, closing position errors, and starting torque errors. After establishing a connection, the controller can share valve actuator data and display it as curves. Curve formats can include line graphs, polygonal graphs, scatter plots, bar charts, Pareto charts, etc. (Example: Line graph...) Figure 3 and Figure 4 As shown, the curves in the figure include motor speed line 1, valve plate position line 2, and motor torque line 3. They can display the current execution cycle and the corresponding motor speed, motor torque, and valve plate position. The data type and display method of the curves can be added, deleted, and adjusted as needed.

[0064] This invention provides precise control and real-time monitoring of the valve displacement in stages, including the starting process, acceleration process, constant speed process, deceleration process, approach process, torque control process, and stopping process. It ensures that the starting process has sufficient torque to overcome the residual torque when closing the valve and the static friction resistance during starting; the constant speed process has an efficient execution rate to achieve rapid valve closing; 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.

[0065] In this embodiment, the valve actuator's stage position, torque, speed, and other parameters are all protected by range and logic. The valve closing process includes stages such as starting, acceleration, constant speed, deceleration, approach, torque control, and stopping. The valve opening process includes stages such as starting, acceleration, constant speed, deceleration, approach, and stopping. The starting position of each stage decreases sequentially as the basic principle of range protection, and the starting and ending positions of each stage should be within the total valve stroke, i.e.:

[0066] 0≤S n ≤S Max

[0067] Among them, S n S represents the initial position of any stage of the valve operation. Max It is the total stroke of the valve opening / closing.

[0068] The torque settings for each stage of valve opening / closing are related to the characteristics and operational requirements of that stage. For example, during the start-up stage, to overcome static friction, residual stress during the closing process, and system inertia, the maximum allowable torque output of the motor is used; during the torque control stage, to reasonably control the sealing specific pressure, the motor torque is generally limited to within 80% of the rated torque. The torque at each stage should also not exceed the output capacity limit of the motor or actuator, i.e.:

[0069] 0≤T≤2T n

[0070] Where T is the torque limit of the valve at any stage, T n It is the rated torque of an AC asynchronous motor.

[0071] The speed settings and limits for each stage of valve opening / closing are related to the characteristics and operational requirements of that stage. For example, the constant speed stage is characterized by a relatively long stroke, small and relatively stable load, and no risk of impact. Therefore, the constant speed stage generally operates at overspeed, with the upper speed limit being the maximum speed of the AC asynchronous motor (generally about twice the rated speed). The approach stage, due to its short stroke and the risk of impact, has a lower speed setting. The speed in each stage should also not exceed the output capacity limit of the motor or drive, i.e.:

[0072] 0 < V n ≤2n

[0073] Among them, V n is the motor speed at any stage of the valve, and n is the rated speed of the drive motor.

[0074] The stroke during the valve closing acceleration process is not less than the acceleration stroke for the corresponding acceleration time, the torque does not exceed the maximum torque of the motor, and the speed does not exceed the maximum speed of the motor. During the valve closing constant speed process, the stroke is not greater than the difference between the total valve stroke and the deceleration stroke, the torque limit is 30% to 80% of the motor's rated torque, and the speed does not exceed the motor's maximum speed. During the valve closing deceleration process, the ending position is not greater than the limit of the total valve stroke, the torque limit is 30% to 100% of the motor's rated torque, and the speed does not exceed 40% of the motor's rated speed. During the valve closing approach process, the ending position is not greater than the limit of the total valve stroke, the torque limit is 30% to 80% of the motor's rated torque, and the speed does not exceed 20% of the motor's rated speed. During the valve closing torque control process, the torque is not greater than the motor's rated torque, and the speed does not exceed 20% of the motor's rated speed. During the valve opening acceleration process, the stroke is not less than the acceleration stroke for the corresponding acceleration time, the torque does not exceed the maximum torque of the motor, and the speed does not exceed the motor's maximum speed. During the valve opening constant speed process, the stroke is not greater than the difference between the total valve stroke and the deceleration stroke, the torque limit is 30% to 70% of the motor's rated torque, and the speed does not exceed the motor's maximum speed.

[0075] 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.

[0076] The above method is applicable to valve actuator control where the encoder is the full-stroke measuring device, and is also compatible with technical solutions using limit switches as the measuring device. If a limit switch is used as the measuring device, the maximum operating speed can be appropriately reduced and the torque limit adjusted to ensure safe operation. Under the premise that the limit switch position is properly adjusted, a stable valve closing sealing pressure can still be ensured.

[0077] The entire operation process includes electrical parameter protection, such as overheat, overcurrent, undervoltage, overvoltage, and phase loss protection for the valve actuator, and overcurrent, overtorque, overvoltage, and phase loss protection for the AC asynchronous motor. Torque protection includes monitoring and protection against jamming, protecting not only the valve actuator and AC asynchronous motor but also, to a certain extent, the valve's mechanical structure. Speed, stroke, torque, and current parameters are monitored at each stage; a shutdown alarm is triggered when the corresponding parameter exceeds the overall or stage limits. Each stage also monitors position sensor input and its failure status. For example, if a sensor is set, a shutdown alarm is triggered when the sensor signal is abnormally disconnected (e.g., both positive and negative limit signals are disconnected simultaneously); if an encoder is set, a shutdown alarm is triggered when the motor is running and the encoder signal has no feedback for a predetermined period. The valve actuator has an internal temperature sensor that detects the internal temperature and controls the intermittent operation of the cooling fan. An alarm and shutdown are triggered when the temperature exceeds the safe temperature (generally, the actuator temperature does not exceed 70°C). The internal DC bus voltage of the valve actuator is monitored, and an alarm and shutdown are triggered when the voltage exceeds the allowable range (adjustable). A DC bus voltage below the lower limit of the allowable range is considered undervoltage, and above the upper limit is considered overvoltage. Overheat protection uses the motor's own temperature sensor (mainly a bimetallic strip sensor with switching output; some high-end motors are equipped with platinum resistance or thermocouple sensors with analog output). The valve actuator receives the sensor signal and determines the motor status, stopping operation and triggering an alarm when overheating occurs. Jamming refers to over-torque, deceleration, or stopping caused by unexpected resistance during valve operation. The valve actuator relies on real-time torque detection to determine jamming. For example, during constant speed operation, the torque is typically 30%–50% of the rated torque. If the torque suddenly increases and exceeds 70% of the rated torque during this phase, it can be considered jamming.

[0078] In this embodiment, overcurrent, overtorque, overvoltage, and phase loss protection can all be implemented by the internal output detection circuit of the valve actuator. (See [link to relevant documentation]). Figure 5 , Figure 5 This is a schematic diagram of the output detection circuit according to another embodiment of the present invention. As shown in the figure, this circuit is one phase of a three-phase output (the circuit structures of the other two phases are the same as this phase). The circuit measures the voltage drop across resistor RC3 and converts it into output current, which can detect overcurrent in a certain phase; based on the relationship between current and torque, overtorque can be determined; when the three-phase output circuit operates simultaneously, it can detect whether there is a phase loss in the output; the current and impedance are converted into output voltage to detect undervoltage, overvoltage, etc.

[0079] This embodiment can also employ logic interlock protection to lock out erroneous operations or incorrect input signals, thereby protecting the safety of equipment and personnel. For example: valve opening or closing operations are not allowed without performing initialization settings; the "close valve" button is not responded to during valve opening; the motor cannot be powered on and started when the electric hand controller is working; and operations other than alarm confirmation are not responded to when the alarm is not confirmed.

[0080] 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 electric valve execution process protection method 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.

[0081] 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 operator 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 corresponding "data string instruction" is selected based on its characteristics and transmitted to the valve actuator. The corresponding subroutine of the logic layer is then reorganized according to the information in the "data string instruction" to complete 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.

[0082] 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.

[0083] 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.

[0084] 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. The readable signal medium may also be any readable medium other than a readable storage medium, capable of transmitting, propagating, or transmitting a program for use by or in connection with an instruction execution system, apparatus, or device. 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.

[0085] 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.

[0086] 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 execute the above-described electric valve execution process protection method by executing the executable instructions.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] The electronic device can also communicate with one or more external devices (e.g., keyboards, pointing devices, Bluetooth devices, etc.), devices that one or more operators can interact with, and / or any device that allows the electronic device to communicate with one or more other computing devices (e.g., routers, modems, etc.). This communication can be achieved 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.

[0091] 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.

[0092] During the operation of electric valves, this invention can obtain the current status, corresponding causes, and development trends of valves and their actuators of different types, specifications, environments, and parameters through status monitoring and fault diagnosis. This provides support to users or helps them make decisions to ensure the safe, rapid, accurate, and long-term operation of valves and their actuators.

[0093] 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 method for protecting an electric valve during its operation, characterized in that, For status monitoring, fault diagnosis, and safety protection during the operation of electric valves, the following steps are included: S100, Status monitoring, real-time detection of voltage, current, torque and / or stroke parameters during the operation of the electric valve; S200, Fault diagnosis: compare the detected voltage, current, torque and / or stroke parameters with the corresponding set thresholds, determine the corresponding fault based on the comparison results and send the corresponding alarm prompts or auxiliary decision suggestions; as well as S300. Based on the alarm prompts or auxiliary decision-making suggestions, adjust the corresponding control parameters or control curves of the electric valve in real time to reduce speed or stop the machine immediately. The operation of the electric valve is automatically controlled using the following steps: S001. 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. S002. 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; S003. Establish the equipment layer and generate a general control mode for electric valve control that meets the full-process control needs of various types and operating conditions; and S004. When the triggering conditions are met, the optimal control method and / or control curve are generated according to 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 control of the specific electric valve. During the full-process control or set control phase of the specific electric valve, monitoring, fault diagnosis, and protection of steps S100-S300 are performed simultaneously.

2. The method for protecting the electric valve during operation as described in claim 1, characterized in that, The set thresholds include a prompt threshold and an alarm threshold, wherein the alarm threshold is greater than the prompt threshold; the prompt threshold includes a stage set current value, a warning voltage value, and a set torque value; the alarm threshold includes an alarm current value, an alarm voltage value, an alarm torque value, and a limit stroke value.

3. The method for protecting the electric valve during operation as described in claim 2, characterized in that, In step S200, based on the comparison results, the corresponding faults are determined to include overcurrent, overpressure, jamming, and overtravel faults. The alarm prompts include overcurrent alarm, overpressure alarm, jamming alarm, and overtravel alarm. After statistical analysis, querying, and analysis of the valve's historical operating information, fault predictions are obtained for abnormal torque points, closing position errors, and / or starting torque errors.

4. The method for protecting the electric valve during operation as described in claim 3, characterized in that, When the real-time detected current value is greater than or equal to the stage set current value, the system continues to detect whether the current value is greater than or equal to the alarm current value. If so, an overcurrent fault is diagnosed and an overcurrent alarm is sent. When the real-time detected voltage value is greater than or equal to the warning voltage value, the system continues to detect whether the voltage value is greater than or equal to the alarm voltage value. If so, an overvoltage fault is diagnosed and an overvoltage alarm is sent. When the real-time detected torque value is greater than or equal to the set torque value, the system continues to detect whether the torque value is greater than or equal to the alarm torque value. If so, a jamming fault is diagnosed and a jamming alarm is sent. When the real-time detected stroke value is greater than or equal to the limit stroke value, an overtravel fault is diagnosed and an overtravel alarm is sent.

5. The method for protecting the electric valve during operation as described in claim 1, characterized in that, Step S100 also includes real-time detection of the vibration, noise, flow rate, temperature, battery power and / or sensor failure parameters of the electric valve. If each parameter meets the set shutdown alarm conditions, a corresponding alarm message is sent.

6. The method for protecting the electric valve during operation as described in claim 1, characterized in that, Using 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, a PID control algorithm is used to monitor and / or correct the speed, torque and / or position parameters of the corresponding control unit in real time, so as to meet the response speed, control accuracy and safety requirements of each stage of the valve control process.

7. A protection device for the operation of an electric valve, characterized in that, It includes a controller and employs the electric valve execution process protection method according to any one of claims 1-6 to perform status monitoring, fault diagnosis, and safety protection during the electric valve control process.

8. A storage medium, characterized in that, The storage medium stores a computer program, which is configured to execute the electric valve actuation process protection method according to any one of claims 1-6 when running.

9. 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 electric valve actuation process protection method according to any one of claims 1-6 by executing the executable instructions.

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