Valve island diagnosis method, control system, bus valve island and storage medium

Abstract

This application discloses a valve island diagnostic method, control system, bus valve island, and storage medium, relating to the field of electrical control. The method includes: acquiring the real-time power signal of the valve seat; when the real-time power signal meets preset power diagnostic conditions, acquiring the valve disc insertion monitoring signal to obtain the number of valve discs inserted on the valve seat, thereby determining the theoretical current value of the valve seat; when the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, acquiring the number of operations of each valve disc and the number of operations of the actuator connected to the valve disc; and diagnosing the mechanical life of the valve island based on the number of operations of the valve discs and the actuator, thereby obtaining the valve island diagnostic result. This application solves the problem that bus valve islands lack fault diagnosis functions, and provides multiple diagnostic functions for the valve island, enabling timely understanding of the valve island's condition and timely implementation of corrective measures.

Description

Technical Field

[0001] This application relates to the field of electrical control technology, and in particular to a valve island diagnostic method, a control system, a bus valve island, and a storage medium. Background Technology

[0002] Valve islands are a new generation of pneumatic components integrating pneumatic and electromechanical systems. They have evolved from the initial valve islands with multi-pin interfaces to those with fieldbus interfaces, greatly simplifying the debugging, performance testing, diagnosis, and maintenance of complex systems. Most existing bus-based valve islands use simple I / O control, and the valve plates are susceptible to various factors during use, leading to issues such as poor valve plate contact and short circuits. When these situations occur, existing bus-based valve islands lack fault diagnosis capabilities, which may not only damage the valve plates but also the entire valve island, affecting subsequent operations.

[0003] Therefore, providing a bus valve island with fault diagnosis function is an urgent problem to be solved. Summary of the Invention

[0004] The main objective of this application is to provide a valve island diagnostic method, a control system, a bus valve island, and a storage medium, aiming to solve the technical problem that bus valve islands in related technologies do not have fault diagnosis functions.

[0005] To achieve the above objectives, this application adopts the following technical solution:

[0006] In a first aspect, this application provides a valve island diagnostic method, wherein the valve island includes a valve seat and a valve disc; the method includes:

[0007] Obtain the real-time power signal of the valve seat;

[0008] When the real-time power signal meets the preset power diagnostic conditions, the valve plate insertion monitoring signal is collected to obtain the number of valve plates inserted on the valve seat, so as to determine the theoretical current value of the valve seat.

[0009] When the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, the number of working times of each valve plate and the number of working times of the actuator connected to the valve plate are obtained.

[0010] The mechanical life of the valve island is diagnosed based on the number of times the valve plate and the actuator operate, and the valve island diagnosis results are obtained.

[0011] Optionally, in the above valve island diagnostic method, the real-time power signal includes the real-time voltage value of the valve plate and the real-time current value of the valve seat.

[0012] Before the step of acquiring the valve disc insertion monitoring signal to obtain the number of valve discs inserted on the valve seat and determining the theoretical current value of the valve seat when the real-time power signal meets the preset power diagnostic conditions, the method further includes:

[0013] Determine whether the real-time voltage value of the valve plate is within the preset threshold range;

[0014] If the real-time voltage value of the valve plate is not within the preset threshold range, an overvoltage alarm or an undervoltage alarm will be triggered.

[0015] If the real-time voltage value of the valve plate is within the preset threshold range, then it is further determined whether the real-time current value of the valve seat is below the preset threshold value.

[0016] If the real-time current value of the valve seat is not below the preset threshold, an overload alarm for the valve plate will be triggered.

[0017] If the real-time current value of the valve seat is below the preset threshold, the real-time power signal is determined to meet the preset power diagnostic conditions.

[0018] Optionally, in the above valve island diagnostic method, the step of acquiring the valve disc insertion monitoring signal to obtain the number of valve discs inserted on the valve seat, and determining the theoretical current value of the valve seat, includes:

[0019] The insertion status value of each valve plate is obtained by collecting the insertion monitoring signal of each valve plate;

[0020] The number of valve discs inserted on the valve seat is determined based on the insertion status value;

[0021] The theoretical current value of the valve seat is obtained by summing the product of the number of valve discs and the theoretical current value of a single valve disc with the static current value of the valve seat; where the static current value of the valve seat is the current value of the valve seat when all valve discs on the valve seat are in the closed state.

[0022] Optionally, in the above valve island diagnostic method, after the step of obtaining the insertion state value of each valve plate by collecting the insertion monitoring signal of each valve plate, the method further includes:

[0023] Determine whether a valve plate has detached based on the insertion status value;

[0024] If a valve disc detaches, a valve disc detachment alarm will be triggered.

[0025] If no valve disc has fallen off, proceed with the step of determining the number of valve discs inserted into the valve seat based on the insertion status value.

[0026] Optionally, in the above valve island diagnostic method, after the step of acquiring the valve disc insertion monitoring signal to obtain the number of valve discs inserted on the valve seat in order to determine the theoretical current value of the valve seat, the method further includes:

[0027] Determine whether the real-time current value in the real-time power signal is greater than the theoretical current value of the valve seat;

[0028] If the real-time current value in the real-time power signal is greater than the theoretical current value of the valve seat, an alarm for abnormal valve plate current will be triggered.

[0029] If the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, then the steps of obtaining the number of times each valve plate operates and the number of times the actuator connected to the valve plate operates are executed.

[0030] Optionally, in the above valve island diagnostic method, the step of diagnosing the mechanical life of the valve island based on the number of times the valve plate and the actuator operate, and obtaining the valve island diagnostic result, includes:

[0031] Determine whether the number of times the valve plate operates exceeds the preset first count value;

[0032] If the number of times the valve plate operates does not exceed the first count value, then it is further determined whether the number of times the actuator operates exceeds the preset second count value;

[0033] If the number of times the valve plate operates exceeds the first count value, then based on the preset first configuration information, a valve plate life warning is performed and / or the step of judging whether the number of times the actuator operates exceeds the preset second count value is executed.

[0034] If the actuator's number of operations does not exceed the second count value, then update the valve plate's number of operations and the actuator's number of operations, and obtain the valve island diagnostic results;

[0035] If the number of times the actuator operates exceeds the second count value, then according to the preset second configuration information, the steps of performing actuator life warning and / or performing updates on the number of times the valve plate operates and the number of times the actuator operates are performed, and valve island diagnostic results are obtained.

[0036] Optionally, in the above valve island diagnosis method, after the step of diagnosing the mechanical life of the valve island based on the number of working cycles of the valve plate and the actuator to obtain the valve island diagnosis result, the method further includes:

[0037] When the valve island diagnostic result meets all diagnostic conditions, a valve control signal is generated to drive the valve to work.

[0038] Secondly, this application provides a valve island control system, the valve island including a valve seat and a valve disc; the system includes:

[0039] The control module is used to implement the valve island diagnostic method described above;

[0040] The power monitoring module is connected to the control module and is used to monitor the power supply of the valve seat and output the real-time power signal of the valve seat to the control module.

[0041] An insertion monitoring module, connected to the control module, is used to monitor the insertion of the valve plate and outputs the valve plate insertion monitoring signal to the control module.

[0042] The valve plate drive module is connected to the control module and is used to drive the valve plate to work according to the valve plate control signal output by the control module.

[0043] Thirdly, this application provides a bus valve island, which includes:

[0044] Valve seat;

[0045] The valve disc inserted into the valve seat; and

[0046] A valve island control system, as described above, is installed within the valve seat.

[0047] Fourthly, this application provides a computer-readable storage medium storing a computer program that, when executed by one or more processors, implements the valve island diagnostic method described above.

[0048] The above-mentioned one or more technical solutions provided in this application may have the following advantages or at least achieve the following technical effects:

[0049] This application proposes a valve island diagnostic method, control system, bus valve island, and storage medium. The method acquires the real-time power signal of the valve seat. When the real-time power signal meets preset power diagnostic conditions, it collects the valve disc insertion monitoring signal to obtain the number of valve discs inserted on the valve seat, thus determining the theoretical current value of the valve seat. When the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, it acquires the number of operations of each valve disc and the number of operations of the actuator connected to the valve disc, diagnosing the mechanical life of the valve island and obtaining the valve island diagnostic result. In this process, valve seat power diagnostics are performed first, followed by valve disc insertion monitoring, then current anomaly diagnostics, and finally mechanical life diagnostics. This provides multiple diagnostic functions for the valve island, allowing for the acquisition of more diagnostic information to facilitate timely understanding of the valve island's condition and timely implementation of measures to avoid affecting its operation. Attached Figure Description

[0050] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these provided drawings without creative effort.

[0051] Figure 1 This is a flowchart illustrating the first embodiment of the valve island diagnostic method of this application;

[0052] Figure 2 This is a schematic diagram of the hardware structure of the bus valve island involved in this application;

[0053] Figure 3 This is a flowchart illustrating the second embodiment of the valve island diagnostic method of this application;

[0054] Figure 4 for Figure 3 Detailed flowchart of step S400;

[0055] Figure 5 This is a functional module diagram of the first embodiment of the valve island control system of this application.

[0056] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and accompanying drawings. Detailed Implementation

[0057] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0058] It should be noted that in this application, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or system. Without further limitations, an element defined by the phrase "comprising..." does not exclude the presence of other identical elements in the process, method, article, or system that includes that element. Furthermore, the meaning of "and / or" throughout the text includes three parallel options; for example, "A and / or B" includes option A, option B, or options where both A and B are satisfied. In this application, unless otherwise expressly specified and limited, the terms "connected," "fixed," etc., should be interpreted broadly. For example, "connected" can be a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal communication of two elements or the interaction between two elements. In this application, descriptions involving terms such as "first" and "second" are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. In this application, suffixes such as "module," "component," or "unit" used to denote elements are used solely for illustrative purposes and have no specific meaning in themselves. Therefore, "module," "component," or "unit" can be used interchangeably. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances. Furthermore, the technical solutions of the various embodiments can be combined with each other; however, this is based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0059] Analysis of the relevant technologies revealed that most existing bus valve islands use simple IO control, and the valve plates are easily affected by various factors during use, resulting in poor valve plate contact, valve plate short circuits, and other problems.

[0060] At the same time, since the mechanical parts of the valve plate have a limited lifespan, if the valve plate is not replaced in time when its lifespan expires, it may cause the valve plate to malfunction.

[0061] When the above situation occurs, the existing bus valve island does not have fault diagnosis function, which may not only cause damage to the valve plate, but also damage to the valve island and affect subsequent execution.

[0062] In view of the technical problem that bus valve islands in related technologies do not have fault diagnosis functions, this application provides a valve island diagnosis method, the general idea of ​​which is as follows:

[0063] Acquire the real-time power signal of the valve seat; when the real-time power signal meets the preset power diagnostic conditions, acquire the valve disc insertion monitoring signal to obtain the number of valve discs inserted on the valve seat, so as to determine the theoretical current value of the valve seat; when the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, acquire the number of working times of each valve disc and the number of working times of the actuator connected to the valve disc; based on the number of working times of the valve discs and the number of working times of the actuator, diagnose the mechanical life of the valve island and obtain the valve island diagnostic result.

[0064] The above technical solution first performs valve seat power supply diagnosis, then valve plate insertion monitoring, followed by current anomaly diagnosis, and finally mechanical life diagnosis. This provides multiple diagnostic functions for the valve island, allowing for the acquisition of more diagnostic information about the valve island. This enables timely understanding of the valve island's condition and timely implementation of measures to avoid affecting its operation.

[0065] The valve island diagnostic method, control system, bus valve island, and storage medium provided in this application will be described in detail below with reference to the accompanying drawings and through specific embodiments and implementation methods.

[0066] Example 1

[0067] Reference Figure 1 This application presents a first embodiment of a valve island diagnostic method, which is applied to a bus valve island.

[0068] Bus-connected valve islands refer to valve islands equipped with fieldbus connectivity, such as... Figure 2 The diagram shows the hardware structure of a bus valve island. A bus valve island may include:

[0069] Valve seat 10;

[0070] The valve disc 20 inserted on the valve seat 10; and

[0071] A valve island control system installed within the valve seat 10.

[0072] The valve island control system includes a control module that can implement the valve island diagnostic method of this embodiment.

[0073] Specifically, the control module may include a processor and memory. The memory stores various types of data, including instructions for any program or method within the control module, as well as program-related data. The memory may be internal memory; alternatively, it may be a processor-independent storage device. The memory may include valve island diagnostic programs. The processor calls the valve island diagnostic programs stored in the memory and performs the following operations:

[0074] Obtain the real-time power signal of the valve seat;

[0075] When the real-time power signal meets the preset power diagnostic conditions, the valve plate insertion monitoring signal is collected to obtain the number of valve plates inserted on the valve seat, so as to determine the theoretical current value of the valve seat.

[0076] When the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, the number of working times of each valve plate and the number of working times of the actuator connected to the valve plate are obtained.

[0077] The mechanical life of the valve island is diagnosed based on the number of times the valve plate and the actuator operate, and the valve island diagnosis results are obtained.

[0078] Based on the aforementioned bus valve island and its control module, the following section combines... Figure 1 The flowchart shown illustrates the valve island diagnostic method of this embodiment in detail. The method may include the following steps:

[0079] Step S100: Obtain the real-time power signal of the valve seat.

[0080] Specifically, a power monitoring module can be installed inside the valve seat to monitor the voltage and current of the valve seat and send the monitored power signal to the control module, so that the control module can obtain the real-time power signal of the valve seat, which may include real-time current and real-time voltage.

[0081] Step S200: When the real-time power signal meets the preset power diagnostic conditions, the valve plate insertion monitoring signal is collected to obtain the number of valve plates inserted on the valve seat, so as to determine the theoretical current value of the valve seat.

[0082] Specifically, after acquiring the real-time power signal, power supply diagnostics can be performed. Power supply diagnostics can include one or more of the following: overvoltage diagnostics, undervoltage diagnostics, or overload diagnostics. The corresponding power supply diagnostic conditions for overvoltage diagnostics can include real-time voltage within a preset range or real-time voltage not exceeding a preset maximum threshold. The corresponding power supply diagnostic conditions for undervoltage diagnostics can include real-time voltage within a preset range or real-time voltage reaching a preset minimum threshold. The corresponding power supply diagnostic conditions for overload diagnostics can include real-time current within a preset range or not exceeding a preset maximum threshold. These conditions can be set according to actual needs. Based on the above power supply diagnostic conditions, if all are met, the valve seat can be considered to be working normally, and there is no overvoltage, undervoltage, or overload fault. At this time, the valve disc insertion monitoring signal can be collected to obtain the number of valve discs inserted on the valve seat, thereby determining the theoretical current value of the valve seat.

[0083] An insertion monitoring module can be installed inside the valve seat to monitor the insertion holes of each valve disc on the valve seat. When the valve disc is properly inserted into the valve seat, a corresponding insertion monitoring signal is generated and sent to the control module. The control module can then acquire the insertion monitoring signal of the valve disc, determine the number of valve discs inserted into the valve seat based on the number of received insertion monitoring signals, and calculate the theoretical current value of the valve seat based on the number of valve discs. The theoretical current value of the valve seat can be the product of the theoretical current value of a single valve disc and the number of valve discs, or it can be the sum of the product of the theoretical current value of a single valve disc and the number of valve discs plus the static current value of the valve seat. The static current value of the valve seat is the current value of the valve seat when all valve discs are in the closed state, which can be obtained through the power monitoring module.

[0084] Step S300: When the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, obtain the number of times each valve plate operates and the number of times the actuator connected to the valve plate operates.

[0085] Specifically, after calculating the theoretical current value of the valve seat based on the number of valve plates inserted on it, this value can be compared with the real-time current in the real-time power signal of the valve seat obtained in step S100. If the real-time current value in the real-time power signal is greater than the theoretical current value of the valve seat, it indicates that the working current of all valve plates on the valve seat, i.e., the total current, exceeds the theoretically achievable total current. In this case, one or more valve plates may be short-circuited, leading to abnormal working current. This indicates that the valve seat is in an abnormal working state, i.e., there is a fault of abnormal valve plate current. If the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, it indicates that the valve seat is in a normal working state, the working current of each valve plate on the valve seat is normal, and there is no fault of abnormal valve plate current. The next step can then be performed, specifically by obtaining the number of times each valve plate operates and the number of times the actuator connected to the valve plate operates.

[0086] A valve disc drive module can be installed inside the valve seat. When it receives a valve disc control signal from the control module, it can drive the valve disc to perform one operation based on the control signal. Correspondingly, the number of valve disc control signals output by the control module indicates the number of times the valve disc has performed operations, thus allowing the determination of the number of operations for each valve disc. One or more actuators can be connected to a single valve disc. The operation of the valve disc drives the actuators to operate. In addition to counting the number of operations of the valve disc, the number of operations of the connected actuators can also be counted to obtain the number of operations for each actuator.

[0087] Step S400: Based on the number of times the valve plate operates and the number of times the actuator operates, diagnose the mechanical life of the valve island and obtain the valve island diagnosis result.

[0088] Specifically, valve plates and actuators, as mechanical structures of the valve island, have limited lifespans. Therefore, the lifespan of valve plates and actuators can be predicted by counting the number of times they operate.

[0089] When the number of operations of the valve disc reaches a preset threshold, it indicates that the remaining lifespan of the valve disc is insufficient and a failure may occur at any time. A lifespan diagnosis result indicating insufficient valve disc lifespan can be obtained. Similarly, when the number of operations of the actuator reaches a preset threshold, it indicates that the remaining lifespan of the actuator is also insufficient and a failure may occur at any time. A lifespan diagnosis result indicating insufficient actuator lifespan can be obtained. Both insufficient valve disc and insufficient actuator lifespan can be summarized in the valve island diagnostic results and displayed to the user. When the number of operations of both the valve disc and the actuator does not reach the preset threshold, it indicates that the mechanical lifespan of the valve island is sufficient and there is no risk of nearing the end of its lifespan. At this point, several stages of diagnostic testing have been completed, including valve seat power supply diagnosis and valve disc insertion monitoring in step S200, current anomaly diagnosis in step S300, and mechanical lifespan diagnosis in step S400. Since all diagnostic results are normal, the final diagnostic result can be summarized as the valve island diagnostic result and displayed to the user.

[0090] The valve island diagnostic method provided in this embodiment acquires the real-time power signal of the valve seat; when the real-time power signal meets the preset power diagnostic conditions, it collects the valve plate insertion monitoring signal to obtain the number of valve plates inserted on the valve seat, thereby determining the theoretical current value of the valve seat; when the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, it acquires the number of working times of each valve plate and the number of working times of the actuator connected to the valve plate, diagnoses the mechanical life of the valve island, and obtains the valve island diagnostic result; in this process, the valve seat power diagnosis is performed first, followed by valve plate insertion monitoring, then current anomaly diagnosis, and finally mechanical life diagnosis, providing multiple diagnostic functions for the valve island, which can acquire more diagnostic information about the valve island, so as to understand the valve island's condition in a timely manner and take timely measures to avoid affecting the operation of the valve island.

[0091] Example 2

[0092] Based on the same inventive concept, referring to Figures 3 to 4 The present application proposes a second embodiment of the valve island diagnostic method, which is applied to a bus valve island.

[0093] The following is combined with Figure 3 The flowchart shown illustrates the valve island diagnostic method of this embodiment in detail. The method may include the following steps:

[0094] Step S100: Obtain the real-time power signal of the valve seat.

[0095] The real-time power signal includes the real-time voltage value of the valve plate and the real-time current value of the valve seat.

[0096] Specifically, such as Figure 3 As shown, step S100 may include:

[0097] Step S110: Obtain the real-time voltage value of the valve plate and the real-time current value of the valve seat.

[0098] In this embodiment, the real-time voltage value of the valve plate and the real-time current value of the valve seat can be collected by the power monitoring module. The real-time current value is the real-time total current of all valve plates on the valve seat. The power monitoring module sends the collected real-time voltage value and real-time current value to the control module in the form of a real-time power signal. The control module parses the data to obtain the real-time voltage value of the valve plate and the real-time current value of the valve seat.

[0099] Step S200: When the real-time power signal meets the preset power diagnostic conditions, the valve plate insertion monitoring signal is collected to obtain the number of valve plates inserted on the valve seat, so as to determine the theoretical current value of the valve seat.

[0100] Specifically, such as Figure 3 As shown, step S200 may include:

[0101] Step S210: When the real-time power signal meets the preset power diagnostic conditions, the insertion status value of each valve plate is obtained by collecting the insertion monitoring signal of each valve plate.

[0102] Step S220: Determine the number of valve plates inserted on the valve seat based on the insertion status value;

[0103] Step S230: Obtain the theoretical current value of the valve seat by summing the product of the number of valve plates and the theoretical current value of a single valve plate with the static current value of the valve seat; wherein, the static current value of the valve seat is the current value of the valve seat when all valve plates on the valve seat are in the closed state.

[0104] Specifically, when the real-time power signal meets the preset power diagnostic conditions, it indicates that there is no power failure in the valve seat and valve plate, and subsequent normal operation can be performed. At this time, the control module can control the insertion monitoring module to collect the insertion monitoring signal of each valve plate. The insertion monitoring signal contains the insertion status value of the valve plate. After the control module obtains the insertion monitoring signal, it analyzes it to obtain the insertion status value of each valve plate. When the insertion status value of a certain valve plate is 1, it means that the valve plate is inserted normally. When the insertion status value of a certain valve plate is 0, it means that the valve plate is not inserted normally and there is a situation where the valve plate is dislodged. Regardless of whether there is a valve plate dislodged, the number of valve plates normally inserted on the valve seat can be determined directly based on the insertion status value of each valve plate. Then, the theoretical current value of the valve seat is obtained by multiplying the number of valve plates and the theoretical current value of a single valve plate, and adding the static current value of the valve seat. The theoretical current value of a single valve disc can be preset. Since the valve discs used on the valve seat are generally of the same type, the theoretical current values ​​of each valve disc can be consistent. Understandably, if the valve seat can use different types of valve discs, then the theoretical current value of that type of valve disc can be determined based on the valve disc type, and then the theoretical current values ​​of that type of valve disc can be summed, and then the theoretical current values ​​of all valve discs can be summed. The static current value of the valve seat can be collected by the power monitoring module during system initialization, when all valve discs on the valve seat are in the closed state.

[0105] In this embodiment, the static power consumption of the valve seat is taken into account, and a more accurate theoretical current value of the valve seat can be calculated so as to achieve more accurate current anomaly diagnosis based on the theoretical current value.

[0106] Step S300: When the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, obtain the number of times each valve plate operates and the number of times the actuator connected to the valve plate operates.

[0107] Specifically, when the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, both the valve seat and the valve disc on the valve island are working normally. The control module can then proceed to the next diagnostic step, first obtaining the number of operations of each valve disc and the number of operations of the actuator connected to the valve disc. The number of operations can be counted by the control module based on its own output valve disc control signal, or it can be counted by the valve disc drive module that receives the valve disc control signal, which then identifies the specific valve disc and actuator being controlled.

[0108] Step S400: Based on the number of times the valve plate operates and the number of times the actuator operates, diagnose the mechanical life of the valve island and obtain the valve island diagnosis result.

[0109] Specifically, such as Figure 4 The detailed process diagram shown may include step S400 as follows:

[0110] Step S410: Determine whether the number of times the valve plate operates exceeds the preset first count value;

[0111] Step S420: If the number of times the valve plate operates does not exceed the first count value, then further determine whether the number of times the actuator operates exceeds the preset second count value;

[0112] Step S430: If the number of times the valve plate operates exceeds the first count value, then according to the preset first configuration information, perform valve plate life warning and / or execute the step of judging whether the number of times the actuator operates exceeds the preset second count value;

[0113] Step S440: If the number of times the actuator operates does not exceed the second count value, then update the number of times the valve plate operates and the number of times the actuator operates, and obtain the valve island diagnosis result;

[0114] Step S450: If the number of times the actuator operates exceeds the second count value, then according to the preset second configuration information, perform actuator life warning and / or update the number of times the valve plate operates and the number of times the actuator operates, and obtain the valve island diagnosis result.

[0115] Specifically, after the control module obtains the number of operations of each valve plate and each actuator connected to the valve plate, it can perform valve plate life prediction and actuator life prediction respectively, i.e., perform mechanical life diagnosis of the valve island. The preset first count value can be the preset maximum number of operations of the valve plate; the preset second count value can be the preset maximum number of operations of the actuator. The preset first configuration information can include whether to allow continued operation after the valve plate reaches its maximum number of operations; the preset second configuration information can include whether to allow continued operation after the actuator reaches its maximum number of operations. This can prevent situations where directly stopping the operation of the valve plate or actuator when it has reached its maximum number of operations but can still continue to operate may actually affect the operation of the valve island.

[0116] The control module performs mechanical life diagnosis on the valve island. First, it determines whether the number of times the valve plate has operated exceeds a preset first count value. If the number of times the valve plate has operated does not exceed the first count value, it can further determine whether the number of times the actuator has operated exceeds a preset second count value. If the number of times the valve plate has operated exceeds the first count value, it can obtain preset first configuration information. If the first configuration information indicates that the valve plate can continue to operate after reaching its maximum number of operations, it can further determine whether the number of times the actuator has operated exceeds the preset second count value. At the same time, it can also issue a valve plate life warning when performing further judgment operations. If the first configuration information indicates that the valve plate will not continue to operate after reaching its maximum number of operations, it can only issue a valve plate life warning to remind the user to replace the valve plate in time.

[0117] Regarding further determining whether the actuator's operating count exceeds a preset second count value; if the actuator's operating count does not exceed the second count value, it indicates that both the valve plate and the actuator still have remaining lifespan. In this case, the valve plate's and actuator's operating counts can be updated, specifically by incrementing each count once, and obtaining the valve island diagnostic result. This result indicates that there is no power supply fault or abnormal current fault, and both the valve plate and actuator have remaining lifespan within the valve island's mechanical lifespan, or the valve plate has no remaining lifespan but the actuator does. If the actuator's operating count exceeds the second count value, then a preset second configuration information is obtained. If the second configuration information indicates that the actuator can continue to operate after reaching its maximum number of working cycles, then the number of working cycles of the valve plate and the actuator can be updated, and the valve island diagnostic results can be obtained. In this case, the valve island diagnostic results show that there is no power failure or abnormal current failure. In the mechanical life of the valve island, the valve plate has remaining life but the actuator has no remaining life, or both the valve plate and the actuator have no remaining life. At the same time, an actuator life warning can be given when performing the update operation. If the second configuration information indicates that the actuator will not continue to operate after reaching its maximum number of working cycles, then only the actuator life warning can be given to remind the user to replace the actuator in time.

[0118] Optionally, valve control can be exited during valve plate life warning and actuator life warning. During the process of updating the valve plate's and actuator's duty cycles and obtaining valve island diagnostic results, the remaining lifespan of the valve plate and actuator can be calculated separately based on the updated duty cycles. Specifically, the remaining lifespan of the valve plate is obtained by subtracting the updated duty cycles of the valve plate from the first count value, and the remaining lifespan of the actuator is obtained by subtracting the updated duty cycles of the actuator from the second count value. Then, the valve island diagnostic results can be obtained based on the remaining lifespan of the valve plate and the actuator.

[0119] In this embodiment, the number of working operations of the valve plate and the actuator are counted separately. The counting can be done independently, and the remaining lifespan of the valve plate and the actuator can be predicted. The lifespan overdue diagnosis function is provided, and the lifespan overdue alarm can also be realized to remind the user to pay attention to the lifespan diagnosis results of the mechanical components of the valve island, namely the valve plate and the actuator.

[0120] Step S500: When the valve island diagnostic result meets all diagnostic conditions, a valve plate control signal is generated to drive the valve plate to work.

[0121] Specifically, when the valve island diagnostic result meets all diagnostic conditions, either in step S440 after updating the number of valve plate operations and the number of actuator operations and obtaining the valve island diagnostic result, or in step S450 after updating the number of valve plate operations and the number of actuator operations and obtaining the valve island diagnostic result, the control module generates a valve plate control signal and outputs it to the valve plate drive module. The valve plate drive module then drives the corresponding valve plate to work according to the valve plate control signal, thereby achieving normal control of the valve plate.

[0122] Furthermore, such as Figure 3 As shown, after step S100 "acquire the real-time power signal of the valve seat" and before step S200 "when the real-time power signal meets the preset power diagnostic conditions, acquire the valve plate insertion monitoring signal to obtain the number of valve plates inserted on the valve seat, so as to determine the theoretical current value of the valve seat", the method may further include:

[0123] Step S610: Determine whether the real-time voltage value of the valve plate is within the preset threshold range;

[0124] Step S620: If the real-time voltage value of the valve plate is not within the preset threshold range, then an overvoltage alarm or an undervoltage alarm for the valve plate is triggered.

[0125] Step S630: If the real-time voltage value of the valve plate is within the preset threshold range, then further determine whether the real-time current value of the valve seat is below the preset threshold value.

[0126] Step S640: If the real-time current value of the valve seat is not below the preset threshold, then an overload alarm for the valve plate is triggered.

[0127] Step S650: If the real-time current value of the valve seat is below the preset threshold, it is determined that the real-time power signal meets the preset power diagnostic conditions, and step S200 is executed.

[0128] Specifically, the real-time voltage value of the valve disc can be compared with the preset minimum allowable voltage value and the preset maximum allowable voltage value to determine whether the real-time voltage value of the valve disc is within the preset threshold range. If the real-time voltage value is lower than the minimum allowable voltage value, it indicates that the valve disc voltage is undervoltage. In this case, an undervoltage alarm can be triggered, and valve disc control can be exited, meaning the control module will not output a valve disc control signal. If the real-time voltage value is higher than the maximum allowable voltage value, it indicates that the valve disc voltage is overvoltage. In this case, an overvoltage alarm can be triggered, and valve disc control can be exited. If the real-time voltage value is higher than or equal to the minimum allowable voltage value and lower than or equal to the maximum allowable voltage value, it can be determined that the real-time voltage value of the valve disc is within the preset threshold range. In this case, the real-time current value of the valve seat can be compared with the preset maximum allowable voltage value. The large current value is compared to further determine whether the real-time current value of the valve seat is below the preset threshold. If the real-time current value of the valve seat exceeds the maximum allowable current value of the valve plate, it can be determined that the real-time current value of the valve seat is not below the preset threshold, indicating that the valve plate current is overloaded. At this time, the valve plate overload alarm can be triggered, and the valve plate control can be exited. If the real-time current value of the valve seat does not exceed the maximum allowable current value of the valve plate, it can be determined that the real-time current value of the valve seat is below the preset threshold. At this time, the real-time voltage value of the valve plate is within the preset threshold range, which meets the voltage diagnosis condition. At the same time, the real-time current value of the valve seat is also below the preset threshold, which meets the current diagnosis condition. Thus, it can be determined that the real-time power signal meets the preset power diagnosis condition. Then, step S200 can be executed to collect the valve plate insertion monitoring signal, obtain the number of valve plates inserted on the valve seat, and determine the theoretical current value of the valve seat.

[0129] In this embodiment, voltage and current are judged separately, providing valve plate undervoltage diagnosis function, valve plate overvoltage diagnosis function, and valve plate current overload diagnosis function. It can also realize valve plate undervoltage alarm, valve plate overvoltage alarm, and valve plate overload alarm, reminding users to pay attention to the valve plate power supply diagnosis results in a timely manner.

[0130] Furthermore, such as Figure 3 As shown, after step S210 "when the real-time power signal meets the preset power diagnostic conditions, obtain the insertion status value of each valve plate by collecting the insertion monitoring signal of each valve plate" and before step S220 "determine the number of valve plates inserted on the valve seat according to the insertion status value", the method may further include:

[0131] Step S710: Determine whether the valve plate has fallen off based on the insertion status value;

[0132] Step S720: If a valve plate is found to be detached, a valve plate detachment alarm will be triggered;

[0133] Step S730: If no valve plate has fallen off, proceed to step S220, that is, determine the number of valve plates inserted on the valve seat based on the insertion status value.

[0134] Specifically, after the control module obtains the insertion status value of each valve piece, it can determine whether a valve piece has fallen off based on the insertion status value. When the insertion status value of a valve piece is 0, it means that the valve piece is not inserted normally and there is a situation where the valve piece is detached. At this time, a valve piece detachment alarm can be triggered, and valve piece control can be exited. When the insertion status value of a valve piece is 1, it means that the valve piece is inserted normally and there is no valve piece detachment. At this time, step S210 can be continued to determine the number of valve pieces inserted on the valve seat based on the insertion status value.

[0135] In this embodiment, valve disc insertion monitoring is added, providing valve disc detachment monitoring function and valve disc detachment diagnosis. Valve disc detachment alarm can be realized to remind users to pay attention to the valve disc detachment diagnosis results in time and avoid valve disc detachment affecting the normal operation of the valve island.

[0136] It should be noted that the above applies to the case where all valve plates need to be inserted into the valve plate insertion interface on the valve seat. Understandably, when only a portion of the valve plates need to be inserted into the valve seat, the number of insertion status values ​​can also be used to determine whether any valve plates have fallen off. For example, if the valve seat has 7 holes, but only 5 valve plates need to be inserted, then if the sum of the obtained insertion status values ​​is less than 5, it indicates that some valve plates have fallen off, and a valve plate detachment alarm can be triggered. Conversely, if the sum of the insertion status values ​​is equal to 5, it means that all 5 valve plates are inserted normally and no valve plates have fallen off. Optionally, if the sum of the insertion status values ​​is greater than 5, it means that the actual number of valve plates inserted is more than the required number, and a reminder can also be issued to remind the user to pay attention to the insertion status or adjust the required number of valve plates.

[0137] Optionally, when it is determined that a valve plate has fallen off, the control module can also lock the control of the valve plate. Specifically, the valve plate control signal can be temporarily stored, and then after the insertion monitoring module detects that the valve plate has been inserted normally, that is, its insertion status value is 1, the previously stored valve plate control signal will continue to be output to continue controlling the valve plate, so as to avoid generating another valve plate control signal later and temporarily using the memory of the control module. In addition, it can also avoid inaccurate counting of the number of times the valve plate works.

[0138] Furthermore, such as Figure 3 As shown, after step S200 "when the real-time power signal meets the preset power diagnostic conditions, acquire the valve plate insertion monitoring signal to obtain the number of valve plates inserted on the valve seat, so as to determine the theoretical current value of the valve seat", and before step S300 "obtain the number of times each valve plate operates and the number of times the actuator connected to the valve plate operates", the method may further include:

[0139] Step S810: Determine whether the real-time current value in the real-time power signal is greater than the theoretical current value of the valve seat;

[0140] Step S820: If the real-time current value in the real-time power signal is greater than the theoretical current value of the valve seat, then an alarm for abnormal valve plate current is triggered.

[0141] Step S830: If the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, then execute step S300, that is, obtain the number of times each valve plate operates and the number of times the actuator connected to the valve plate operates.

[0142] Specifically, the calculated theoretical current value of the valve seat can be compared with the real-time current value of the valve seat in the real-time power signal to determine whether the real-time current value in the real-time power signal is greater than the theoretical current value of the valve seat. If the real-time current value is greater than the theoretical current value, it indicates that the valve plate may be faulty and the valve seat is in an abnormal working state. At this time, an abnormal valve plate current alarm can be triggered, and valve plate control can be exited. If the real-time current value is less than or equal to the theoretical current value, it indicates that the valve plates are all in normal working state. At this time, it can be determined that the real-time current value of the valve seat does not exceed the theoretical current value, thus determining that the real-time power signal meets the preset current abnormality diagnosis conditions. Then, step S300 can be executed to obtain the number of times each valve plate operates and the number of times the actuator connected to the valve plate operates.

[0143] In this embodiment, the real-time current of the valve seat is used to determine whether the valve island is working properly, providing a current abnormality diagnosis function. It can also realize a current abnormality alarm to remind users to pay attention to the valve plate current abnormality diagnosis results in a timely manner.

[0144] For further details on the specific implementation of the above method steps, please refer to the description of the specific implementation in Example 1. For the sake of brevity, these details will not be repeated here.

[0145] The valve island diagnostic method provided in this embodiment diagnoses valve plate voltage and current, valve plate detachment, and valve island hardware lifespan by monitoring valve plate insertion and valve seat power supply. It obtains valve plate power supply diagnostic results, valve plate detachment diagnostic results, valve plate current anomaly diagnostic results, and valve plate lifespan prediction results, providing users with multiple diagnostic information for the valve island. This helps prevent the impact of abnormal valve plate insertion current, poor valve plate contact, or valve plate open circuits on valve island operation. Furthermore, by monitoring the voltage and current of all valve plates for power supply diagnostics, it eliminates the need to monitor the voltage and current of each individual valve plate; only one power monitoring module is required on the valve island, saving costs. Accumulating the number of valve plate and actuator operation cycles allows for convenient direct recall during the next work cycle's lifespan diagnostic operation, simplifying the diagnostic process.

[0146] Example 3

[0147] Based on the same inventive concept, referring to Figure 5 The present application presents a first embodiment of a valve island control system, which can also be applied to the aforementioned bus valve island.

[0148] The following is combined with Figure 5 The functional module diagram shown illustrates the valve island control system provided in this embodiment in detail. The system may include:

[0149] The control module is used to implement the valve island diagnostic method described above;

[0150] The power monitoring module is connected to the control module and is used to monitor the power supply of the valve seat and output the real-time power signal of the valve seat to the control module.

[0151] An insertion monitoring module, connected to the control module, is used to monitor the insertion of the valve plate and outputs the valve plate insertion monitoring signal to the control module.

[0152] The valve plate drive module is connected to the control module and is used to drive the valve plate to work according to the valve plate control signal output by the control module.

[0153] The control module may include a processor and a memory. The memory stores a valve island diagnostic program. When the processor executes the valve island diagnostic program, it implements all or part of the steps of the various embodiments of the valve island diagnostic method of this application.

[0154] The memory is used to store various types of data, such as instructions for any application or method in the bus island, as well as application-related data. The memory can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as Random Access Memory (RAM), Static Random Access Memory (SRAM), Read-Only Memory (ROM), Programmable Read-Only Memory (PROM), Erasable Programmable Read-Only Memory (EPROM), Electrically Erasable Programmable Read-Only Memory (EEPROM), magnetic storage, flash memory, magnetic disk or optical disk, etc. Optionally, the memory can also be a processor-independent storage device.

[0155] The processor is used to call the valve island diagnostic program stored in the memory and execute the valve island diagnostic method as described above. The processor may be an application-specific integrated circuit (ASIC), a digital signal processor (DSP), a digital signal processing device (DSPD), a programmable logic device (PLD), a field-programmable gate array (FPGA), a controller, a microcontroller, a microprocessor, or other electronic components, and is used to execute all or part of the steps of the various embodiments of the valve island diagnostic method described above.

[0156] It should be noted that the functions and corresponding technical effects of each module in the valve island control system provided in this embodiment can be referred to the description of the specific implementation methods in the various embodiments of the valve island diagnosis method of this application. For the sake of brevity, they will not be repeated here.

[0157] Example 4

[0158] Based on the same inventive concept, referring to Figure 2 This embodiment provides a bus valve island, which may include:

[0159] Valve seat 10;

[0160] Multiple valve discs 20 inserted into the valve seat 10; and

[0161] A valve island control system, as described in Embodiment 3 above, is installed within the valve seat 10.

[0162] Furthermore, the bus valve island may also include:

[0163] The interface 30 provided on the valve seat 10 is used to connect the valve island to other devices.

[0164] It needs to be explained that, Figure 2 The hardware structure shown does not constitute a limitation on the bus valve island of this application, and may include more or fewer components than shown, or combine certain components, or have different component arrangements.

[0165] The functions and corresponding technical effects of each component in the bus valve island provided in this embodiment can be referred to the description of the specific implementation methods in the various embodiments of the valve island diagnosis method of this application. For the sake of brevity, they will not be repeated here.

[0166] Example 5

[0167] Based on the same inventive concept, this embodiment provides a computer-readable storage medium, such as flash memory, hard disk, multimedia card, card-type memory (e.g., SD or DX memory), random access memory (RAM), static random access memory (SRAM), read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), magnetic memory, disk, optical disk, server, etc. The storage medium stores a computer program, which can be executed by one or more processors. When the computer program is executed by the processor, it can implement all or part of the steps of the various embodiments of the valve island diagnosis method of this application.

[0168] It should be noted that the sequence numbers of the embodiments in this application are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments. The above embodiments are only optional embodiments of this application and do not limit the patent scope of this application. Any equivalent structural or procedural transformations made based on the concept of this application and the content of the specification and drawings of this application, or direct or indirect applications in other related technical fields, are included within the patent protection scope of this application.

Claims

1. A valve island diagnostic method, characterized in that, The valve island includes a valve seat and a valve plate; the method includes: Acquire the real-time power signals of the valve seat and the valve plate, wherein the real-time power signals include the real-time voltage value of the valve plate and the real-time current value of the valve seat; When the real-time power signal meets the preset power diagnostic conditions, the valve plate insertion monitoring signal is collected to obtain the number of valve plates inserted on the valve seat, so as to determine the theoretical current value of the valve seat. When the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, the number of working times of each valve plate and the number of working times of the actuator connected to the valve plate are obtained. The mechanical life of the valve island is diagnosed based on the number of times the valve plate and the actuator operate, and the valve island diagnosis result is obtained.

2. The valve island diagnostic method as described in claim 1, characterized in that, Before the step of acquiring the valve plate insertion monitoring signal and obtaining the number of valve plates inserted on the valve seat when the real-time power signal meets the preset power diagnostic conditions, in order to determine the theoretical current value of the valve seat, the method further includes: Determine whether the real-time voltage value of the valve plate is within a preset threshold range; If the real-time voltage value of the valve plate is not within the preset threshold range, an overvoltage alarm or an undervoltage alarm will be triggered. If the real-time voltage value of the valve plate is within the preset threshold range, then it is further determined whether the real-time current value of the valve seat is below the preset threshold value. If the real-time current value of the valve seat is not below the preset threshold, an overload alarm for the valve plate will be triggered. If the real-time current value of the valve seat is below the preset threshold, then the real-time power signal is determined to meet the preset power diagnostic conditions.

3. The valve island diagnostic method as described in claim 1, characterized in that, The step of acquiring the valve disc insertion monitoring signal to obtain the number of valve discs inserted on the valve seat, and determining the theoretical current value of the valve seat, includes: The insertion status value of each valve plate is obtained by collecting the insertion monitoring signal of each valve plate; The number of valve plates inserted on the valve seat is determined based on the insertion state value; The theoretical current value of the valve seat is obtained by summing the product of the number of valve plates and the theoretical current value of a single valve plate with the static current value of the valve seat; wherein, the static current value of the valve seat is the current value of the valve seat when all valve plates on the valve seat are in the closed state.

4. The valve island diagnostic method as described in claim 3, characterized in that, After the step of obtaining the insertion status value of each valve plate by collecting the insertion monitoring signal of each valve plate, the method further includes: Determine whether the valve plate has detached based on the insertion status value; If a valve disc detaches, a valve disc detachment alarm will be triggered. If no valve disc has fallen off, then proceed with the step of determining the number of valve discs inserted on the valve seat based on the insertion state value.

5. The valve island diagnostic method as described in claim 1, characterized in that, After the step of acquiring the valve disc insertion monitoring signal to obtain the number of valve discs inserted on the valve seat, and determining the theoretical current value of the valve seat, the method further includes: Determine whether the real-time current value in the real-time power signal is greater than the theoretical current value of the valve seat; If the real-time current value in the real-time power signal is greater than the theoretical current value of the valve seat, an alarm for abnormal valve plate current will be triggered. If the real-time current value in the real-time power signal is less than or equal to the theoretical current value of the valve seat, then the step of obtaining the number of times each valve plate operates and the number of times the actuator connected to the valve plate operates is executed.

6. The valve island diagnostic method as described in claim 1, characterized in that, The step of diagnosing the mechanical life of the valve island based on the number of times the valve plate operates and the number of times the actuator operates, and obtaining the valve island diagnosis result, includes: Determine whether the number of times the valve plate operates exceeds a preset first count value; If the number of times the valve plate operates does not exceed the first count value, then it is further determined whether the number of times the actuator operates exceeds the preset second count value; If the number of times the valve plate operates exceeds the first count value, then according to the preset first configuration information, a valve plate life warning is performed and / or the step of judging whether the number of times the actuator operates exceeds the preset second count value is executed; If the number of times the actuator operates does not exceed the second count value, then update the number of times the valve plate operates and the number of times the actuator operates, and obtain the valve island diagnostic result; If the number of times the actuator operates exceeds the second count value, then according to the preset second configuration information, the steps of performing actuator life warning and / or updating the number of times the valve plate operates and the number of times the actuator operates are performed, and valve island diagnostic results are obtained.

7. The valve island diagnostic method according to any one of claims 1 to 6, characterized in that, After the step of diagnosing the mechanical life of the valve island based on the number of times the valve plate operates and the number of times the actuator operates, and obtaining the valve island diagnosis result, the method further includes: When the valve island diagnostic result meets all diagnostic conditions, a valve plate control signal is generated to drive the valve plate to work.

8. A valve island control system, characterized in that, The valve island includes a valve seat and a valve plate; the system includes: A control module is configured to implement the valve island diagnostic method as described in any one of claims 1 to 7; A power monitoring module, connected to the control module, is used to monitor the power supply of the valve seat and output real-time power signals of the valve seat and the valve plate to the control module. An insertion monitoring module, connected to the control module, is used to monitor the insertion of the valve plate and output the insertion monitoring signal of the valve plate to the control module. A valve plate drive module, connected to the control module, is used to drive the valve plate to work according to the valve plate control signal output by the control module.

9. A bus valve island, characterized in that, The bus valve island includes: Valve seat; The valve disc inserted on the valve seat; and The valve island control system as described in claim 8 is disposed within the valve seat.

10. A computer-readable storage medium, characterized in that, The storage medium stores a computer program, which, when executed by one or more processors, implements the valve island diagnostic method as described in any one of claims 1 to 7.

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