A step unloading valve control device and method for direct pressure relief in an ultra-high pressure zone

Abstract

The application discloses a kind of for directly unloading pressure of superhigh pressure area step unloading valve control device and method, including step unloading valve, motor, with the induction rod of step unloading valve synchronous rotation, inductive switch and hydraulic control system.Hydraulic control system output pulse and control motor drive step unloading valve rotation from homing point to carry out pressure relief, and real-time cumulative calculation is carried out to output pulse, whenever induction rod reaches the position of reference point, and hydraulic control system receives the reference point position signal sent by inductive switch and carries out the step loss amplitude control of step unloading valve.The control method and system in the application are based on the number of hydraulic control system output pulse cumulative real-time calculation step unloading valve open-close circle number, and increase reference point correction function, can accurately control the step loss amplitude of step unloading valve, and provide step loss amplitude detection, automatic correction and step loss amplitude exception when automatic alarm, improve the reliability of step unloading valve in pressure relief process control.

Description

Technical Field

[0001] This invention belongs to the field of hydraulic technology, specifically relating to a step unloading valve control device and method for direct pressure relief in ultra-high pressure zones. Background Technology

[0002] With the increasing maturity of reciprocating turbocharger application technology, the overpressure holding requirements of large-scale hydraulic systems and long-term process operation can now be met. However, when the reciprocating turbocharger enters the depressurization stage, the hydraulic system can only depressurize directly from the ultra-high pressure zone. Due to the excessively high pressure, complex oil circuits, high control difficulty, and poor stability, the improvement of direct depressurization technology in the ultra-high pressure zone has become an inevitable requirement for the large-scale development and long-term process operation of hydraulic systems.

[0003] Invention patent CN112096677B discloses a control method for safe pressure relief in an ultra-high pressure hydraulic circuit, which enables the stepping unloading valve to directly and stably relieve pressure from the ultra-high pressure zone under normal operating conditions, and the pressure relief rate can be automatically adjusted. Furthermore, invention patent CN113847292A discloses a hydraulic system and pressure control method for a six-sided top press, which optimizes the control method disclosed in invention patent CN112096677B, adds protection functions during the pressure relief process, and improves the safety of the pressure relief process.

[0004] However, in the two patents mentioned above, determining the zero point of the stepper unloading valve requires the stepper motor to drive the valve to close to the zero position, and the control system automatically determines whether the valve is closed tightly. Therefore, the valve will remain at the zero point for a certain period. This control method requires the stepper unloading valve to frequently move near the zero point to determine whether it is closed tightly. During this process, the stepper motor continuously applies external force to the valve, which can easily cause zero-point offset or jamming, preventing the system from achieving smooth pressure relief according to the preset parameters. Furthermore, the opening and closing of the stepper unloading valve depends entirely on the system's given signal; the number of opening turns cannot be calculated in real time. If a control abnormality occurs during actual operation, it is highly likely that the actual pressure relief rate will deviate significantly from the set rate, or even lead to a pressure relief accident.

[0005] To ensure the long-term stable operation of the hydraulic system and improve the safety of control during the depressurization process, the control method of the step unloading valve used for direct depressurization in ultra-high pressure areas still needs further improvement. Summary of the Invention

[0006] To address the technical problem of uncontrollable step loss in the step unloading valve during the depressurization process, this invention provides a step unloading valve control device and method for direct depressurization in ultra-high pressure zones. The specific technical solution is as follows:

[0007] This invention provides a stepping unloading valve control device for direct pressure relief in ultra-high pressure areas, comprising a stepping unloading valve, a motor for driving the stepping unloading valve to rotate, and further comprising:

[0008] A sensing rod that rotates synchronously with the step unloading valve is vertically fixed on the edge of a concentric turntable at the top of the step unloading valve.

[0009] An inductive switch is fixedly installed outside the concentric turntable. When the step unloading valve is fully closed, it can sense the position of the sensing rod. The position of the inductive switch is a fixed point position. The inductive switch is used to generate a fixed point position signal and send it to the hydraulic control system when the sensing rod reaches the fixed point position.

[0010] The hydraulic control system has its input terminal connected to the output terminal of the inductive switch and its output terminal connected to the input terminal of the motor. When the stepping unloading valve is fully closed, the hydraulic control system resets the output pulse count to zero. The hydraulic control system includes a human-machine interface for inputting a set return point pulse count. The return point is a position of the stepping unloading valve that is different from the zero point. The return point is the start and end position of the pressure relief step of the stepping unloading valve. The hydraulic control system outputs return point pulses according to the return point pulse count, controlling the stepping unloading valve to reach the return point first. When the pressure relief step is opened, the hydraulic control system starts outputting pulses and controls the motor to drive the stepping unloading valve to rotate. The hydraulic control system accumulates and calculates the output pulses in real time. The hydraulic control system receives the calibration point position signal and simultaneously controls the stepping unloading valve to control the step loss amplitude.

[0011] This invention introduces a sensing device, including a sensing rod and a sensing switch, to sense the rotational position of the stepping unloading valve in real time. Simultaneously, it correlates the rotational position of the stepping unloading valve with the number of pulses output by the hydraulic control system for easy real-time calculation. By accumulating the pulse count, it achieves the judgment and control of the step loss amplitude. Considering that the stepping unloading valve requires a certain opening degree in practical applications, this invention introduces a return point to prevent the control device from starting at zero point, thus preventing zero-point jamming or zero-point offset malfunctions and ensuring the safe and normal operation of the pressure relief system.

[0012] As a further improvement of the present invention, the hydraulic control system calculates the number of opening and closing turns of the step unloading valve in real time based on the number of output pulses. The step loss amplitude control includes: if the step loss amplitude is within the set range, the system automatically corrects the count data; if the step loss amplitude exceeds the set range, the system automatically alarms.

[0013] As a further improvement of the present invention, the inductive switch is a proximity switch, which is mounted on a disc.

[0014] This invention also provides a step-by-step unloading valve control method for direct pressure relief in ultra-high pressure zones, comprising the following steps:

[0015] S1: The hydraulic control system controls the stepping unloading valve to fully close to reset the zero point, and the pulse count of the zero point is set to zero. At this time, the sensing rod reaches the fixed point position.

[0016] S2: The hydraulic control system controls the stepping unloading valve to rotate to the return point according to the set number of pulses at the return point, waiting for the pressure relief step to start;

[0017] S3: The hydraulic control system controls the operation of the pressure relief step. The hydraulic control system outputs pulses to the motor, and the motor drives the stepping unloading valve to rotate. The hydraulic control system calculates the number of opening and closing turns of the stepping unloading valve in real time based on the number of output pulses. The hydraulic control system adjusts the degree of opening of the stepping unloading valve according to the comparison between the actual pressure relief rate and the set pressure relief rate. Whenever the stepping unloading valve rotates and the sensing rod reaches the fixed point position, the sensing switch generates a fixed point position signal and sends it to the hydraulic control system, proceeding to step S3.1. When the pressure relief is completed, proceed to step S4.

[0018] S3.1: The hydraulic control system receives the positioning signal from the inductive switch and begins to determine the step loss amplitude. The step loss amplitude determination includes subtracting the number of opening turns and closing turns of the step unloading valve to obtain the actual number of turns, and rounding down the actual number of turns to determine the step loss amplitude of the step unloading valve. Specifically, it is divided into the following three cases:

[0019] If the obtained decimal is less than or equal to the set value a, the hydraulic control system automatically rounds down the number of revolutions to correct the number of pulses at this time, and the hydraulic control system continues to depressurize and returns to step S3;

[0020] If the obtained decimal is greater than or equal to the set value b, the hydraulic control system automatically rounds up the number of revolutions to correct the number of pulses at this time, and the hydraulic control system continues to depressurize and returns to step S3;

[0021] If the obtained decimal is greater than the set value a and less than the set value b, the hydraulic control system will automatically alarm and stop depressurization, and proceed to step S4.

[0022] As a further improvement of the present invention, the values ​​of the set values ​​a and b in this step are set according to the unloading accuracy of the step unloading valve required by the ultra-high pressure hydraulic system. Preferably, the set value a is 0.1 and the set value b is 0.9.

[0023] S4: Pressure relief is complete. The hydraulic control system controls the stepping unloading valve to automatically rotate to the return point.

[0024] The beneficial effects of this invention are as follows: The control method and system of this invention are based on the real-time calculation of the number of opening and closing turns of the step unloading valve by accumulating the output pulse count of the hydraulic control system, and a fixed point correction function is added. This enables precise control of the step loss amplitude of the step unloading valve, and provides step loss amplitude detection, automatic correction, and automatic alarm when the step loss amplitude is abnormal. This improves the reliability of the step unloading valve control during the pressure relief process. By introducing a return point as the pressure relief start position, the step unloading valve is prevented from losing steps due to failure to start pressure relief at zero point, which would interfere with the calculation of subsequent opening and closing turns. At the same time, the frequent operation of the step unloading valve near zero point is avoided, which would cause frequent zero point deviation and zero point jamming, thus ensuring the stability of the hydraulic system during long-term operation. Attached Figure Description

[0025] The following is a detailed description of the step unloading valve control device and method for direct pressure relief in ultra-high pressure zones according to the present invention, with reference to the accompanying drawings.

[0026] Figure 1 This is a system framework diagram of a stepping unloading valve control device for direct pressure relief in ultra-high pressure zones according to the present invention.

[0027] Figure 2 This is a diagram showing the installation structure of the sensing rod and sensing switch of a step unloading valve control device for direct pressure relief in ultra-high pressure zones according to the present invention.

[0028] Figure 3 This is a flowchart of a step unloading valve control method for direct pressure relief in ultra-high pressure zones according to the present invention.

[0029] Figure 4 This is a logic diagram for judging the step loss amplitude in a step unloading valve control method for direct pressure relief in ultra-high pressure areas according to the present invention.

[0030] Explanation of reference numerals in the attached diagram: 1-Stepping unloading valve, 2-Concentric turntable, 3-Sensing rod, 4-Inductive switch, 5-Disc. Detailed Implementation

[0031] like Figure 1 and Figure 2 As shown, the present invention provides a stepping unloading valve control device for direct pressure relief in ultra-high pressure areas, including a stepping unloading valve 1, a motor for driving the stepping unloading valve 1 to rotate, and further comprising:

[0032] The sensing rod 3 rotates synchronously with the step unloading valve 1. The sensing rod 3 is vertically fixed on the edge of the concentric turntable 2 at the top of the step unloading valve 1. The sensing rod 3 is used to provide feedback on the position information of the step unloading valve 1.

[0033] The induction switch 4 is fixedly installed outside the concentric turntable 2. When the step unloading valve 1 is fully closed, it can sense the position of the sensing rod 3. The position of the induction switch 4 is the fixed point position. The induction switch 4 is used to generate a fixed point position signal and send it to the hydraulic control system when the sensing rod 3 reaches the fixed point position.

[0034] The hydraulic control system has its input terminal connected to the output terminal of the inductive switch and its output terminal connected to the input terminal of the motor. When the stepping unloading valve 1 is fully closed, the hydraulic control system resets the output pulse count to zero. The hydraulic control system includes a human-machine interface (HMI) for inputting the set return point pulse count. The return point is the position of the stepping unloading valve 1 that is different from the zero point. The return point is the start and end position of the pressure relief step of the stepping unloading valve 1. The hydraulic control system outputs return point pulses according to the return point pulse count, controlling the stepping unloading valve 1 to reach the return point first. When the pressure relief step is opened, the hydraulic control system starts to output pulses and controls the motor to drive the stepping unloading valve 1 to rotate. The hydraulic control system accumulates and calculates the output pulses in real time. The hydraulic control system receives the calibration point position signal and simultaneously controls the stepping unloading valve 1 to control the step loss amplitude.

[0035] In this embodiment, when the inductive switch 4 is installed, the stepping unloading valve 1 is first rotated clockwise until it can no longer be rotated, ensuring that the inductive switch 4 can successfully sense the sensing rod 3. Since the calibration point is fixed, the inductive switch 4 only outputs a signal when the stepping unloading valve 1 rotates to the calibration point. Because in actual production, the ultra-high pressure hydraulic system only begins to depressurize when the stepping unloading valve 1 has a certain opening degree, this invention introduces a return point as the depressurization start position. This also avoids the stepping unloading valve 1 failing to start successfully at zero point, thus preventing missed steps and interfering with the calculation of subsequent opening and closing cycles.

[0036] In this embodiment, the hydraulic control system calculates the number of opening and closing turns of the step unloading valve 1 in real time based on the number of output pulses. The step loss amplitude control includes: if the step loss amplitude is within the set range, the system automatically corrects the count data; if the step loss amplitude exceeds the set range, the system automatically alarms.

[0037] In this embodiment, the inductive switch 4 is a proximity switch, and for ease of fixing, the proximity switch is mounted on a disc 5.

[0038] like Figure 3 As shown, the present invention also provides a step-by-step unloading valve control method for direct pressure relief in ultra-high pressure zones, comprising the following steps:

[0039] S1: The hydraulic control system controls the stepping unloading valve 1 to be completely closed to reset the zero point. The number of pulses at the zero point is set to zero. At this time, the sensing rod 3 reaches the fixed point position.

[0040] S2: The hydraulic control system controls the stepping unloading valve 1 to rotate to the return point according to the set number of pulses at the return point, and waits for the pressure relief step to start;

[0041] S3: The hydraulic control system controls the operation of the pressure relief step. The hydraulic control system outputs pulses to the motor, and the motor drives the stepping unloading valve 1 to rotate. The hydraulic control system calculates the number of opening and closing turns of the stepping unloading valve 1 in real time based on the number of output pulses. The hydraulic control system adjusts the degree of opening of the stepping unloading valve 1 according to the comparison between the actual pressure relief rate and the set pressure relief rate. Whenever the stepping unloading valve 1 rotates and the sensing rod 3 reaches the fixed point position, the sensing switch 4 generates a fixed point position signal and sends it to the hydraulic control system, and enters step S3.1. When the pressure relief is completed, enter step S4.

[0042] S3.1: The hydraulic control system receives the positioning signal from the inductive switch and begins to determine the step loss amplitude. The step loss amplitude determination includes subtracting the number of opening turns and closing turns of the step unloading valve 1 to obtain the actual number of turns, and then rounding down the actual number of turns to determine the step loss amplitude of the step unloading valve 1. Specifically, it is divided into the following three cases:

[0043] If the obtained decimal is less than or equal to the set value a, the hydraulic control system automatically rounds down the number of revolutions to correct the number of pulses at this time, and the hydraulic control system continues to depressurize and returns to step S3;

[0044] If the obtained decimal is greater than or equal to the set value b, the hydraulic control system automatically rounds up the number of revolutions to correct the number of pulses at this time, and the hydraulic control system continues to depressurize and returns to step S3;

[0045] If the obtained decimal is greater than the set value a and less than the set value b, the hydraulic control system will automatically alarm and stop depressurization, and proceed to step S4.

[0046] In this embodiment, the values ​​of a and b in this step are set according to the unloading accuracy of the step unloading valve 1 required by the ultra-high pressure hydraulic system.

[0047] S4: Pressure relief is complete. The hydraulic control system controls the stepping unloading valve 1 to automatically rotate to the return position.

[0048] In this embodiment, the setpoint a is 0.1, and the setpoint b is 0.9. Whenever the stepping unloading valve 1 rotates to the set point, the hydraulic control system receives a signal from the inductive switch and proceeds according to... Figure 4The logic for judging the step loss magnitude shown is automatic. If the step loss magnitude is within the set range, the system automatically corrects the lap count data; if the step loss magnitude exceeds the set range, the system automatically alarms.

[0049] In this embodiment, the logic for judging the step loss amplitude is illustrated as follows: Assuming the pulse count at the initial position homing point is 200, and the number of rotations is calculated based on the zero point, the number of pulses required for the stepping unloading valve 1 to rotate one revolution is 800. If the number of forward pulses when the stepping unloading valve 1 reaches the set point is 1000 and the number of reverse pulses is 300, then the number of rotations for opening is 1.25, and the number of rotations for closing is 0.375. Subtracting the number of rotations for opening and closing gives the actual number of rotations as 0.875. The decimal value of the actual number of rotations is 0.875. If the value is between 0.1 and 0.9, the hydraulic control system alarms and the pressure relief step is stopped. If the number of positive pulses when the stepping unloading valve 1 reaches the set point is 1000 and the number of negative pulses is 180, then the number of opening turns is 1.25 and the number of closing turns is 0.225. Subtracting the number of opening turns from the number of closing turns gives the actual number of turns as 1.025. Taking the decimal value of the actual number of turns gives 0.025, which is less than 0.1. The hydraulic control system rounds the actual number of turns down to 1, and then corrects the number of turns to continue pressure relief.

[0050] The control method and system in this embodiment calculate the number of opening and closing turns of the step unloading valve in real time by accumulating the output pulse count of the hydraulic control system. A calibration point correction function is added, which can accurately control the step loss amplitude of the step unloading valve and provides step loss amplitude detection, automatic correction, and automatic alarm when the step loss amplitude is abnormal. This improves the reliability of the step unloading valve control during the pressure relief process. By introducing a return point as the pressure relief start position, the step unloading valve is prevented from losing steps due to failure to start pressure relief at zero point, thus interfering with the calculation of subsequent opening and closing turns. It also avoids frequent zero-point deviations and zero-point jamming caused by the step unloading valve frequently operating near zero point, ensuring the stability of the hydraulic system during long-term operation.

[0051] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A stepping unloading valve control device for direct pressure relief in ultra-high pressure zones, comprising a stepping unloading valve (1) and a motor for driving the stepping unloading valve (1) to rotate, characterized in that, Also includes: The sensing rod (3) rotates synchronously with the step unloading valve (1), and the sensing rod (3) is vertically fixed on the edge of the concentric turntable (2) at the top of the step unloading valve (1); The induction switch (4) is fixedly installed outside the concentric turntable (2). When the step unloading valve (1) is fully closed, it can sense the position of the sensing rod (3). The position of the induction switch (4) is the fixed point position. The induction switch (4) is used to generate a fixed point position signal and send it to the hydraulic control system when the sensing rod (3) reaches the fixed point position. The hydraulic control system has an input terminal connected to the output terminal of the inductive switch (4) and an output terminal connected to the input terminal of the motor. When the step unloading valve (1) is fully closed, the hydraulic control system resets the output pulse count to zero. The hydraulic control system includes a human-machine interface for inputting the set return point pulse count. The return point is the position of the step unloading valve (1) that is different from the zero point. The return point is the start and end position of the pressure relief step of the step unloading valve (1). The hydraulic control system outputs the return point pulse according to the return point pulse count and controls the step unloading valve (1) to reach the return point first. When the pressure relief step is opened, the hydraulic control system starts to output pulses and controls the motor to drive the step unloading valve (1) to rotate. The hydraulic control system accumulates and calculates the output pulses in real time. The hydraulic control system receives the calibrated position signal and simultaneously controls the step loss amplitude of the step unloading valve (1).

2. The stepping unloading valve control device for direct pressure relief in ultra-high pressure zones as described in claim 1, characterized in that, The hydraulic control system calculates the number of opening and closing turns of the stepping unloading valve (1) in real time based on the number of output pulses. The step loss amplitude control includes: if the step loss amplitude is within the set range, the system automatically corrects the count data; if the step loss amplitude exceeds the set range, the system automatically alarms.

3. The stepping unloading valve control device for direct pressure relief in ultra-high pressure zones as described in claim 1, characterized in that: The inductive switch (4) is a proximity switch.

4. The stepping unloading valve control device for direct pressure relief in ultra-high pressure zones as described in claim 3, characterized in that: The proximity switch is fixed on a disc (5).

5. A control method for a stepping unloading valve control device for direct pressure relief in ultra-high pressure zones as described in claim 1, characterized in that, Includes the following steps: S1: The hydraulic control system controls the step unloading valve (1) to be completely closed to reset the zero point, and the number of pulses at the zero point is set to zero. At this time, the sensing rod (3) reaches the fixed point position. S2: The hydraulic control system controls the step unloading valve (1) to rotate to the return point according to the set return point pulse number, and waits for the pressure relief step to start; S3: The hydraulic control system controls the operation of the pressure relief step. The hydraulic control system outputs pulses to the motor, and the motor drives the stepping unloading valve (1) to rotate. The hydraulic control system calculates the number of opening and closing turns of the stepping unloading valve (1) in real time based on the number of output pulses. The hydraulic control system adjusts the degree of opening of the stepping unloading valve (1) according to the comparison between the actual pressure relief rate and the set pressure relief rate. Whenever the stepping unloading valve (1) rotates and the sensing rod (3) reaches the fixed point position, the sensing switch (4) generates the fixed point position signal and sends it to the hydraulic control system, and enters step S3.

1. When the pressure relief is completed, enter step S4. S3.1: The hydraulic control system receives the positioning signal from the inductive switch (4) and begins to judge the step loss amplitude. The step loss amplitude judgment includes subtracting the number of opening turns and the number of closing turns of the step unloading valve (1) to obtain the actual number of turns. The actual number of turns is rounded down to a decimal to judge the step loss amplitude of the step unloading valve (1). Specifically, there are three cases: If the obtained decimal is less than or equal to the set value a, the hydraulic control system automatically rounds down the number of revolutions to correct the number of pulses at this time, and the hydraulic control system continues to depressurize and returns to step S3; If the obtained decimal is greater than or equal to the set value b, the hydraulic control system automatically rounds up the number of revolutions to correct the number of pulses at this time, and the hydraulic control system continues to depressurize and returns to step S3; If the obtained decimal is greater than the set value a and less than the set value b, the hydraulic control system will automatically alarm and stop depressurization, and proceed to step S4. S4: Pressure relief is completed, and the hydraulic control system controls the stepping unloading valve (1) to automatically rotate to the return point.

6. The method as described in claim 5, characterized in that: The values ​​of a and b are set according to the unloading accuracy of the step unloading valve (1) required by the ultra-high pressure hydraulic system.

7. The method as described in claim 5, characterized in that: The set value a is 0.1, and the set value b is 0.9.

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