Design method of intelligent sensing optimal control modular valve control module

Abstract

The invention discloses a design method of an intelligent sensing optimal control modular valve control module, relates to the technical field of automation, and aims to solve the technical problem of sensing and alarming a fault part of a valve. A control module is arranged on the basis of a standard valve, and the control module is used for sensing working condition information and / or state information of the standard valve; when the standard valve is abnormal, the control module generates alarm information with a fault part, and the alarm information is fed back to the upper computer in a direct or indirect mode. According to the design method of the intelligent sensing optimal control modular valve control module provided by the embodiment of the invention, a series of data such as the valve state, the fluid flow speed, the fluid temperature and the fluid pressure which can be collected through a sensor or a signal collector can be quickly sensed; and alarm information with a clear fault part can be generated in time for data abnormity.

Description

Technical Field

[0001] The present invention relates to the field of automation technology, and in particular to a design method for an intelligent sensing optimal control modular valve control module. Background Art

[0002] With the acceleration of industrialization, automated production lines are being established rapidly like mushrooms after a spring rain. With the rapid development of digital processes and the extensive application of valves, the traditional valve plus sensor method has put forward higher requirements for wiring and signal processing. In order to save a lot of costs and shorten the wiring cycle, and facilitate the maintenance and replacement of valves in the future, based on this, the present invention proposes a design method for an intelligent sensing and optimal control modular valve control module. Summary of the invention

[0003] An embodiment of the present invention provides a design method for an intelligent sensing and optimal control modular valve control module to at least solve the technical problem of sensing and alarming the valve fault part. By using a modular ball valve optimal control system, standard valves can be modified and replaced, reducing the construction cost of an automated production line and the cost of future operations.

[0004] To achieve the above object, the embodiments of the present invention adopt the following technical solutions: A design method for an intelligent sensing and optimally controlled modular valve control module, the specific steps are as follows: One standard valve is provided; A control module is provided on the basis of the standard valve, and the control module is used to sense the working condition information and / or state information of the standard valve; When an abnormality occurs in the standard valve, the information sensed by the control module is lower or higher than the set value, the control module generates alarm information with the fault location, sets the alarm level for the alarm information, performs logical processing according to the alarm level, and feeds back to the host computer directly or indirectly.

[0005] In a possible design, the control module includes a collection unit, a processing unit, an execution unit and a feedback unit. The collection unit is used to collect the condition information data and status information data of the valve operation, the processing unit processes the collected data, the execution unit receives the instruction issued by the host computer to perform the action, and the feedback unit transmits the data processed by the processing unit to the host computer. With such a setting, the control module can automatically obtain and process the data of the valve status in real time, thereby improving the measurement efficiency and accuracy.

[0006] In a possible design, the valve core of the standard valve is connected to the detection unit of the control module to sense the opening and closing state or opening and closing degree of the valve core. In this way, the execution unit can drive the valve core to open and close, and sense the opening and closing degree of the valve core.

[0007] In a possible design, the power source of the execution unit adopts an electric or pneumatic drive mode. Such a configuration improves the compatibility of the control module and expands the scope of application.

[0008] In a possible design, the control module uses a digital module to sense the opening and closing state of the standard valve or uses an analog module to sense the opening and closing degree of the valve core of the standard valve.

[0009] In a possible design, the acquisition unit includes a plurality of sensors, which are respectively arranged at the inlet end and / or the outlet end of the standard valve for collecting data and are electrically connected to the processing unit.

[0010] In a possible design, each of the multiple sensors includes but is not limited to one of a pressure sensor, a temperature sensor, a flow sensor, and a liquid level sensor, so as to achieve real-time monitoring of data such as pressure, temperature, flow, and liquid level.

[0011] In a possible design, the multiple sensors are specifically any combination of the first sensor, the second sensor, the third sensor and the fourth sensor, and the combination of the multiple sensors is connected in parallel or in series.

[0012] In a possible design, the control module also includes a PLC control module, which converts the collected electrical signals into digital signals and then pushes them to the host computer.

[0013] In a possible design, the control module uses a function selection dial switch to select a function, and the control module uses a standard data interface. This arrangement improves matching and facilitates replacement.

[0014] In a possible design, the control module also has a backup power supply. In this way, in order to ensure the accuracy of the alarm output when the control module loses power, the control module has a backup power supply. Once the module loses power, the backup power supply is used to transmit the alarm signal to the host computer.

[0015] In a possible design, the standard valve includes but is not limited to any one of a ball valve, a plug valve, a butterfly valve, a gate valve and a stop valve.

[0016] In a possible design, an intelligent sensing module is also included. The intelligent sensing module and the host computer use the system bus to exchange data, so as to reduce wiring and cost and achieve functions such as adaptive matching after module replacement.

[0017] Beneficial effect: The design method of the intelligent sensing and optimal control modular valve control module provided in the embodiment of the present invention adopts a valve that exchanges data with a host computer in a wired or wireless manner, which can quickly sense a series of data that can be collected by sensors or signal collectors, such as valve status, fluid flow rate, fluid temperature, fluid pressure, etc., and can promptly generate alarm information with clear fault locations for data anomalies, which facilitates the automated production line to perform logical processing in a timely manner according to the alarm level, thereby reducing user losses. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a flow chart of a design method of an intelligent sensing and optimally controlled modular valve control module according to an embodiment of the present invention; Figure 2 is a block diagram of a control module according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the principle of the intelligent sensing and optimal control modular valve control module according to an embodiment of the present invention.

[0019] In the figure: 1. standard valve, 2. first sensor, 3. second sensor, 4. third sensor, 5. fourth sensor, 6. compressed air inlet, 7. compressed air outlet, 8. valve opening / closing solenoid valve, 9. valve opening and closing position feedback signal line, 10. 24V power line, 11. data transmission line, 12. backup power supply, 13. valve opening and closing position sensor, 14. modular sensor signal input interface, 15. PLC control module, 16. compressed air pressure sensor, 17. control module. DETAILED DESCRIPTION

[0020] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0021] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal connection of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances. The terms "first", "second", etc. are used for the purpose of distinguishing different components and do not have order and importance. In addition, in the following description, when referring to the drawings, unless otherwise explained, the same figure numbers in different drawings represent the same or similar elements.

[0022] The present application embodiment provides a design method for an intelligent sensing and optimally controlled modular valve control module. Figure 1 , the specific steps are as follows: S1, provide a standard valve 1; S2. A control module 17 is provided on the basis of the standard valve 1, and the control module 17 is used to sense the working condition information and / or state information of the standard valve 1; S3. When an abnormality occurs in the standard valve 1, the information sensed by the control module 17 is lower or higher than the set value, the control module generates alarm information with the fault location, and sets the alarm level for the alarm information. After logical processing according to the alarm level, it is fed back to the host computer directly or indirectly.

[0023] The design method of the intelligent sensing and optimal control modular valve control module provided in the embodiment of the present invention adopts a valve that exchanges data with a host computer in a wired or wireless manner, and can quickly sense a series of data that can be collected by sensors or signal collectors, such as valve status, fluid flow rate, fluid temperature, fluid pressure, etc., and can promptly generate alarm information with clear fault locations for data anomalies, so as to facilitate the automated production line to perform logical processing in a timely manner according to the alarm level, thereby reducing user losses.

[0024] It should be noted that for automated chemical production lines of different scales, whether to use the PLC module in the valve is determined according to the scale of sensor use. If the I / O points of the PLC are less than 200 and the transmission distance is less than 100 meters, the valve can be pre-processed without PLC, that is, without PLC module, to achieve the purpose of reducing costs. If the I / O points of the PLC are greater than 200 and the transmission distance is greater than 100 meters, the valve can be pre-processed with PLC, that is, using PLC module. At the same time, multi-node PLC will increase the scanning cycle of the host computer accordingly. In order to reduce the scanning cycle of the host computer, improve the response speed, and improve the safety of production line operation, it is necessary to reduce the processing volume of the host computer data. In addition, in order to facilitate future maintenance and other factors, the PLC in the valve is used for data pre-processing, such as the conversion of high and low levels of signals, the processing of analog signals, the generation of alarms with relevant information, and whether the analog quantity exceeds the threshold, etc., which are judged and processed by the PLC in the valve. For the compilation of alarm rules, based on the different needs of different production lines, rules suitable for the production line are compiled to generate alarms of different levels. For some alarms that endanger the safety of the production line, they are high-level alarms, such as the high-pressure tank pressure, the high-pressure tank valve status alarms, etc. The PLC in the valve will give priority to sending alarms to the host computer. For some alarms that do not involve the safety of the production line, the PLC in the valve can convert the alarm information into digital characters and transmit them to the host computer. The compilation of the string needs to follow certain rules. For example, the position of the No. 1 skid-mounted normal pressure mixing tank is defined as the number "4", the first section of the mixing tank pressure sensor is defined as "1", the normal pressure is defined as "1", the excessive pressure is defined as "2", and the low pressure is defined as "0". If the pressure is too high, the string "412" will be generated, and if it is too low, "410" will be generated. When it is normal, "411" will be generated and fed back to the host computer. The host computer performs character reverse translation and extracts useful information. Of course, high-level alarms can also be compiled according to the rules to provide relevant information. The PLC in the optimal control valve only processes the I / O point data connected to it. During operation, the host computer PLC periodically scans to check whether there is any alarm information output by the priority control valves of the entire line. The alarm level and logic processing of the entire line are processed by the host computer PLC.

[0025] The following is a specific description of the alarm information with fault location generated by the control module mentioned above. According to the different needs of different production lines, the rules that adapt to the production line are compiled. For some alarms that do not involve the safety of the production line, the PLC in the valve converts the alarm information into digital characters and transmits it to the host computer. The compilation of the string needs to follow certain rules. For example, the position of the No. 1 skid-mounted normal pressure mixing tank is defined as the number "4", the first section of the mixing tank pressure sensor is defined as "1", the normal pressure is defined as "1", the excessive pressure is defined as "2", and the low pressure is defined as "0". If the pressure is too high, the string "412" will be generated, and if it is too low, "410" will be generated. If it is normal, "411" will be generated and fed back to the host computer. In this way, the PLC in the valve will feed back information such as the fault location to the host computer through the master-slave station method, so that the host computer can make logical judgments and realize automatic control. Of course, for alarms with high alarm levels, the coding mode can also be used to transmit information.

[0026] The following is a specific description of the above-mentioned setting of alarm levels for alarm information, and feeding back to the host computer in a direct or indirect manner after logical processing according to the alarm levels; For the PLC alarm level and processing logic, during the production line design stage, according to different functional areas, the designer will determine which signals belong to high-level alarms and which belong to low-level alarms. According to the specific requirements of the production line designer, the signal alarm level is set.

[0027] For devices without PLC logic controller in the valve, the alarm level and alarm processing logic are completed by the host computer.

[0028] For devices with PLC logic controllers inside the valve, it is necessary to set the alarm level and compile the processing logic according to the rules provided by the designer.

[0029] For example, when a fault alarm occurs simultaneously in the high-pressure pressure tank and the No. 1 skid-mounted atmospheric mixing tank, the alarm information of the high-pressure pressure tank is sent first and submitted to the host computer for processing to ensure the stable operation of the automated production line.

[0030] See also Figure 2 The control module 17 mentioned above is specifically described below by way of example. The control module 17 includes a collection unit, a processing unit, an execution unit and a feedback unit. The collection unit is used to collect the condition information data and status information data of the valve operation. The processing unit processes the collected data. The execution unit receives the instruction from the host computer to perform the action. The feedback unit transmits the data processed by the processing unit to the host computer. The control module can automatically obtain and process the data of the valve status in real time, thereby improving the measurement efficiency and accuracy.

[0031] Connect the valve core of the standard valve to the detection unit of the control module to sense the opening and closing state or opening and closing degree of the valve core. The actuator can drive the valve core to open and close, and sense the opening and closing degree of the valve core.

[0032] In order to improve compatibility, the power source of the execution unit adopts electric or pneumatic drive mode, which improves the compatibility of the control module and expands the scope of application.

[0033] See also Figure 3 In this embodiment, the driving method is compressed air. The control module 17 has a compressed air inlet 6 and a compressed air outlet 7, and is sensed by a compressed air pressure sensor 16. If it is lower than the set value, an alarm trigger signal is issued.

[0034] Continue to see Figure 3 In order to control the opening and closing of the valve, a valve opening / closing solenoid valve 8 is installed at the control chamber position of the standard valve 1.

[0035] The control module 17 uses a digital module to sense the opening and closing state of the standard valve 1 or uses an analog module to sense the valve core opening and closing degree of the standard valve 1. Other sensors can also be used to quickly collect a series of data that can be collected by sensors or signal collectors, such as fluid flow rate, fluid temperature, and fluid pressure, and also includes a valve opening and closing position sensor 13 and a valve opening and closing position feedback signal line 9, which are used to sense the opening and closing position of the feedback valve.

[0036] The following is a specific example of the acquisition unit mentioned above. Please continue to refer to Figure 3 The collection unit includes a plurality of sensors, which are respectively arranged at the inlet end and / or the outlet end of the standard valve 1 for collecting data and are electrically connected to the processing unit.

[0037] Each of the multiple sensors includes but is not limited to one of a pressure sensor, a temperature sensor, a flow sensor and a liquid level sensor, so as to achieve real-time monitoring of data such as pressure, temperature, flow and liquid level.

[0038] In this example, see Figure 3 The multiple sensors are specifically any combination of the first sensor 2, the second sensor 3, the third sensor 4 and the fourth sensor 5, and the combination of the multiple sensors is connected in parallel or in series.

[0039] Please continue to see Figure 3 The control module 17 also includes a PLC control module 15, which converts the collected electrical signals into digital signals and then pushes them to the host computer.

[0040] In order to reduce costs, the control module 17 uses a function selection dial switch for function selection and is connected in parallel. At this time, the alarm output is only for a specific alarm. The control module 17 uses a standard data interface and has a modular sensor signal input interface 14 to improve matching and facilitate replacement.

[0041] The control module 17 and the upper computer ASI safety integration module use the system bus to exchange data, which can accurately transmit the alarm content, implement Modbus or RS-232 or RS-485 or I2C or SPI, CAN communication protocol, use the data transmission line 11 for data exchange, and are powered by the 24V power line 10. The 24V power line 10 is a wire without breakpoints, and the data transmission line 11 is a wire without breakpoints.

[0042] The control module 17 also has a backup power supply 12. To ensure the accuracy of the alarm output when the control module 17 loses power, the control module 17 has a backup power supply 12. Once the module loses power, the backup power supply 12 is used to transmit the alarm signal to the host computer.

[0043] The standard valve 1 includes but is not limited to any one of a ball valve, a plug valve, a butterfly valve, a gate valve and a stop valve.

[0044] Any unit in the control module 17 can be freely replaced after being damaged. If only one control module is replaced, the host computer ASI can automatically change the ID of the control module to complete the adaptive repair work, and the control module ID can also be set through the programmer.

[0045] This intelligent sensing and optimal control modular valve control module can also simplify its functions according to actual usage requirements to reduce the user's usage cost. For example, the PLC control processing function is not added, and the control processing function is handed over to the host computer to perform corresponding inspections instead of people to ensure the automatic operation of the production line. All status information is transmitted indirectly or directly to the host computer through the PLC. The host computer judges the status, provides the location for maintenance, and sends out an alarm signal.

[0046] It also includes an intelligent sensing module, which uses a system bus to exchange data with the host computer to reduce wiring and costs and achieve functions such as adaptive matching after module replacement.

[0047] In the description of this specification, specific features, structures, materials or characteristics may be combined in an appropriate manner in any one or more embodiments or examples.

[0048] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A design method for an intelligent sensing and optimally controlled modular valve control module, characterized in that: The specific steps are as follows: One standard valve is provided; A control module is provided on the basis of the standard valve, and the control module is used to sense the working condition information and / or state information of the standard valve; When an abnormality occurs in the standard valve, the information sensed by the control module is lower or higher than the set value, the control module generates alarm information with the fault location, sets the alarm level for the alarm information, performs logical processing according to the alarm level, and feeds back to the host computer directly or indirectly.

2. The design method of the intelligent sensing and optimal control modular valve control module according to claim 1 is characterized in that: The control module includes an acquisition unit, a processing unit, an execution unit and a feedback unit. The acquisition unit is used to acquire condition information data and status information data of the valve operation. The processing unit processes the acquired data. The execution unit receives instructions from a host computer to perform execution actions. The feedback unit transmits the data processed by the processing unit to the host computer.

3. The design method of the intelligent sensing and optimal control modular valve control module according to claim 2 is characterized in that: The valve core of the standard valve is connected to the detection unit of the control module to sense the opening and closing state or opening and closing degree of the valve core.

4. The design method of the intelligent sensing and optimal control modular valve control module according to claim 3 is characterized in that: The power source of the execution unit adopts an electric or pneumatic driving mode.

5. The design method of the intelligent sensing and optimal control modular valve control module according to claim 3 is characterized in that: The control module uses a digital module to sense the opening and closing state of the standard valve or uses an analog module to sense the opening and closing degree of the valve core of the standard valve.

6. The design method of the intelligent sensing and optimal control modular valve control module according to claim 2 is characterized in that: The acquisition unit includes a plurality of sensors, which are respectively arranged at the inlet end and / or the outlet end of the standard valve, for acquiring data, and are electrically connected to the processing unit.

7. The design method of the intelligent sensing and optimal control modular valve control module according to claim 6 is characterized in that: Each of the plurality of sensors includes, but is not limited to, one of a pressure sensor, a temperature sensor, a flow sensor, and a liquid level sensor.

8. The design method of the intelligent sensing and optimal control modular valve control module according to claim 6 is characterized in that: The multiple sensors are specifically any combination of the first sensor, the second sensor, the third sensor and the fourth sensor, and the combination of the multiple sensors is connected in parallel or in series.

9. The design method of the intelligent sensing and optimal control modular valve control module according to claim 2 is characterized in that: The control module also includes a PLC control module, which converts the collected electrical signals into digital signals and then pushes them to the host computer.

10. The design method of the intelligent sensing and optimal control modular valve control module according to claim 1 is characterized in that: The control module uses a function selection dial switch to select a function, and the control module adopts a standard data interface.

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