Valve performance test and diagnosis device and method

Abstract

The present invention discloses a valve performance test and diagnosis device and method thereof, and belongs to the field of automated diagnostic equipment. The present invention utilizes a data acquisition box DAU to provide a plug-in serial port for a sensor component, which can realize personalized configuration of the sensor component, and collect valve physical quantity signals in real time and upload them to a host computer. At the same time, the present invention constructs a signal control module and a data analysis module in the host computer, and the two can cooperate to construct a change curve with jump information using the data detected by the controller signal sensor, the displacement sensor, and the drive stress sensor, and perform stuck fault identification and diagnosis based on the information in the jump signal. The valve performance test and diagnosis device of the present invention can realize automated testing and intelligent diagnosis of valves by integrating advanced sensors, data acquisition boxes, and host computer systems, and has broad application prospects.

Description

Technical Field

[0001] The invention belongs to the technical field of valve detection, and in particular relates to a valve performance testing and diagnosis device and a method thereof. Background Art

[0002] As a key component in a fluid control system, the performance stability and reliability of the valve are crucial to the safe operation of the entire system. Valve performance testing and fault diagnosis are important means to ensure valve quality and prevent system failures. However, traditional valve testing and diagnosis methods often have problems such as complex operation, low efficiency, and inaccurate results, which are difficult to meet the high requirements of modern industry for valve performance testing and fault diagnosis. The main manifestations are: 1) Traditional valve testing and diagnosis methods often require a lot of manual operation, such as manually switching valves, recording data, etc., which is not only time-consuming and laborious, but also easy to introduce human errors; 2) Due to the limitations of manual operation, traditional testing methods often cannot complete the testing and diagnosis of a large number of valves in a short time, resulting in low testing efficiency; 3) Manual recording and judgment of test results are often subjective, resulting in inaccurate test results, and it is difficult to objectively evaluate the performance of the valve. Therefore, in view of the defects of the existing technology and development needs, it is urgent to provide a valve performance testing and diagnosis device and method that can automatically test valve faults. Summary of the invention

[0003] The purpose of the present invention is to solve the defects in the prior art such as low degree of automated testing of valve faults and inability to identify and diagnose faults, and to provide a valve performance testing and diagnosis device and method thereof.

[0004] The technical solutions specifically adopted in the present invention are as follows:

[0005] In a first aspect, the present invention provides a valve performance test and diagnosis device, which includes a host computer, a data acquisition unit (DAU), and a sensor assembly;

[0006] The sensor assembly at least includes a controller signal sensor, a displacement sensor and a drive stress sensor, and all are installed on the valve to be diagnosed; the controller signal sensor is used to output a control signal to the valve drive head and collect the control signal at the same time; the displacement sensor is used to collect the stroke of the valve stem; the drive stress sensor is used to collect the valve stem drive stress on the valve stem; each sensor in the sensor assembly is formed by a sensor front end and a sensor rear end connected in pairs, and the sensor rear end is provided with a first aviation plug;

[0007] The data acquisition box DAU comprises a central processing module, a communication module, a power module and a serial port module; the communication module, the power module and the data conversion module are all connected to the central processing module, and the data conversion module is connected to the serial port module; the serial port module has a plurality of serial ports for inputting data to the data acquisition box DAU or for the data acquisition box DAU to output data, each serial port has a second aviation plug that matches the first aviation plug, and each sensor back end can be connected to the serial port module by way of aviation plug pairing connection. When the serial port module detects that a new sensor back end is connected, a handshake protocol must be executed first, and the sensor impedance range and handshake key must be detected. After verifying that the handshake key is correct, the sensor is powered according to the detected sensor impedance range and a communication protocol is established; the communication module is used to establish a communication connection with the host computer; the power module is used to power each module in the data acquisition box DAU; the data conversion module is used to perform signal conversion between the central processing module and the serial port module;

[0008] The host computer is provided with a signal control module and a data analysis module; the signal control module is used to send control instructions to the data acquisition box DAU, and at the same time receive and store the signal data collected by the sensor component and uploaded by the data acquisition box DAU; the data analysis module is used to analyze the signal data collected by the sensor component, and identify and diagnose the stuck fault according to the jump information between different categories of signals.

[0009] As a preferred embodiment of the first aspect, the valve to be diagnosed is a pneumatic valve or an electric valve.

[0010] As a preferred embodiment of the above-mentioned first aspect, the sensor assembly also includes one or more of a pressure sensor, a current sensor, a voltage sensor, and a switch node signal sensor; the pressure sensor is used to detect the cylinder pressure in the pneumatic valve; the current sensor is used to detect the motor current in the electric valve; the voltage sensor is used to detect the motor voltage in the electric valve; the switch node signal sensor is used to detect whether the valve stem has reached its stroke.

[0011] As a preferred embodiment of the above-mentioned first aspect, the driving stress sensor is a torque sensor suitable for an angular stroke valve or a thrust sensor suitable for a linear stroke valve; for an angular stroke valve, the driving stress detected by the torque sensor is the torque applied to the valve stem by the driving head; for a linear stroke valve, the driving stress detected by the thrust sensor is the thrust applied to the valve stem by the driving head.

[0012] As a preferred embodiment of the first aspect, the first aviation plug and the matching second aviation plug both use 9-core wires, of which 2-core wires are used for impedance range detection of the sensor and detection of the handshake key.

[0013] As a preferred embodiment of the first aspect, in the host computer, the signal control module and the data analysis module cooperate to perform stuck fault identification and diagnosis, and the diagnosis process is as follows:

[0014] A1. The host computer outputs a ramp signal through the signal control module, and outputs a valve position control signal to the valve drive head through the data acquisition box DAU and the controller signal sensor, thereby controlling the valve drive head to drive the valve stem of the valve to be diagnosed to actuate; in the ramp signal, the signal value rises from the lowest value to the highest value at a fixed slope, and then drops from the highest value to the lowest value at a fixed slope, and the opening of the valve to be diagnosed is positively correlated with the signal value; at the same time, during the ramp signal output process, the travel signal and the driving stress signal of the valve stem in the valve to be diagnosed are synchronously collected by the displacement sensor and the driving stress sensor, and uploaded to the host computer in real time through the data acquisition box DAU together with the control signal output by the controller signal sensor for storage;

[0015] A2. After the ramp signal is output, the data analysis module reads the time domain data of the control signal, the stroke signal and the driving stress signal, and converts the valve stem stroke in the stroke signal into the actual valve position, thereby generating a first change curve of the actual valve position changing with the control signal during the ramp signal output process and a second change curve of the actual valve position changing with the driving stress signal during the ramp signal output process on the coordinate axis;

[0016] A3: Mark the signal dead zone and all first jumps on the first change curve, and record the dead zone range S of the signal dead zone on the control signal coordinate axis d and the jump range S of each first jump on the control signal coordinate axis en ; Mark all second jumps on the second change curve, and record the maximum absolute value F of each second jump on the driving stress coordinate axis en ; The first jump on the first change curve and the second jump on the second change curve correspond one to one based on the actual valve position, and the actual valve position where each group of corresponding first jump and second jump are located at the same time is the jump valve position;

[0017] A4. For each jump valve position, calculate the viscosity coefficient c of each jump valve position n =(S d -S en ) / (S d +S en ), and classify the sticking degree of each jump valve position based on the viscosity coefficient;

[0018] A5. For each jump valve position, combined with the driving stress value F when there is no sticking base , calculate the valve core sticking force F at the jump valve positionkzn =F en -F base , completing the quantitative characterization of the valve core sticking force.

[0019] Furthermore, when the sticking degree of each jump valve position is graded based on the viscosity coefficient, the viscosity coefficient in the range of 0 to 1 is divided into multiple levels according to a preset number of grades, wherein the smaller the viscosity coefficient, the higher the sticking degree, and the smaller the viscosity coefficient, the lower the sticking degree.

[0020] Furthermore, the host computer is also provided with a report output module for outputting all jump valve positions and their corresponding grading labels of the degree of sticking and the quantitative value of the sticking force of the valve core.

[0021] Furthermore, the report output module also outputs adjustment suggestions for the driving stress, and the recommended adjusted driving stress value is the sum of the rated driving stress value and the incremental stress value; the incremental stress value is the quotient obtained by dividing the average value of the valve core sticking force of all jump valve positions by the average value of the viscosity coefficient of all jump valve positions.

[0022] In a second aspect, the present invention provides a valve performance test and diagnosis method using the valve performance test and diagnosis device described in any one of the first aspects, comprising:

[0023] S1. Install the controller signal sensor, displacement sensor and drive stress sensor on the valve to be diagnosed respectively, and selectively install other sensors according to the diagnostic requirements of the valve to be diagnosed; the sensor back ends of all sensors are connected to the serial port module of the data acquisition box DAU through aviation plug-in pairing and plug-in. After the serial port module executes the handshake protocol, each sensor establishes a communication connection and power supply with the data acquisition box DAU respectively;

[0024] S2. In the host computer, the signal control module and the data analysis module cooperate to execute the diagnostic process, so as to identify and diagnose the stuck fault; at the same time, according to the diagnostic requirements of the valve to be diagnosed, other installed sensors are used to collect corresponding sensor signal data during the valve actuation process, and the data is uploaded to the host computer through the data acquisition box DAU for data analysis and visual display;

[0025] S3. After all valve performance test and diagnosis items are completed, turn off the host computer and data acquisition box DAU, and remove the sensors installed on the valves to be diagnosed.

[0026] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0027] 1) The present invention utilizes the data acquisition box DAU to provide a plug-in serial port for the sensor component, and can personalize the specific form of the sensor component according to the diagnostic requirements of the valve to be diagnosed. The data acquisition box DAU can automatically match the connected sensor for power supply and communication, collect relevant physical quantity signals of the valve in real time and upload them to the host computer for subsequent diagnostic analysis.

[0028] 2) The present invention constructs a signal control module and a data analysis module in the host computer, and the two can cooperate to construct a change curve with jump information using the data detected by the controller signal sensor, displacement sensor and drive stress sensor, thereby performing stuck fault identification and diagnosis based on the information in the jump signal.

[0029] 3) The valve performance test and diagnosis equipment of the present invention can realize automatic testing and intelligent diagnosis of valves by integrating advanced sensors, data acquisition boxes and host computer systems, and can detect the stuck faults in valves non-destructively and efficiently, so it has broad application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 A schematic diagram of the basic structure of a valve performance test and diagnosis device in an embodiment of the present invention;

[0031] Figure 2 A schematic diagram of all optional sensor components in a valve performance test and diagnosis device according to an embodiment of the present invention;

[0032] Figure 3 A complete connection and data transmission flow chart of the valve performance test and diagnosis device in an embodiment of the present invention;

[0033] Figure 4 is a schematic diagram of a ramp signal in an embodiment of the present invention;

[0034] Figure 5 is a schematic diagram of a first change curve in an embodiment of the present invention;

[0035] Figure 6 Schematic diagram of a second change curve in an embodiment of the present invention. DETAILED DESCRIPTION

[0036] In order to make the above-mentioned purpose, features and advantages of the present invention more obvious and easy to understand, the specific implementation mode of the present invention is described in detail below in conjunction with the accompanying drawings. In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below. The technical features in each embodiment of the present invention can be combined accordingly without conflicting with each other.

[0037] In the description of the present invention, it is to be understood that when an element is considered to be "connected" to another element, it may be directly connected to the other element or indirectly connected, that is, there are intermediate elements. On the contrary, when an element is said to be "directly" connected to another element, there are no intermediate elements.

[0038] In the description of the present invention, it should be understood that the terms "first" and "second" are only used for the purpose of distinguishing descriptions, and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features.

[0039] like Figure 1 As shown, in a preferred embodiment of the present invention, a valve performance test and diagnosis device is provided, which comprises three parts, namely a host computer, a data acquisition box (DAU) and a sensor assembly.

[0040] In the valve performance test and diagnosis equipment, the sensor assembly includes a series of different types of sensors, which need to be installed on the valve to be diagnosed and are used to detect a series of different physical quantities on the valve to be diagnosed. In the present invention, the specific sensor types that should be included in the sensor assembly can be selected according to the diagnostic requirements of the valve to be diagnosed, but it includes three necessary sensors required for valve jamming diagnosis, namely, a controller signal sensor, a displacement sensor, and a drive stress sensor. Among them, the controller signal sensor is installed on the valve drive head, and is used to output a control signal to the valve drive head. At the same time, the controller signal sensor also has the function of collecting control signals; the displacement sensor is installed on a fixed bracket, and the operation of the valve stem is monitored by laser or wire, and is used to collect the stroke of the valve stem; the drive stress sensor is installed on the valve stem, and is used to collect the valve stem drive stress on the valve stem.

[0041] The valve to be diagnosed in the present invention can be a pneumatic valve or an electric valve, and the valve drive head of the two is different. For a pneumatic valve, its drive head is in the form of a drive motor, while for a pneumatic valve, its drive head is a diaphragm-type, piston-type gas drive mechanism. Therefore, for different types of valves to be diagnosed, the specific installation positions of the controller signal sensor, displacement sensor, and drive stress sensor can be adjusted according to actual conditions, as long as the corresponding physical quantities can be accurately detected.

[0042] In addition, in addition to the three necessary sensors, namely, the controller signal sensor, the displacement sensor and the drive stress sensor, other sensors, such as pressure sensors, current sensors, voltage sensors and switch node signal sensors, can be provided in the above sensor components according to the diagnostic requirements. The pressure sensor is applicable to pneumatic valves to detect the cylinder pressure in the pneumatic valves; the current sensor is applicable to electric valves to detect the motor current in the electric valves; the voltage sensor is applicable to electric valves to detect the motor voltage in the electric valves; and the switch node signal sensor can be used for both pneumatic valves and electric valves to detect whether the valve stem has reached the desired stroke.

[0043] However, whether it is a pneumatic valve or an electric valve, the actuation form of the valve stem in the valve has two types: rotary drive and linear drive, that is, the valve to be diagnosed can be divided into an angular stroke valve and a linear stroke valve according to the valve stem actuation mode. Therefore, the sensor used to detect the physical quantities related to the valve stem in the above-mentioned sensor assembly needs to be matched in form according to the actuation mode of the valve stem, and the physical quantities detected may also be different. Taking the drive stress sensor as an example, the drive stress sensor suitable for the angular stroke valve is a torque sensor, and the drive stress sensor suitable for the linear stroke valve is a thrust sensor. For the angular stroke valve, the drive stress detected by the torque sensor is the torque applied to the valve stem by the drive head; but for the linear stroke valve, the drive stress detected by the thrust sensor is the thrust applied to the valve stem by the drive head. For another example, for the displacement sensor, the valve stem stroke collected for the linear stroke valve is the axial displacement of the valve stem, while for the angular stroke valve, the valve stem stroke collected is the rotation angle of the valve stem.

[0044] In an embodiment of the present invention, each sensor in the above-mentioned sensor assembly is formed by pairing and connecting a sensor front end and a sensor back end. The sensor front end, as a sensor front end sensing unit, is the part of the sensor that is in direct contact with the measured physical quantity. Its main function is to sense the measured physical quantity and convert it into an electrical signal. The sensor back end, as the back end signal processing unit of the sensor, is the part where the sensor is connected to the data acquisition box DAU. The sensor back end generally needs to include a communication module, a data processing center (i.e., a processor) and a data conversion module. The main function is to receive the electrical signal output by the sensor front end, and to perform necessary data processing such as amplification, filtering, and conversion to obtain accurate and reliable measurement results. In an embodiment of the present invention, the sensor back end of each sensor is connected to the data acquisition box DAU in the form of an aviation plug, so the sensor back end of each sensor needs to be equipped with a first aviation plug. In practical applications, the specific form and parameter requirements of the front end and back end of each sensor need to be selected and adjusted according to specific application requirements and measurement requirements.

[0045] In an embodiment of the present invention, all optional sensors in the sensor assembly such as Figure 2As shown, the respective detected physical quantities and specific forms are preferably as follows:

[0046] Displacement sensor: used to monitor the travel of the valve stem. Displacement sensors such as laser, wire, and resistance encoder can be used.

[0047] Pressure sensor: used for pressure monitoring of the cylinder in the pneumatic valve. Pressure sensors of different specifications and models are provided according to the requirements of the test pressure.

[0048] Current sensor: used for current monitoring of the driving motor in the electric valve, with a current clamp at the front end of the sensor;

[0049] Voltage sensor: used for three-phase voltage monitoring of the driving motor in the electric valve. It has three-phase voltage input. The collected power supply signal is converted by the data at the back end of the sensor and uploaded to the DAU through R485 communication. The three-phase voltage is collected through a universal channel in the DAU, and the phase sequence is calculated in the host computer.

[0050] Thrust / torque sensor: used to monitor the thrust or torque of the valve stem. The front end of the sensor adopts a patch type, and the back end of the sensor adopts a current amplifier for signal amplification and stress calculation.

[0051] Switch node signal sensor: used for signal monitoring of limit switch or torque switch. DAU supplies 5V power and collects high and low levels when the limit switch or torque switch is on and off.

[0052] Controller signal sensor: used to output control signals and signal acquisition of valve pneumatic head or electric head.

[0053] In the valve performance test and diagnosis equipment, the data acquisition box DAU is a core part connecting the sensor assembly and the host computer. The data acquisition box DAU includes a central processing module, a communication module, a power module and a serial port module. Among them, the communication module, the power module and the data conversion module are all connected to the central processing module, and the data conversion module is connected to the serial port module. The function of the data conversion module is to convert between analog signals and digital signals between the central processing module and the serial port module.

[0054] The above-mentioned serial port module is an interface for serial communication between the data acquisition box DAU and sensors and other external devices. Since a series of different sensors need to be selectively set for different valves to be diagnosed in the present invention, the sensors cannot be pre-connected to the data acquisition box DAU. Instead, multiple input / output serial ports need to be set on the serial port module for inputting data to the data acquisition box DAU or for the data acquisition box DAU to output data to the outside. Each serial port has a second aviation plug that matches the first aviation plug. These aviation plugs all use the same specifications, and any optional sensor rear end can be connected to the serial port module by pairing and connecting the aviation plugs. In actual applications, if a certain sensor needs to be connected to the serial port module, the first aviation plug on the sensor rear end of the sensor can be inserted into the currently vacant second aviation plug on the serial port module, so that the connected sensor can be flexibly adjusted according to actual diagnostic needs.

[0055] In the present invention, the communication mode between the data acquisition box DAU and the sensor preferably adopts R485 communication. The serial port module is preferably provided with 12 input / output serial ports so as to fully meet the detection requirements of different valve types.

[0056] However, since the data acquisition box DAU is not pre-connected with a fixed sensor, a handshake protocol needs to be set for a series of sensors that may be connected in the data acquisition box DAU of the present invention. When the serial port module detects that a new sensor backend is connected, the handshake protocol must be executed first, that is, the impedance range of the sensor is detected and the handshake key is detected. After verifying that the handshake key is correct, the sensor is powered according to the detected sensor impedance range and a communication protocol is established. Different sensor types and the supply voltages corresponding to the sensor impedance can be stored in the data acquisition box DAU in advance in the form of a mapping relationship for actual connection. Therefore, on the serial port modules of each sensor backend and DAU of the present invention, the first aviation plug and the matching second aviation plug both use 9-core wires, of which 2 cores of the 9 core wires are used for the impedance range detection of the sensor and the detection of the handshake key. After the handshake protocol is passed, the DAU can power the sensor and establish a communication protocol. The handshake protocol can be used to ensure that the equipment manufacturer effectively controls the range of accessible sensors and avoids DAU access to unknown sensors.

[0057] Since the type of sensor connected to the serial port module is uncertain, whether each serial port is an input serial port or an output serial port depends on whether the sensor has input or output. If the sensor is an output sensor (such as a controller signal sensor), after docking with a serial port of the data acquisition box DAU, the serial port is an output channel. For the controller signal sensor, in an embodiment of the present invention, the serial port module can provide a 4~20mA or 0~10V signal output to the controller signal sensor. However, even if the output sensor is connected to the signal output serial port, it should also have a signal collection function, that is, through the sensor back end, the signal can be collected to the data acquisition box DAU and transmitted to the host computer for detection and analysis. In general, in addition to the controller signal sensor, other air pressure sensors, displacement sensors, current sensors, voltage sensors, thrust / torque sensors, and switch node signal sensors (used to detect switch input and switch output) can all use input serial ports, that is, the data collected by the sensor will be input into the data acquisition box DAU.

[0058] In addition, other modules in the above-mentioned data acquisition box DAU are also used to provide other functions, and their respective functions are similar to those of the lower computer connected to the sensor. Among them, the central processing module is the core part of the data acquisition box DAU, which is responsible for data processing, analysis and control, etc. Generally speaking, the central processing module can receive the raw data from the sensor, and perform filtering, calibration, conversion and other processing to improve the accuracy and reliability of the data, and cooperate with the communication module to package and transmit the processed data according to the specified communication protocol and format. The communication module is used to establish a communication connection between the data acquisition box DAU and the host computer, which can be in the form of a wireless communication module or a wired communication module, and can transmit the data processed by the central processing module to the host computer by wire or wireless. The communication module can support a variety of communication protocols and interfaces, such as GPRS / CDMA, 4G, 5G, WiFi, Ethernet, etc., to ensure compatibility with different devices and systems. In addition, the communication module can also receive control instructions from the host computer, allowing remote users to configure, monitor and maintain the DAU, improving the manageability and flexibility of the equipment.

[0059] The above-mentioned power module is used to power each module in the data acquisition box DAU. The power module can be connected to the mains or have its own power supply in the form of a battery. If connected to the mains, the AC or DC power input to the data acquisition box DAU can be converted by the power module into the stable voltage required by other modules. When the power input is abnormal, such as overcurrent, overvoltage, etc., it can also automatically cut off the power supply or reduce the output voltage to protect the internal circuits and components of the DAU from damage. In this power module, the voltage supplied to the serial port module can be further adjusted according to the type of sensor connected to meet the voltage requirements of each connected sensor.

[0060] In the valve performance test and diagnosis equipment, the host computer plays the role of upper control and data analysis of the valve diagnosis process, so at least a signal control module and a data analysis module are required in the host computer. The signal control module is used to send control instructions to the data acquisition box DAU, and at the same time receive and store the signal data collected by the sensor assembly uploaded by the data acquisition box DAU. The data analysis module is used to analyze the signal data collected by the sensor assembly, and identify and diagnose the stuck fault according to the jump information between different types of signals.

[0061] Therefore, in the valve performance test and diagnosis device of the present invention, the overall connection and data transmission process among the host computer, the data acquisition box DAU and the sensor assembly is as follows: Figure 3 shown.

[0062] The data analysis module in the present invention needs to have a built-in diagnostic algorithm flow for diagnosing stuck faults. The algorithm can theoretically be implemented using an existing diagnostic algorithm flow as long as it can identify and diagnose stuck faults based on the transition information between different types of signals.

[0063] In an embodiment of the present invention, a diagnostic process is provided in which a signal control module and a data analysis module in a host computer cooperate to perform stuck fault identification and diagnosis. The diagnostic process is as follows:

[0064] A1. The host computer outputs a ramp signal through the signal control module, and outputs a valve position control signal to the valve drive head through the data acquisition box DAU and the controller signal sensor, thereby controlling the valve drive head to drive the valve stem of the valve to be diagnosed. In the above ramp signal, the signal value rises from the lowest value to the highest value at a fixed slope, and then drops from the highest value to the lowest value at a fixed slope, and the opening of the valve to be diagnosed is positively correlated with the signal value.

[0065] In the present invention, the host computer sends a ramp signal about the valve position to control the output of the controller signal sensor. In the embodiment of the present invention, since the controller signal sensor provides a signal output range of 4~20mA, the output current is a Figure 4 The ramp signal shown in the figure has a cycle of t1~t2. During this cycle, the signal strength increases from 4~20mA at a certain slope, and then decreases from 20~4mA at the same slope. The peak time is t up The signal corresponds to the set valve position value of 0~100%. When the signal value is 4mA, the corresponding valve position is 0, which means the valve is fully closed. When the signal value is 20mA, the corresponding valve position is 100%, which means the valve is fully open. Therefore, with the output of this ramp signal, the valve position should change from fully closed to fully open, and then return to fully closed.

[0066] At the same time, during the ramp signal output process, the displacement sensor and the drive stress sensor are required to synchronously collect the stroke signal and the drive stress signal of the valve stem in the valve to be diagnosed, and upload them to the host computer in real time through the data acquisition box DAU together with the control signal output by the controller signal sensor for storage.

[0067] A2. After the ramp signal is output, the data analysis module reads the time domain data of the control signal, stroke signal and drive stress signal from the memory of the host computer, and converts the valve stem stroke at each moment in the stroke signal into the actual valve position according to the pre-calibrated relationship curve between the valve stem stroke and the valve position, thereby generating a first change curve on the coordinate axis in which the actual valve position changes with the control signal during the ramp signal output process, and a second change curve in which the actual valve position changes with the drive stress signal during the ramp signal output process.

[0068] In an embodiment of the present invention, the first variation curve is as follows: Figure 5 As shown, the horizontal axis is the control signal for setting the valve position value (in the figure, the set valve position value corresponding to the current value output by the controller signal sensor is used to represent it, in unit %), and the vertical axis is the actual valve position (in unit %). In the embodiment of the present invention, the above second change curve is as shown in Figure 6 As shown, the horizontal axis is the actual valve position (unit: %), and the vertical axis is the driving stress signal value in the form of torque (i.e., the angle stroke valve used in this embodiment).

[0069] A3: Mark the signal dead zone and all first jumps on the first change curve, and record the dead zone range S of the signal dead zone on the control signal coordinate axis d (i.e., the absolute difference between the two lateral endpoints of the signal dead zone on the control signal coordinate axis) and the jump range S of each first jump on the control signal coordinate axis en (i.e., the absolute difference of the coordinates of the two lateral endpoints of the jump point area on the control signal coordinate axis); mark all the second jumps on the second change curve, and record the maximum absolute value F of each second jump on the driving stress coordinate axis en (That is, the coordinate values ​​of the two longitudinal endpoints of the jump point area on the driving stress coordinate axis have the largest absolute value).

[0070] It should be noted that, according to the principle of signal jump, the first jump on the first change curve and the second jump on the second change curve must correspond one-to-one based on the actual valve position, that is, each group of corresponding first jumps and second jumps are located at the same actual valve position. The present invention calls the actual valve position where each group of corresponding first jumps and second jumps are simultaneously located a jump valve position.

[0071] In an embodiment of the present invention, Figure 5 and Figure 6For example, there are i jump valve positions in total, so the jump range S of the i jump valve positions is en Marked as S e1 , S e2 , ...S ei The torque jump value of the i-th jump valve position, that is, the maximum absolute value of the jump on the vertical axis of the second change curve F en , marked as F e1 , F e2 , ... F ei .

[0072] A4. For each jump valve position, calculate the viscosity coefficient of each jump valve position. The viscosity coefficient c of any nth jump valve position is n =(S d -S en ) / (S d +S en ), and classify the sticking degree of each jump valve position based on the viscosity coefficient.

[0073] In the present invention, since the value of the viscosity coefficient is between 0 and 1, when the sticking degree of each jump valve position is graded based on the viscosity coefficient, the viscosity coefficient within the range of 0 to 1 can be divided into multiple levels according to a preset number of grades, wherein the smaller the viscosity coefficient, the higher the sticking degree, and the smaller the viscosity coefficient, the lower the sticking degree. The specific number of grades can be adjusted according to actual needs. In the embodiment of the present invention, it can be set that when c n is 1, indicating that there is no sticking in the nth jump valve position; when c n When (0~0.33), it means that the nth jump valve position is severely stuck; when c n When [0.33~0.67), it means that the nth jump valve position is moderately stuck; when c n When [0.67,1), it means that the nth jump valve position is slightly stuck.

[0074] A5. When the valve core is stuck, for each jump valve position, take the maximum absolute value F of the jump on the vertical axis of the second change curve. en , combined with the driving stress value F when there is no jamming base , calculate the valve core sticking force F at the jump valve position kzn =F en -F base , completing the quantitative characterization of the valve core sticking force.

[0075] Therefore, based on the above steps A1 to A5, the automatic detection of all jump valve positions in a cycle can be realized, and the corresponding stagnation degree classification labels and the quantitative value of the valve core stagnation force can also be obtained. Of course, in actual applications, in order to ensure accuracy, the ramp signal can be output cyclically to obtain the diagnosis results of multiple cycles.

[0076] In an embodiment of the present invention, a report output module may be provided in the host computer to output all jump valve positions and their corresponding grading labels of sticking degrees and quantified values ​​of the sticking force of the valve core.

[0077] In another embodiment of the present invention, a driving stress adjustment suggestion generation module may be further provided in the report output module, for calculating and outputting adjustment suggestions for the driving stress. 输出 It is the sum of the rated driving stress value and the incremental stress value; the incremental stress value is the quotient obtained by dividing the average value of the valve core sticking force of all jump valve positions by the average value of the viscosity coefficient of all jump valve positions, and is expressed by the formula:

[0078]

[0079] Where: c is the total jump valve position c n The average value of the viscosity coefficient, i is the total number of all jump valve positions. Rated drive stress value F 额定 This can be achieved by calibrating the valve at the factory to prevent sticking.

[0080] In order to better understand the valve core stuck process shown in A1~A5 of the present invention, its detection principle is described in detail below. Since the control signal output by the present invention corresponds to the set valve position value of 0%~100%. The displacement sensor obtains the valve stem displacement and converts it into the actual valve position, which can also be expressed as a percentage, that is, 0%~100%. When the valve is actuated, there is a dead zone value Sd due to factors such as structural clearance and packing. When the valve is given a signal in the opposite direction, a dead zone will be generated. When the signal is given in the same direction, if the valve core is stuck, the control signal will continue to increase. At this time, the valve position does not increase. This area is the stuck area. When the control signal continues to increase to a certain value, the valve position suddenly changes. This sudden change process is the movement of the valve stem after overcoming the static friction. Therefore, there are static friction and sliding friction in this process. In order to obtain the magnitude of static friction and sliding friction, the present invention considers that the calculated value of the sliding friction of the valve stem is f d =(S d -S e ) / 2, the calculated value of the static friction force of the valve stem is f s =(S d +S e) / 2. The ratio of sliding friction to static friction is a dimensionless number, recorded as the sticking coefficient, which is the relative size of sliding friction to static friction. Ideally, sliding friction is equal to static friction, which means there is no sticking, but if the two are different, it means there is sticking.

[0081] In another embodiment of the present invention, based on the above valve performance test and diagnosis device, a valve performance test and diagnosis method is also provided, and the specific steps are as follows:

[0082] S1. Install the controller signal sensor, displacement sensor and drive stress sensor on the valve to be diagnosed respectively, and selectively install other sensors according to the diagnostic requirements of the valve to be diagnosed; the sensor back ends of all sensors are connected to the serial port module of the data acquisition box DAU through aviation plug-in pairing and plug-in. After the serial port module executes the handshake protocol, each sensor establishes a communication connection and power supply with the data acquisition box DAU respectively.

[0083] In actual applications, after starting the host computer and DAU, the DAU power supply supplies power to the DAU and the installed sensors. After the sensor connection is detected again, the host computer sends configuration commands to the sensor through the DAU. The test items to be tested can be selected in the host computer, and the DAU automatically outputs control signals to the valve under test, and collects and transmits the state quantity of the valve action process through the sensor back end and the DAU at a certain frequency. In this embodiment, the subsequent stuck fault diagnosis is mainly performed, but other fault type diagnosis can also be achieved through this device.

[0084] S2. In the host computer, the signal control module and the data analysis module cooperate to execute the diagnostic process, so as to identify and diagnose the stuck fault; at the same time, according to the diagnostic requirements of the valve to be diagnosed, other installed sensors are used to collect corresponding sensor signal data during the valve actuation process, and the data is uploaded to the host computer through the data acquisition box DAU for data analysis and visualization.

[0085] For example, if you need to detect the motor current and voltage in an electric valve, you can configure a current sensor and a voltage sensor, and then upload the collected current and voltage to the host computer. If you need to detect the pressure in a pneumatic valve, you can configure a pressure sensor, and then upload the collected pressure to the host computer. The host computer can analyze and visualize the data as needed to facilitate diagnosis of the valve's operation.

[0086] The specific data analysis and visualization display methods in the host computer can be adjusted according to actual needs. For example, during the test process, the collected data can be presented in the host computer operating system in the form of a curve. After the selected test items are completed, the host computer system can automatically enter the data calculation and analysis, and perform necessary automatic punctuation on the curve; after calculation and analysis, the performance parameters of the valve and the valve core fault conditions are automatically diagnosed according to the punctuation of the curve and the fault diagnosis algorithm. After the calculation and diagnosis are completed, the host computer system can automatically output a performance diagnosis report.

[0087] S3. After all valve performance test and diagnosis items are completed, turn off the host computer and data acquisition box DAU, remove the sensors installed on the valves to be diagnosed, and complete the valve action performance test and diagnosis process.

[0088] The above-described embodiment is only a preferred solution of the present invention, but it is not intended to limit the present invention. A person skilled in the relevant technical field can make various changes and deformations without departing from the spirit and scope of the present invention. Therefore, any technical solution obtained by equivalent replacement or equivalent transformation falls within the protection scope of the present invention.

Claims

1. A valve performance test and diagnosis device, characterized in that: Including host computer, data acquisition box and sensor components; The sensor assembly at least includes a controller signal sensor, a displacement sensor and a drive stress sensor, and all are installed on the valve to be diagnosed; the controller signal sensor is used to output a control signal to the valve drive head and collect the control signal at the same time; the displacement sensor is used to collect the stroke of the valve stem; the drive stress sensor is used to collect the valve stem drive stress on the valve stem; each sensor in the sensor assembly is formed by a sensor front end and a sensor rear end connected in pairs, and the sensor rear end is provided with a first aviation plug; The data acquisition box comprises a central processing module, a communication module, a power module and a serial port module; the communication module, the power module and the data conversion module are all connected to the central processing module, and the data conversion module is connected to the serial port module; the serial port module has a plurality of serial ports for inputting data into the data acquisition box or for outputting data from the data acquisition box, each serial port has a second aviation plug that matches the first aviation plug, and each sensor back end can be connected to the serial port module by pairing and connecting the aviation plugs. When the serial port module detects that a new sensor back end is connected, a handshake protocol must be executed first, and the sensor impedance range and handshake key must be detected. After verifying that the handshake key is correct, the sensor is powered according to the detected sensor impedance range and a communication protocol is established; the communication module is used to establish a communication connection with the host computer; the power module is used to power each module in the data acquisition box; the data conversion module is used to perform signal conversion between the central processing module and the serial port module; The host computer is provided with a signal control module and a data analysis module; the signal control module is used to send control instructions to the data acquisition box, and at the same time receive and store the signal data collected by the sensor assembly uploaded by the data acquisition box; the data analysis module is used to analyze the signal data collected by the sensor assembly, and identify and diagnose the stuck fault according to the jump information between different types of signals; In the host computer, the signal control module and the data analysis module cooperate to perform stuck fault identification and diagnosis, and the diagnosis process is as follows: A1. The host computer outputs a ramp signal through the signal control module, and outputs a valve position control signal to the valve drive head through the data acquisition box and the controller signal sensor, thereby controlling the valve drive head to drive the valve stem of the valve to be diagnosed to actuate; in the ramp signal, the signal value rises from the lowest value to the highest value at a fixed slope, and then drops from the highest value to the lowest value again at a fixed slope, and the opening of the valve to be diagnosed is positively correlated with the signal value; at the same time, during the ramp signal output process, the travel signal and the driving stress signal of the valve stem in the valve to be diagnosed are synchronously collected by the displacement sensor and the driving stress sensor, and uploaded to the host computer in real time through the data acquisition box together with the control signal output by the controller signal sensor for storage; A2. After the ramp signal is output, the data analysis module reads the time domain data of the control signal, the stroke signal and the driving stress signal, and converts the valve stem stroke in the stroke signal into the actual valve position, thereby generating a first change curve of the actual valve position changing with the control signal during the ramp signal output process and a second change curve of the actual valve position changing with the driving stress signal during the ramp signal output process on the coordinate axis; A3: Mark the signal dead zone and all first jumps on the first change curve, and record the dead zone range of the signal dead zone on the control signal coordinate axis S d and the jump range of each first jump on the control signal coordinate axis S en ; Mark all second jumps on the second change curve, and record the maximum absolute value of each second jump on the driving stress coordinate axis F en ; The first jump on the first change curve and the second jump on the second change curve correspond one to one based on the actual valve position, and the actual valve position where each group of corresponding first jump and second jump are located at the same time is the jump valve position; A4. Calculate the viscosity coefficient of each jump valve position for each jump valve position c n =( S d - S en ) / ( S d + S en ), and classify the sticking degree of each jump valve position based on the viscosity coefficient; A5. For each jump valve position, combined with the driving stress value when there is no sticking F base , calculate the valve core sticking force at the jump valve position F kzn = F en - F base , completing the quantitative characterization of the valve core sticking force.

2. The valve performance test and diagnosis equipment according to claim 1, characterized in that: The valve to be diagnosed is a pneumatic valve or an electric valve.

3. The valve performance test and diagnosis equipment according to claim 2, characterized in that: The sensor assembly also includes one or more of a pressure sensor, a current sensor, a voltage sensor, and a switch node signal sensor; the pressure sensor is used to detect the cylinder pressure in the pneumatic valve; the current sensor is used to detect the motor current in the electric valve; the voltage sensor is used to detect the motor voltage in the electric valve; the switch node signal sensor is used to detect whether the valve stem has reached its stroke.

4. The valve performance test and diagnosis equipment according to claim 1, characterized in that: The driving stress sensor is a torque sensor suitable for an angular stroke valve or a thrust sensor suitable for a linear stroke valve; for an angular stroke valve, the driving stress detected by the torque sensor is the torque applied to the valve stem by the driving head; for a linear stroke valve, the driving stress detected by the thrust sensor is the thrust applied to the valve stem by the driving head.

5. The valve performance test and diagnosis equipment according to claim 1, characterized in that: The first aviation plug and the matching second aviation plug both use 9-core wires, of which 2-core wires are used for impedance range detection of the sensor and detection of the handshake key.

6. The valve performance test and diagnosis equipment according to claim 1, characterized in that: When the sticking degree of each jump valve position is graded based on the viscosity coefficient, the viscosity coefficient in the range of 0 to 1 is divided into multiple levels according to a preset number of grades, wherein the smaller the viscosity coefficient, the higher the sticking degree, and the smaller the viscosity coefficient, the lower the sticking degree.

7. The valve performance test and diagnosis equipment according to claim 1, characterized in that: The host computer is also provided with a report output module for outputting all jump valve positions and their corresponding stagnation degree classification labels and the quantified value of the valve core stagnation force.

8. The valve performance test and diagnosis equipment according to claim 7, characterized in that: The report output module also outputs adjustment suggestions for the driving stress, and the recommended adjusted driving stress value is the sum of the rated driving stress value and the incremental stress value; the incremental stress value is the quotient obtained by dividing the average value of the valve core sticking force of all jump valve positions by the average value of the viscosity coefficient of all jump valve positions.

9. A valve performance test and diagnosis method using the valve performance test and diagnosis device according to any one of claims 1 to 8, characterized in that: include: S1. Install the controller signal sensor, displacement sensor and drive stress sensor on the valve to be diagnosed respectively, and selectively install other sensors according to the diagnostic requirements of the valve to be diagnosed; the sensor back ends of all sensors are connected to the serial port module of the data acquisition box by means of aviation plug-in and pairing, and after the serial port module executes the handshake protocol, each sensor establishes a communication connection and power supply with the data acquisition box respectively; S2, in the host computer, the signal control module and the data analysis module cooperate to execute the diagnostic process, so as to identify and diagnose the stuck fault; at the same time, according to the diagnostic requirements of the valve to be diagnosed, other installed sensors are used to collect corresponding sensor signal data during the valve actuation process, and the data is uploaded to the host computer through the data acquisition box for data analysis and visual display; S3. After all valve performance test and diagnosis items are completed, turn off the host computer and data acquisition box, and remove the sensors installed on the valves to be diagnosed.

Images