Pneumatic control valve fault reproduction method and system under experimental condition

Abstract

The invention discloses a pneumatic control valve fault reproduction method and system under experimental conditions, and belongs to the technical field of control valve fault diagnos.The method comprises the steps that occurrence reasons and evolution mechanisms of control valve faults under real working conditions are analyzed, and relevant key component positions under different fault types of a control valve are obtained; carrying out profile map disassembly analysis operation on the key component containing the fault; on the basis of the profile maps of the key components, all parts forming the components are obtained, and one or more parts associated with the control valve fault are obtained on the basis of a fault evolution mechanism; and based on the parts associated with the faults of the control valve, key parts capable of triggering fault conditions are screened out in combination with the part fault influence table, the parts are damaged, and reproduction of different fault types of the control valve is completed. Based on the evolution mechanism of the control valve fault, starting from the component parts of the control valve, the fault of the control valve in accordance with the actual working condition can be reproduced.

Description

Technical Field

[0001] The present invention relates to the technical field of control valve fault diagnosis, and more particularly to a method and system for reproducing a pneumatic control valve fault under experimental conditions. Background Art

[0002] At present, the fault diagnosis of control valves generally adopts a data-driven method. The advantage of this method is that it can avoid the establishment of complex mathematical and physical operation models of control valves. Therefore, this method has been widely used in the vast majority of fault diagnosis research.

[0003] The data-driven method is to collect the data of control valve failure under real working conditions, put it into the built neural network model for training, and after the model iteration is completed and converged, the subsequent new fault data can be accurately classified. The fault samples of the control valve under real working conditions are in small batches, and the fault types are in a small number. It is difficult to build a large number of fault data sets with multiple fault types. However, the premise of deep neural network training is to have a large amount of data support, so this deeply limits the performance of the neural network model. In this case, in order to obtain better training results, it is necessary to use the application of transfer learning algorithms, that is, first train the model in the source domain, freeze the weight parameters after training, and then put it into the target domain for verification. Here, the source domain refers to the control valve failure data collected under experimental conditions, and the target domain refers to the control valve failure data under real working conditions. The key to using the transfer learning algorithm to achieve high accuracy is that the control valve failure data under experimental conditions must be real and reliable. Therefore, the collection of fault data under experimental conditions requires some "destruction" of the control valve to achieve the reproduction of the fault under real working conditions.

[0004] At present, the method of reproducing control valve faults under experimental conditions is to directly reproduce with the help of external tools. For example, the method of reproducing valve body blockage is to use thick asbestos paper, dig several holes of different sizes on the asbestos paper, and place them at the flange and the valve body inlet to reproduce different degrees of blockage. The reproduction of these faults seems to have met the requirements of the fault, but the reproduction of these faults does not consider the evolution mechanism of the fault, and is only a mechanical reproduction method; the disadvantage of the above method is that the control valve blockage refers to the presence of more attachments on the valve core or valve seat, which leads to the inability to completely close the valve when it is closed. Therefore, the amount affected by the valve blockage is mainly the displacement of the valve rather than the medium flow, and even if it affects the medium flow, the point of influence of the medium flow should be inside the valve body rather than the valve body inlet and flange.

[0005] Therefore, the control valve fault data collected under this fault reproduction method is unreliable, and the classification accuracy of the trained model is not high, which cannot meet the requirements of fine classification diagnosis. Based on the shortcomings of the above-mentioned reproduction method, the present invention considers studying the method of control valve fault reproduction from the fault evolution mechanism, combining the evolution mechanism of each fault to "destroy" the components of the control valve and then reproduce the fault; making the control valve fault data collected under experimental conditions closer to the fault data generated under real working conditions, and having more abundant fault types, and then constructing a fault data set to meet the training requirements of the transfer learning algorithm, which helps to improve the training accuracy of the model and meet the requirements of detailed diagnosis. Summary of the invention

[0006] In view of this, the present invention provides a method and system for reproducing pneumatic control valve faults under experimental conditions that at least solves some of the above-mentioned technical problems. Based on the evolution mechanism of control valve faults and starting from the components of the control valve, the faults of the control valves under actual working conditions are reproduced, which helps to make the control valve fault data collected under experimental conditions closer to the fault data generated under actual working conditions, so as to meet the training requirements of the transfer learning algorithm, and is conducive to improving the training accuracy of the model and meeting the requirements of refined diagnosis.

[0007] To achieve the above object, the technical solution adopted by the present invention is:

[0008] In a first aspect, the present invention provides a method for reproducing a pneumatic control valve fault under experimental conditions, the method comprising the following steps:

[0009] S1. Analyze the causes and evolution mechanisms of control valve failures under real working conditions, obtain the locations of key components associated with different types of control valve failures, construct cross-sectional views of key components, and perform cross-sectional view disassembly and analysis of key components containing failures;

[0010] S2. Based on the cross-sectional view of the key components, obtain the components of the control valve, obtain one or more components associated with the control valve failure based on the failure evolution mechanism, and construct a component failure impact table;

[0011] S3. Based on the components associated with the control valve failure, the key components that can trigger the failure conditions are screened out in combination with the component failure impact table, and the failure processing is performed on the key components to complete the reproduction of different control valve failure types.

[0012] In an optional embodiment, in step S1, the different types of control valve failures include: valve failure, actuator failure and air source pressure failure; wherein:

[0013] The valve failures include: valve body sedimentation, increased valve friction, valve internal leakage, valve external leakage;

[0014] The actuator failures include: diaphragm perforation, spring failure, and loose frame terminals.

[0015] In an optional implementation, in step S2, the component failure impact table constructed includes: component code, component name, component function, failure mode, failure cause and failure impact.

[0016] In an optional embodiment, in step S3, the method for reproducing different fault types of the control valve includes:

[0017] Reproduction of valve body sedimentation fault: Use rubber products to adhere impurities on the valve core surface and valve seat surface;

[0018] Valve friction increase fault recurrence: Replace the packing components, the friction coefficient of the replaced packing components is greater than the friction coefficient of the original packing components;

[0019] Reproduce the internal leakage of the valve: remove the sealing gasket between the valve core and the valve seat or replace the spring;

[0020] Reproduce the valve external leakage fault: remove the sealing gasket between the valve body and the flange, and replace the loose bolts or rusted bolts;

[0021] Diaphragm perforation fault recurrence: replace the diaphragm;

[0022] Spring failure Fault reproduction: Replace the original spring, the rigidity coefficient of the replacement spring is smaller than the original spring;

[0023] Re-occurence of the rack terminal loosening fault: loosen the bolts or reduce the pressure at the air supply;

[0024] Reproduce the air source pressure failure: loosen the bolts, replace the original spring, replace the spring with a spring with a stiffness coefficient greater than the original spring, and replace the actuator diaphragm.

[0025] In an optional embodiment, in the reproduction of the valve body sedimentation failure, the rubber product is a washable quick-adhesive glue, and the impurities are mud and rust.

[0026] In an optional embodiment, in reproducing the valve friction increase fault, the replaced packing component is PTFE packing.

[0027] In a second aspect, the present invention further provides a pneumatic control valve fault reproduction system under experimental conditions, which executes the above-mentioned pneumatic control valve fault reproduction method under experimental conditions to complete the reproduction of different fault types of the control valve, and the system includes: an analysis module, a fault-related component acquisition module and a fault reproduction module, wherein:

[0028] The analysis module is used to analyze the causes and evolution mechanisms of control valve failures under real working conditions, obtain the positions of key components associated with different types of control valve failures, construct cross-sectional views of key components, and perform cross-sectional view disassembly and analysis of key components containing failures;

[0029] The fault-related component acquisition module is used to obtain the various components of the control valve components based on the cross-sectional view of the key components, obtain one or more components associated with the control valve fault based on the fault evolution mechanism, and construct a component fault impact table;

[0030] The fault reproduction module is used to screen out key components that can trigger fault conditions based on components associated with the control valve fault and in combination with a component fault impact table, and perform fault processing on the key components to complete the reproduction of different control valve fault types.

[0031] Compared with the prior art, the present invention has at least the following beneficial technical effects:

[0032] The present invention provides a method for reproducing pneumatic control valve faults under experimental conditions. Based on the evolution mechanism of control valve faults, starting from the components of the control valve, the faults of the control valves under actual working conditions are reproduced, which helps to make the control valve fault data collected under experimental conditions closer to the fault data generated under actual working conditions. In addition, there are more abundant fault types, which supports the collection of high-quality data, and then constructs a fault data set to meet the training requirements of the transfer learning algorithm, which is beneficial to improving the training accuracy of the model and meeting the requirements of detailed diagnosis.

[0033] Other features and advantages of the present invention will be described in the following description, and partly become apparent from the description, or understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the written description and the accompanying drawings.

[0034] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, a brief introduction will be given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0036] The accompanying drawings are used to provide further understanding of the present invention and constitute a part of the specification. They are used to explain the present invention together with the embodiments of the present invention and do not constitute a limitation of the present invention.

[0037] Figure 1 A schematic flow chart of a method for reproducing a pneumatic control valve fault under experimental conditions provided in an embodiment of the present invention.

[0038] Figure 2 A schematic diagram of the functional framework of a valve portion provided in an embodiment of the present invention.

[0039] Figure 3 A partial cross-sectional schematic diagram of an actuator provided in an embodiment of the present invention.

[0040] Figure 4 A partial cross-sectional schematic diagram of a valve provided in an embodiment of the present invention.

[0041] Among them, 1-spring; 2-top cover; 3-nut; 4-diaphragm; 5-push rod; 6-connecting pin; 7-indicator scale; 8-valve stem; 9-bracket; 10-packing cover; 11-upper valve cover; 12-hexagonal bolt; 13-packing part; 14-right flange; 15-valve seat; 16-sealing gasket; 17-valve body; 18-left flange. DETAILED DESCRIPTION

[0042] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments.

[0043] In the description of the present invention, it should be noted that: in some processes described in the specification and drawings of this application, multiple operations appearing in a specific order are included, but it should be clearly understood that these operations may not be performed in the order in which they appear in this document or may be performed in parallel. In addition, various serial numbers are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0044] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0045] See also Figure 1 As shown, the embodiment of the present invention provides a method for reproducing a pneumatic control valve failure under experimental conditions based on the evolution mechanism of the failure of the control valve during use and combined with the analysis of the impact of component failures. The method mainly includes:

[0046] S1. Analyze the causes and evolution mechanisms of control valve failures under real working conditions, obtain the locations of key components associated with different types of control valve failures, construct cross-sectional views of key components, and perform cross-sectional view disassembly and analysis of key components containing failures;

[0047] S2. Based on the cross-sectional view of the key components, obtain the components of the control valve, obtain one or more components associated with the control valve failure based on the failure evolution mechanism, and construct a component failure impact table;

[0048] S3. Based on the components associated with the control valve failure, the key components that can trigger the failure conditions are screened out in combination with the component failure impact table, and the failure of the key components is processed to complete the reproduction of different control valve failure types.

[0049] Combination Figure 2-Figure 4 As shown, the specific implementation of the method of the present invention is described in detail below by taking the control valve body as an air-opened straight-through valve as an example:

[0050] In this embodiment, the functional architecture of the valve part of the control valve is as follows: Figure 2 As shown in Figure 1, the structure of the actuator part is as follows: Figure 3 As shown, the structure of the valve part is as follows Figure 4 As shown; according to the composition of the control valve and the frequency of failure, the valve failure is reproduced. The valve failures are valve body sedimentation, increased valve friction, valve internal leakage, and valve external leakage in order of frequency; the failures at the actuator are: diaphragm perforation, spring failure, and loose rack terminal; the remaining failure types are gas source pressure failures.

[0051] Furthermore, when the functions of various components are obtained, the analysis of valve failure is clearer. The functions of various components can be used to analyze what kind of failure phenomena will be caused if the components fail, and then a component failure impact table (FMECA table) is constructed as shown in Table 1. The FMECA (Failure Modes, Effects, and Criticality Analysis) method is used to analyze the failure modes and failure impacts of the valve part.

[0052] Table 1 Impact of failure of some valve parts

[0053]

[0054]

[0055] In this embodiment, based on the above table, it can be clearly seen which parts the valve part of the control valve is composed of, and it can be clearly seen what impact each component failure will have on the local and overall valve, so that the overall failure of the control valve can be linked to the component failure. When the failure is reproduced later, the component corresponding to the failure can be quickly and accurately found, and then the component is destroyed to achieve the purpose of failure reproduction. For example, at this time, the overall failure of the control valve is manifested as valve body precipitation, which is caused by the deposition of impurities in the fluid medium. Therefore, the corresponding component is the valve seat or valve core. During the simulation, we can smear the impurities on the valve seat or valve core to reproduce different degrees of blockage failure.

[0056] In a specific embodiment, the evolution mechanism of various faults and the fault reproduction method involved in the present invention are as follows:

[0057] 1. Valve failure type:

[0058] (1) Valve body precipitation evolution mechanism: When the industrial medium flows through the control valve, impurities are deposited on the valve seat and valve core, resulting in thick layer adhesion failure, which is less severe than valve blockage;

[0059] Reproduction method: The components related to valve body precipitation are: valve core and valve seat. From the fault evolution mechanism, we know that the method to reproduce the fault is to use glue products to adhere impurities on the surface of the valve core and the surface of the valve seat, where the impurities are mud, sand and rust; the glue product is a washable quick-adhesive glue. The advantage of this method is that valve body precipitation faults of different intensities can be reproduced according to the number of adhered impurities, making the fault data richer; because it is coated with industrial media, the effect after reproduction is more in line with the actual working conditions; because it is a washable quick-adhesive glue, the valve core and the entire control valve can be used many times, and the remaining faults can be reproduced after cleaning.

[0060] (2) Valve friction increase evolution mechanism: The control valve is used for a long time, resulting in packing aging, deposition on the valve core or valve seat, which in turn leads to valve tracking lag failure;

[0061] Reproduction method: The components related to the increase of valve body friction are: packing components, valve core, valve seat. Since there is a lot of relative movement between the valve stem and the packing components during valve operation, the main component is the packing component. The fault reproduction method is to replace it with PTFE packing with greater friction.

[0062] (3) Evolution mechanism of valve internal leakage: internal leakage caused by rust of valve core and valve seat, damage of sealing gasket due to long-term erosion of corrosive media, or damage of guide sleeve due to long-term movement of valve stem, which in turn causes damage of valve core;

[0063] Reproduction method: The components related to internal leakage are: valve core, valve seat, sealing gasket and guide sleeve. Internal leakage is actually insufficient sealing. The fault can be reproduced by removing the sealing gasket at the valve core and valve seat or replacing the spring with a small rigidity coefficient.

[0064] (4) Evolution mechanism of valve external leakage: The control valve is used for a long time, resulting in aging of packing and spring, damage of gasket, insufficient sealing of valve body, or loosening of bolts due to vibration in the working environment, leading to leakage.

[0065] Reproduction method: The parts related to external leakage are packing, gasket, and hexagonal bolts. The leakage can be reproduced by removing the gasket between the valve body and the flange; loosening the hexagonal bolts; and replacing the rusted bolts.

[0066] 2. Actuator failure type:

[0067] (5) Evolution mechanism of diaphragm perforation: The diaphragm ages due to long-term use of the control valve or the effective area of ​​the diaphragm decreases during operation due to the tilt of the spring inside the actuator;

[0068] Reproduction method: The component related to diaphragm perforation is the diaphragm. Since the fault is actually due to insufficient output gas source pressure, it can be replaced with a diaphragm with a smaller area.

[0069] (6) Spring failure evolution mechanism: The use of the control valve test piece causes the spring stiffness coefficient inside the actuator to decrease, resulting in insufficient valve preload and the valve cannot be fully closed;

[0070] Reproduction method: The component related to spring failure is the spring. When reproducing, you can replace the original spring with a spring of smaller kilograms.

[0071] (7) Evolution mechanism of rack terminal loosening: The control valve loosens the terminals at the gas pipeline or the bolts at the actuator cover due to vibration in the factory environment;

[0072] Reproduction method: The parts related to the loosening of the rack terminals are: hexagonal bolts. When reproducing, you can loosen the hexagonal bolts or reduce the pressure at the air supply.

[0073] 3. Other reproducible faults:

[0074] (8) Gas source pressure failure evolution mechanism: Due to damage to the gas source pipeline and loose gas supply port, the output pressure of the actuator is too low, resulting in the failure of the valve to fully open.

[0075] Reproduction method: The components related to the gas source pressure failure are: gas source pipeline, hexagonal bolts, spring, and diaphragm. The failure can be reproduced by loosening the hexagonal bolts, replacing the spring with a larger rigidity coefficient to provide a larger valve sealing force while keeping other conditions unchanged, and replacing the actuator diaphragm with a damaged one or a diaphragm with a smaller effective area.

[0076] In this embodiment, the working principle of fault reproduction is to first determine the key component of the fault through the cause of the fault, then dissect the component to obtain the components of the component; obtain one or several components associated with the fault through the fault evolution mechanism; then find the component with the highest correlation in this fault mode through the component fault impact table, and reproduce various control valve faults by destroying and replacing the components. In terms of function and effect, this reproduction method can keep the control valve structure intact, save economic costs, and make the fault under experimental conditions closer to the fault mode under actual conditions.

[0077] The following is a more specific reproduction method to illustrate the relationship between the evolution mechanism and fault reproduction:

[0078] 1. External leakage fault reproduction: Through the component failure impact table, the components related to the external leakage fault can be obtained as follows: Figure 4 The packing part 13, gasket 16, and hexagonal bolt 12 of the middle valve part; since the packing and gasket parts are less likely to age in the early stage of the control valve, and the factory environment may cause the hexagonal bolt 12 to loosen due to excessive vibration and noise, which may lead to leakage. Therefore, when reproducing this fault, you can use a hexagonal wrench to loosen the hexagonal bolt 12 at the upper valve cover 11, or if there is an external pipe, you can also loosen the bolt here; or Figure 4 The sealing gaskets connected to the pipeline at the right flange 14 and the left flange 18 are removed.

[0079] 2. Reproduction of spring failure: When reproducing this failure, the cross-sectional view of the actuator ( Figure 3 ), the components of the actuator were obtained, including: spring 1, top cover 2, nut 3, diaphragm 4, push rod 5, connecting pin 6, indicator scale 7, valve stem 8, bracket 9, packing cover 10; loosen the Figure 3 The nut 3 of the top cover of the middle actuator. After removing the top cover, 3-5 springs 1 can be seen (depending on the different types of actuators). Then, springs 1 with different kilograms (rigidity coefficients) are replaced. One or more springs can be replaced to reproduce the spring failure.

[0080] 3. Reproduction of valve body sedimentation fault: First of all, the cause of valve body sedimentation fault may be that impurities in the medium are deposited and attached to a certain place inside the valve, which leads to a large error in the valve position. Therefore, the present invention locates the fault on the key component of the valve based on the cause; through the cross-sectional view of the valve (i.e. Figure 4 , some parts have been hidden for the convenience of display) and the various components inside the valve were obtained, including: upper valve cover 11, hexagonal bolts 12, packing part 13, right flange 14, valve seat 15, sealing gasket 16, valve body 17, left flange 18; the evolution mechanism of valve body precipitation failure is that when the industrial medium flows through the control valve, impurities are deposited on the valve seat and valve core, resulting in a thick layer of attachment failure. Combined with the fault evolution mechanism, it is known that the components associated with this failure are the valve seat and valve core; based on this component, through the FMECA table (i.e., component failure impact table), it is known that both the valve core and the valve seat may have precipitation failures, but due to the difference in function, the valve core will have more relative movement, and the valve seat plays a supporting role, so relatively more media will be deposited and attached to the valve seat, so the key component is the valve seat, and this failure can be reproduced by smearing common industrial impurities on the valve seat.

[0081] From the description of the above embodiments, those skilled in the art can know that: the present invention provides a method for reproducing pneumatic control valve faults under experimental conditions. In the reproduction of faults, the evolution mechanism of each fault is studied in depth, and the components of the control valve are "destroyed" in combination with the evolution mechanism of each fault to reproduce the fault. The advantage of the present invention is that it fully considers and studies the evolution mechanism of control valve faults, starts with the components of the control valve, reproduces the faults of the control valve under actual working conditions, and then supports the collection of high-quality data. The present invention has the following advantages:

[0082] 1. Application of fault evolution mechanism analysis in control valve fault reproduction:

[0083] Most of the literature on the method of reproducing control valve failure is only an attempt at mechanical structure, while the present invention is the first to characterize the failure from the root of the control valve failure based on the control valve failure evolution mechanism, so that the failure under experimental conditions is closer to the control valve failure under real working conditions.

[0084] 2. Application of valve body component function analysis:

[0085] In traditional fault reproduction design, it is often just a mechanical simulation. For example, the common valve blockage is to simulate different degrees of blockage of asbestos paper with holes dug. The present invention locates the fault on the component of the control valve based on the fault evolution mechanism. This not only reduces the scope of damage when the fault is reproduced, but also the function of the component can clearly understand which fault mode should correspond to which component, laying the foundation for subsequent fault impact analysis.

[0086] 3. Application of component failure impact analysis:

[0087] Another advantage of the present invention is that when reproducing different types of control valve failures, the influence of the components that make up the control valve on each failure will be analyzed. Therefore, during reproduction, only the components of the control valve will be destroyed without destroying the control valve as a whole. This not only ensures the integrity of the remaining structure of the control valve, but also makes the reproduction of the failure closer to the failure mode of the control valve under actual working conditions.

[0088] 4. Advantages of minor damage:

[0089] Since only the control valve components are damaged when the fault is reproduced, only slight damage is required. After reproducing one fault, the valve body can be slightly repaired. There is no need to directly eliminate the complete control valve and then reproduce the next fault, which can save costs.

[0090] Furthermore, the present invention also provides a pneumatic control valve fault reproduction system under experimental conditions, which is applied to a pneumatic control valve fault reproduction method under experimental conditions described in the above embodiment to complete the reproduction of different fault types of the control valve. The system includes: an analysis module, a fault-related component acquisition module and a fault reproduction module, wherein:

[0091] The analysis module is used to analyze the causes and evolution mechanisms of control valve failures under real working conditions, obtain the positions of key components associated with different types of control valve failures, construct cross-sectional views of key components, and perform cross-sectional view disassembly and analysis of key components containing failures;

[0092] The fault-related component acquisition module is used to obtain the various components of the control valve components based on the cross-sectional view of the key components, obtain one or more components associated with the control valve fault based on the fault evolution mechanism, and construct a component fault impact table;

[0093] The fault reproduction module is used to screen out key components that can trigger fault conditions based on components associated with the control valve fault and in combination with a component fault impact table, and perform fault processing on the key components to complete the reproduction of different control valve fault types.

[0094] An embodiment of the present invention provides a pneumatic control valve fault reproduction system under experimental conditions, and its implementation principle and technical effects are the same as those of the aforementioned method embodiment. For the sake of brief description, parts not mentioned in this embodiment can be referred to the corresponding contents in the aforementioned method embodiment, which will not be repeated here.

[0095] It should be understood by those skilled in the art that the embodiments of the present invention may be provided as methods, systems or computer products, etc. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0096] It should be noted that the word "comprising" does not exclude the presence of components or steps not listed in the claims. The word "a" or "an" preceding a component does not exclude the presence of a plurality of such components. The invention can be implemented by means of hardware comprising several distinct components, and by means of a suitably programmed computer.

[0097] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0098] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for reproducing a pneumatic control valve fault under experimental conditions, characterized in that: The method comprises the following steps: S1. Analyze the causes and evolution mechanisms of control valve failures under real working conditions, obtain the locations of key components associated with different types of control valve failures, construct cross-sectional views of key components, and perform cross-sectional view disassembly and analysis of key components containing failures; S2. Based on the cross-sectional view of the key components, obtain the components of the control valve, obtain one or more components associated with the control valve failure based on the failure evolution mechanism, and construct a component failure impact table; S3. Based on the components associated with the control valve failure, the key components that can trigger the failure conditions are screened out in combination with the component failure impact table, and the failure processing is performed on the key components to complete the reproduction of different control valve failure types.

2. The method for reproducing a pneumatic control valve fault under experimental conditions according to claim 1, characterized in that: In step S1, the different types of control valve failures include: valve failure, actuator failure and gas source pressure failure; wherein: The valve failures include: valve body sedimentation, increased valve friction, valve internal leakage, valve external leakage; The actuator failures include: diaphragm perforation, spring failure, and loose frame terminals.

3. The method for reproducing a pneumatic control valve fault under experimental conditions according to claim 1, characterized in that: In step S2, the component failure impact table constructed includes: component code, component name, component function, failure mode, failure cause and failure impact.

4. The method for reproducing a pneumatic control valve fault under experimental conditions according to claim 2, characterized in that: In step S3, the method for reproducing different fault types of the control valve includes: Reproduction of valve body sedimentation fault: Use rubber products to adhere impurities on the valve core surface and valve seat surface; Valve friction increase fault recurrence: Replace the packing components, the friction coefficient of the replaced packing components is greater than the friction coefficient of the original packing components; Reproduce the internal leakage of the valve: remove the sealing gasket between the valve core and the valve seat or replace the spring; Reproduce the valve external leakage fault: remove the sealing gasket between the valve body and the flange, and replace the loose bolts or rusted bolts; Diaphragm perforation fault recurrence: replace the diaphragm; Spring failure Fault reproduction: Replace the original spring, the rigidity coefficient of the replacement spring is smaller than the original spring; Re-occurence of the rack terminal loosening fault: loosen the bolts or reduce the pressure at the air supply; Reproduce the air source pressure failure: loosen the bolts, replace the original spring, replace the spring with a spring with a stiffness coefficient greater than the original spring, and replace the actuator diaphragm.

5. The method for reproducing a pneumatic control valve fault under experimental conditions according to claim 4, characterized in that: In the reproduction of the valve body sedimentation failure, the rubber product is a washable quick-adhesive rubber, and the impurities are mud and rust.

6. The method for reproducing a pneumatic control valve fault under experimental conditions according to claim 4, characterized in that: In the reproduction of the valve friction increase fault, the replaced packing component is PTFE packing.

7. A pneumatic control valve fault reproduction system under experimental conditions, characterized in that: When applied, a method for reproducing a pneumatic control valve fault under experimental conditions as described in any one of claims 1 to 6 is performed to reproduce different types of control valve faults. The system includes: an analysis module, a fault-related component acquisition module, and a fault reproduction module, wherein: The analysis module is used to analyze the causes and evolution mechanisms of control valve failures under real working conditions, obtain the locations of key components associated with different types of control valve failures, construct cross-sectional views of key components, and perform cross-sectional view disassembly and analysis of key components containing failures; The fault-related component acquisition module is used to obtain the various components of the control valve components based on the cross-sectional view of the key components, obtain one or more components associated with the control valve fault based on the fault evolution mechanism, and construct a component fault impact table; The fault reproduction module is used to screen out key components that can trigger fault conditions based on components associated with the control valve fault and in combination with a component fault impact table, and perform fault processing on the key components to complete the reproduction of different control valve fault types.

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