RTO switching valve leakage fault intelligent monitoring system and process

Abstract

The present application relates to the technical field of RTO switching valve, and particularly relates to an RTO switching valve leakage fault intelligent monitoring system and process, comprising: a first aspect, an RTO switching valve leakage fault intelligent monitoring system, comprising: a monitoring layer, an analysis layer and a diagnosis layer; the operating state parameters of the switching valve are monitored in real time through the monitoring layer, the monitored switching valve operating state parameters are synchronously executed data cleaning, and are stored after the data cleaning is completed, the present application comprehensively collects the operating state parameters of the switching valve, further based on data cleaning after collection, retains high-value reference parameters, and further based on parameter analysis, brings distributed analysis of the leakage risk of the switching valve, further comprehensively analyzes and sets leakage fault judgment logic, realizes the leakage fault judgment of the switching valve, and effectively guarantees the long-term stable operation of the switching valve.

Description

Technical Field

[0001] This invention relates to the field of RTO switching valve technology, specifically to an intelligent monitoring system and process for RTO switching valve leakage faults. Background Technology

[0002] The RTO switching valve is a key component of the RTO system. It is mainly used to control the switching of airflow between different regenerator beds and treatment channels. Through precise, fast and stable switching actions, it ensures that the exhaust gas can enter the corresponding area for treatment and heat exchange at the appropriate time, ensuring the efficient and stable operation of the RTO system and achieving the purpose of exhaust gas purification.

[0003] The invention patent application number 202010717087.X discloses a method for monitoring leakage of a carbon canister cleaning solenoid valve, characterized by the following steps: Step 1, after the engine starts successfully, the EVAP system closes the cleaning solenoid valve and the ventilation valve of the evaporation system to keep the evaporation system in a sealed state; Step 2, at the set desorption flow rate integral value Δ... INT Monitoring the evaporation system

[0004] The vacuum degree change value is converted into a real vehicle vacuum degree change curve; Step 3: The EVAP system compares the real vehicle vacuum degree change curve with the calibrated vacuum degree change curve to obtain the equivalent leakage orifice diameter of the cleaning solenoid valve; Step 4: The EVAP system detects whether the equivalent leakage orifice diameter is greater than the set value; Step 5: If the equivalent leakage orifice diameter is greater than the set value, the OBD system determines that there is a leak in the cleaning solenoid valve and prompts for maintenance of the cleaning solenoid valve; The acquisition of the calibrated vacuum degree change curve specifically includes the following steps: controlling the engine Under the same cleaning solenoid valve duty cycle and different intake manifold vacuum levels, the desorption flow rate at different intake manifold vacuum levels with a calibrated step size is obtained by connecting a flow meter. The desorption flow rate is then normalized to obtain the desorption flow rate coefficient under different intake manifold vacuum levels. The engine is controlled to operate under the same intake manifold pressure and different cleaning solenoid valve duty cycles. The desorption flow rate at different cleaning solenoid valve duty cycles with a calibrated step size is obtained by connecting a flow meter. The desorption flow rate is then normalized to obtain the desorption flow rate coefficient under different cleaning solenoid valve duty cycles.

[0005] The application aims to address the problems of "inaccurate determination of leakage orifice diameter in evaporation systems and high detection costs".

[0006] For switching valves in RTO systems, the operating conditions are quite harsh, making leakage fault monitoring during operation particularly important. Most current monitoring systems lack predictive capabilities or have poor predictive accuracy.

[0007] To address this, we propose an intelligent monitoring system and process for RTO switching valve leakage faults. Summary of the Invention

[0008] To address the aforementioned shortcomings of existing technologies, this invention provides an intelligent monitoring system and process for RTO switching valve leakage faults, solving the technical problems mentioned in the background section.

[0009] To achieve the above objectives, the present invention provides the following technical solution:

[0010] In the first aspect, an intelligent monitoring system for leakage faults of an RTO switching valve includes: a monitoring layer, an analysis layer, and a diagnostic layer;

[0011] The operating status parameters of the switching valve are monitored in real time by the monitoring layer. The monitored operating status parameters of the switching valve are cleaned synchronously and stored after the data cleaning is completed. The analysis layer runs in the monitoring layer to retrieve the stored operating status parameters of the switching valve and analyzes the leakage risk of the switching valve using the operating status parameters of the switching valve. The diagnostic layer further receives the leakage risk analysis results of the switching valve in the analysis layer and predicts whether there is a leakage fault in the switching valve based on the leakage risk analysis results.

[0012] The monitoring layer includes a data acquisition module, a cleaning module, and a storage module. The data acquisition module is used to acquire the operating status parameters of the switching valve. The cleaning module is used to receive the operating status parameters of the switching valve acquired by the data acquisition module and clean the operating status parameters of the switching valve. The storage module is used to obtain the operating status parameters of the switching valve after cleaning in the cleaning module and store the operating status parameters of the switching valve.

[0013] The analysis layer includes a retrieval module, an analysis module, and a correction module. The retrieval module is used to retrieve the switching valve operating status parameters stored in the monitoring layer. The analysis module is used to receive the switching valve operating status parameters retrieved by the retrieval module and analyze the switching valve leakage risk based on the switching valve operating status parameters. The correction module is used to obtain the switching valve leakage risk analysis results in the analysis module and correct the switching valve leakage risk analysis results.

[0014] The switching valve operating status parameters retrieved by the retrieval module are: the switching valve operating status parameters corresponding to the time threshold from the most recent start to the end of the switching valve's operation. The analysis logic for the switching valve leakage risk in the analysis module is expressed as follows:

[0015]

[0016] In the formula: k1 and k2 represent the leakage risk of the switching valve; H safe H unsafe This refers to the types of non-abnormal parameters and the types of abnormal parameters; u safe u unsafe For non-abnormal parameters, the total number of type u abnormal parameters; for abnormal parameters, the total number of type u abnormal parameters.v A l A represents the value of the vth non-abnormal parameter among the uth non-abnormal parameters and the value of the lth abnormal parameter among the uth abnormal parameters; max A min The maximum and minimum values ​​of the parameter's safe range; ω v ω l As weight;

[0017] in, The smaller the leakage risks k1 and k2 of the switching valve, the lower the leakage risk of the switching valve; conversely, the larger the values, the higher the leakage risk. The types of non-abnormal parameters H... safe Types of abnormal parameters H unsafe None of them contain the vibration spectrum parameters of the valve core during operation;

[0018] The diagnostic layer includes a receiving module, a judgment module, and an evaluation module. The receiving module receives the final analysis switching valve leakage risk K analyzed in the analysis layer. The judgment module sets a switching valve leakage fault judgment threshold, compares the switching valve leakage fault judgment threshold with the final analysis switching valve leakage risk K, and determines whether the switching valve has a leakage fault problem based on the comparison result. The evaluation module records the final analysis switching valve leakage risk K received by the receiving module and the judgment result of the judgment module in the diagnostic layer under continuous system operation, and evaluates the reliability of the switching valve by combining the final analysis switching valve leakage risk K and the judgment result of the judgment module.

[0019] Furthermore, the switching valve operating status parameters collected by the acquisition module include: valve stroke, sealing surface pressure, gas flow rate, gas pressure loss during gas flow, driving voltage, current, and valve core vibration spectrum. The cleaning module is equipped with parameter cleaning logic, which cleans the switching valve operating status parameters collected by the acquisition module based on the parameter cleaning logic. All switching valve operating status parameters are marked with an acquisition timestamp, and the storage module distinguishes and stores the switching valve operating status parameters based on their acquisition timestamps.

[0020] Furthermore, the acquisition module is configured with a collection cycle for the switching valve operating status parameters, and the acquisition module collects the switching valve operating status parameters in real time based on the collection cycle.

[0021] The logic for setting the acquisition cycle of the switching valve's operating status parameters is as follows:

[0022]

[0023] Where: T is the acquisition period for the operating status parameters of the switching valve; T0 is the base number of the acquisition period; T now T represents the current time. faultT is the time since the last failure of the switching valve. fault ′ is compared to T fault The time since the last failure of the switching valve; n is the total number of operating status parameters of the switching valve; |p now -p′| i It is the absolute value of the difference between the current value and the previously collected value of the i-th switching valve operating status parameter;

[0024] Where max(p) now ,p′) i This indicates that the maximum value within the parentheses is taken. The base number of the acquisition period T0 is defined by the system user. The acquisition period T of the switching valve operating status parameters is applied to the next operation of the switching valve. After the next operation of the switching valve is completed, the latest operating status parameters of the switching valve are used to obtain a new acquisition period of the switching valve operating status parameters. When the switching valve is run again, the newly obtained acquisition period of the switching valve operating status parameters is used. The switching valve operating status parameters are collected in real time during the operation of the switching valve, and so on.

[0025] Furthermore, the cleaning logic for the switching valve's operating status parameters in the cleaning module is expressed as follows:

[0026] Based on the time sequence of the acquisition of various switching valve operating status parameters, a sequence of various switching valve operating status parameters is generated, and the mean and standard deviation of the parameter sequence are calculated.

[0027]

[0028] Set up abnormal parameter judgment logic to judge each switching valve operating status parameter in the switching valve operating status parameter sequence;

[0029]

[0030] Parameters that meet one of the above conditions are considered abnormal parameters; otherwise, they are considered non-abnormal parameters.

[0031] In the formula: The mean is denoted as m; m is the total number of parameters in the switching valve operating state parameter sequence; x is the mean value. j Let be the operating status parameter value of the j-th switching valve; σ be the standard deviation; and k be a constant.

[0032] Wherein, the constant k is a positive integer, defined by the system user. Based on the above formula, abnormal and non-abnormal parameters are determined for the operating status parameters of various switching valves. Abnormal parameters are retained in each type of switching valve operating status parameters. When there is only one non-abnormal parameter between two adjacent abnormal parameter groups, the non-abnormal parameter is retained. When there is at least one non-abnormal parameter between two adjacent abnormal parameter groups, the non-abnormal parameter in the middle position is selected for retention, and the remaining non-abnormal parameters are discarded.

[0033] Furthermore, after receiving the switching valve operating status parameters retrieved by the retrieval module, the analysis module simultaneously classifies the abnormal and non-abnormal parameters in the switching valve operating status parameters, and analyzes the leakage risk of the switching valve operation based on the abnormal and non-abnormal parameters respectively.

[0034] After the leakage risks k1 and k2 of the switching valve are obtained, the leakage risk of the valve core operating vibration spectrum is further added to the leakage risks k1 and k2 of the switching valve:

[0035]

[0036] In the formula: k1′ and k2′ represent the leakage risk of the switching valve, which incorporates the leakage risk based on the vibration spectrum of the valve core during operation; (f low f high X(f) represents the main frequency band range of the valve core's vibration spectrum; X(f) is the spectrum obtained by performing a fast Fourier transform on the valve core's vibration spectrum.

[0037] Furthermore, the correction logic for the leakage risk analysis results of the switching valve in the correction module is expressed as follows:

[0038] K=k1′×(1-λ)+k2′×λ;

[0039] In the formula: K represents the final analysis risk of leakage in the switching valve; λ is the risk reference scaling factor;

[0040] Among them, risk reference ratio factor q represents the type of operating status parameter for the switching valve; (t) first-last ) r t represents the time interval between the earliest and latest abnormal parameters in the operating status parameters of the r-th type of switching valve; all This represents the total operating time of the switching valve in this cycle. Indicates to Find the average.

[0041] Furthermore, the threshold for judging the leakage fault of the switching valve set in the judgment module is customized by the system user. The system user can read the latest recorded final analysis of the switching valve leakage risk K and the judgment result in real time in the evaluation module.

[0042] Furthermore, the evaluation module records the final analysis of the switching valve leakage risk K and generates a trend chart of the final switching valve leakage risk K based on the time series. The trend chart is presented as a line graph, with the horizontal axis representing time and the vertical axis representing the final analysis of the switching valve leakage risk K. When the trend chart shows at least three consecutive increases in the final analysis of the switching valve leakage risk K, the corresponding switching valve is determined to be a switching valve to be replaced. The switching valve is then manually replaced by the system user. After the system user replaces the switching valve to be replaced, the system is synchronously reset and running.

[0043] Furthermore, the retrieval module is interconnected with a storage module via a wireless network, the storage module is interconnected with a cleaning module and a data acquisition module via a wireless network, the retrieval module is interconnected with an analysis module and a correction module via a wireless network, the correction module is interconnected with a receiving module via a wireless network, and the receiving module is interconnected with a judgment module and an evaluation module via a wireless network.

[0044] Secondly, an intelligent monitoring technology for leakage faults in RTO switching valves includes:

[0045] Collect the operating status parameters of the switching valve, set the cleaning logic for the operating status parameters of the switching valve, and clean the operating status parameters of the switching valve based on the cleaning logic;

[0046] Set up abnormal parameter analysis logic, analyze whether the parameters in the operating status parameters of the switching valve after cleaning are abnormal based on the analysis logic, and classify the operating status parameters of the switching valve according to the analysis results of whether the operating status parameters of the switching valve are abnormal.

[0047] The leakage risk of the switching valve is analyzed based on the abnormal and non-abnormal operating status parameters of the switching valve.

[0048] The leakage risk of the switching valve is comprehensively analyzed based on the two sets of leakage risk analysis results, and the leakage risk analysis results of the switching valve are recorded.

[0049] The decision to replace the switching valve is made based on the recorded leakage risk analysis results. After the switching valve is replaced, the system operation is reset synchronously.

[0050] Compared with known public technologies, the technical solution provided by this invention has the following advantages:

[0051] Beneficial effects:

[0052] This invention provides an intelligent monitoring system and process for leakage faults in RTO switching valves. During operation, the system comprehensively collects the operating status parameters of the switching valves. After data cleaning, high-value reference parameters are retained. Based on parameter analysis, a distributed analysis of leakage risks to the switching valves is conducted. Further comprehensive analysis and setting of leakage fault judgment logic enable the determination of leakage faults in the switching valves, effectively ensuring the long-term stable operation of the switching valves. At the same time, based on the recorded leakage fault judgment results, a recommended replacement cycle for the switching valves can be generated, thereby serving the RTO system where the switching valves are located and achieving safe and stable gas treatment.

[0053] Furthermore, based on the limitations of the aforementioned process methods, the stability of system operation is further maintained, enabling the system to operate more logically and continuously, thus bringing maintenance benefits to the RTO system. Attached Figure Description

[0054] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0055] Figure 1 This is a schematic diagram of a smart monitoring system for leakage faults in an RTO switching valve;

[0056] Figure 2 This is a schematic diagram of a process for intelligent monitoring of leakage faults in an RTO switching valve.

[0057] Figure 3 This is a schematic diagram of the application logic for the acquisition cycle of the switching valve operating status parameters in this invention;

[0058] Figure 4 This is a trend chart showing the change in leakage risk K of the switching valve in the final analysis of this invention. Detailed Implementation

[0059] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0060] The present invention will be further described below with reference to embodiments.

[0061] Example 1:

[0062] This embodiment presents an intelligent monitoring system for leakage faults in an RTO switching valve, such as... Figure 1 As shown, it includes: a monitoring layer, an analysis layer, and a diagnostic layer;

[0063] The operating status parameters of the switching valve are monitored in real time by the monitoring layer. The monitored operating status parameters of the switching valve are cleaned synchronously and stored after the data cleaning is completed. The analysis layer runs in the monitoring layer to retrieve the stored operating status parameters of the switching valve and analyzes the leakage risk of the switching valve using the operating status parameters of the switching valve. The diagnostic layer further receives the leakage risk analysis results of the switching valve in the analysis layer and predicts whether there is a leakage fault in the switching valve based on the leakage risk analysis results.

[0064] The monitoring layer includes a data acquisition module, a cleaning module, and a storage module. The data acquisition module is used to acquire the operating status parameters of the switching valve. The cleaning module is used to receive the operating status parameters of the switching valve acquired by the data acquisition module and clean the operating status parameters of the switching valve. The storage module is used to obtain the operating status parameters of the switching valve after cleaning in the cleaning module and store the operating status parameters of the switching valve.

[0065] The acquisition module collects the following operating status parameters of the switching valve: valve stroke, sealing surface pressure, gas flow rate, gas pressure loss during gas flow, driving voltage, current, and valve core vibration spectrum. The cleaning module is equipped with parameter cleaning logic. The cleaning module cleans the operating status parameters of the switching valve collected by the acquisition module based on the parameter cleaning logic. All operating status parameters of the switching valve are marked with an acquisition timestamp. The storage module distinguishes and stores the operating status parameters of the switching valve based on the acquisition timestamp.

[0066] The acquisition module is set with a collection period for the switching valve's operating status parameters. The acquisition module collects the switching valve's operating status parameters in real time based on the collection period.

[0067] The logic for setting the acquisition cycle of switching valve operating status parameters is as follows:

[0068]

[0069] Where: T is the acquisition period for the operating status parameters of the switching valve; T0 is the base number of the acquisition period; T now T represents the current time. fault T is the time since the last failure of the switching valve. fault ′ is compared to T fault The time since the last failure of the switching valve; n is the total number of operating status parameters of the switching valve; |p now -p′| iIt is the absolute value of the difference between the current value and the previously collected value of the i-th switching valve operating status parameter;

[0070] Where max(p) now ,p′) i This indicates that the maximum value within the parentheses is taken. The base number of the acquisition period T0 is defined by the system user. The acquisition period T of the switching valve operating status parameters is applied to the next operation of the switching valve. After the next operation of the switching valve is completed, the latest operating status parameters of the switching valve are used to obtain a new acquisition period of the switching valve operating status parameters. When the switching valve is running again, the newly obtained acquisition period of the switching valve operating status parameters is used. The switching valve operating status parameters are collected in real time during the operation of the switching valve, and so on.

[0071] The cleaning logic for the switching valve's operating status parameters in the cleaning module is expressed as follows:

[0072] Based on the time sequence of the acquisition of various switching valve operating status parameters, a sequence of various switching valve operating status parameters is generated, and the mean and standard deviation of the parameter sequence are calculated.

[0073]

[0074] Set up abnormal parameter judgment logic to judge each switching valve operating status parameter in the switching valve operating status parameter sequence;

[0075]

[0076] Parameters that meet one of the above conditions are considered abnormal parameters; otherwise, they are considered non-abnormal parameters.

[0077] In the formula: The mean is denoted as m; m is the total number of parameters in the switching valve operating state parameter sequence; x is the mean value. j Let be the operating status parameter value of the j-th switching valve; σ be the standard deviation; and k be a constant.

[0078] Wherein, the constant k is a positive integer, defined by the system user. Based on the above formula, abnormal and non-abnormal parameters are determined for the operating status parameters of various switching valves. Abnormal parameters are retained in each type of switching valve operating status parameters. When there is only one non-abnormal parameter between two adjacent abnormal parameter groups, the non-abnormal parameter is retained. When there is at least one non-abnormal parameter between two adjacent abnormal parameter groups, the non-abnormal parameter in the middle position is selected for retention, and the remaining non-abnormal parameters are discarded.

[0079] The analysis layer includes a retrieval module, an analysis module, and a correction module. The retrieval module is used to retrieve the switching valve operating status parameters stored in the monitoring layer. The analysis module is used to receive the switching valve operating status parameters retrieved by the retrieval module and analyze the switching valve leakage risk based on the switching valve operating status parameters. The correction module is used to obtain the switching valve leakage risk analysis results from the analysis module and correct the switching valve leakage risk analysis results.

[0080] The switching valve operating status parameters retrieved by the retrieval module are: the switching valve operating status parameters corresponding to the time threshold from the most recent start to the end of the switching valve's operation. The analysis logic for the switching valve leakage risk in the analysis module is expressed as follows:

[0081]

[0082] In the formula: k1 and k2 represent the leakage risk of the switching valve; H safe H unsafe This refers to the types of non-abnormal parameters and the types of abnormal parameters; u safe u unsafe For non-abnormal parameters, the total number of type u abnormal parameters; for abnormal parameters, the total number of type u abnormal parameters. v A l A represents the value of the vth non-abnormal parameter among the uth non-abnormal parameters and the value of the lth abnormal parameter among the uth abnormal parameters; max A min The maximum and minimum values ​​of the parameter's safe range; ω v ω l As weight;

[0083] in, The smaller the leakage risks k1 and k2 of the switching valve, the lower the leakage risk of the switching valve; conversely, the larger the values, the higher the leakage risk. The types of non-abnormal parameters H... sa f e Types of abnormal parameters H unsafe None of them contain the vibration spectrum parameters of the valve core during operation;

[0084] The diagnostic layer includes a receiving module, a judgment module, and an evaluation module. The receiving module receives the final analysis switching valve leakage risk K analyzed in the analysis layer. The judgment module sets the switching valve leakage fault judgment threshold, compares the switching valve leakage fault judgment threshold with the final analysis switching valve leakage risk K, and determines whether the switching valve has a leakage fault problem based on the comparison result. The evaluation module records the final analysis switching valve leakage risk K received by the receiving module and the judgment result of the judgment module in the diagnostic layer under continuous system operation, and evaluates the reliability of the switching valve by combining the final analysis switching valve leakage risk K and the judgment result of the judgment module.

[0085] The threshold for judging the leakage fault of the switching valve set in the judgment module is defined by the system user. The system user reads the latest recorded final analysis of the leakage risk K of the switching valve and the judgment result in real time in the evaluation module.

[0086] The retrieval module is connected to the storage module via a wireless network. The storage module is connected to the cleaning module and the acquisition module via a wireless network. The retrieval module is connected to the analysis module and the correction module via a wireless network. The correction module is connected to the receiving module via a wireless network. The receiving module is connected to the judgment module and the evaluation module via a wireless network.

[0087] In this embodiment, the acquisition module collects the operating status parameters of the switching valve. The cleaning module, running after the acquisition module, receives the collected operating status parameters and cleans them. The storage module then retrieves and stores the cleaned operating status parameters. The retrieval module retrieves the stored operating status parameters from the monitoring layer. The analysis module receives the retrieved parameters and analyzes the valve leakage risk. The correction module obtains the leakage risk analysis results and corrects them. The receiving module receives the final analyzed valve leakage risk K from the analysis layer. The judgment module simultaneously sets a valve leakage fault judgment threshold and compares it with the final analyzed valve leakage risk K to determine if the valve has a leakage fault. Finally, the evaluation module records the final analyzed valve leakage risk K and the judgment result from the receiving module in the diagnostic layer during continuous system operation. The reliability of the switching valve is evaluated by combining the final analyzed valve leakage risk K and the judgment result.

[0088] Through the operation of the above system, a relatively comprehensive and highly accurate leakage fault monitoring service is provided for the switching valve, ensuring the long-term stable operation of the RTO system where the switching valve is located;

[0089] Meanwhile, the above system logically limits the acquisition cycle of the switching valve's operating status parameters during operation and performs distributed analysis of the switching valve's leakage risk, effectively ensuring the reliability of the system's final output results.

[0090] See Figure 3 As shown in the figure, the start and stop of the switching valve's operation tasks are represented by the division on the linear axis, and the application and generation of the acquisition cycle of the operating status parameters of each switching valve are output based on the annotation.

[0091] See Figure 4As shown in the figure, this figure further illustrates the trend of the leakage risk K of the switching valve in the final analysis. By observing this figure, it is possible to determine whether the switching valve needs to be replaced.

[0092] Example 2:

[0093] At the implementation level, based on Example 1, this example refers to... Figure 1 A further detailed description of the intelligent monitoring system for RTO switching valve leakage faults in Example 1 is provided below:

[0094] After receiving the switching valve operating status parameters retrieved by the retrieval module, the analysis module simultaneously classifies the abnormal and non-abnormal parameters in the switching valve operating status parameters, and analyzes the leakage risk of the switching valve operation based on the abnormal and non-abnormal parameters respectively.

[0095] After calculating the leakage risks k1 and k2 of the switching valve, the leakage risk based on the vibration spectrum of the valve core operation is further incorporated into the leakage risks k1 and k2 of the switching valve:

[0096]

[0097] In the formula: k1′ and k2′ represent the leakage risk of the switching valve, which incorporates the leakage risk based on the vibration spectrum of the valve core during operation; (f low f high X(f) represents the main frequency band range of the valve core's vibration spectrum; X(f) is the spectrum obtained by performing a fast Fourier transform on the valve core's vibration spectrum.

[0098] The correction logic for the leakage risk analysis results of the switching valve in the correction module is expressed as follows:

[0099] K=k1′×(1-λ)+k2′×λ;

[0100] In the formula: K represents the final analysis risk of leakage in the switching valve; λ is the risk reference scaling factor;

[0101] Among them, risk reference ratio factor q represents the type of operating status parameter for the switching valve; (t) first-last ) r t represents the time interval between the earliest and latest abnormal parameters in the operating status parameters of the r-th type of switching valve; all This represents the total operating time of the switching valve in this cycle. Indicates to Find the average.

[0102] Using the above logical formula, the leakage risk of the valve core's operating vibration spectrum is further incorporated into the calculation of the switching valve leakage risk k1 and k2, providing the necessary prerequisites for the final calculation of the switching valve leakage risk K.

[0103] The following is a detailed explanation of the logical process of obtaining the spectrum by performing a fast Fourier transform on the vibration spectrum of the valve core:

[0104] Discrete sampling:

[0105] First, the vibration of the valve core is measured using a suitable sensor (such as an accelerometer), and then sampled at a certain frequency f using a data acquisition system. s Discrete sampling is performed on the vibration signal. Let the sequence of discrete vibration signals obtained by sampling be x[n], where n = 0, 1, 2, ..., N-1, and N is the number of sampling points.

[0106] Padding with zeros (optional):

[0107] To improve the frequency resolution of FFT calculations or to ensure the data length meets the requirements of specific FFT algorithms, the original signal sequence is sometimes padded with zeros. Zero padding does not change the spectral content of the signal, but it provides a more refined representation of the spectrum in the frequency domain.

[0108] FFT calculation:

[0109] The discrete signal x[n] is computed using a Fast Fourier Transform (FFT) algorithm, such as the Cooley-Tukey algorithm. In most programming environments, there are readily available FFT functions. For example, in Python, the numpy.fft.fft function can be used. Assume the result obtained by the FFT is X[k], k = 0, 1, 2, ..., N-1, where X[k] is a complex sequence.

[0110] Spectral amplitude calculation:

[0111] To obtain the amplitude information of the spectrum (for subsequent energy calculation), the following calculations are performed. in and These are the real and imaginary parts of X[k], respectively. This yields the spectral amplitude sequence of the vibration signal, representing the intensity of different frequency components.

[0112] After the above steps, the FFT process of the vibration signal is completed, and spectral data that can be used to calculate the energy proportion of the main frequency band is obtained. It is important to note that the sampling frequency f... s The selection of the sampling point N must satisfy the Nyquist sampling theorem to avoid spectral aliasing. At the same time, determining the appropriate number of sampling points N requires comprehensive consideration of factors such as signal duration and frequency resolution.

[0113] like Figure 1As shown, the evaluation module records the final analysis of the switching valve leakage risk K. Based on the time series, it generates a trend chart of the final switching valve leakage risk K. The trend chart is presented as a line graph, with the horizontal axis representing time and the vertical axis representing the final analysis of the switching valve leakage risk K. When the final analysis of the switching valve leakage risk K shown in the trend chart increases for no less than three consecutive sets, the corresponding switching valve is determined to be a switching valve to be replaced. The switching valve is then manually replaced by the system user. After the system user replaces the switching valve to be replaced, the system is simultaneously reset and running.

[0114] In this embodiment, the above settings further define the operating logic of the diagnostic layer in the system, and further realize the logic for determining whether the switching valve needs to be replaced and the basis for resetting the system.

[0115] Example 3:

[0116] At the implementation level, based on Example 1, this example refers to... Figure 2 A further detailed description of the intelligent monitoring system for RTO switching valve leakage faults in Example 1 is provided below:

[0117] A smart monitoring technology for leakage faults in RTO switching valves includes:

[0118] Collect the operating status parameters of the switching valve, set the cleaning logic for the operating status parameters of the switching valve, and clean the operating status parameters of the switching valve based on the cleaning logic;

[0119] Set up abnormal parameter analysis logic, analyze whether the parameters in the operating status parameters of the switching valve after cleaning are abnormal based on the analysis logic, and classify the operating status parameters of the switching valve according to the analysis results of whether the operating status parameters of the switching valve are abnormal.

[0120] The leakage risk of the switching valve is analyzed based on the abnormal and non-abnormal operating status parameters of the switching valve.

[0121] The leakage risk of the switching valve is comprehensively analyzed based on the two sets of leakage risk analysis results, and the leakage risk analysis results of the switching valve are recorded.

[0122] The decision to replace the switching valve is made based on the recorded leakage risk analysis results. After the switching valve is replaced, the system operation is reset synchronously.

[0123] In summary, the system in the above embodiments comprehensively collects the operating status parameters of the switching valve during operation. After collection, it further cleans the data to retain high-value reference parameters. Based on parameter analysis, it conducts distributed analysis of leakage risks to the switching valve, further comprehensively analyzes and sets leakage fault judgment logic, and realizes leakage fault judgment of the switching valve, effectively ensuring the long-term stable operation of the switching valve. At the same time, based on the recording of the leakage fault judgment results of the switching valve, it can further generate a recommendation for the replacement cycle of the switching valve, thereby serving the RTO system where the switching valve is located and completing safe and stable gas treatment.

[0124] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An intelligent monitoring system for leakage faults in an RTO switching valve, characterized in that, include: Monitoring layer, analysis layer, and diagnostic layer; The operating status parameters of the switching valve are monitored in real time by the monitoring layer. The monitored operating status parameters of the switching valve are cleaned synchronously and stored after the data cleaning is completed. The analysis layer runs in the monitoring layer to retrieve the stored operating status parameters of the switching valve and analyzes the leakage risk of the switching valve using the operating status parameters of the switching valve. The diagnostic layer further receives the leakage risk analysis results of the switching valve in the analysis layer and predicts whether there is a leakage fault in the switching valve based on the leakage risk analysis results. The analysis layer includes a retrieval module, an analysis module, and a correction module. The retrieval module is used to retrieve the switching valve operating status parameters stored in the monitoring layer. The analysis module is used to receive the switching valve operating status parameters retrieved by the retrieval module and analyze the switching valve leakage risk based on the switching valve operating status parameters. The correction module is used to obtain the switching valve leakage risk analysis results in the analysis module and correct the switching valve leakage risk analysis results. The switching valve operating status parameters retrieved by the retrieval module are: the switching valve operating status parameters corresponding to the time threshold from the most recent start to the end of the switching valve's operation. The analysis logic for the switching valve leakage risk in the analysis module is expressed as follows: In the formula: k1 and k2 represent the leakage risk of the switching valve; H safe H unsafe This refers to the types of non-abnormal parameters and the types of abnormal parameters; u safe u unsafe For non-abnormal parameters, the total number of type u abnormal parameters; for abnormal parameters, the total number of type u abnormal parameters. v A l A represents the value of the vth non-abnormal parameter among the uth non-abnormal parameters and the value of the lth abnormal parameter among the uth abnormal parameters; max A min The maximum and minimum values ​​of the parameter's safe range; ω v ω l As weight; in, The smaller the leakage risks k1 and k2 of the switching valve, the lower the leakage risk of the switching valve; conversely, the larger the values, the higher the leakage risk. The types of non-abnormal parameters H... safe Types of abnormal parameters H unsafe None of them contain the vibration spectrum parameters of the valve core during operation.

2. The intelligent monitoring system for leakage faults of an RTO switching valve according to claim 1, characterized in that, The monitoring layer includes a data acquisition module, a cleaning module, and a storage module. The data acquisition module is used to acquire the operating status parameters of the switching valve. The cleaning module is used to receive the operating status parameters of the switching valve acquired by the data acquisition module and clean the operating status parameters of the switching valve. The storage module is used to obtain the operating status parameters of the switching valve after cleaning in the cleaning module and store the operating status parameters of the switching valve. The acquisition module collects the operating status parameters of the switching valve, including: valve stroke, sealing surface pressure, gas flow rate, gas pressure loss during gas flow, driving voltage, current, and valve core vibration spectrum. The cleaning module is equipped with parameter cleaning logic, which cleans the operating status parameters of the switching valve collected by the acquisition module. All the operating status parameters of the switching valve are marked with an acquisition timestamp. The storage module distinguishes and stores the operating status parameters of the switching valve based on the acquisition timestamp.

3. The intelligent monitoring system for leakage faults of an RTO switching valve according to claim 2, characterized in that, The acquisition module is set with a switching valve operating status parameter acquisition cycle, and the acquisition module collects the switching valve operating status parameters in real time based on the switching valve operating status parameter acquisition cycle. The logic for setting the acquisition cycle of the switching valve's operating status parameters is as follows: Where: T is the acquisition period for the operating status parameters of the switching valve; T0 is the base number of the acquisition period; T now T represents the current time; fault This is the time since the switching valve last failed. T fault ′ is compared to T fault The time since the last failure of the switching valve; n is the total number of operating status parameters of the switching valve; |p now -p′| i It is the absolute value of the difference between the current value and the previously collected value of the i-th switching valve operating status parameter; Where max(p) now ,p′) i This indicates that the maximum value within the parentheses is taken. The base number of the acquisition period T0 is defined by the system user. The acquisition period T of the switching valve operating status parameters is applied to the next operation of the switching valve. After the next operation of the switching valve is completed, the latest operating status parameters of the switching valve are used to obtain a new acquisition period of the switching valve operating status parameters. When the switching valve is run again, the newly obtained acquisition period of the switching valve operating status parameters is used. The switching valve operating status parameters are collected in real time during the operation of the switching valve, and so on.

4. The intelligent monitoring system for leakage faults of an RTO switching valve according to claim 2, characterized in that, The cleaning logic for the switching valve's operating status parameters in the cleaning module is expressed as follows: Based on the time sequence of the acquisition of various switching valve operating status parameters, a sequence of various switching valve operating status parameters is generated, and the mean and standard deviation of the parameter sequence are calculated. Set up abnormal parameter judgment logic to judge each switching valve operating status parameter in the switching valve operating status parameter sequence; Parameters that meet one of the above conditions are considered abnormal parameters; otherwise, they are considered non-abnormal parameters. In the formula: The mean is denoted as m; m is the total number of parameters in the switching valve operating state parameter sequence; x is the mean value. j Let be the operating status parameter value of the j-th switching valve; σ be the standard deviation; and k be a constant. Wherein, the constant k is a positive integer, defined by the system user. Based on the above formula, abnormal and non-abnormal parameters are determined for the operating status parameters of various switching valves. Abnormal parameters are retained in each type of switching valve operating status parameters. When there is only one non-abnormal parameter between two adjacent abnormal parameter groups, the non-abnormal parameter is retained. When there is at least one non-abnormal parameter between two adjacent abnormal parameter groups, the non-abnormal parameter in the middle position is selected for retention, and the remaining non-abnormal parameters are discarded.

5. The intelligent monitoring system for leakage faults of an RTO switching valve according to claim 1, characterized in that, After receiving the switching valve operating status parameters retrieved by the retrieval module, the analysis module simultaneously classifies the abnormal and non-abnormal parameters in the switching valve operating status parameters, and analyzes the leakage risk of the switching valve operation based on the abnormal and non-abnormal parameters respectively. After the leakage risks k1 and k2 of the switching valve are obtained, the leakage risk of the valve core operating vibration spectrum is further added to the leakage risks k1 and k2 of the switching valve: In the formula: k1′ and k2′ represent the leakage risk of the switching valve, which incorporates the leakage risk based on the vibration spectrum of the valve core during operation; (f low f high X(f) represents the main frequency band range of the valve core's vibration spectrum; X(f) is the spectrum obtained by performing a fast Fourier transform on the valve core's vibration spectrum.

6. The intelligent monitoring system for leakage faults of an RTO switching valve according to claim 1 or 5, characterized in that, The correction logic for the leakage risk analysis results of the switching valve in the correction module is expressed as follows: K=k1′×(1-λ)+k2′×λ; In the formula: K represents the final analysis risk of leakage in the switching valve; λ is the risk reference scaling factor; Among them, risk reference ratio factor q represents the type of operating status parameter for the switching valve; (t) first-last ) r t represents the time interval between the earliest and latest abnormal parameters in the operating status parameters of the r-th type of switching valve; all This represents the total operating time of the switching valve in this cycle. Indicates to Find the average of the terms.

7. The intelligent monitoring system for leakage faults of an RTO switching valve according to claim 1, characterized in that, The diagnostic layer includes a receiving module, a judgment module, and an evaluation module. The receiving module receives the final analyzed switching valve leakage risk K from the analysis layer. The judgment module sets a switching valve leakage fault judgment threshold, compares the switching valve leakage fault judgment threshold with the final analyzed switching valve leakage risk K, and determines whether the switching valve has a leakage fault problem based on the comparison result. The evaluation module records the final analyzed switching valve leakage risk K received by the receiving module and the judgment result of the judgment module in the diagnostic layer under continuous system operation, and evaluates the reliability of the switching valve by combining the final analyzed switching valve leakage risk K and the judgment result of the judgment module. The threshold for judging the leakage fault of the switching valve set in the judgment module is customized by the system user. The system user reads the latest recorded final analysis of the leakage risk K of the switching valve and the judgment result in real time in the evaluation module.

8. The intelligent monitoring system for leakage faults of an RTO switching valve according to claim 7, characterized in that, The evaluation module records the final analysis of the switching valve leakage risk K and generates a trend chart of the final switching valve leakage risk K based on time series. The trend chart is a line graph, with the horizontal axis representing time and the vertical axis representing the final analysis of the switching valve leakage risk K. When the final analysis of the switching valve leakage risk K shown in the trend chart increases for no less than three consecutive sets, the corresponding switching valve is determined to be a switching valve to be replaced. The switching valve is then manually replaced by the system user. After the system user replaces the switching valve to be replaced, the system is reset and running synchronously.

9. The intelligent monitoring system for leakage faults of an RTO switching valve according to claim 1, characterized in that, The retrieval module is interconnected with a storage module via a wireless network. The storage module is interconnected with a cleaning module and a data acquisition module via a wireless network. The retrieval module is interconnected with an analysis module and a correction module via a wireless network. The correction module is interconnected with a receiving module via a wireless network. The receiving module is interconnected with a judgment module and an evaluation module via a wireless network.

10. A smart monitoring process for leakage faults in an RTO switching valve, wherein the process is an implementation process of the smart monitoring system for leakage faults in an RTO switching valve as described in any one of claims 1-9, characterized in that, include: Collect the operating status parameters of the switching valve, set the cleaning logic for the operating status parameters of the switching valve, and clean the operating status parameters of the switching valve based on the cleaning logic; Set up abnormal parameter analysis logic, analyze whether the parameters in the operating status parameters of the switching valve after cleaning are abnormal based on the analysis logic, and classify the operating status parameters of the switching valve according to the analysis results of whether the operating status parameters of the switching valve are abnormal. The leakage risk of the switching valve is analyzed based on the abnormal and non-abnormal operating status parameters of the switching valve. The leakage risk of the switching valve is comprehensively analyzed based on the two sets of leakage risk analysis results, and the leakage risk analysis results of the switching valve are recorded. The decision to replace the switching valve is made based on the recorded leakage risk analysis results. After the switching valve is replaced, the system operation is reset synchronously.

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