High-temperature torque test system based on adaptive PID control

Abstract

The invention discloses a high-temperature torque testing system based on adaptive PID control, and relates to the field of rotary valve pulser torque testing, the system comprises a loading mechanism, a heating mechanism, an electro-hydraulic servo valve, a torque sensor signal converter, an incremental rotary encoder, an adaptive PID controller and a pulse signal acquisition analyzer; the loading mechanism is used for applying torque to the rotary valve pulser according to a preset reference loading waveform under the condition that the rotary valve pulser is detected to reach the calibration test temperature; the self-adaptive PID controller is used for dynamically adjusting PID parameters according to the monitoring data by adopting a self-adaptive PID algorithm and calculating corresponding driving correction information; the electro-hydraulic servo valve is used for updating the applied torque of the rotary valve pulser according to the driving correction information; and the pulse signal acquisition analyzer is used for testing whether the rotary valve pulser has an electrical fault or not according to the acquired electrical pulse signal. Therefore, the high-temperature working condition can be accurately simulated, and accurate torque test and electrical signal analysis can be carried out.

Description

Technical Field

[0001] The present application relates to the field of torque testing of rotary valve pulsers, and in particular to a high-temperature torque testing system based on adaptive PID control. Background Art

[0002] Rotary valve pulsers are widely used in oilfield logging, industrial flow control, precision hydraulic systems and other fields. Their core function is to achieve precise control of fluid or pressure through the periodic opening and closing of the internal valve core. During long-term operation, the pulser needs to withstand harsh environmental tests such as high temperature, high pressure, and high impact load. Once a failure occurs, it often has a significant impact on the safety and efficiency of the entire production system.

[0003] At present, most users still rely on the original manufacturer to return the pulser for inspection and repair when maintaining it. Although the original manufacturer has a mature detection and maintenance platform, the maintenance cost is expensive and the cycle is long. At the same time, when there is a dispute over the fault responsibility or warranty terms, the attribution of responsibility often causes disputes, which also affects the production progress and causes additional losses. In order to reduce maintenance costs, shorten the maintenance cycle and master the core detection and diagnosis methods of the equipment, many users have begun to try to maintain and troubleshoot the pulser on their own.

[0004] However, due to the lack of a systematic test system and a complete test plan, the user unit also encountered various difficulties in self-maintenance. Especially in a high temperature environment, the pulser's seal, torque output, and the working state of the internal stepper motor are significantly different from those in a normal temperature environment. If effective torque testing and waveform observation cannot be performed under high temperature conditions, it will be difficult to accurately locate the pulser's fault point, resulting in repeated maintenance, frequent failures, and even safety hazards.

[0005] In response to the above problems, the industry has not yet proposed a better technical solution. Summary of the invention

[0006] The present application provides a high-temperature torque testing system based on adaptive PID control, which is used to at least solve the problem of lack of high-temperature environment simulation and precise torque measurement and control of rotary valve pulsers in the current related technology.

[0007] The embodiment of the present application provides a high temperature torque test system based on adaptive PID control, including a loading mechanism, a heating mechanism, an electro-hydraulic servo valve, a torque sensor signal converter, an incremental rotary encoder, an adaptive PID controller and a pulse signal acquisition analyzer; The heating mechanism is used to heat the rotary valve pulser to be tested to a calibrated test temperature; The loading mechanism is used to apply torque to the rotary valve pulser according to a preset reference loading waveform when detecting that the rotary valve pulser reaches the calibration test temperature; The torque sensor signal converter is used to collect torque monitoring data of the rotary valve pulser, and the incremental rotary encoder is used to collect the output shaft rotation angle and output shaft angular velocity of the rotary valve pulser; The adaptive PID controller is used to receive the output shaft rotation angle, the output shaft angular velocity and the torque monitoring data, dynamically adjust the PID parameters using an adaptive PID algorithm in combination with the reference loading waveform, and calculate corresponding drive correction information; The electro-hydraulic servo valve is used to receive the drive correction information and adjust the valve core displacement according to the drive correction information to adjust the hydraulic oil channel width between the hydraulic oil and the drive cylinder of the loading mechanism, thereby updating the torque applied by the loading mechanism to the rotary valve pulser; The pulse signal acquisition and analysis device is used to acquire the electrical pulse signal generated by the rotary valve pulser during the torque loading process, and to test whether the rotary valve pulser has an electrical fault based on the acquired electrical pulse signal.

[0008] The high temperature torque test system based on adaptive PID control provided by the present application can produce at least the following technical effects: (1) The temperature of the rotary valve pulser is controlled by the heating mechanism to reach the calibration test temperature, which can truly reproduce the operating characteristics of the rotary valve pulser simulated by torque loading in a high temperature environment, thereby improving the credibility of the test data. In addition, by adopting an adaptive PID controller, the output shaft angle, angular velocity and torque monitoring data of the rotary valve pulser can be combined to dynamically adjust the PID parameters so that the torque output by the loading mechanism strictly follows the reference loading waveform, which can accurately control the applied torque and improve the test accuracy.

[0009] (2) The hydraulic oil flow channel of the loading mechanism is adjusted by an electro-hydraulic servo valve, and dynamic feedback adjustment is achieved through adaptive PID control to make the torque loading process smoother and avoid the influence of transient shock on the test results, thereby improving the dynamic response capability of torque loading. The electrical pulse signal of the rotary valve pulser is synchronously collected by the pulse signal acquisition and analyzer, and a comprehensive analysis is performed in combination with the torque monitoring data. If the pulse signal fluctuates abnormally and the torque loading curve is normal, it can be determined that the fault may come from the internal stepper motor or control circuit, which improves the accuracy of fault location and avoids unnecessary maintenance due to misjudgment.

[0010] Through the embodiments of the present application, high-temperature working conditions can be accurately simulated and precise torque testing and electrical signal analysis can be performed. The user unit does not need to return the pulser to the factory for testing and repair, but can quickly self-check and troubleshoot on-site or on an autonomous maintenance platform, thereby reducing maintenance time and shortening downtime, achieving autonomous maintenance and efficient operation and maintenance of the rotary valve pulser, and reducing external maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] 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.

[0012] Figure 1 A structural schematic diagram of an example of a high temperature torque test system based on adaptive PID control according to an embodiment of the present application is shown; Figure 2 A schematic diagram showing a principle of an example of a PID closed-loop circuit according to an embodiment of the present application is shown. DETAILED DESCRIPTION

[0013] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0014] It should be noted that high temperature will have a significant impact on the sealing materials, motor coils, solenoid valve structures, etc. inside the pulser. If the actual working conditions cannot be simulated under high temperature conditions, there will be a significant deviation between the test results and the actual usage. In the current related technologies, most traditional platforms are only tested at room temperature or low temperature, making it difficult to evaluate the performance and failure mode of the pulser at high temperatures.

[0015] The torque output of the rotary valve pulser at high temperature is an important indicator for judging its working status and reliability. Many general or simple tooling can only obtain approximate torque values, or can only load low-frequency, single waveforms, and cannot meet the multi-waveform and multi-band testing requirements of the pulser in actual working conditions. Insufficient torque test accuracy and dynamic control capabilities directly lead to the inability to accurately judge the reliability of the pulser under different working cycles and different load waveforms.

[0016] It should be understood that the purpose of the above description of the current related art is only to facilitate the public to better understand the inventive spirit and motivation of the present application, and is not to be regarded as a limitation of the present application. In addition, the technical solutions described in the above-mentioned current related art are not prior art, and may also be undisclosed technical solutions, such as solutions under research or in the laboratory stage.

[0017] Figure 1 A structural schematic diagram of an example of a high temperature torque testing system based on adaptive PID control according to an embodiment of the present application is shown.

[0018] like Figure 1 As shown, the high temperature torque testing system 100 based on adaptive PID control includes a heating mechanism 110, a loading mechanism 120, a torque sensor signal converter 130, an incremental rotary encoder 140, an adaptive PID controller 150, an electro-hydraulic servo valve 160 and a pulse signal acquisition analyzer 170.

[0019] The heating mechanism 110 is used to heat the rotary valve pulser 10 to be tested to a calibrated test temperature.

[0020] It should be understood that the heating mechanism can be in various forms, such as using an electric heater or a hot air circulation device to uniformly heat the rotary valve pulser to ensure that the temperature of the entire test environment reaches the calibrated test temperature. In addition, the calibrated test temperature can be given by input information to the test bench and can effectively simulate a high temperature working environment.

[0021] In some embodiments, the heating mechanism 110 may use a high temperature box, and in order to ensure that all parts of the pulser are heated evenly and to restore the temperature gradient that it may encounter on site as much as possible, a multi-section heating unit is designed in the high temperature box, each section has an independent temperature control circuit, and multiple temperature sensors are arranged inside the box. Therefore, by controlling the temperature of the high temperature box sections, the pulser can be heated to the target temperature range in the shortest time, and high-precision and uniform temperature control can be achieved, providing a more realistic and controllable high temperature working condition for subsequent torque measurement and control.

[0022] The loading mechanism 120 is used to apply torque to the rotary valve pulser 10 according to a preset reference loading waveform when it is detected that the rotary valve pulser 10 reaches a calibrated test temperature.

[0023] Here, the loading system 120 may adopt a hydraulic torque loading device or a motor torque loading device to ensure that a controllable and adjustable torque loading can be provided. After detecting that the rotary valve pulser 10 reaches the preset calibration test temperature, the loading mechanism 120 applies torque to it according to the preset reference loading waveform, thereby simulating the actual working condition and verifying the working performance of the equipment in a high temperature environment.

[0024] In addition, the reference loading waveform can be a sine wave, step wave or other custom waveform to simulate the actual working state of the pulser. Therefore, through targeted loading modes, the torque loading working state of the rotary valve pulser in a high temperature environment can be accurately simulated to meet various test requirements.

[0025] The torque sensor signal converter 130 is used to collect torque monitoring data of the rotary valve pulser 10 , and the incremental rotary encoder 140 is used to collect the output shaft rotation angle and output shaft angular velocity of the rotary valve pulser 10 .

[0026] Here, the torque sensor signal converter 130 may adopt a high-precision dynamic torque sensor to monitor the torque output of the rotary valve pulser in real time. In addition, the torque sensor signal converter 130 may also be equipped with a signal conditioning circuit to convert the analog signal output by the sensor into a digital signal and perform filtering to remove high-frequency noise and signal interference.

[0027] More preferably, the torque sensor signal converter 130 can use a high temperature torque sensor, which has excellent high temperature anti-interference and stability. The sensor range and sensitivity are customized according to the pulser torque range, which can meet the multi-band and multi-waveform loading requirements.

[0028] In some embodiments, the incremental rotary encoder 140 uses a high-resolution incremental rotary encoder to collect the output shaft rotation angle and angular output shaft speed of the rotary valve pulser in real time.

[0029] The adaptive PID controller 150 is used to receive the output shaft rotation angle, output shaft angular velocity and torque monitoring data, dynamically adjust the PID parameters using an adaptive PID algorithm in combination with a reference loading waveform, and calculate corresponding drive correction information.

[0030] It should be noted that the traditional PID (proportional-integral-differential) controller has fixed proportional (P), integral (I) and differential (D) parameters, which will not change during the operation of the system. The adaptive PID algorithm refers to the ability to automatically adjust the parameters of the PID controller according to the operating state of the system (such as changes in the characteristics of the controlled object, the impact of interference, etc.) during the operation of the control system to adapt to changes in the dynamic characteristics of the system, so that the system always maintains good control performance. In particular, in systems with nonlinearity, time-varying and uncertainty, the use of adaptive PID control can improve the stability, response speed and anti-interference ability of the system.

[0031] It should be understood that the adaptive PID algorithm suitable for application in the present application may be diverse, such as a gain-scheduled adaptive PID algorithm or a fuzzy adaptive PID algorithm.

[0032] Specifically, in the gain-scheduled adaptive PID algorithm, a set of PID parameter tables under different working conditions is established in advance, which can be based on the system's operating point or certain measurable variables (such as temperature, pressure, etc.). When the system is running, the appropriate PID parameters are selected from the parameter table according to the current operating point or measured value. However, this method requires a large amount of experimental data to be obtained in advance to establish the parameter table. For complex and changeable systems, the parameter table may not cover all working conditions.

[0033] In the fuzzy adaptive PID algorithm, fuzzy logic reasoning is used to adjust the parameters of the PID controller in real time according to the system error and error change rate through the fuzzy rule base. However, the formulation of fuzzy rules depends on expert experience, which is subjective, and the calculation amount of fuzzy reasoning is relatively large.

[0034] Figure 2 A schematic diagram showing a principle of an example of a PID closed-loop circuit according to an embodiment of the present application is shown.

[0035] like Figure 2 As shown in the figure, in order to further improve the PID control performance of the system and give full play to the function of the computer, in the PID closed loop, adaptive PID adjustment is first performed in the computer, the loaded standard waveform is generated by the computer and output through D / A, amplified and loaded to the servo valve, and then the actual torque value is collected through the torque sensor, and the output loading waveform is readjusted using the digital PID controller and analog PID regulator to form a closed-loop control system.

[0036] about Figure 2 Description of some components in the figure, "Adaptive PID" is an adaptive PID algorithm module running in the computer, which can adjust the PID parameters online according to real-time feedback data. "Standard load" refers to the reference load waveform (such as sine, triangle, trapezoid, etc.) that the system expects to apply to the rotary valve pulser. The D / A board is used to convert the digital signal output by the adaptive PID into an analog signal. K represents the gain or amplification factor, which is used to amplify or scale the analog signal output by the D / A board. The A / D board is used to convert the analog quantity output by the torque sensor signal converter into a digital quantity to feed back the real-time torque data to the adaptive PID controller or computer for closed-loop regulation. "Collected torque" refers to the torque measurement value collected by the system from the A / D board in each sampling cycle to compare with the reference load to form an error signal in the closed-loop control to ensure accurate torque application. The timing / counting board is used to count or time the pulses from the incremental rotary encoder to provide accurate data such as angle and angular velocity to assist in accurate analysis of torque errors.

[0037] In such Figure 2In the loop operation logic shown, the "standard load" (or reference load) is first transmitted to the adaptive PID through the computer to set the reference waveform to be applied. The adaptive PID continuously calculates the control error and outputs the digital control signal based on the actual torque feedback (collected from the A / D board) and the incremental rotary encoder data. The D / A board converts the digital signal into an analog quantity, which is sent to the electro-hydraulic servo valve after gain K adjustment. The electro-hydraulic servo valve adjusts the valve core displacement based on the analog control quantity, changes the width of the hydraulic oil channel, and then updates the torque applied by the loading mechanism to the rotary valve pulser. The torque sensor monitors the actual torque in real time, and after the signal conversion, it is fed back to the adaptive PID through the A / D board for the next cycle adjustment.

[0038] It should be noted that the computer plays a core role in the entire closed-loop control system, and is mainly responsible for signal acquisition, data processing, adaptive adjustment of PID parameters, and generation of loading waveforms. Specifically, a reference loading waveform (such as a sine wave, square wave, step wave, etc.) can be preset inside the computer, which is used to simulate the torque demand of the rotary valve pulser under different working conditions. In addition, the computer dynamically adjusts the PID parameters based on the real-time collected torque data and the set reference waveform, so that the loading waveform is consistent with the reference waveform, thereby improving the torque test control accuracy. Furthermore, the loading signal calculated by the computer is converted into an analog signal through a D / A (digital-to-analog) conversion board for execution by the loading system.

[0039] The electro-hydraulic servo valve 160 is used to receive the drive correction information and adjust the valve core displacement according to the drive correction information to adjust the hydraulic oil channel width between the hydraulic oil and the drive cylinder (not shown) of the loading mechanism 120, thereby updating the torque applied by the loading mechanism to the rotary valve pulser 10.

[0040] Specifically, the electro-hydraulic servo valve serves as a bridge between digital control and hydraulic execution. Its core task is to receive the drive correction information output by the adaptive PID controller and use this information to dynamically adjust the width of the hydraulic oil channel, thereby accurately controlling the loading torque of the hydraulic system. Preferably, the power servo valve 160 can adopt a high-frequency response electro-hydraulic servo valve, which can monitor the valve core displacement in real time by integrating a high-precision displacement sensor to ensure control accuracy. In addition, a high-temperature resistant sealing component is added to the valve body of the power servo valve 160 to reduce the impact of high temperature on valve core wear and flow control accuracy.

[0041] In some embodiments, the drive correction information can be integrated into the correction control instruction, which is usually a digital quantity, and the digital instruction is converted into a corresponding analog voltage signal through digital-to-analog conversion. Inside the servo valve, the input analog signal drives the built-in electromagnetic actuator, causing the valve core (spool) to produce a small displacement in the valve body, and this displacement directly determines the degree of opening of the valve port.

[0042] Specifically, the servo valve adjusts the displacement of its internal spool to change the channel width between the hydraulic oil and the loading mechanism drive cylinder, thereby regulating the flow and pressure of the hydraulic oil in real time and realizing the dynamic update of the torque applied by the loading mechanism to the rotary valve pulser. For example, when the control instruction requires an increase in the loading torque, the servo valve will cause the spool to deflect to one side, increasing the flow and pressure of the hydraulic oil to the loading mechanism drive cylinder, so that the drive cylinder pushes the loading mechanism to generate a greater mechanical torque. On the other hand, when the control instruction needs to reduce the loading torque, the spool will move in the opposite direction, reducing the flow and pressure of the hydraulic oil to the actuator, causing the loading mechanism to reduce the torque applied.

[0043] The pulse signal acquisition and analysis device 170 is used to acquire the electrical pulse signal generated by the rotary valve pulser 10 during the torque loading process, and to test whether the rotary valve pulser 10 has an electrical fault according to the acquired electrical pulse signal.

[0044] In some embodiments, during the torque drive test, the current and voltage waveforms of the stepper motor or drive circuit can be collected in real time to analyze electrical problems such as motor winding failure and coil short circuit. More specifically, for key data such as pulse current and torque waveform, time domain, frequency domain and time-frequency domain analysis (such as short-time Fourier transform STFT, wavelet transform) can be integrated to extract characteristic parameters (peak value, envelope, harmonic component, mutation point, etc.), and then identify various electrical fault modes.

[0045] Exemplarily, the computational processing of this part can also be supported by an intelligent algorithm integrated in a computer (or host computer). For example, by running the fault diagnosis software in the computer, the collected waveform features can be automatically identified. When the system detects abnormal features, it automatically outputs possible fault types and location prompts, and can also intuitively display the working status of the pulser at high temperatures for reference by maintenance personnel. In this way, with the help of time-frequency domain signal analysis, a comprehensive evaluation of multi-dimensional data such as pulse current, torque waveform, valve core opening and closing signals is performed to quickly locate the fault location of the pulser and infer the cause of the fault, providing an effective reference for maintenance decisions of rotary valve pulsers.

[0046] Through the embodiments of the present application, modules such as high-temperature environment simulation, adaptive PID torque loading, electro-hydraulic servo dynamic adjustment and electrical signal synchronization analysis are integrated in the high-temperature torque test system, which can accurately reproduce the actual operating status of the rotary valve pulser, provide high-precision torque and electrical fault detection, significantly improve the fault diagnosis capability, and effectively support fault mode location, shorten the maintenance cycle, and help support the user's independent maintenance and efficient operation of the rotary valve pulser, thereby reducing maintenance costs.

[0047] Regarding the details of the adaptive PID algorithm, in some examples of the embodiments of the present application, the adaptive PID algorithm adopts an online parameter identification adaptive PID algorithm based on the recursive least squares method.

[0048] At this time, the adaptive PID controller 150 is used to perform the following operations: The regression vector is constructed using the rotation angle, angular velocity, torque and historical drive correction information, and the system parameter vector is continuously updated through the recursive least squares method to reflect the real-time changes in the dynamic characteristics of the system under high temperature and load changes. The specific process includes: The system model is established by the following formula. This system mathematical model describes the dynamic response of the rotary valve pulser during loading (such as when torque is applied). This model is used to predict the system output and provide a basis for subsequent parameter identification.

[0049] , Formula (1) , Formula (2) , formula (3) In the formula, is the moment of torque sampling The system historical dynamic contribution value represents the dynamic prediction value of the current output torque based on historical data; For the moment The rotation state output contribution value reflects the influence of the rotation state on the current output torque; Indicates time Measured torque monitoring data; Indicates at time The modeling error reflects the difference between actual measurements and model predictions; Indicates at time Dynamic coefficient of the effect of rotation angle on output torque, Indicates at time The measured output shaft rotation angle, Indicates at time Dynamic coefficient of angular velocity on output torque, Indicates at time The measured angular velocity of the output shaft; Indicates time Historical output torque The weight coefficient affecting the current torque, Indicates time The measured output torque value, Indicates time Historical output torque The weight coefficient affecting the current torque, Indicates time The measured output torque value; Indicates time Historical driver revision information The weight coefficient affecting the current torque, Indicates time Historical driver revision information, Indicates time Historical driver revision information The weight coefficient affecting the current torque, Indicates time Historical driver revision information.

[0050] It should be noted that in the above formula (1), the system output torque is decomposed into three parts: , and In other words, splitting the output torque into two quantifiable controllable / identifiable parts and a noise term can more finely describe the multi-source influences (friction, changes in material properties, etc.) of the rotary valve pulser in a high-temperature environment, and can provide a precise and clear architectural foundation for subsequent online identification and adaptive control.

[0051] about Description, through and Capture the inertia and delay characteristics of the system by and It reflects the effect of control signals (such as electro-hydraulic servo valve input) on the current torque at historical moments, and can capture the friction and damping characteristics that may drift over time in a high-temperature environment. The system can separate the influence of past torque and control input on the current state in real time, providing a basis for the online identification algorithm to accurately estimate the "inertia-control" relationship of the current system, and improving the adaptability to dynamic changes of the system caused by high temperature.

[0052] about By introducing the quantitative evaluation of the influence of rotation angle (position) and angular velocity (movement speed) on the current torque, the system has a more intuitive quantification of the mechanical motion state of the rotary valve pulser, and can reflect the contribution of the changes in the motion characteristics of the valve core, seal and other components after heating to the output torque under high temperature conditions.

[0053] Rewrite the system model into vector form: , Formula (4) , Formula (5) In the formula, represents the regression vector, yes The transposed vector of Indicates the time obtained by online identification The system parameter vector.

[0054] Update system parameters using recursive least squares method: , Formula (6) In the formula, Indicates at time The system parameter vector, Indicates at time The RLS gain vector, Represents the system model at time The difference between the predicted value of an output and the actual measured value.

[0055] Here, when the system state changes (for example, due to temperature changes, increased friction, etc.), the model prediction error will deviate. The RLS (Recursive Least Squares) algorithm uses the error to adjust , so that the model can more accurately describe the current system, so that the subsequent When adjusting PID parameters, the latest dynamic characteristics can be reflected. In addition, it can reduce the need for repeated manual parameter adjustments and improve the robustness to uncertain factors such as friction coefficient and viscosity changes.

[0056] The comprehensive index is extracted through the linear weighted function, and the basic PID parameters are proportionally corrected using the comprehensive index. The three parameters of the PID controller (proportional, integral, and differential gain) are dynamically adjusted to compensate for system changes caused by high temperature, friction, etc., making the control effect better.

[0057] , Formula (7) , Formula (8) , Formula (9) , Formula (10) In the formula, Indicates at time A comprehensive index, a scalar index reflecting the current nonlinear and time-varying characteristics of the system; Represents the system parameter vector The n Quantity, Indicates n The design weight of each component is Indicates the initial PID parameters; Represents the adjustment coefficient, which is used to adjust the parameter sensitivity; At the time The proportional gain, integral gain and derivative gain of the adaptive PID controller under .

[0058] here, It is a comprehensive indicator. All dynamic parameters obtained through online identification are integrated into a scalar through weighting. Different parameter components can represent different effects under high temperature (such as increased inertia and changes in friction). The weight determines the importance of each component. It should be noted that in high temperature scenarios, the weights can be flexibly set according to experimental data so that the parameters most susceptible to temperature receive more attention. Therefore, by reflecting the real-time identified system dynamic characteristics on the PID parameters, the controller can "follow" system changes. For example, when When the system damping increases, it can automatically reduce or increase Etc., to prevent overshoot or oscillation, realize online adaptive tuning of PID parameters, improve the adaptability to nonlinear and time-varying characteristics in high temperature environment, and significantly reduce torque tracking overshoot and oscillation.

[0059] The drive correction information is calculated based on the adjusted PID parameters and the real-time calculated torque tracking error. The final control signal is calculated based on the updated PID parameters and the current control error. , used to adjust the torque applied by the loading mechanism to the rotary valve pulser.

[0060] , formula (11) , Formula (12) In the formula, Indicates at time Output drive correction information, Indicates at time The torque tracking error, Indicates the reference loading waveform at time The default value of Indicates the sampling time interval; , and They represent the proportional control part, integral control part and differential control part of the PID controller respectively.

[0061] It should be noted that the error The system can immediately judge the accuracy of the current high-temperature torque loading through real-time calculation. If the error is large, the control strength will be increased; if the error is small, the system will converge smoothly. Adjust the control signal; in the integral link, accumulate past errors to eliminate the steady-state deviation that may exist under high temperature conditions; in the differential link, predict the system dynamics and suppress oscillation through the error change rate. Add the control effects of each part to form a comprehensive closed-loop control signal After digital-to-analog conversion, the electro-hydraulic servo valve is driven to adjust the torque loading of the hydraulic system on the rotary valve pulser in real time, thereby accurately controlling the torque applied by the loading mechanism, making the actual torque gradually approach the reference loading waveform, and ultimately ensuring the stability and accuracy of the high-temperature torque test.

[0062] In the embodiment of the present application, block modeling (Formula (1)-Formula (3)) helps the system to better quantify multiple influences (historical control, mechanical state, noise, etc.) under high temperature, and online identification (Formula (4)-(6)) is used to ensure that the system can update its own understanding of the high temperature environment at any time to enhance robustness. Adaptive PID (Formula (7)-(12)) is used to map the identification results to the PID gain, realizing real-time scheduling of parameters and dynamic correction of control signals, and finally achieving accurate tracking of the torque loading of the rotary valve pulser.

[0063] Through the embodiments of the present application, through the RLS algorithm, the system can identify the dynamic parameter changes caused by high temperature, friction and nonlinear factors in real time online, ensuring that parameter drift can be compensated in time even under high temperature conditions, so that the PID controller always uses the latest parameters for adjustment to ensure the accuracy and stability of the loading torque. In addition, a mapping function is used to convert the multi-dimensional system parameters obtained by online identification into a comprehensive index, and then the PID gain is dynamically adjusted based on this, so as to achieve rapid convergence of the torque loading error. In addition, by combining online parameter identification and adaptive PID control to form a closed-loop control, the system can still maintain excellent robustness when facing multiple interferences such as high temperature, friction, nonlinearity and noise.

[0064] Regarding the details of driving and adjusting the width of the hydraulic oil channel according to the driving correction information, in some examples of the embodiments of the present application, In order to ensure that the servo valve can respond smoothly to the drive correction information in a high temperature environment, the drive correction information is converted into valve core displacement by introducing a nonlinear saturation function.

[0065] , Formula (13) In the formula, Indicates at time Next, the driver corrects the information The converted valve core displacement; Indicates the maximum allowable displacement of the valve core. Indicates at time Output drive correction information; Represents the normalization constant of the drive correction information, which is used to adjust the response sensitivity so that for smaller The valve core displacement is approximately linear, and for larger Smooth saturation.

[0066] Specifically, use The function ensures fine adjustment within the small signal range and avoids excessive movement of the valve core (saturation phenomenon) when a large signal is input. It ensures that even if the drive correction information changes drastically under high temperature conditions, the valve core displacement can be smoothly controlled and the hydraulic mechanism is prevented from working in the saturation area, thereby protecting the mechanical structure and improving the system stability.

[0067] There is a linear functional relationship between the hydraulic oil channel width and the valve core displacement.

[0068] , Formula (14) In the formula, Indicates at time Next, the driver corrects the information The width of the hydraulic oil channel under action; Indicates the basic hydraulic oil channel width when the valve core displacement is zero, represents the proportionality constant.

[0069] Through the linear relationship in equation (14), it is ensured that as the valve core moves As the pressure increases, the width of the hydraulic oil channel increases proportionally, thereby increasing the flow rate and pressure, and realizing the increase and regulation of the output torque of the loading mechanism. As a result, the loading mechanism can accurately adjust the output torque and realize closed-loop tracking of the reference loading waveform.

[0070] In some examples of the embodiments of the present application, after collecting the electrical pulse signal generated by the rotary valve pulser during the torque loading process, the pulse signal acquisition and analyzer is also used to perform temperature adaptive wavelet denoising on the collected original electrical pulse signal. This filtering scheme combines discrete wavelet transform (DWT), temperature adaptive threshold setting and soft threshold processing, aiming to efficiently reduce the noise of the electrical pulse signal collected by the rotary valve pulser in a high temperature torque test scenario, while retaining key signal features to ensure the accuracy of subsequent fault detection.

[0071] Specifically, the collected original electrical pulse signal is subjected to discrete wavelet transform and decomposed into multiple wavelet coefficients: , Formula (15) In the formula, is the pulse sampling moment The original electrical pulse signal, represents discrete wavelet transform function; Indicated in scale and location The wavelet coefficients on can reflect the local characteristics of the signal in different frequency bands.

[0072] Here, the original pulse signal Decomposed into multiple scales, coefficients of different scales Contains signal details and trend information, making it easier to separate signals from noise.

[0073] The denoising threshold is adjusted based on the real-time measured temperature of the rotary valve pulser: , Formula (16) In the formula, represents the real-time measured temperature of the rotary valve pulser, represents the reference temperature, Indicated at reference temperature The baseline noise reduction threshold under Indicates the denoising threshold adjusted in real time, Represents the temperature sensitivity coefficient.

[0074] It should be noted that temperature affects sensor noise and device characteristics. In high temperature environments, the noise level usually increases. By adjusting the denoising threshold in real time through formula (16), the denoising process can be adapted to the current temperature conditions, ensuring that the important features of the signal are retained as much as possible while removing the noise.

[0075] Soft threshold processing is performed on the wavelet coefficients of each scale to suppress noise and retain signal characteristics: , Formula (17) In the formula, Represents the wavelet coefficients after soft threshold processing; is a sign function used to maintain the positive and negative signs of the original coefficients; represents the soft threshold processing function, ensuring that Less than threshold is set to zero when it is greater than the threshold When the value is reduced, the corresponding amplitude is reduced.

[0076] Here, the soft threshold function is used to process the wavelet coefficients, which can smoothly reduce the noise while retaining the edge features and details of the signal. By using soft threshold processing, compared with hard threshold processing, better signal smoothing effect can be achieved and artifacts generated when reconstructing the signal can be reduced.

[0077] Use the processed wavelet coefficients to perform inverse wavelet transform and reconstruct the denoised signal: , Formula (18) In the formula, represents the denoised signal after inverse wavelet transform reconstruction; Represents the inverse discrete wavelet transform function.

[0078] Here, the coefficients of each scale are reconstructed into a denoised signal through inverse wavelet transform ,The signal-to-noise ratio of the signal is improved, which can provide high-quality input data for subsequent feature extraction and fault detection, and support the realization of a fully automatic electrical fault monitoring and early warning system.

[0079] Through the embodiment of the present application, temperature-adaptive wavelet denoising is applied to filter the collected electrical pulse signal. First, the collected electrical pulse signal is decomposed into multiple scales using discrete wavelet transform, and the coefficients of each scale are subjected to temperature-adaptive soft threshold processing, and the change of noise level is dynamically compensated, thereby effectively suppressing the random noise and transient noise generated in a high temperature environment. In this way, the interference of noise on the signal can be reduced, and the signal-to-noise ratio (SNR) of the output signal can be improved. The key edges and pulse details of the electrical pulse signal can be retained at the same time through soft threshold processing, which can provide high-quality data support for fault detection.

[0080] In some examples of the embodiments of the present application, the electrical fault includes at least one of the following: an electrical short circuit fault, an electrical open circuit fault, a pulse period abnormality, or a pulse width abnormality.

[0081] Regarding electrical open or broken circuit faults, when the system has an open circuit or broken circuit, the rotary valve pulser will not be able to generate the expected electrical pulse signal, causing the entire test system to lose feedback basis.

[0082] Regarding electrical short circuit or overload faults, short circuit or overload will not only cause output signal distortion, but may also cause chain problems such as overheating and damage of internal components of the equipment, posing a serious threat to system safety and equipment life.

[0083] Regarding abnormal pulse period or pulse width, the width and period of the pulse represent the accuracy of the device switching timing. Abnormal pulse width or period may cause the control signal to be out of sync with the actual loading action, thereby affecting the precise application of the loading torque and interfering with the overall performance.

[0084] Through the above four types of faults, identification and detection are carried out from the aspects of basic functions, equipment safety and timing synchronization to ensure that the system can fully grasp the electrical status and working performance of the rotary valve pulser.

[0085] Regarding the operational details of detecting electrical faults from pulse signals, in some implementations, multiple key time domain features are extracted from the collected electrical pulse signals: , Formula (19) In the formula, Indicates The starting time of a pulse, Indicates The starting time of a pulse, Indicates the pulse period.

[0086] , formula (20) In the formula, Indicates the rising edge time of the pulse signal. Indicates the falling edge time of the pulse signal. Indicates pulse width.

[0087] , Formula (21) In the formula, Indicates at time The measured voltage value, Indicates the maximum voltage value during the pulse high level period.

[0088] Here, three types of key time domain features of the pulse signal are mainly extracted, namely, pulse period, pulse width and pulse amplitude, to fully reflect the dynamic information of the electrical pulse signal.

[0089] According to the extracted key time domain features and the preset standard values, the corresponding time domain feature relative error is calculated: , Formula (22) In the formula, Represents the relative error of the pulse period, Indicates the preset reference pulse period.

[0090] , Formula (23) In the formula, Relative error of pulse width, Indicates the reference pulse width.

[0091] , Formula (24) In the formula, Represents the relative error of the pulse amplitude, Indicates the reference pulse amplitude.

[0092] Furthermore, it is determined whether the rotary valve pulser has an electrical fault based on the relative errors of each time domain feature.

[0093] It should be noted that It is the time interval between two adjacent pulses, that is, the pulse period, which reflects the repetition frequency of the pulse signal; if this value deviates significantly from the preset standard, there may be a timing anomaly. The duration of the pulse in the high level state represents the pulse width, which reflects the duration of the device switch response. Abnormal width may indicate switch response problems or contact wear. It can be the maximum signal value during the high level of the pulse, reflecting the strength of the output of the electrical component; abnormal amplitude may indicate a short circuit (amplitude is too high) or an open circuit (amplitude is too low).

[0094] Through the embodiments of the present application, the time domain characteristics are used to comprehensively reflect the dynamic information of the electrical pulse signal, and combined with strict relative error calculation, through preset standards and intelligent pattern recognition, it is possible to effectively distinguish between signal anomalies caused by temperature drift and actual electrical faults at high temperatures, thereby providing reliable data support for early warning and maintenance of equipment, reducing maintenance risks and improving the level of automation.

[0095] It should be understood that the signal feature extraction methods and types can be diverse and can be used to monitor various types of pulser faults that require analysis. The description here is only used as an example and is not intended to limit the scope of implementation of this application.

[0096] Regarding the details of pulser fault type detection, in some examples of the embodiments of the present application, when or When , it is determined that the rotary valve pulser has an electrical short circuit fault; Indicates the threshold ratio of the increase in the magnitude of the electrical short circuit fault, Indicates the upper limit of the allowable amplitude error.

[0097] when or When , it is determined that the rotary valve pulser has an electrical open circuit fault; Indicates the threshold ratio by which the magnitude of an electrical open circuit fault is reduced.

[0098] when When the pulse cycle of the rotary valve pulser is abnormal, Indicates the allowable pulse period relative error threshold.

[0099] when When the pulse width of the rotary valve pulser is abnormal, Indicates the allowed pulse width relative error threshold.

[0100] It should be noted that various preset quantities involved in the fault detection process, such as , , , , , etc., which can all be obtained based on the calibration data of the rotary valve pulser under standard conditions, and appropriately adjusted in combination with possible changes in a high temperature environment, thereby providing a clear reference standard for fault detection.

[0101] Through the embodiments of the present application, based on high-speed sampling, temperature compensation and time domain feature extraction, the subtle changes of the electrical pulse signal can be captured in real time, the relative error can be quickly calculated, and the comprehensive fault index can be used to determine whether it exceeds the preset threshold, and the abnormality of electrical short circuit, open circuit, cycle, width or amplitude can be detected within milliseconds. As a result, the accurate quantitative judgment of the fault type of the rotary valve pulser is achieved, and the real-time automatic detection and intelligent fault diagnosis can quickly identify and locate potential electrical faults, provide accurate fault warning data, and allow the user to test whether the equipment itself has faults through high-temperature torque testing as soon as the pulser is purchased, which can effectively avoid disputes after the downhole operation, and can also facilitate the operation and maintenance personnel to intervene in maintenance and correction at an early stage, ensuring the reliability of the rotary valve pulser during actual operation.

[0102] It should be noted that, for the aforementioned system embodiments, for the sake of simplicity of description, they are all expressed as a series of combined actions, but those skilled in the art should be aware that the present application is not limited by the order of actions described, because according to the present application, certain steps can be performed in other orders or simultaneously. Secondly, those skilled in the art should also be aware that the embodiments described in the specification are all preferred embodiments, and the actions and modules involved are not necessarily required by the present application. In the above embodiments, the description of each embodiment has its own emphasis. For parts that are not described in detail in a certain embodiment, please refer to the relevant description of other embodiments.

[0103] The system embodiment described above is merely illustrative, wherein the units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0104] Through the description of the above implementation methods, those skilled in the art can clearly understand that each implementation method can be implemented by means of software plus a general hardware platform, and of course, by hardware. Based on this understanding, the above technical solution is essentially or the part that contributes to the relevant technology can be embodied in the form of a software product, and the computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, a disk, an optical disk, etc., including a number of instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to execute the system described in each embodiment or some parts of the embodiment.

[0105] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit it. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A high temperature torque test system based on adaptive PID control, characterized in that: It includes a loading mechanism, a heating mechanism, an electro-hydraulic servo valve, a torque sensor signal converter, an incremental rotary encoder, an adaptive PID controller and a pulse signal acquisition analyzer; The heating mechanism is used to heat the rotary valve pulser to be tested to a calibrated test temperature; The loading mechanism is used to apply torque to the rotary valve pulser according to a preset reference loading waveform when detecting that the rotary valve pulser reaches the calibration test temperature; The torque sensor signal converter is used to collect torque monitoring data of the rotary valve pulser, and the incremental rotary encoder is used to collect the output shaft rotation angle and output shaft angular velocity of the rotary valve pulser; The adaptive PID controller is used to receive the output shaft rotation angle, the output shaft angular velocity and the torque monitoring data, dynamically adjust the PID parameters using an adaptive PID algorithm in combination with the reference loading waveform, and calculate corresponding drive correction information; The electro-hydraulic servo valve is used to receive the drive correction information and adjust the valve core displacement according to the drive correction information to adjust the hydraulic oil channel width between the hydraulic oil and the drive cylinder of the loading mechanism, thereby updating the torque applied by the loading mechanism to the rotary valve pulser; The pulse signal acquisition and analysis device is used to acquire the electrical pulse signal generated by the rotary valve pulser during the torque loading process, and to test whether the rotary valve pulser has an electrical fault based on the acquired electrical pulse signal.

2. The system according to claim 1, characterized in that The adaptive PID algorithm adopts an online parameter identification adaptive PID algorithm based on recursive least squares method; the adaptive PID controller is used to perform the following operations: The regression vector is constructed using the rotation angle, angular velocity, torque and historical drive correction information, and the system parameter vector is continuously updated through the recursive least squares method. The specific process includes: The system model is established by the following formula: ， ， ， In the formula, is the moment of torque sampling The system historical dynamic contribution value represents the dynamic prediction value of the current output torque based on historical data; For the moment The rotation state output contribution value reflects the influence of the rotation state on the current output torque; Indicates time Measured torque monitoring data; Indicates at time The modeling error reflects the difference between actual measurements and model predictions; Indicates at time Dynamic coefficient of the effect of rotation angle on output torque, Indicates at time The measured output shaft rotation angle, Indicates at time Dynamic coefficient of angular velocity on output torque, Indicates at time The measured angular velocity of the output shaft; Indicates time Historical output torque The weight coefficient affecting the current torque, Indicates time The measured output torque value, Indicates time Historical output torque The weight coefficient affecting the current torque, Indicates time The measured output torque value; Indicates time Historical driver revision information The weight coefficient affecting the current torque, Indicates time Historical driver revision information, Indicates time Historical driver revision information The weight coefficient affecting the current torque, Indicates time Historical driver revision information; Rewrite the system model into vector form: ， ， In the formula, represents the regression vector, yes The transposed vector of Indicates the time obtained by online identification The system parameter vector of Update system parameters using recursive least squares method: ， In the formula, Indicates at time The system parameter vector, Indicates at time The RLS gain vector, Represents the system model at time The difference between the predicted value of the output and the actual measured value; The comprehensive index is extracted through the linear weighted function, and the basic PID parameters are proportionally corrected using the comprehensive index: ， ， ， ， In the formula, Indicates at time A comprehensive index, a scalar index reflecting the current nonlinear and time-varying characteristics of the system; Represents the system parameter vector The n Quantity, Indicates n The design weight of each component is Indicates the initial PID parameters; Represents the adjustment coefficient, which is used to adjust the parameter sensitivity; At the time Proportional gain, integral gain and derivative gain of the adaptive PID controller under; According to the adjusted PID parameters and the real-time calculated torque tracking error, the drive correction information is calculated: ， ， In the formula, Indicates at time Output drive correction information, Indicates at time The torque tracking error, Indicates the reference loading waveform at time The default value of Indicates the sampling time interval; , and They represent the proportional control part, integral control part and differential control part of the PID controller respectively.

3. The system according to claim 1, characterized in that The adjusting the displacement of the valve core according to the drive correction information to adjust the width of the hydraulic oil channel between the hydraulic oil and the drive cylinder of the loading mechanism includes: In order to ensure that the servo valve can smoothly respond to the drive correction information in a high temperature environment, the drive correction information is converted into valve core displacement by introducing a nonlinear saturation function: ， In the formula, Indicates at time Next, the driver corrects the information The converted valve core displacement; Indicates the maximum allowable displacement of the valve core. Indicates at time Output drive correction information; Represents the normalization constant of the drive correction information, which is used to adjust the response sensitivity so that for smaller The valve core displacement is approximately linear, and for larger Then smooth saturation; The hydraulic oil channel width and the valve core displacement conform to a linear function relationship: ， In the formula, Indicates at time Next, the driver corrects the information The width of the hydraulic oil channel under action; Indicates the basic hydraulic oil channel width when the valve core displacement is zero, represents the proportionality constant.

4. The system according to claim 1, characterized in that After collecting the electrical pulse signal generated by the rotary valve pulser during the torque loading process, the pulse signal collection and analysis device is further used to perform temperature adaptive wavelet denoising on the collected original electrical pulse signal, specifically including: The collected original electrical pulse signal is subjected to discrete wavelet transform and decomposed into multiple wavelet coefficients: ， In the formula, is the pulse sampling moment The original electrical pulse signal, represents discrete wavelet transform function; Indicated in scale and location The wavelet coefficients on , to reflect the local characteristics of the signal in different frequency bands; The denoising threshold is adjusted based on the real-time measured temperature of the rotary valve pulser: ， In the formula, represents the real-time measured temperature of the rotary valve pulser, represents the reference temperature, Indicated at reference temperature The baseline noise reduction threshold under Indicates the denoising threshold adjusted in real time, represents the temperature sensitivity coefficient; Soft threshold processing is performed on the wavelet coefficients of each scale to suppress noise and retain signal characteristics: ， In the formula, Represents the wavelet coefficients after soft threshold processing; is a sign function used to maintain the positive and negative signs of the original coefficients; represents the soft threshold processing function, ensuring that Less than threshold is set to zero when it is greater than the threshold When the corresponding amplitude is reduced; Use the processed wavelet coefficients to perform inverse wavelet transform and reconstruct the denoised signal: ， In the formula, represents the denoised signal after inverse wavelet transform reconstruction; Represents the inverse discrete wavelet transform function.

5. The system according to claim 1, characterized in that The electrical fault includes at least one of the following: an electrical short circuit fault, an electrical open circuit fault, a pulse period abnormality, or a pulse width abnormality.

6. The system according to claim 1 or 5, characterized in that: The step of testing whether the rotary valve pulser has an electrical fault according to the collected electrical pulse signal comprises: Extract multiple key time domain features from the acquired electrical pulse signal: ， In the formula, Indicates The starting time of a pulse, Indicates The starting time of a pulse, represents the pulse period; ， In the formula, Indicates the rising edge time of the pulse signal. Indicates the falling edge time of the pulse signal. Indicates pulse width; ， In the formula, Indicates at time The measured voltage value, Indicates the maximum voltage value during the pulse high level period; According to the extracted key time domain features and the preset standard values, the corresponding time domain feature relative error is calculated: ， In the formula, Represents the relative error of the pulse period, Indicates the preset reference pulse period; ， In the formula, Relative error of pulse width, Indicates the reference pulse width; ， In the formula, Represents the relative error of the pulse amplitude, Indicates the reference pulse amplitude; Whether the rotary valve pulser has an electrical fault is determined according to the relative errors of the time domain characteristics.

7. The system according to claim 6, characterized in that Determining whether the rotary valve pulser has an electrical fault according to the relative errors of the time domain characteristics includes: when or When the rotary valve pulser is determined to have an electrical short circuit fault; Indicates the threshold ratio of the increase in the magnitude of the electrical short circuit fault, Indicates the upper limit of the allowable amplitude error; when or When the rotary valve pulser is determined to have an electrical open circuit fault; Indicates the threshold ratio at which the magnitude of an electrical open circuit fault is reduced; when When the pulse cycle of the rotary valve pulser is abnormal, Indicates the relative error threshold of the allowed pulse period; when When the pulse width of the rotary valve pulser is abnormal, Indicates the allowed pulse width relative error threshold.

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