High-temperature Torque Testing System Based on Adaptive PID Control

Abstract

The present application discloses a high-temperature torque test system based on adaptive PID control, which relates to the field of torque testing of rotary valve pulsators. The system 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 and analyzer. The loading mechanism is used to apply torque to the rotary valve pulsator according to a preset reference loading waveform when it detects that the rotary valve pulsator reaches the calibrated test temperature. The adaptive PID controller is used to dynamically adjust the PID parameters according to the monitoring data by using the adaptive PID algorithm and calculate the corresponding drive correction information. The electro-hydraulic servo valve is used to update the applied torque to the rotary valve pulsator according to the drive correction information. The pulse signal acquisition and analyzer is used to test whether there is an electrical fault in the rotary valve pulsator according to the collected electrical pulse signals. Thus, it can accurately simulate high-temperature working conditions and perform accurate torque testing and electrical signal analysis.

Description

Technical Field

[0001] This application relates to the field of torque testing of rotary valve pulsators, and particularly to a high-temperature torque testing system based on adaptive PID control. Background Art

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

[0003] Currently, most user units still mainly rely on the original manufacturer for factory repair during the maintenance of pulsators. Although the original manufacturer has a mature detection and repair platform, the maintenance cost is expensive and the cycle is long. At the same time, when there are disputes over fault liability or warranty terms, the liability attribution often causes disputes, which also affects the production progress and causes additional losses. To reduce maintenance costs, shorten the repair cycle, and master the core detection and diagnosis means of the equipment, many user units have begun to try to maintain and troubleshoot pulsators by themselves.

[0004] However, due to the lack of a systematic testing system and a complete testing plan, user units have also encountered various problems during self-maintenance. Especially in a high-temperature environment, there are significant differences in the sealing, torque output, and working state of the internal stepping motor of the pulsator compared to the normal temperature environment. If effective torque testing and waveform observation cannot be carried out under high-temperature conditions, it is difficult to accurately locate the fault points of the pulsator, resulting in repeated repairs, frequent failures, and even potential safety hazards.

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

[0006] This application provides a high-temperature torque testing system based on adaptive PID control to at least solve the problem in the current related technologies of lacking high-temperature environment simulation and precise torque measurement and control for rotary valve pulsators.

[0007] An embodiment of this application provides a high-temperature torque testing 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 and analyzer;

[0008] The heating mechanism is used to heat the rotary valve pulsator to be tested to the calibrated test temperature;

[0009] The loading mechanism is used to apply torque to the rotary valve pulsator according to a preset reference loading waveform when it is detected that the rotary valve pulsator reaches the calibrated test temperature;

[0010] The torque sensor signal converter is used to collect the torque monitoring data of the rotary valve pulsator, and the incremental rotary encoder is used to collect the rotation angle and angular velocity of the output shaft of the rotary valve pulsator;

[0011] The adaptive PID controller is used to receive the rotation angle of the output shaft, the angular velocity of the output shaft and the torque monitoring data, dynamically adjust the PID parameters by using the adaptive PID algorithm in combination with the reference loading waveform, and calculate the corresponding drive correction information;

[0012] The electro-hydraulic servo valve is used to receive the drive correction information and adjust the spool displacement according to the drive correction information to adjust the width of the hydraulic oil passage between the hydraulic oil and the drive cylinder of the loading mechanism, so as to update the torque applied by the loading mechanism to the rotary valve pulsator;

[0013] The pulse signal acquisition and analyzer is used to collect the electrical pulse signals generated by the rotary valve pulsator during the torque loading process, and test whether there is an electrical fault in the rotary valve pulsator according to the collected electrical pulse signals.

[0014] Through a high-temperature torque test system based on adaptive PID control provided by the present application, at least the following technical effects can be produced:

[0015] (1) By controlling the temperature of the rotary valve pulsator through the heating mechanism to make it reach the calibrated test temperature, the operating characteristics of the rotary valve pulsator can be simulated and tested by torque loading in a high-temperature environment, thereby improving the credibility of the test data. In addition, by using an adaptive PID controller, the PID parameters can be dynamically adjusted in combination with the output shaft angle, angular velocity and torque monitoring data of the rotary valve pulsator, so that the torque output by the loading mechanism strictly follows the reference loading waveform, the applied torque can be accurately controlled, and the test accuracy can be improved.

[0016] (2) The electro-hydraulic servo valve is used to adjust the hydraulic oil flow passage of the loading mechanism, and dynamic feedback adjustment is realized through adaptive PID control, so that the torque loading process is more stable, the influence of transient impact on the test results is avoided, and the dynamic response ability of torque loading is improved. The electrical pulse signals of the rotary valve pulsator are synchronously collected by the pulse signal acquisition and analyzer, and comprehensive analysis is carried out in combination with the torque monitoring data. If the pulse signal shows abnormal fluctuations while 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 caused by misjudgment.

[0017] Through the embodiments of the present application, it is possible to accurately simulate high-temperature working conditions and conduct precise torque tests and electrical signal analyses. The user does not need to return the pulsator to the factory for testing and repair, but can quickly perform self-checks and fault troubleshooting on-site or on an independent maintenance platform, thereby reducing the repair time, shortening the downtime period, achieving independent maintenance and efficient operation and maintenance of the rotary valve pulsator, and reducing external repair costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0019] Figure 1 FIG. 1 shows a schematic structural diagram of an example of a high-temperature torque test system based on adaptive PID control according to an embodiment of the present application;

[0020] Figure 2 FIG. 2 shows a schematic principle diagram of an example of a PID closed-loop circuit according to an embodiment of the present application. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0021] In order to make the objectives, technical solutions, and advantages of the embodiments of the present application clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present application with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some, but not all, of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present application.

[0022] It should be noted that high temperature will have a significant impact on the internal sealing materials, motor coils, solenoid valve structures, etc. of the pulsator. 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 use situation. In the current related technologies, most traditional platforms only conduct tests in normal temperature or low-temperature environments, and it is difficult to evaluate the performance and fault modes of the pulsator at high temperature.

[0023] The torque output of the rotary valve pulsator at high temperature is an important indicator for judging its working state and reliability. Many general-purpose or simple tooling can only obtain approximate torque values, or can only perform low-frequency and single-waveform loading, and cannot meet the multi-waveform and multi-frequency test requirements of the pulsator in actual working conditions. Insufficient torque test accuracy and dynamic control ability directly lead to the inability to accurately judge the reliability of the pulsator under different working cycles and different load waveforms.

[0024] It should be understood that the purpose of the above description of the current related technology is only to facilitate the public's better understanding of the inventive spirit and motivation of the present application, and is not regarded as a limitation of the present application. In addition, the technical solutions described in the above current related technology are not prior art and may also be unpublished technical solutions, such as those under research or in the laboratory stage.

[0025] Figure 1 Fig. 5 shows a schematic structural diagram of an example of a high-temperature torque test system based on adaptive PID control according to an embodiment of the present application.

[0026] As Figure 1 shown, the high-temperature torque test 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 and analyzer 170.

[0027] The heating mechanism 110 is used to heat the rotary valve pulsator 10 to be tested to the calibrated test temperature.

[0028] It should be understood that the form of the heating mechanism can be diversified. For example, an electric heater or a hot air circulation device can be used to uniformly heat the rotary valve pulsator 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 inputting information to the test bench and can effectively simulate the high-temperature working environment.

[0029] In some embodiments, the heating mechanism 110 can adopt a high-temperature chamber. To ensure that each part of the pulsator is heated evenly and to restore as much as possible the temperature gradient it may encounter on site, a multi-segment heating unit is designed in the high-temperature chamber. Each segment has an independent temperature control loop, and multiple temperature sensors are arranged inside the chamber. Thus, by controlling the temperature of the high-temperature chamber in sections, the pulsator can be heated to the target temperature range in the shortest time, and high-precision uniform temperature control can be achieved, providing a more realistic and controllable high-temperature working condition for subsequent torque measurement and control.

[0030] The loading mechanism 120 is used to apply torque to the rotary valve pulsator 10 according to a preset reference loading waveform when it is detected that the rotary valve pulsator 10 reaches the calibrated test temperature.

[0031] Here, the loading system 120 can adopt a hydraulic torque loading device or an electric motor torque loading device to ensure that controllable and adjustable torque loading can be provided. After it is detected that the rotary valve pulsator 10 reaches the preset calibrated 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 device in a high-temperature environment.

[0032] In addition, the reference loading waveform can be a sine wave, a step wave, or other custom waveforms to simulate the actual working state of the pulser. Thus, through a targeted loading mode, the torque loading working state of the rotary valve pulser under high-temperature environment can be accurately simulated, meeting various test requirements.

[0033] The torque sensor signal converter 130 is used to collect the torque monitoring data of the rotary valve pulser 10, and the incremental rotary encoder 140 is used to collect the rotation angle and angular velocity of the output shaft of the rotary valve pulser 10.

[0034] Here, the torque sensor signal converter 130 can 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 can 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.

[0035] More preferably, the torque sensor signal converter 130 can select a high-temperature type torque sensor, which has excellent high-temperature anti-interference and stability. The range and sensitivity of the sensor are customized according to the torque range of the pulser, meeting the requirements of multi-band and multi-waveform loading.

[0036] In some embodiments, the incremental rotary encoder 140 adopts a high-resolution incremental rotary encoder to collect the rotation angle of the output shaft and the angular velocity of the output shaft of the rotary valve pulser in real time.

[0037] The adaptive PID controller 150 is used to receive the rotation angle of the output shaft, the angular velocity of the output shaft, and the torque monitoring data, and dynamically adjust the PID parameters by using the adaptive PID algorithm in combination with the reference loading waveform, and calculate the corresponding drive correction information.

[0038] It should be noted that the traditional PID (Proportional-Integral-Derivative) controller has fixed proportional (P), integral (I), and derivative (D) parameters, and these parameters do not change during the operation of the system. The adaptive PID algorithm means that during the operation of the control system, it can automatically adjust the parameters of the PID controller according to the operating state of the system (such as the change of the characteristics of the controlled object, the influence of interference, etc.) to adapt to the change of the dynamic characteristics of the system, so that the system always maintains good control performance. In particular, in those systems with nonlinearity, time-variation, and uncertainty, by adopting adaptive PID control, the stability, response speed, and anti-interference ability of the system can be improved.

[0039] It should be understood that the adaptive PID algorithms suitable for application in the present application can be diverse, such as gain-scheduling adaptive PID algorithm or fuzzy adaptive PID algorithm.

[0040] Specifically, in the gain-scheduling adaptive PID algorithm, a set of PID parameter tables under different working conditions are established in advance, which can be based on the operating point of the system or some measurable variables (such as temperature, pressure, etc.). During system operation, appropriate PID parameters are selected from the parameter table according to the current operating point or measured value. However, this type of method requires a large amount of experimental data to be obtained in advance to establish the parameter table, and for complex and variable systems, the parameter table may not cover all working conditions.

[0041] 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 error and error change rate of the system through a fuzzy rule base. However, the formulation of fuzzy rules depends on expert experience, has a certain degree of subjectivity, and the computational complexity of fuzzy reasoning is relatively large.

[0042] Figure 2 FIG. shows a schematic diagram of the principle of an example of a PID closed-loop circuit according to an embodiment of the present application.

[0043] As Figure 2 shown, in the PID closed-loop circuit, in order to further improve the PID control performance of the system and give full play to the function of the computer. First, adaptive PID adjustment is performed in the computer. The standard waveform loaded is generated by the computer and output through D / A, amplified and loaded onto the servo valve, and then the actual torque value is collected by the torque sensor. The digital PID controller and the analog PID regulator are used to readjust the output loading waveform to form a closed-loop control system.

[0044] Regarding Figure 2 the description of some components in, "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 loading" represents the reference loading waveform (such as sine, triangle, trapezoid, etc.) that the system expects to apply to the rotary valve pulsator. 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 feedback the real-time torque data to the adaptive PID controller or the computer for closed-loop adjustment. "Collect torque" represents the torque measurement value collected by the system from the A / D board in each sampling period to form an error signal in the closed-loop control by comparing with the reference loading to ensure accurate torque application. The timing / counting board is used to count the pulses from the incremental rotary encoder or perform timing measurements to provide accurate data such as angle, angular velocity, etc., to assist in the accurate analysis of torque error.

[0045] In as Figure 2In the circuit operation logic shown, the computer first inputs "standard loading" (or reference loading) into the adaptive PID to set the reference waveform to be applied. The adaptive PID continuously calculates the control error and outputs a digital control signal based on the actual torque feedback (collected from the A / D board) and the data of the incremental rotary encoder. The D / A board converts the digital signal into an analog quantity, which is sent to the electro-hydraulic servo valve after being adjusted by the gain K. The electro-hydraulic servo valve adjusts the spool displacement according to this analog control quantity, changes the width of the hydraulic oil passage, and then updates the torque applied by the loading mechanism to the rotary valve pulsator. The torque sensor monitors the actual torque in real time, and after signal conversion, it is fed back to the adaptive PID through the A / D board for the next cycle of adjustment.

[0046] It should be noted that the computer plays a core role in the entire closed-loop control system, mainly responsible for signal acquisition, data processing, adaptive adjustment of PID parameters, and generation of the loading waveform. Specifically, a reference loading waveform (such as a sine wave, square wave, step wave, etc.) can be preset inside the computer, and this waveform is used to simulate the torque requirements of the rotary valve pulsator under different working conditions. In addition, the computer dynamically adjusts the PID parameters according to the torque data collected in real time and the set reference waveform, so that the loading waveform is consistent with the reference waveform, improving the control accuracy of torque testing. Furthermore, the loading signal calculated by the computer is converted into an analog signal through a D / A (digital-to-analog) conversion board for the loading system to execute.

[0047] The electro-hydraulic servo valve 160 is used to receive the drive correction information and adjust the spool displacement according to the drive correction information to adjust the width of the hydraulic oil passage 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 pulsator 10.

[0048] Specifically, as a bridge between digital control and hydraulic execution, the core task of the electro-hydraulic servo valve 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 passage, 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, and by integrating a high-precision displacement sensor, the spool displacement is monitored in real time to ensure the control accuracy. In addition, a high-temperature resistant sealing component is added inside the valve body of the power servo valve 160 to reduce the influence of high temperature on the spool wear and flow control accuracy.

[0049] In some embodiments, the drive correction information can be integrated into the correction control instruction, which is usually a digital quantity, and this 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 spool to generate a small displacement inside the valve body, and this displacement directly determines the opening degree of the valve port.

[0050] Specifically, the servo valve adjusts the displacement of its internal spool, changing the channel width between the hydraulic oil and the drive cylinder of the loading mechanism, thereby regulating the flow rate and pressure of the hydraulic oil in real time and achieving dynamic update of the torque applied by the loading mechanism to the rotary valve pulsator. Exemplarily, when the control instruction requires an increase in the loading torque, the servo valve will bias the spool to one side, increasing the flow rate and pressure of the hydraulic oil flowing to the drive cylinder of the loading mechanism, so that the drive cylinder pushes the loading mechanism to generate a greater mechanical torque. On the other hand, when the control instruction requires a decrease in the loading torque, the spool will move in the opposite direction, reducing the flow rate and pressure of the hydraulic oil flowing to the actuator, causing the loading mechanism to reduce the applied torque.

[0051] The pulse signal acquisition and analyzer 170 is used to acquire the electrical pulse signals generated by the rotary valve pulsator 10 during the torque loading process and test whether there are electrical faults in the rotary valve pulsator 10 according to the acquired electrical pulse signals.

[0052] In some embodiments, during the torque drive test, the current and voltage waveforms of the stepper motor or the drive circuit can be acquired in real time to analyze electrical problems such as motor winding faults and coil short circuits. More specifically, for key data such as pulse current and torque waveforms, 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 components, mutation points, etc.), and then various electrical fault modes can be identified.

[0053] Exemplarily, the calculation and processing of this part can also be supported and implemented by intelligent algorithms integrated in a computer (or host computer). For example, by running the fault diagnosis software in the computer, it can effectively automatically discriminate the acquired waveform features. When the system detects abnormal features, it automatically outputs possible fault types and location prompts, and can also intuitively display the working state of the pulsator at high temperatures for the maintenance personnel to refer to. In this way, with the help of time-frequency domain signal analysis, comprehensive evaluation of multi-dimensional data such as pulse current, torque waveform, and spool opening and closing signals is carried out to quickly locate the fault location of the pulsator and infer the cause of the fault, providing an effective reference for the maintenance decision of the rotary valve pulsator.

[0054] Through the embodiments of the present application, by integrating modules such as high-temperature environment simulation, adaptive PID torque loading, electro-hydraulic servo dynamic regulation, and electrical signal synchronous analysis in the high-temperature torque test system, it is possible to accurately reproduce the actual operating state of the rotary valve pulsator, provide high-precision torque and electrical fault detection, significantly improve the fault diagnosis ability, effectively support the fault mode location, shorten the maintenance cycle, help support the user's independent maintenance and efficient operation and maintenance of the rotary valve pulsator, and thus reduce the maintenance cost.

[0055] 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.

[0056] At this time, the adaptive PID controller 150 is used to perform the following operations:

[0057] Construct a regression vector using the rotation angle, angular velocity, torque, and historical drive correction information, and continuously update the system parameter vector 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:

[0058] Establish a system model through the following formula. This system mathematical model describes the dynamic response of the rotary valve pulser during the loading process (such as when applying torque). This model is used to predict the system output and provide a basis for subsequent parameter identification.

[0059] , Equation (1)

[0060] , Equation (2)

[0061] , Equation (3)

[0062] In the formula, is the moment of torque sampling is the system historical dynamic contribution value at, representing the dynamic prediction value of the current output torque based on historical data; is the rotary state output contribution value at the moment , reflecting the influence of the rotary state on the current output torque; represents the torque monitoring data measured at the moment ; represents the modeling error at the moment , reflecting the difference between the actual measurement and the model prediction; represents the dynamic coefficient of the influence of the rotation angle on the output torque at the moment ; represents the output shaft rotation angle measured at the moment ; represents the dynamic coefficient of the influence of the angular velocity on the output torque at the moment ; represents the output shaft angular velocity measured at the moment ; represents the moment historical output torque is the weight coefficient of the influence on the current torque, represents the moment measured output torque value, Indicates the moment Historical output torque Weight coefficient for the influence on the current torque, Indicates the moment Measured output torque value; Indicates the moment Historical drive correction information Weight coefficient for the influence on the current torque, Indicates the moment of the historical drive correction information, Indicates the moment Historical drive correction information Weight coefficient for the influence on the current torque, Indicates the moment of the historical drive correction information.

[0063] It should be noted that in the above formula (1), the system output torque is decomposed into three parts: , and , that is to say, the output torque is split into two quantifiable and controllable / identifiable parts and a noise term, which can more precisely describe the multi-source influence (such as friction, material property changes, etc.) of the rotary valve pulsator in a high-temperature environment, and can provide an accurate and clear architecture basis for subsequent online identification and adaptive control.

[0064] Regarding 's description, by and capturing the inertia and delay characteristics of the system, and by and reflecting the effect of the control signal (such as the input of the electro-hydraulic servo valve) at historical moments on the current torque, which can capture the friction and damping characteristics that may drift with time in a high-temperature environment. Moreover, 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 the system dynamic changes caused by high temperature.

[0065] Regarding 's description, by introducing a quantitative evaluation of the influence of the rotation angle (position) and angular velocity (motion speed) on the current torque, the system has a more intuitive quantification of the mechanical motion state of the rotary valve pulsator, and can reflect the contribution of the motion characteristic changes of components such as the valve core and seal after heating to the output torque under high-temperature conditions.

[0066] Rewrite the system model into vector form:

[0067] , Equation (4)

[0068] , Equation (5)

[0069] wherein represents the regression vector is the transposed vector of represents the system parameter vector obtained through online identification at time .

[0070] Update the system parameters using the recursive least squares method:

[0071] , Equation (6)

[0072] wherein represents the system parameter vector at time , represents the RLS gain vector at time , represents the difference between the predicted value and the actual measured value of the output of the system model at time .

[0073] Here, when the system state changes (such as 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, enabling subsequent adjustment of the PID parameters according to to reflect the latest dynamic characteristics. In addition, it can also reduce the need for manual repeated parameter tuning and improve the robustness to uncertain factors such as friction coefficient and viscosity changes.

[0074] Extract the comprehensive index through the linear weighting function and use the comprehensive index to perform proportional correction on the basic PID parameters. According to the parameters obtained by real-time identification dynamically adjust the three parameters (proportional, integral, and derivative gains) of the PID controller, thereby compensating for system changes caused by high temperature, friction, etc., and making the control effect better.

[0075] , Equation (7)

[0076] , Equation (8)

[0077] , Equation (9)

[0078] , Equation (10)

[0079] wherein Indicates at time The comprehensive index, a scalar index reflecting the current non - linear and time - varying characteristics of the system; Indicates the system parameter vector The n th component in Indicates the n th component's design weight, Indicates the initial PID parameters; Indicates the adjustment coefficient, used to adjust the sensitivity of the parameter pair ; Are respectively the proportional gain, integral gain, and derivative gain of the adaptive PID controller at time .

[0080] Here, Is a comprehensive index, which integrates all the dynamic parameters obtained by online identification into a scalar through weighting. Different parameter components can represent different influences at high temperatures (such as increased inertia, friction change), and the weight determines the importance of each component. It should be noted that in the high - temperature scenario, the weight can be flexibly set according to experimental data, so that the parameters most susceptible to temperature are given more attention. Therefore, by reflecting the real - time identified system dynamic characteristics onto the PID parameters, the controller can "follow" the system changes. For example, when reflects that the system damping becomes larger, it can automatically reduce or increase , etc., prevent overshoot or oscillation, realize the online adaptive tuning of PID parameters, and can enhance the adaptability to non - linear and time - varying characteristics in high - temperature environments, significantly reducing torque tracking overshoot and oscillation.

[0081] Calculate the drive correction information according to the adjusted PID parameters and the torque tracking error calculated in real - time. Calculate the final control signal , used to adjust the torque applied by the loading mechanism to the rotary valve pulsator.

[0082] , Equation (11)

[0083] , Equation (12)

[0084] In the formula, Indicates the drive correction information output at time , Indicates the torque tracking error at time , Indicates the preset value of the reference loading waveform at time , Indicates the sampling time interval; , and respectively represent the proportional control part, integral control part and derivative control part of the PID controller.

[0085] It should be noted that through the real-time calculation of the error , the system can immediately judge the accuracy of the current high-temperature torque loading. If the error is large, the control force is increased; if the error is small, it converges smoothly. In the proportional link, the control signal is adjusted according to the instantaneous error ; in the integral link, the past errors are accumulated to eliminate the possible steady-state deviation under high-temperature conditions; in the derivative link, the system dynamics are predicted through the error change rate and oscillations are suppressed. The control actions of each part are added together to form a comprehensive closed-loop control signal , which is converted by digital-to-analog conversion to drive the electro-hydraulic servo valve, and the torque loading on the rotary valve pulsator of the hydraulic system is adjusted in real time, so as to accurately control the torque applied by the loading mechanism, make the actual torque gradually approach the reference loading waveform, and finally ensure the stability and accuracy of the high-temperature torque test.

[0086] In the embodiment of the present application, through block modeling (Equations (1)-(3)), the system can better quantify the multiple influences (historical control, mechanical state, noise, etc.) at high temperature, and use online identification (Equations (4)-(6)) to ensure that the system can update its own understanding of the high-temperature environment at any time and enhance robustness. By using adaptive PID (Equations (7)-(12)), the identification results are mapped to the PID gains, realizing real-time scheduling of parameters and dynamic correction of control signals, and finally achieving precise tracking of the torque loading of the rotary valve pulsator.

[0087] Through the embodiment of the present application, through the RLS algorithm, the system can identify the dynamic parameter changes caused by high temperature, friction and non-linear factors in real time and online, ensure that even under high-temperature conditions, parameter drift can be compensated in time, so that the PID controller always adjusts with the latest parameters, ensuring 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 gains are dynamically adjusted based on this, realizing the 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 in the face of multiple interferences such as high temperature, friction, non-linearity and noise.

[0088] Regarding the details of driving and adjusting the width of the hydraulic oil channel according to the drive correction information, in some examples of the embodiment of the present application,

[0089] 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 spool displacement by introducing a non-linear saturation function.

[0090] , Equation (13)

[0091] where represents the spool displacement converted from the drive correction information at time ; represents the maximum allowable spool displacement; represents the drive correction information output at time ; represents the normalization constant of the drive correction information, which is used to adjust the response sensitivity so that for a relatively small spool displacement, it is approximately linear, while for a relatively large it is smoothly saturated. Specifically, the

[0092] function is used to ensure fine adjustment within the small signal range, avoid excessive spool movement (saturation phenomenon) under large signal input, ensure stable control of the spool displacement even when the drive correction information changes violently under high temperature conditions, and prevent the hydraulic mechanism from operating in the saturation region, thereby protecting the mechanical structure and improving the system stability. There is a linear functional relationship between the hydraulic oil channel width and the spool displacement.

[0093] That is, Equation (14)

[0094] , Equation (14)

[0095] where represents the hydraulic oil channel width under the action of the drive correction information at time ; represents the basic hydraulic oil channel width when the spool displacement is zero; represents the proportionality constant.

[0096] Through the linear relationship as in Equation (14), it is ensured that as the spool displacement increases, the hydraulic oil channel width increases proportionally, thereby increasing the flow rate and pressure to achieve an increase in the output torque of the loading mechanism. Thus, the loading mechanism can accurately adjust the output torque to achieve closed-loop tracking of the reference loading waveform.

[0097] In some examples of the embodiments of the present application, after collecting the electrical pulse signals generated by the rotary valve pulser during the torque loading process, the pulse signal acquisition and analyzer is further configured to perform temperature adaptive wavelet denoising on the collected original electrical pulse signals. 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 signals collected by the rotary valve pulser in high-temperature torque test scenarios, while retaining the key signal features to ensure the accuracy of subsequent fault detection.

[0098] Specifically, the collected original electrical pulse signals are subjected to discrete wavelet transform and decomposed into multiple wavelet coefficients:

[0099] , Equation (15)

[0100] where is the original electrical pulse signal at the moment of pulse sampling , represents the discrete wavelet transform function; represents the wavelet coefficient at scale and position , reflecting the local characteristics of the signal in different frequency bands.

[0101] Here, the original pulse signal is decomposed into multiple scales, and the coefficients of different scales contain the detail and trend information of the signal, facilitating the separation of the signal from the noise.

[0102] Adjust the denoising threshold according to the temperature of the rotary valve pulser measured in real time:

[0103] , Equation (16)

[0104] where represents the temperature of the rotary valve pulser measured in real time, represents the reference temperature, represents the reference denoising threshold at the reference temperature , represents the denoising threshold adjusted in real time, represents the temperature sensitivity coefficient.

[0105] It should be noted that temperature affects sensor noise and device characteristics. In a high-temperature environment, the noise level usually increases. Through Equation (16), the denoising threshold is adjusted in real time, so that the denoising process adapts to the current temperature conditions, ensuring that the important features of the signal are retained as much as possible while removing the noise.

[0106] Perform soft thresholding on wavelet coefficients at each scale to suppress noise and retain signal features:

[0107] , Equation (17)

[0108] where represents the wavelet coefficient after soft thresholding; is the sign function, used to maintain the positive or negative sign of the original coefficient; represents the soft thresholding function, ensuring that when is less than the threshold , it is set to zero, and when it is greater than the threshold , the corresponding amplitude is reduced.

[0109] Here, by using the soft thresholding function to process the wavelet coefficients, noise can be smoothly reduced while retaining the edge features and details of the signal. By adopting soft thresholding, compared with hard thresholding, a better signal smoothing effect can be achieved, and artifacts generated during signal reconstruction can be reduced.

[0110] Use the processed wavelet coefficients to perform inverse wavelet transform to reconstruct the denoised signal:

[0111] , Equation (18)

[0112] where represents the denoised signal reconstructed by inverse wavelet transform; represents the inverse discrete wavelet transform function.

[0113] Here, the coefficients at each scale are reconstructed into a denoised signal through inverse wavelet transform , and the signal-to-noise ratio of this signal is improved, which can provide high-quality input data for subsequent feature extraction and fault detection, supporting the realization of a fully automatic electrical fault monitoring and warning system.

[0114] Through the embodiments of the present application, temperature adaptive wavelet denoising is applied to filter the collected electrical pulse signals. First, the collected electrical pulse signals are decomposed into multiple scales by discrete wavelet transform, and temperature adaptive soft thresholding is performed on the coefficients at each scale to dynamically compensate for changes in the noise level, thereby effectively suppressing random noise and transient noise generated in high-temperature environments. Thus, the interference of noise on the signal can be reduced, the signal-to-noise ratio (SNR) of the output signal can be improved, and the key edges and pulse details of the electrical pulse signals can be retained simultaneously through the soft thresholding method, providing high-quality data support for fault detection.

[0115] In some examples of the embodiments of the present application, electrical faults include at least one of the following: electrical short circuit faults, electrical open circuit faults, abnormal pulse periods, or abnormal pulse widths.

[0116] Description of electrical open - circuit or break - circuit faults: When an open - circuit or break - circuit occurs in the system, the rotary valve pulsator will not be able to generate the expected electrical pulse signal, resulting in the entire test system losing the basis for feedback.

[0117] Description of electrical short - circuit or overload faults: Short - circuit or overload will not only cause the output signal to be distorted, but may also trigger a series of problems such as overheating and damage of internal components of the device, posing a serious threat to system safety and device life.

[0118] Description of abnormal pulse period or abnormal 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 accurate application of the loading torque and interfering with the overall performance.

[0119] Through the above four types of fault types, identification and detection are carried out from various aspects such as basic functions, equipment safety, and timing synchronization to ensure that the system can comprehensively grasp the electrical state and working performance of the rotary valve pulsator.

[0120] Regarding the operation details of detecting electrical faults from pulse signals, in some embodiments, multiple key time - domain features are extracted from the collected electrical pulse signals:

[0121] , Equation (19)

[0122] In the formula, represents the starting time of the th pulse, represents the starting time of the th pulse, represents the pulse period.

[0123] , Equation (20)

[0124] In the formula, represents the rising - edge time of the pulse signal, represents the falling - edge time of the pulse signal, represents the pulse width.

[0125] , Equation (21)

[0126] In the formula, represents the voltage value measured at time , represents the maximum voltage value during the high - level period of the pulse.

[0127] Here, three key time-domain features of the pulse signal are mainly extracted, namely the pulse period, pulse width, and pulse amplitude, to comprehensively reflect the dynamic information of the electrical pulse signal.

[0128] According to each of the extracted key time-domain features and the preset standard values, calculate the corresponding relative error of the time-domain feature:

[0129] , Equation (22)

[0130] In the formula, represents the relative error of the pulse period, represents the preset reference pulse period.

[0131] , Equation (23)

[0132] In the formula, represents the relative error of the pulse width, represents the reference pulse width.

[0133] , Equation (24)

[0134] In the formula, represents the relative error of the pulse amplitude, represents the reference pulse amplitude.

[0135] Furthermore, based on the relative error of each time-domain feature, determine whether there is an electrical fault in the rotary valve pulsator.

[0136] It should be noted that 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 has a significant deviation from the preset standard, there may be a timing anomaly. is the duration when the pulse is in the high-level state, representing the pulse width, which reflects the response duration of the device switch, and an abnormal width may indicate a switch response problem or contact wear. can be the maximum signal value during the high level of the pulse, which reflects the output intensity of the electrical component; an abnormal amplitude may imply a short circuit (amplitude too high) or an open circuit (amplitude too low).

[0137] Through the embodiments of the present application, the dynamic information of the electrical pulse signal is comprehensively reflected by using the time-domain features, combined with strict relative error calculation, and at the same time, through preset standards and intelligent pattern recognition, it is possible to effectively distinguish signal anomalies caused by temperature drift and actual electrical faults at high temperatures, providing reliable data support for equipment early warning and maintenance, reducing maintenance risks and improving the automation level.

[0138] It should be understood that the methods and types of signal feature extraction can be diversified and can be used to monitor various types of pulser faults required for analysis. The descriptions herein are only used as examples and do not limit the scope of implementation of this application.

[0139] Regarding the details of the detection of pulser fault types, in some examples of the embodiments of this application, when or then it is determined that there is an electrical short circuit fault in the rotary valve pulser; represents the threshold ratio of the increase in the amplitude of the electrical short circuit fault, represents the upper limit value of the allowable amplitude error.

[0140] When or then it is determined that there is an electrical open circuit fault in the rotary valve pulser; represents the threshold ratio of the decrease in the amplitude of the electrical open circuit fault.

[0141] When then it is determined that there is an abnormal pulse period in the rotary valve pulser, represents the threshold of the allowable relative error of the pulse period.

[0142] When then it is determined that there is an abnormal pulse width in the rotary valve pulser, represents the threshold of the allowable relative error of the pulse width.

[0143] It should be noted that various preset quantities involved in the fault detection process, such as 、 、 、 、 、 etc., can all be obtained based on the calibration data of the rotary valve pulser under standard conditions and appropriately adjusted in combination with the possible changes under high-temperature environments, thereby providing a clear reference standard for fault detection.

[0144] Through the embodiments of the present application, based on high-speed sampling, temperature compensation, and time-domain feature extraction, the subtle changes of electrical pulse signals can be captured in real time, the relative error can be quickly calculated, and the comprehensive fault index is used to determine whether it exceeds the preset threshold, and electrical short circuits, open circuits, periods, widths, or amplitude anomalies can be detected within milliseconds. Thus, an accurate judgment on the quantification of the fault types of the rotary valve pulsator is achieved. Real-time automated detection and intelligent fault diagnosis can quickly identify and locate potential electrical faults, provide accurate fault warning data, and also enable the user to check whether there are faults in the equipment itself through high-temperature torque tests immediately after purchasing the pulsator, which can effectively avoid disputes after downhole operations and facilitate maintenance personnel to intervene early for maintenance and correction, ensuring the reliability of the rotary valve pulsator during actual operation.

[0145] It should be noted that for the foregoing system embodiments, for the sake of simple description, they are all expressed as a series of actions combined. However, those skilled in the art should know that the present application is not limited by the described action sequence, because according to the present application, certain steps can be performed in other sequences or simultaneously. Secondly, those skilled in the art should also know that the embodiments described in the specification are all preferred embodiments, and the actions and modules involved are not necessarily essential to the present application. In the above embodiments, the descriptions of each embodiment have their own focuses. For the parts not detailed in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0146] The system embodiments described above are merely illustrative. 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 to multiple network units. Some or all of the modules can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0147] Through the description of the above embodiments, those skilled in the art can clearly understand that each embodiment can be implemented by means of software plus a general hardware platform, and of course, it can also be implemented by hardware. Based on such an understanding, the essence of the above technical solution, or the part that contributes to the related technology, can be embodied in the form of a software product. The computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., including several instructions to enable a computer device (which can be a personal computer, a server, or a network device, etc.) to execute the systems described in each embodiment or some parts of the embodiments.

[0148] 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 them; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the various 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 according to the acquired electrical pulse signal; 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 is 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; Wherein, 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; A normalization constant representing the drive correction information, used to adjust the response sensitivity; 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.

2. 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 time at which the pulse is sampled 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.

3. 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.

4. The system according to claim 1 or 3, 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.

5. The system according to claim 4, 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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