A valve fault self-detection method, system and storage medium based on current detection

Abstract

The present invention provides a valve fault self-detection method, system and storage medium based on current detection. First, the working current of the valve drive chip is collected in real time through a non-contact current sensor, and the interference of external signals on the measurement signal is reduced through non-invasive design; secondly, real-time model matching data is obtained by analyzing the current curve, current operating amplitude and instantaneous current change rate; then, dynamic characteristic model reference data is established based on the historical current data of the valve state switching process to improve the adaptability of the alarm threshold and the valve working state; finally, by comparing the real-time model matching data with the theoretical characteristic model reference data, abnormal conditions are analyzed and identified, and then hierarchical early warning responses or redundant control operations are triggered according to the abnormal conditions; among them, a multi-level early warning mechanism is adopted to reduce invalid warnings and improve the efficiency of equipment maintenance; in addition, the fault tolerance of instrument / meter valve operation is also improved through redundant control operations.

Description

Technical Field

[0001] The present invention relates to the field of valve self-test, and more specifically to a valve fault self-test method, system and storage medium based on current detection. Background Art

[0002] Currently, there are many defects in instrument / meter valve control, mainly due to the following factors:

[0003] The first is electromagnetic interference-induced signal anomalies. The signals controlling valves are susceptible to external interference, particularly electromagnetic interference. For example, in complex electromagnetic environments, electromagnetic radiation generated by electrical equipment and transmission lines can distort control signals during transmission. When valves receive distorted signals, command deviations can cause malfunctions, seriously impacting system operation and control accuracy.

[0004] The second aspect is the wear and aging of mechanical parts: under long-term use, the valve core, valve stem, seals and other mechanical parts of the valve will inevitably wear and age; and under the influence of reciprocating motion, pressure and environmental factors, the accuracy of the parts will decrease, the fit will deteriorate, and the valve will easily get stuck or even fail to open and close normally.

[0005] The third issue is foreign matter interfering with normal operation: Since valves operate mechanically, foreign matter can easily interfere with normal operation. When foreign matter gets between the valve core and the valve seat, it blocks the movement of the valve core, preventing the valve from opening and closing as instructed, leading to control failure.

[0006] Therefore, there is an urgent need for a self-test technology for instrument valve failures that can automatically detect and report the valve working status. Summary of the Invention

[0007] In view of the above problems, the purpose of the present invention is to provide a valve fault self-detection method, system and storage medium based on current detection. First, the working current of the valve drive chip is collected in real time by a non-contact current sensor, and the interference of external signals on the measurement signal is reduced by non-invasive design; secondly, real-time model matching data is obtained by analyzing the current curve, current operating amplitude and instantaneous change rate of current; then, dynamic characteristic model reference data is established based on the historical current data of the valve state switching process to improve the adaptability of the alarm threshold and the valve working state; finally, by comparing the real-time model matching data with the theoretical characteristic model reference data, abnormal conditions are analyzed and identified, and then hierarchical early warning responses or redundant control operations are triggered according to the abnormal conditions; among them, a multi-level early warning mechanism is adopted to reduce invalid warnings and improve the efficiency of equipment maintenance; in addition, the fault tolerance of instrument / meter valve operation is also improved through redundant control operations.

[0008] A first aspect of the present invention provides a valve fault self-detection method based on current detection, the method comprising:

[0009] When judging to send valve control signal;

[0010] Dynamically collecting first current information of the valve driver chip according to a preset first sampling frequency;

[0011] Obtaining a first current curve, a first operating amplitude, and a first instantaneous change rate according to the first sampling frequency and the first current information;

[0012] Performing pattern matching analysis based on the first current curve, the first operating amplitude, and the first instantaneous rate of change to obtain first model matching information;

[0013] Get the feature model reference value;

[0014] When it is determined that the first model matching information does not meet the preset parameter conditions;

[0015] Based on a preset fault classification model, analyzing first model matching information that does not meet preset parameter conditions, obtaining first confidence information and triggering a classification alarm mechanism;

[0016] When it is determined that the first confidence information exceeds a preset first confidence threshold, redundancy control is started.

[0017] This plan also includes:

[0018] Obtaining first operation number information of the valve;

[0019] determining first weight information according to the first running number information;

[0020] updating a characteristic model reference value based on the current data of the historical operation of the valve and the first weight information;

[0021] The characteristic model reference value at least includes a first rising change rate in the opening phase, a first steady-state amplitude in the steady-state phase, and a first decay time in the closing phase.

[0022] In this solution, the first model matching information exceeds the feature model reference value, specifically:

[0023] When the valve state is switched on, the first instantaneous rate of change exceeds the rate of change range set based on the first rising rate of change;

[0024] When the valve state is switched, the first operating amplitude exceeds the amplitude range set based on the first steady-state amplitude;

[0025] When the valve state switching is at the end stage, the decay time obtained based on the first current curve exceeds the time range set based on the first decay time.

[0026] In this solution, the triggering of the hierarchical alarm mechanism specifically includes:

[0027] The graded alarm has at least three levels, including level one warning, level two warning and level three warning;

[0028] When the first current information exceeds a preset first current threshold, a first-level warning is triggered and log recording is performed;

[0029] When the first operating amplitude exceeds a preset first steady-state amplitude threshold, a second-level warning is triggered, a status prompt is issued, and the first confidence information is adjusted upward;

[0030] When it is determined based on the first current curve that the valve state switching duration exceeds a preset first duration threshold, a third-level warning is triggered, a local sound and light prompt is executed, and the first confidence information is adjusted upward.

[0031] In this solution, starting redundant control specifically includes:

[0032] Stop the current valve state switching operation and start the obstacle removal procedure;

[0033] Determining whether the obstacle removal procedure can be completed;

[0034] If so, lowering the first confidence information;

[0035] If not, then adjusting the first confidence information upward;

[0036] When the first confidence information exceeds a preset second confidence threshold, the standby valve is automatically switched and a maintenance request is sent.

[0037] In this solution, the first current information of the valve driver chip is dynamically collected as follows:

[0038] Measure the power supply circuit current of the valve driver chip through a non-contact sensor;

[0039] Wherein, the non-contact sensor is a Hall current sensor;

[0040] Wherein, an electromagnetic shielding layer is provided between the Hall current sensor and the current loop.

[0041] A second aspect of the present invention provides a valve fault self-detection system based on current detection, including a valve fault self-detection method program based on current detection. When the valve fault self-detection method program based on current detection is executed by the processor, the following steps are implemented:

[0042] When judging to send valve control signal;

[0043] Dynamically collecting first current information of the valve driver chip according to a preset first sampling frequency;

[0044] Obtaining a first current curve, a first operating amplitude, and a first instantaneous change rate according to the first sampling frequency and the first current information;

[0045] Performing pattern matching analysis based on the first current curve, the first operating amplitude, and the first instantaneous rate of change to obtain first model matching information;

[0046] Get the feature model reference value;

[0047] When it is determined that the first model matching information does not meet the preset parameter conditions;

[0048] Based on a preset fault classification model, analyzing first model matching information that does not meet preset parameter conditions, obtaining first confidence information and triggering a classification alarm mechanism;

[0049] When it is determined that the first confidence information exceeds a preset first confidence threshold, redundancy control is started.

[0050] This plan also includes:

[0051] Obtaining first operation number information of the valve;

[0052] determining first weight information according to the first running number information;

[0053] updating a characteristic model reference value based on the current data of the historical operation of the valve and the first weight information;

[0054] The characteristic model reference value at least includes a first rising change rate in the opening phase, a first steady-state amplitude in the steady-state phase, and a first decay time in the closing phase.

[0055] In this solution, starting redundant control specifically includes:

[0056] Stop the current valve state switching operation and start the obstacle removal procedure;

[0057] Determining whether the obstacle removal procedure can be completed;

[0058] If so, lowering the first confidence information;

[0059] If not, then adjusting the first confidence information upward;

[0060] When the first confidence information exceeds a preset second confidence threshold, the standby valve is automatically switched and a maintenance request is sent.

[0061] A third aspect of the present invention provides a computer-readable storage medium, which includes a valve fault self-detection method program based on current detection. When the valve fault self-detection method program based on current detection is executed by a processor, the steps of the valve fault self-detection method based on current detection as described in any one of the above items are implemented.

[0062] The present invention provides a valve fault self-detection method, system and storage medium based on current detection. First, the working current of the valve drive chip is collected in real time through a non-contact current sensor, and the interference of external signals on the measurement signal is reduced through non-invasive design; secondly, real-time model matching data is obtained by analyzing the current curve, current operating amplitude and instantaneous current change rate; then, dynamic characteristic model reference data is established based on the historical current data of the valve state switching process to improve the adaptability of the alarm threshold and the valve working state; finally, by comparing the real-time model matching data with the theoretical characteristic model reference data, abnormal conditions are analyzed and identified, and then hierarchical early warning responses or redundant control operations are triggered according to the abnormal conditions; among them, a multi-level early warning mechanism is adopted to reduce invalid warnings and improve the efficiency of equipment maintenance; in addition, the fault tolerance of instrument / meter valve operation is also improved through redundant control operations. BRIEF DESCRIPTION OF THE DRAWINGS

[0063] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope.

[0064] Figure 1 A flow chart of a valve fault self-detection method based on current detection according to the present invention is shown;

[0065] Figure 2 A flowchart of dynamically updating a feature model reference value provided by an embodiment of the present invention is shown;

[0066] Figure 3 shows an execution flow chart of redundancy control provided by an embodiment of the present invention;

[0067] Figure 4 A block diagram of a valve fault self-detection system based on current detection according to the present invention is shown. DETAILED DESCRIPTION

[0068] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0069] Unless otherwise defined, all terms (including technical and scientific terms) used in the embodiments of the present invention have the same meaning as commonly understood by those skilled in the art to which the present invention belongs. It should also be understood that terms such as those defined in common dictionaries should be interpreted as having meanings consistent with their meanings in the context of the relevant technology, and should not be interpreted in an idealized or extremely formal sense, unless explicitly defined in this manner in the embodiments of the present invention.

[0070] The words "first", "second" and similar terms used in the embodiments of the present invention do not indicate any order, quantity or importance, but are only used to distinguish different components. Words such as "one", "an" or "the" do not indicate a quantity limitation, but rather indicate the existence of at least one. Similarly, words such as "include" or "comprise" mean that the elements or objects preceding the word include the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Words such as "connect" or "connected" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. The steps before or after the method of the embodiment of the present invention do not necessarily have to be performed in exact order. On the contrary, the various steps may be processed in reverse order or simultaneously. At the same time, other operations may be added to these processes, or one or more steps may be removed from these processes.

[0071] In addition, the functional modules in the various embodiments of the present invention may be integrated together to form an independent part, or each module may exist independently, or two or more modules may be integrated to form an independent part.

[0072] Figure 1 The flowchart of a valve fault self-detection method based on current detection of the present invention is shown.

[0073] like Figure 1 As shown, the first aspect of the present invention discloses a valve fault self-detection method based on current detection, the method comprising:

[0074] S102, determining when a valve control signal is sent;

[0075] S104, dynamically collecting first current information of the valve driver chip according to a preset first sampling frequency;

[0076] S106, obtaining a first current curve, a first operating amplitude, and a first instantaneous change rate according to the first sampling frequency and the first current information;

[0077] S108, performing pattern matching analysis based on the first current curve, the first operating amplitude, and the first instantaneous change rate to obtain first model matching information;

[0078] S110, obtaining a characteristic model reference value;

[0079] S112, when it is determined that the first model matching information does not meet the preset parameter conditions;

[0080] S114, analyzing the first model matching information that does not meet the preset parameter conditions based on the preset fault classification model to obtain first confidence information and trigger a classification alarm mechanism;

[0081] S116: When it is determined that the first confidence information exceeds a preset first confidence threshold, redundancy control is started.

[0082] It should be noted that the first current information is the working current of the valve driver chip; the first current curve is a current curve that changes with time and is drawn based on the sampling frequency with time as the working current of the valve driver chip; the first operating amplitude is the current value when the working current of the valve driver chip is in a stable state within a set period; the first instantaneous change rate is the rate of change of the working current of the valve driver chip, that is, the current change speed, in A / s; the first model matching information includes at least the first current curve, the first operating amplitude and the first instantaneous change rate; the first confidence information is used to indicate the probability of the existence of a fault that affects the opening and closing of the valve.

[0083] In this embodiment, when an instrument / meter controls a valve switching state, including opening or closing the valve, it sends a valve control signal to a valve driver chip (such as the BL8310) to drive the valve. Upon detecting the valve control signal, a current detection sensor dynamically collects the operating current of the valve driver chip in real time at a predetermined first sampling frequency of at least 1kHz. In practical applications, the first sampling frequency is 1kHz. Next, a time-varying current curve is plotted based on the sampling frequency and real-time current value. The current change rate (in A / s) and the steady-state current value at each sampling moment are then analyzed and calculated. The analyzed data is then used as first model matching information for comparison with the dynamically updated characteristic model reference value. If the model data in the first model matching information falls outside the characteristic model reference value range, a valve switching anomaly is determined. In this case, the data in the first model matching information that falls outside the characteristic model reference value range is analyzed based on a predetermined fault classification model to determine a corresponding warning level. Finally, the corresponding level of alarm mechanism is executed according to the warning level, and redundant control is started according to the confidence level of valve failure; a multi-level warning mechanism is adopted to reduce invalid warnings and improve the efficiency of equipment maintenance, and the fault tolerance of instrument / meter valve operation is improved through redundant control operations.

[0084] Figure 2 A flow chart of dynamically updating a feature model reference value provided by an embodiment of the present invention is shown.

[0085] According to an embodiment of the present invention, Figure 2 As shown, it also includes:

[0086] S202, obtaining first operation number information of the valve;

[0087] S204, determining first weight information according to the first running number information;

[0088] S206, updating a characteristic model reference value based on the historical operating current data of the valve and the first weight information;

[0089] The characteristic model reference value at least includes a first rising change rate in the opening phase, a first steady-state amplitude in the steady-state phase, and a first decay time in the closing phase.

[0090] It should be noted that the first operation count information is the cumulative number of valve switching times; the first weight information is the calculation parameter for updating the characteristic model reference value; the first rising change rate is a reasonable range of the current change rate of the working current in the rising stage when the valve state is switched on, and is one of the characteristic model reference values; the first steady-state amplitude is the current value of the working current in the stable stage during the valve state switching process, and is one of the characteristic model reference values; the first decay time is the decay time of the working current in the descending stage when the valve state is completed, and is one of the characteristic model reference values.

[0091] In this embodiment, the characteristic model reference value of the valve is dynamically adjusted and updated based on valve usage, avoiding the limitations of traditional fixed threshold solutions. As an implementation, a preset number-weighted correspondence table is searched based on the cumulative number of valve switching cycles to determine first weight information. This first weight information is used as a weighting coefficient for historical data. Based on the historical current data of the valve, a preset standard reference value algorithm is used in conjunction with the corresponding weighting coefficient to obtain the characteristic model reference value.

[0092] According to an embodiment of the present invention, the first model matching information exceeds the feature model reference value, specifically:

[0093] When the valve state is switched on, the first instantaneous rate of change exceeds the rate of change range set based on the first rising rate of change;

[0094] When the valve state is switched, the first operating amplitude exceeds the amplitude range set based on the first steady-state amplitude;

[0095] When the valve state switching is at the end stage, the decay time obtained based on the first current curve exceeds the time range set based on the first decay time.

[0096] It should be noted that in this embodiment, a segmented comparison model is used to analyze the valve switching conditions based on the dynamic process of valve switching. During the valve state switching opening phase, the rate of change of the current rise is verified. For example, if the instantaneous rate of change of the current during the opening phase is within the range of 0.5A / s to 1.5A / s, it indicates that the valve is operating normally. During the valve state switching process, the current amplitude and current fluctuation are verified. If the amplitude is outside the reference range, it indicates that the valve is continuously blocked; if the current fluctuation exceeds the reference range, it indicates that the valve is intermittently blocked. In other words, by verifying the current amplitude and current fluctuation, it is used to determine whether the valve has a mechanical fault. At the end of the valve state switching phase, the current decay time is verified. If the decay time exceeds the reference range, it is determined that the internal valve components are experiencing increased wear. In addition, the valve operating condition is analyzed by verifying data such as the duration of the current in steady state, the current decay rate, and the current curve trend.

[0097] According to an embodiment of the present invention, the triggering of the hierarchical alarm mechanism specifically includes:

[0098] The graded alarm has at least three levels, including level one warning, level two warning and level three warning;

[0099] When the first current information exceeds a preset first current threshold, a first-level warning is triggered and log recording is performed;

[0100] When the first operating amplitude exceeds a preset first steady-state amplitude threshold, a second-level warning is triggered, a status prompt is issued, and the first confidence information is adjusted upward;

[0101] When it is determined based on the first current curve that the valve state switching duration exceeds a preset first duration threshold, a third-level warning is triggered, a local sound and light prompt is executed, and the first confidence information is adjusted upward.

[0102] It should be noted that, as an implementation, this embodiment provides at least three levels of early warning mechanisms. Level 1 early warning refers to abnormal conditions that have no impact on valve operation, such as when the operating current briefly exceeds a set current threshold. For such abnormalities, a log is used to record the site of the abnormality. Level 2 early warning refers to abnormal conditions that have a minor impact on valve operation. For example, when the valve operating current amplitude exceeds the steady-state current amplitude, this can be considered a mechanical obstruction. While such abnormalities may affect the valve switching process but not the switching result, a status prompt is provided during the valve switching process, using devices such as LEDs. Furthermore, the confidence level of a valve failure is increased. Level 3 early warning refers to abnormal conditions that have a significant impact on valve operation, indicating a probability that the valve will fail to complete the switching operation. For example, if the valve switching time is too long, this can be considered a problem with valve component wear. Such abnormalities may affect the switching result, and an audio and visual prompt is provided at the valve site to indicate the risk of valve wear and to facilitate local maintenance.

[0103] Figure 3 The flowchart of the execution of redundancy control provided by the embodiment of the present invention is shown.

[0104] According to an embodiment of the present invention, Figure 3 As shown, the starting redundancy control specifically includes:

[0105] S302, stop the current valve state switching operation and start the obstacle removal program;

[0106] S304, determining whether the obstacle removal program can be completed;

[0107] S306: If yes, lower the first confidence information;

[0108] S308, if not, upwardly adjust the first confidence information;

[0109] S310: When the first confidence information exceeds a preset second confidence threshold, the standby valve is automatically switched and a maintenance request is sent.

[0110] It should be noted that in this embodiment, when the fault confidence exceeds a set first confidence threshold, redundant control operations are executed, attempting to self-clear the fault or requesting maintenance to improve the fault tolerance of the instrument / meter valve. When the fault confidence exceeds the set threshold, the valve switching operation is first stopped, and then the fault clearance procedure is initiated, attempting to resolve the fault through the set self-clearing action. If the fault clearance procedure is fully executed, the valve operating condition meets the basic requirements for open / close switching, and the valve fault confidence is lowered. If the fault clearance procedure is not fully executed, the current valve operating condition does not meet the requirements for open / close switching, and the valve fault confidence is raised. When the valve fault confidence exceeds a set second confidence threshold, a maintenance request is immediately issued to improve maintenance efficiency. In addition, in instrument / meter systems with backup valves, the system automatically switches to the backup valve to ensure the operation of the instrument / meter. When the valve fault confidence does not exceed the set second confidence threshold, the valve switching operation is allowed to continue.

[0111] According to an embodiment of the present invention, the first current information of the valve driving chip is dynamically collected, specifically:

[0112] Measure the power supply circuit current of the valve driver chip through a non-contact sensor;

[0113] Wherein, the non-contact sensor is a Hall current sensor;

[0114] Wherein, an electromagnetic shielding layer is provided between the Hall current sensor and the current loop.

[0115] It should be noted that, as an implementation, this embodiment uses a Hall effect current sensor to measure the operating current of the valve driver chip. Using a non-contact sensor to detect the power supply circuit current shields the power supply circuit from its effects on the measurement circuit, improving measurement accuracy. Furthermore, an electromagnetic shielding layer is provided between the Hall effect current sensor and the current circuit to further suppress external electromagnetic interference.

[0116] It is worth mentioning that it also includes:

[0117] Acquire first environmental parameter information, wherein the first environmental information includes at least a temperature value, a humidity value, and an electromagnetic intensity;

[0118] According to the first environmental parameter information, searching a preset weight correspondence table to obtain second weight information;

[0119] The feature model reference value is modified according to the second weight information.

[0120] It should be noted that this embodiment also incorporates environmental parameters (such as temperature, humidity, and electromagnetic intensity) to adaptively adjust the characteristic model reference value. Secondary weight information is determined based on these environmental parameters and used as an adjustment coefficient to modify the characteristic model reference value, further improving the adaptability of the alarm threshold to the valve operating status.

[0121] It is worth mentioning that it also includes:

[0122] Send the historical current data of the valve to the time series prediction model to obtain the first life information;

[0123] When it is determined that the first life information is lower than a preset life threshold, a preventive maintenance request is sent.

[0124] It should be noted that in this embodiment, a time series algorithm (such as ARIMA or LSTM) is used to analyze historical current data during valve switching to predict the remaining service life of the valve. Based on the remaining service life, maintenance recommendations are generated in advance.

[0125] It is worth mentioning that it also includes:

[0126] Sending historical valve current data and maintenance processing logs to a preset fault analysis neural network model to obtain first sensitivity adjustment information;

[0127] According to the first sensitivity adjustment information, the feature model reference value and the confidence threshold are modified.

[0128] It should be noted that in this embodiment, the preset fault analysis neural network model combines historical valve current data and maintenance logs uploaded by maintenance personnel to dynamically optimize the feature model or alarm threshold. It automatically reduces sensitivity after multiple false alarms or improves detection accuracy after missed alarms.

[0129] Figure 4 A block diagram of a valve fault self-detection system based on current detection according to the present invention is shown.

[0130] like Figure 4 As shown, the second aspect of the present invention discloses a valve fault self-detection system 4 based on current detection, including a memory 41 and a processor 42. The memory includes a valve fault self-detection method program based on current detection. When the valve fault self-detection method program based on current detection is executed by the processor, the following steps are implemented:

[0131] When judging to send valve control signal;

[0132] Dynamically collecting first current information of the valve driver chip according to a preset first sampling frequency;

[0133] Obtaining a first current curve, a first operating amplitude, and a first instantaneous change rate according to the first sampling frequency and the first current information;

[0134] Performing pattern matching analysis based on the first current curve, the first operating amplitude, and the first instantaneous rate of change to obtain first model matching information;

[0135] Get the feature model reference value;

[0136] When it is determined that the first model matching information does not meet the preset parameter conditions;

[0137] Based on a preset fault classification model, analyzing first model matching information that does not meet preset parameter conditions, obtaining first confidence information and triggering a classification alarm mechanism;

[0138] When it is determined that the first confidence information exceeds a preset first confidence threshold, redundancy control is started.

[0139] It should be noted that the first current information is the working current of the valve driver chip; the first current curve is a current curve that changes with time and is drawn based on the sampling frequency with time as the working current of the valve driver chip; the first operating amplitude is the current value when the working current of the valve driver chip is in a stable state within a set period; the first instantaneous change rate is the rate of change of the working current of the valve driver chip, that is, the current change speed, in A / s; the first model matching information includes at least the first current curve, the first operating amplitude and the first instantaneous change rate; the first confidence information is used to indicate the probability of the existence of a fault that affects the opening and closing of the valve.

[0140] In this embodiment, when an instrument / meter controls a valve switching state, including opening or closing the valve, it sends a valve control signal to a valve driver chip (such as the BL8310) to drive the valve. Upon detecting the valve control signal, a current detection sensor dynamically collects the operating current of the valve driver chip in real time at a predetermined first sampling frequency of at least 1kHz. In practical applications, the first sampling frequency is 1kHz. Next, a time-varying current curve is plotted based on the sampling frequency and real-time current value. The current change rate (in A / s) and the steady-state current value at each sampling moment are then analyzed and calculated. The analyzed data is then used as first model matching information for comparison with the dynamically updated characteristic model reference value. If the model data in the first model matching information falls outside the characteristic model reference value range, a valve switching anomaly is determined. In this case, the data in the first model matching information that falls outside the characteristic model reference value range is analyzed based on a predetermined fault classification model to determine a corresponding warning level. Finally, the corresponding level of alarm mechanism is executed according to the warning level, and redundant control is started according to the confidence level of valve failure; a multi-level warning mechanism is adopted to reduce invalid warnings and improve the efficiency of equipment maintenance, and the fault tolerance of instrument / meter valve operation is improved through redundant control operations.

[0141] According to an embodiment of the present invention, the further embodiment includes:

[0142] Obtaining first operation number information of the valve;

[0143] determining first weight information according to the first running number information;

[0144] updating a characteristic model reference value based on the current data of the historical operation of the valve and the first weight information;

[0145] The characteristic model reference value at least includes a first rising change rate in the opening phase, a first steady-state amplitude in the steady-state phase, and a first decay time in the closing phase.

[0146] It should be noted that the first operation count information is the cumulative number of valve switching times; the first weight information is the calculation parameter for updating the characteristic model reference value; the first rising change rate is a reasonable range of the current change rate of the working current in the rising stage when the valve state is switched on, and is one of the characteristic model reference values; the first steady-state amplitude is the current value of the working current in the stable stage during the valve state switching process, and is one of the characteristic model reference values; the first decay time is the decay time of the working current in the descending stage when the valve state is completed, and is one of the characteristic model reference values.

[0147] In this embodiment, the characteristic model reference value of the valve is dynamically adjusted and updated based on valve usage, avoiding the limitations of traditional fixed threshold solutions. As an implementation, a preset number-weighted correspondence table is searched based on the cumulative number of valve switching cycles to determine first weight information. This first weight information is used as a weighting coefficient for historical data. Based on the historical current data of the valve, a preset standard reference value algorithm is used in conjunction with the corresponding weighting coefficient to obtain the characteristic model reference value.

[0148] According to an embodiment of the present invention, the first model matching information exceeds the feature model reference value, specifically:

[0149] When the valve state is switched on, the first instantaneous rate of change exceeds the rate of change range set based on the first rising rate of change;

[0150] When the valve state is switched, the first operating amplitude exceeds the amplitude range set based on the first steady-state amplitude;

[0151] When the valve state switching is at the end stage, the decay time obtained based on the first current curve exceeds the time range set based on the first decay time.

[0152] It should be noted that in this embodiment, a segmented comparison model is used to analyze the valve switching conditions based on the dynamic process of valve switching. During the valve state switching opening phase, the rate of change of the current rise is verified. For example, if the instantaneous rate of change of the current during the opening phase is within the range of 0.5A / s to 1.5A / s, it indicates that the valve is operating normally. During the valve state switching process, the current amplitude and current fluctuation are verified. If the amplitude is outside the reference range, it indicates that the valve is continuously blocked; if the current fluctuation exceeds the reference range, it indicates that the valve is intermittently blocked. In other words, by verifying the current amplitude and current fluctuation, it is used to determine whether the valve has a mechanical fault. At the end of the valve state switching phase, the current decay time is verified. If the decay time exceeds the reference range, it is determined that the internal valve components are experiencing increased wear. In addition, the valve operating condition is analyzed by verifying data such as the duration of the current in steady state, the current decay rate, and the current curve trend.

[0153] According to an embodiment of the present invention, the triggering of the hierarchical alarm mechanism specifically includes:

[0154] The graded alarm has at least three levels, including level one warning, level two warning and level three warning;

[0155] When the first current information exceeds a preset first current threshold, a first-level warning is triggered and log recording is performed;

[0156] When the first operating amplitude exceeds a preset first steady-state amplitude threshold, a second-level warning is triggered, a status prompt is issued, and the first confidence information is adjusted upward;

[0157] When it is determined based on the first current curve that the valve state switching duration exceeds a preset first duration threshold, a third-level warning is triggered, a local sound and light prompt is executed, and the first confidence information is increased.

[0158] It should be noted that, as an implementation, this embodiment provides at least three levels of early warning mechanisms. Level 1 early warning refers to abnormal conditions that have no impact on valve operation, such as when the operating current briefly exceeds a set current threshold. For such abnormalities, a log is used to record the site of the abnormality. Level 2 early warning refers to abnormal conditions that have a minor impact on valve operation. For example, when the valve operating current amplitude exceeds the steady-state current amplitude, this can be considered a mechanical obstruction. While such abnormalities may affect the valve switching process but not the switching result, a status prompt is provided during the valve switching process, using devices such as LEDs. Furthermore, the confidence level of a valve failure is increased. Level 3 early warning refers to abnormal conditions that have a significant impact on valve operation, indicating a probability that the valve will fail to complete the switching operation. For example, if the valve switching time is too long, this can be considered a problem with valve component wear. Such abnormalities may affect the switching result, and an audio and visual prompt is provided at the valve site to indicate the risk of valve wear and to facilitate local maintenance.

[0159] According to an embodiment of the present invention, starting redundancy control specifically includes:

[0160] Stop the current valve state switching operation and start the obstacle removal procedure;

[0161] Determining whether the obstacle removal procedure can be completed;

[0162] If so, lowering the first confidence information;

[0163] If not, then adjusting the first confidence information upward;

[0164] When the first confidence information exceeds a preset second confidence threshold, the standby valve is automatically switched and a maintenance request is sent.

[0165] It should be noted that in this embodiment, when the fault confidence exceeds a set first confidence threshold, redundant control operations are executed, attempting to self-clear the fault or requesting maintenance to improve the fault tolerance of the instrument / meter valve. When the fault confidence exceeds the set threshold, the valve switching operation is first stopped, and then the fault clearance procedure is initiated, attempting to resolve the fault through the set self-clearing action. If the fault clearance procedure is fully executed, the valve operating condition meets the basic requirements for open / close switching, and the valve fault confidence is lowered. If the fault clearance procedure is not fully executed, the current valve operating condition does not meet the requirements for open / close switching, and the valve fault confidence is raised. When the valve fault confidence exceeds a set second confidence threshold, a maintenance request is immediately issued to improve maintenance efficiency. In addition, in instrument / meter systems with backup valves, the system automatically switches to the backup valve to ensure the operation of the instrument / meter. When the valve fault confidence does not exceed the set second confidence threshold, the valve switching operation is allowed to continue.

[0166] According to an embodiment of the present invention, the first current information of the valve driving chip is dynamically collected, specifically:

[0167] Measure the power supply circuit current of the valve driver chip through a non-contact sensor;

[0168] Wherein, the non-contact sensor is a Hall current sensor;

[0169] Wherein, an electromagnetic shielding layer is provided between the Hall current sensor and the current loop.

[0170] It should be noted that, as an implementation, this embodiment uses a Hall effect current sensor to measure the operating current of the valve driver chip. Using a non-contact sensor to detect the power supply circuit current shields the power supply circuit from its effects on the measurement circuit, improving measurement accuracy. Furthermore, an electromagnetic shielding layer is provided between the Hall effect current sensor and the current circuit to further suppress external electromagnetic interference.

[0171] It is worth mentioning that it also includes:

[0172] Acquire first environmental parameter information, wherein the first environmental information includes at least a temperature value, a humidity value, and an electromagnetic intensity;

[0173] According to the first environmental parameter information, searching a preset weight correspondence table to obtain second weight information;

[0174] The feature model reference value is modified according to the second weight information.

[0175] It should be noted that this embodiment also incorporates environmental parameters (such as temperature, humidity, and electromagnetic intensity) to adaptively adjust the characteristic model reference value. Secondary weight information is determined based on these environmental parameters and used as an adjustment coefficient to modify the characteristic model reference value, further improving the adaptability of the alarm threshold to the valve operating status.

[0176] It is worth mentioning that it also includes:

[0177] Send the historical current data of the valve to the time series prediction model to obtain the first life information;

[0178] When it is determined that the first life information is lower than a preset life threshold, a preventive maintenance request is sent.

[0179] It should be noted that in this embodiment, a time series algorithm (such as ARIMA or LSTM) is used to analyze historical current data during valve switching to predict the remaining service life of the valve. Based on the remaining service life, maintenance recommendations are generated in advance.

[0180] It is worth mentioning that it also includes:

[0181] Sending historical valve current data and maintenance processing logs to a preset fault analysis neural network model to obtain first sensitivity adjustment information;

[0182] According to the first sensitivity adjustment information, the feature model reference value and the confidence threshold are modified.

[0183] It should be noted that in this embodiment, the preset fault analysis neural network model combines historical valve current data and maintenance logs uploaded by maintenance personnel to dynamically optimize the feature model or alarm threshold. It automatically reduces sensitivity after multiple false alarms or improves detection accuracy after missed alarms.

[0184] A third aspect of the present invention provides a computer-readable storage medium, which includes a valve fault self-detection method program based on current detection. When the valve fault self-detection method program based on current detection is executed by a processor, the steps of the valve fault self-detection method based on current detection as described in any one of the above items are implemented.

[0185] In summary, the present invention provides a valve fault self-detection method, system and storage medium based on current detection. First, the working current of the valve drive chip is collected in real time through a non-contact current sensor, and the interference of external signals on the measurement signal is reduced through non-invasive design; secondly, real-time model matching data is obtained by analyzing the current curve, current operating amplitude and instantaneous change rate of current; then, dynamic characteristic model reference data is established based on the historical current data of the valve state switching process to improve the adaptability of the alarm threshold and the valve working state; finally, by comparing the real-time model matching data with the theoretical characteristic model reference data, abnormal conditions are analyzed and identified, and then hierarchical early warning responses or redundant control operations are triggered according to the abnormal conditions; among them, a multi-level early warning mechanism is adopted to reduce invalid warnings and improve the efficiency of equipment maintenance; in addition, the fault tolerance of instrument / meter valve operation is improved through redundant control operations.

[0186] If the functions are implemented as software modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the portion that contributes to the prior art, or the portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes instructions for enabling a computer device (which can be a personal computer, server, or network device, etc.) to perform all or part of the steps of the methods described in various embodiments of the present invention. The aforementioned storage media include various media capable of storing program code, such as USB flash drives, mobile hard drives, read-only memories (ROMs), random access memories (RAMs), magnetic disks, or optical disks.

[0187] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A valve fault self-detection method based on current detection, characterized in that: The method comprises: When judging to send valve control signal; Dynamically collecting first current information of the valve driver chip according to a preset first sampling frequency; Obtaining a first current curve, a first operating amplitude, and a first instantaneous change rate according to the first sampling frequency and the first current information; Performing pattern matching analysis based on the first current curve, the first operating amplitude, and the first instantaneous rate of change to obtain first model matching information; Get the feature model reference value; Acquire first environmental parameter information, wherein the first environmental information includes at least a temperature value, a humidity value, and an electromagnetic intensity; According to the first environmental parameter information, searching a preset weight correspondence table to obtain second weight information; Correcting the feature model reference value according to the second weight information; When it is determined that the first model matching information does not meet the preset parameter conditions; Based on a preset fault classification model, analyzing first model matching information that does not meet preset parameter conditions, obtaining first confidence information and triggering a classification alarm mechanism; When it is determined that the first confidence information exceeds a preset first confidence threshold, starting redundancy control; The first model matching information exceeds the characteristic model reference value, specifically: When the valve state is switched on, the first instantaneous rate of change exceeds the rate of change range set based on the first rising rate of change; When the valve state is switched, the first operating amplitude exceeds the amplitude range set based on the first steady-state amplitude.

2. A valve fault self-detection method based on current detection according to claim 1, characterized in that: Also includes: Obtaining first operation number information of the valve; determining first weight information according to the first running number information; updating a characteristic model reference value based on the current data of the historical operation of the valve and the first weight information; The characteristic model reference value at least includes a first rising change rate in the opening phase, a first steady-state amplitude in the steady-state phase, and a first decay time in the closing phase.

3. A valve fault self-detection method based on current detection according to claim 1, characterized in that: The triggering hierarchical alarm mechanism specifically includes: The graded alarm has at least three levels, including level one warning, level two warning and level three warning; When the first current information exceeds a preset first current threshold, a first-level warning is triggered and log recording is performed; When the first operating amplitude exceeds a preset first steady-state amplitude threshold, a second-level warning is triggered, a status prompt is issued, and the first confidence information is adjusted upward; When it is determined based on the first current curve that the valve state switching duration exceeds a preset first duration threshold, a third-level warning is triggered, a local sound and light prompt is executed, and the first confidence information is adjusted upward.

4. A valve fault self-detection method based on current detection according to claim 1, characterized in that: The starting redundancy control specifically includes: Stop the current valve state switching operation and start the obstacle removal procedure; Determining whether the obstacle removal procedure can be completed; If so, lowering the first confidence information; If not, then adjusting the first confidence information upward; When the first confidence information exceeds a preset second confidence threshold, the standby valve is automatically switched and a maintenance request is sent.

5. The valve fault self-detection method based on current detection according to claim 1, characterized in that: The first current information of the valve driving chip is dynamically collected as follows: Measure the power supply circuit current of the valve driver chip through a non-contact sensor; Wherein, the non-contact sensor is a Hall current sensor; Wherein, an electromagnetic shielding layer is provided between the Hall current sensor and the current loop.

6. A valve fault self-detection system based on current detection, characterized in that: The system includes a memory and a processor. The memory includes a valve fault self-detection method program based on current detection. When the valve fault self-detection method program based on current detection is executed by the processor, the following steps are implemented: When judging to send valve control signal; Dynamically collecting first current information of the valve driver chip according to a preset first sampling frequency; Obtaining a first current curve, a first operating amplitude, and a first instantaneous change rate according to the first sampling frequency and the first current information; Performing pattern matching analysis based on the first current curve, the first operating amplitude, and the first instantaneous rate of change to obtain first model matching information; Get the feature model reference value; Acquire first environmental parameter information, wherein the first environmental information includes at least a temperature value, a humidity value, and an electromagnetic intensity; According to the first environmental parameter information, searching a preset weight correspondence table to obtain second weight information; Correcting the feature model reference value according to the second weight information; When it is determined that the first model matching information does not meet the preset parameter conditions; Based on a preset fault classification model, analyzing first model matching information that does not meet preset parameter conditions, obtaining first confidence information and triggering a classification alarm mechanism; When it is determined that the first confidence information exceeds a preset first confidence threshold, starting redundancy control; The first model matching information exceeds the characteristic model reference value, specifically: When the valve state is switched on, the first instantaneous rate of change exceeds the rate of change range set based on the first rising rate of change; When the valve state is switched, the first operating amplitude exceeds the amplitude range set based on the first steady-state amplitude.

7. A valve fault self-detection system based on current detection according to claim 6, characterized in that: Also includes: Obtaining first operation number information of the valve; determining first weight information according to the first running number information; updating a characteristic model reference value based on the current data of the historical operation of the valve and the first weight information; The characteristic model reference value at least includes a first rising change rate in the opening phase, a first steady-state amplitude in the steady-state phase, and a first decay time in the closing phase.

8. A valve fault self-detection system based on current detection according to claim 6, characterized in that: The starting redundancy control specifically includes: Stop the current valve state switching operation and start the obstacle removal procedure; Determining whether the obstacle removal procedure can be completed; If so, lowering the first confidence information; If not, then adjusting the first confidence information upward; When the first confidence information exceeds a preset second confidence threshold, the standby valve is automatically switched and a maintenance request is sent.

9. A computer-readable storage medium having a computer program stored thereon, characterized in that: The computer-readable storage medium includes a valve fault self-detection method program based on current detection. When the valve fault self-detection method program based on current detection is executed by a processor, the steps of the valve fault self-detection method based on current detection as described in any one of claims 1 to 5 are implemented.

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