Electric actuating mechanism signal feedback replacement device and method

Abstract

The invention belongs to the technical field of electrics, and particularly relates to an electric actuating mechanism signal feedback replacement device and method. Comprising a PLC analog-to-digital conversion module, a current sensor, a power supply, a rectifying device, a current transmitter, a touch screen, a plurality of intermediate relays, a touch screen, an electric actuating mechanism and a remote controller. The method has the beneficial effects that valve signal fault processing can be completed under the condition that the valve does not arrive at the site, equipment functions are recovered, and economic benefits are improved; and meanwhile, personal injury caused by the fact that maintenance personnel enter a severe site can be avoided.

Description

Technical Field

[0001] The present invention belongs to the field of electrical technology, and particularly relates to a signal feedback substitution device and method for an electric actuator. Background Art

[0002] There are various types and a large number of industrial electric actuators. Due to the influence of factors such as personnel skills, on-site environment, and usage frequency, during the actual use process, accidents caused by electric actuator failures account for a large proportion, consuming a large amount of time cost and economic cost. Generally, for valves with failures, on-site treatment methods are adopted to promptly handle defects and ensure the normal functions of the equipment.

[0003] However, due to reasons such as regional restrictions and radiation doses, the maintenance of electric actuators used in harsh environments, such as high temperature, confined spaces, high radiation doses, toxic or explosive hazards, etc., will be severely restricted when failures occur, resulting in the inability to promptly complete the handling of defects and affecting the equipment availability. Especially for electric actuators within the RX area of nuclear power plants, if they need to be processed in the RX area after a failure, but the RX area is strictly controlled during normal operation of the unit, the processing cost is high, and at the same time, personnel have to bear the risk of high-dose irradiation. Summary of the Invention

[0004] The purpose of the present invention is to provide a signal feedback substitution device and method for an electric actuator. Aiming at the defect that the electric actuator must reach the valve on-site for treatment relying on the existing technology, through the substitution of the electric actuator signal, the normal function of the electric actuator is restored, while ensuring the equipment availability, the risk of personal injury to maintenance personnel is reduced.

[0005] The technical solution of the present invention is as follows: A signal feedback substitution device for an electric actuator includes a PLC input / output module, a CPU, an analog-to-digital conversion module, a current sensor, a power supply, a rectification device, a current transmitter, a touch screen, a plurality of intermediate relays, a touch screen, an electric actuator, and a remote controller;

[0006] The rectification device is connected to the power supply to provide power for the PLC input / output module, the analog-to-digital conversion module, the current sensor, and the transmitter;

[0007] The touch screen is connected to the PLC and is used to set a preset valve opening safety time, a preset valve closing safety time, a first preset current value, a second preset current value, a third preset current value, a preset startup time, a preset overload time, and monitor the operating state of the electric actuator;

[0008] The current sensor is connected to the PLC analog-to-digital conversion module and the electric actuator and is used to detect whether current passes through the power supply line of the electric actuator and detect the magnitude of the current;

[0009] The current transmitter is connected to the current sensor and the PLC analog-to-digital conversion module, and is used to convert the current detected by the current sensor into an analog quantity recognizable by the PLC analog-to-digital conversion module for the PLC analog-to-digital conversion module to process;

[0010] The intermediate relay is connected to the PLC input / output module; the current sensor is connected to the power supply cable of the electric actuator, and the detected current is obtained by sensing the working state of the electric actuator; the PLC analog-to-digital conversion module is connected to the current transformer, and the detected current is detected and timed through PLC program processing to obtain the detection time; the remote controller of the electric actuator is respectively connected to the electric actuator and the PLC analog-to-digital conversion module, and is used to send remote control instructions and receive feedback signals.

[0011] The intermediate relay includes a first intermediate relay, a second intermediate relay, a third intermediate relay, a fourth intermediate relay, a fifth intermediate relay, a sixth intermediate relay and a seventh intermediate relay.

[0012] The first intermediate relay is connected to the PLC input / output module, and is used to transmit the opening command issued by the remote controller to the input / output module of the PLC in the form of auxiliary contacts.

[0013] The second intermediate relay is connected to the PLC input / output module, and is used to transmit the closing command issued by the remote controller to the input / output module of the PLC in the form of auxiliary contacts.

[0014] The third intermediate relay is connected to the PLC input / output module, and is used to feedback the opening indication of the electrical panel cabinet, that is, to indicate whether the electric actuator is in the open position on the power supply drawer side.

[0015] The fourth intermediate relay is connected to the PLC input / output module, and is used to feedback the closing indication of the electrical panel cabinet, that is, to indicate whether the electric actuator is in the closed position on the power supply drawer side.

[0016] The fifth intermediate relay is connected to the PLC input / output module, and is used to feedback the remote controller opening indication, that is, to display whether the electric actuator is in the open position on the remote controller screen.

[0017] The sixth intermediate relay is connected to the PLC input / output module, and is used to feedback the main control electric actuator closing indication, that is, to display whether the electric actuator is in the closed position on the remote controller screen.

[0018] The seventh intermediate relay is connected to the PLC input / output module, and is used to feedback the fault state of the electric actuator.

[0019] A method for replacing the signal feedback of an electric actuator, comprising the following steps:

[0020] Step 1: Receive a remote control instruction and obtain a detected current; the receiving of the remote control instruction includes: receiving a remote valve opening control instruction and receiving a remote valve closing control instruction;

[0021] Step 2: After receiving the remote control instruction, a first timer starts timing;

[0022] Step 3: Continuously compare the timing time of the first timer with a preset start time. When the detected current is greater than a first preset current value, judge the state of the electric actuator in the start-up stage, specifically including:

[0023] If the timing time of the first timer is greater than or equal to the preset start time, it indicates that the electric actuator fails in the start-up stage, and a fault alarm is sent;

[0024] If the timing time of the first timer is less than the preset start time, it indicates that the electric actuator is normal in the start-up stage and no signal is sent out;

[0025] Step 4: After the electric actuator starts up normally, judge the state of the electric actuator in the running stage according to the magnitude of the detected current, specifically including:

[0026] When the detected current is greater than the first preset current value, a second timer starts timing. After the detected current is less than the second preset current value, the second timer stops timing;

[0027] When the detected current is greater than the third preset current value, a third timer starts timing. After the detected current is less than the third preset current value, the third timer stops timing;

[0028] Step 5: Determine the state of the electric actuator in the running stage through the detection times obtained by the second timer and the third timer, specifically including the following:

[0029] Step 51: Judge whether the detection time of the third timer is within the preset overload safety time range;

[0030] Step 52: If the detection time of the third timer exceeds the preset overload safety time, the electric actuator fails in the running stage and a fault alarm is sent;

[0031] Step 53: If the detection time of the third timer does not exceed the preset overload safety time, the electric actuator is normal in the running stage and no signal is sent out;

[0032] Step 54: Judge whether the detection time of the second timer is within the preset safety time range;

[0033] The preset safety time includes a preset safety valve opening time and a preset safety valve closing time, and the preset safety time is determined by the stroke distance of the valve stem output of the electric actuator, the rotation speed of the valve motor, the transmission ratio of the transmission mechanism, and the thread pitch of the valve stem, or obtained through multiple valve opening and closing tests;

[0034] Step 55: If the detection time is within the preset safety time range, the electric actuator is normal;

[0035] The determination that the electric actuator is in a normal state by the detection time includes:

[0036] Receive a remote valve opening control instruction, and determine whether the detection time is within the preset safety valve opening time range;

[0037] If the detection time is within the preset safety valve opening time range, the valve opening of the electric actuator is normal;

[0038] Receive a remote valve closing control instruction, and determine that the detection time is within the preset safety valve closing time range;

[0039] If the detection time is within the preset safety valve closing time range, the valve closing of the electric actuator is normal;

[0040] Step 56: If the detection time is not within the preset safety time range, the electric actuator fails, and a fault alarm is sent out;

[0041] Step 6: After determining the state of the electric actuator by the detection time, send the state signal of the electric actuator to the remote controller of the electric actuator.

[0042] The beneficial effects of the present invention are as follows: The present invention can complete the processing of valve signal faults without reaching the valve site, restore the equipment function, and improve economic benefits; at the same time, it can avoid personal injuries caused by maintenance personnel entering harsh sites. Description of the Drawings

[0043] Figure 1 It is a schematic diagram of a signal feedback alternative device for an electric actuator provided by the present invention;

[0044] Figure 2 It is a flowchart of a signal feedback alternative method for an electric actuator provided by the present invention. Detailed Embodiments

[0045] The present invention will be further described in detail below with reference to the drawings and specific embodiments.

[0046] Such as Figure 1As shown, a signal feedback replacement device for an electric actuator includes a PLC input and output module, a CPU, an analog-to-digital conversion module, a current sensor, a power supply, a rectifier, a current transmitter, a touch screen, a plurality of intermediate relays, a touch screen, an electric actuator and a remote controller;

[0047] The power supply is drawn from a 220V, 50Hz AC power supply through a wire to provide or disconnect power for the device.

[0048] The rectifier is connected to the power supply to rectify the 220V, 50Hz AC power supply into 24V DC, which is used to provide power for PLC input and output modules, analog-to-digital conversion modules, current sensors, etc.

[0049] The PLC CPU is the core processing module of this device, which is used to process input signals, detected analog quantities, etc., and calculate according to the built-in algorithm and then output.

[0050] The touch screen is connected to the PLC CPU to set parameters such as the preset valve opening safety time, the preset valve closing safety time, the first preset current value, the second preset current value, the third preset current value, the preset start time, the preset overload time, and monitor the operating status of the electric actuator; the touch screen needs to be configured according to requirements before use.

[0051] The current sensor is connected to the PLC analog-to-digital conversion module and the electric actuator to detect whether current passes through the power supply circuit of the electric actuator and to detect the magnitude of the current.

[0052] The current transmitter is connected to the current sensor and the PLC analog-to-digital conversion module to convert the current detected by the current sensor into an analog quantity recognizable by the PLC analog-to-digital conversion module for processing by the PLC.

[0053] The first intermediate relay is connected to the PLC input-output module and is used to transmit the opening command issued by the remote controller to the input-output module connected to the PLC analog-to-digital conversion module in the form of auxiliary contacts.

[0054] The second intermediate relay is connected to the PLC input-output module and is used to transmit the closing command issued by the remote controller to the input-output module of the PLC analog-to-digital conversion module in the form of auxiliary contacts.

[0055] The third intermediate relay is connected to the PLC input and output module and is used to feedback the opening indication of the electrical panel cabinet, that is, to indicate whether the electric actuator is in the open position on the power supply drawer side.

[0056] The fourth intermediate relay is connected to the PLC input and output module and is used to feed back the closing indication of the electrical panel cabinet, that is, to indicate whether the electric actuator is in the closed position on the power supply drawer side.

[0057] The fifth intermediate relay is connected to the PLC input / output module and is used to feedback the open indication of the remote controller, that is, to display whether the electric actuator is in the open position on the remote controller screen.

[0058] The sixth intermediate relay is connected to the PLC input / output module and is used to feedback the close indication of the remote controller, that is, to display whether the electric actuator is in the closed position on the remote controller screen.

[0059] The seventh intermediate relay is connected to the PLC input / output module and is used to feedback the fault state of the electric actuator.

[0060] The current sensor is connected to the power supply cable of the electric actuator, and the detected current is obtained by sensing the working state of the electric actuator; the PLC analog-to-digital conversion module is connected to the current transformer, and the detected current is detected and timed through the analog-to-digital conversion module and PLC program processing to obtain the detection time; the remote controller of the electric actuator is connected to the PLC and is used to send remote control instructions and receive feedback signals.

[0061] A method for replacing the signal feedback of an electric actuator includes the following steps:

[0062] Step 1: Receive a remote control instruction according to the above replacement device and obtain the detected current; the receiving of the remote control instruction includes: receiving a remote valve opening control instruction and receiving a remote valve closing control instruction.

[0063] Step 2: After the replacement device receives the remote control instruction, the first timer starts timing.

[0064] Step 3: The timing time of the first timer is continuously compared with the preset start time, and the first timer stops timing when the detected current is greater than the first preset current value to judge the state of the electric actuator in the start-up stage. Specifically, it includes:

[0065] The purpose of setting the first preset current value is to use it for timing after the current transformer detects current in the circuit after the electric actuator starts to move. However, considering the interference in the actual on-site environment, the first preset current value is a value greater than zero and must be less than the minimum current when the electric actuator operates normally. It can be adjusted according to the actual situation.

[0066] The preset startup time is set to monitor whether the electric actuator starts normally when it receives the startup command. If it still does not operate after exceeding the preset time, it indicates that the electric actuator has a fault, and this preset time is the preset startup time. The preset startup time is mainly affected by the delay of the remote signal and the action time of the relay and contactor, generally in milliseconds. In actual on-site applications, it can be set within the range of 0.5 - 2 s.

[0067] If the timing time of the first timer is greater than or equal to the preset startup time, it indicates a fault in the electric actuator during the startup stage, and a fault alarm is sent.

[0068] If the timing time of the first timer is less than the preset startup time, it indicates that the electric actuator is normal during the startup stage and no signal is sent out.

[0069] Step 4: After the electric actuator starts normally, judge the state of the electric actuator during the operation stage according to the magnitude of the detected current, specifically including:

[0070] When the detected current is greater than the first preset current value, the second timer starts timing. After the detected current is less than the second preset current value, the second timer stops timing;

[0071] When the detected current is greater than the third preset current value, the third timer starts timing. After the detected current is less than the third preset current value, the third timer stops timing;

[0072] The purpose of setting the second preset current value is that after the electric actuator stops operating and the current transformer detects no current in the circuit, the timing stops. However, considering the interference in the actual on-site environment, the second preset current value is a certain value greater than zero and must be less than the minimum current when the electric actuator operates normally, and it can be adjusted according to the actual situation. When the current transformer detects that the current is lower than the second preset current value, it can be considered that the electric actuator has stopped operating.

[0073] The purpose of setting the third preset current value is to detect the overload current of the electric actuator. When the electric actuator has an overload situation and it still does not disappear after exceeding the preset overload safety time, it is a value set to protect the electric actuator motor. This value should be greater than the rated current of the electric actuator motor and can be adjusted according to the actual situation.

[0074] Step 5: Determine the state of the electric actuator during the operation stage through the detection time obtained by the second timer and the third timer, specifically including the following:

[0075] Step 51: Judge whether the detection time of the third timer is within the preset overload safety time range;

[0076] The preset overload safety time is set by comprehensively considering the electric actuator motor and the start-up time of the electric actuator, and must ensure that the motor can operate safely when subjected to a current value greater than the third preset current value and exceed the start-up time of the electric actuator.

[0077] Step 52: If the detection time of the third timer exceeds the preset overload safety time, the electric actuator fails during the operation phase and a fault alarm is sent;

[0078] Step 53: If the detection time of the third timer does not exceed the preset overload safety time, the electric actuator is normal in the operation phase and does not send any signal;

[0079] Step 54: Determine whether the detection time of the second timer is within a preset safety time range;

[0080] The preset safety time includes a preset safety valve opening time and a preset safety valve closing time. The preset safety time is determined by the valve stem output stroke distance of the electric actuator, the motor speed of the electric actuator, the transmission ratio of the transmission mechanism, and the valve stem thread pitch, or is obtained through multiple valve opening and closing tests.

[0081] Step 55: If the detection time is within the preset safety time range, the electric actuator is normal;

[0082] Determining that the electric actuator is in a normal state by detecting the time includes:

[0083] Receiving a remote valve opening control instruction, and determining whether the detection time is within a preset safe valve opening time range;

[0084] If the detection time is within the preset safety valve opening time range, the electric actuator opens the valve normally;

[0085] Receiving a remote valve closing control instruction, and determining that the detection time is within a preset safety valve closing time range;

[0086] If the detection time is within the preset safety valve closing time range, the electric actuator closes the valve normally;

[0087] Step 56: If the detection time is not within the preset safety time range, the electric actuator fails and a fault alarm is sent.

[0088] Step 6: After the state of the electric actuator is determined through the detection time, a state signal of the electric actuator is sent to the electric actuator remote controller.

[0089] In actual work, the faults of many electric actuators are only problems with signal feedback, and their control and functions are not affected. Therefore, when similar faults occur in electric actuators, using the tool of this patent can not only ensure the availability of the equipment but also prevent maintenance personnel from entering harsh areas and causing personal injuries.

[0090] Refer to Figure 2 , complete the installation of the device and the design and debugging of the corresponding program. The specific implementation process of the signal substitution device for the electric actuator includes:

[0091] S10. Receive a remote control instruction and obtain the detected current

[0092] After the detection starts, the remote controller of the electric actuator issues a remote control instruction, which is sent to both the electric actuator and the PLC at the same time. After receiving the remote control instruction, the electric actuator starts to perform the corresponding action, and after receiving the remote control instruction, the PLC starts to obtain the detected current. The detected current is generated by the current transformer according to the operation of the electric actuator, and the current transformer transmits the detected current to the PLC.

[0093] S20. Start timing when the detected current is greater than the first preset current value. In this embodiment, when the detected current in the current transformer is greater than the first preset current value, the timer starts timing.

[0094] S30. Stop timing when the detected current is less than the second preset current value to obtain the detection time.

[0095] In this embodiment, when the detected current in the current transformer is less than the second preset current value, the timer stops timing. As an option, the second preset current value can be 0. However, in the actual measurement process, considering the interference in the circuit and being unable to ensure that the detected current value is 0, a certain fixed value greater than 0 is set as the second preset current value.

[0096] S40. Determine the state of the electric actuator based on the detection time. The state of the electric actuator includes normal operation of the electric actuator and a fault in the electric actuator.

[0097] S50. If the detection time is within the preset safe time, it indicates that the electric actuator is operating normally.

[0098] S51. When the electric actuator is operating normally, feedback the open or closed position signal of the electric actuator to the drawer and the remote controller through the third, fourth, fifth, and sixth intermediate relays.

[0099] S90. After S10 receives the remote control instruction, if no current greater than the first preset current value is detected within the preset startup time, it indicates that the electric actuator does not respond as expected, indicating that there is a fault in the electric actuator.

[0100] In step S91 and step S20, the PLC has detected that the current is greater than the first preset current value. However, if it is detected that the current is greater than the third preset current value and the duration is greater than the preset overload safety time, it indicates that there is a fault in the electric actuator.

[0101] After step S92 and step S40, if the detection time is not within the preset safety time range, it indicates that the electric actuator is operating abnormally and there is a fault.

[0102] In the case of a fault in the operation of the electric actuator, the fault signal of the electric actuator is fed back through the seventh intermediate relay.

Claims

1. An electric actuator signal feedback replacement device, characterized in that: It includes a PLC input / output module, a CPU, an analog-to-digital conversion module, a current sensor, a power supply, a rectifier device, a current transmitter, a touch screen, multiple intermediate relays, a touch screen, an electric actuator, and a remote controller; The rectifier device is connected to the power supply to provide power for the PLC input / output module, the analog-to-digital conversion module, the current sensor, and the transmitter; The touch screen is connected to the PLC and is used to set the preset valve-opening safety time, the preset valve-closing safety time, the first preset current value, the second preset current value, the third preset current value, the preset start time, the preset overload time, and to monitor the operating state of the electric actuator; The current sensor is connected to the PLC analog-to-digital conversion module and the electric actuator, and is used to detect whether there is current passing through the power supply line of the electric actuator and to detect the magnitude of the current; The current transmitter is connected to the current sensor and the PLC analog-to-digital conversion module, and is used to convert the current detected by the current sensor into an analog quantity recognizable by the PLC analog-to-digital conversion module for the PLC analog-to-digital conversion module to process; The intermediate relay is connected to the PLC input / output module; the current sensor is connected to the power supply cable of the electric actuator, and the detected current is obtained by sensing the working state of the electric actuator; the PLC analog-to-digital conversion module is connected to the current transformer, and the detected current is detected and timed through PLC program processing to obtain the detection time; the remote controller of the electric actuator is respectively connected to the electric actuator and the PLC analog-to-digital conversion module, and is used to send remote control commands and receive feedback signals.

2. The signal feedback substitution device of an electric actuator according to claim 1, characterized in that: The intermediate relay includes a first intermediate relay, a second intermediate relay, a third intermediate relay, a fourth intermediate relay, a fifth intermediate relay, a sixth intermediate relay, and a seventh intermediate relay.

3. The signal feedback replacement device of an electric actuator according to claim 2, wherein: The first intermediate relay is connected to the PLC input / output module and is used to transmit the opening command issued by the remote controller to the PLC input / output module in the form of auxiliary contacts.

4. The signal feedback substitution device of an electric actuator according to claim 2, characterized in that: The second intermediate relay is connected to the PLC input / output module and is used to transmit the closing command issued by the remote controller to the PLC input / output module in the form of auxiliary contacts.

5. The signal feedback substitution device for an electric actuator according to claim 2, wherein: The third intermediate relay is connected to the PLC input / output module and is used to feedback the opening indication of the electrical panel cabinet, that is, to indicate whether the electric actuator is in the open position on the power supply drawer side.

6. The signal feedback substitution device for an electric actuator according to claim 2, characterized in that: The fourth intermediate relay is connected to the PLC input / output module and is used to feedback the closing indication of the electrical panel cabinet, that is, to indicate whether the electric actuator is in the closed position on the power supply drawer side.

7. The signal feedback substitution device for an electric actuator according to claim 2, characterized in that: The fifth intermediate relay is connected to the PLC input / output module and is used to feedback the remote controller opening indication, that is, to display whether the electric actuator is in the open position on the remote controller screen.

8. The signal feedback substitution device for an electric actuator according to claim 2, wherein: The sixth intermediate relay is connected to the PLC input / output module and is used to feedback the remote controller closing indication, that is, to display whether the electric actuator is in the closed position on the remote controller screen.

9. The signal feedback replacement device for an electric actuator according to claim 2, wherein: The seventh intermediate relay is connected to the PLC input / output module and is used to feedback the fault state of the electric actuator.

10. A method of applying a signal feedback substitution device for an electric actuator as claimed in any one of claims 1-9, characterized in that, It includes the following steps: Step 1: Receive a remote control instruction and obtain a detected current; the receiving of the remote control instruction includes: receiving a remote valve opening control instruction and receiving a remote valve closing control instruction; Step 2: After receiving the remote control instruction, a first timer starts timing; Step 3: Continuously compare the timing time of the first timer with a preset startup time. When the detected current is greater than a first preset current value, judge the state of the electric actuator during the startup stage, specifically including: If the timing time of the first timer is greater than or equal to the preset startup time, it indicates that there is a fault in the electric actuator during the startup stage, and a fault alarm is sent; If the timing time of the first timer is less than the preset startup time, it indicates that the electric actuator during the startup stage is normal and no signal is sent out; Step 4: After the electric actuator starts up normally, judge the state of the electric actuator during the operation stage according to the magnitude of the detected current, specifically including: When the detected current is greater than the first preset current value, a second timer starts timing. After the detected current is less than the second preset current value, the second timer stops timing; When the detected current is greater than the third preset current value, a third timer starts timing. After the detected current is less than the third preset current value, the third timer stops timing; Step 5: Determine the state of the electric actuator during the operation stage through the detection times obtained by the second timer and the third timer, specifically including the following: Step 51: Judge whether the detection time of the third timer is within the preset overload safety time range; Step 52: If the detection time of the third timer exceeds the preset overload safety time range, the electric actuator during the operation stage has a fault and a fault alarm is sent; Step 53: If the detection time of the third timer does not exceed the preset overload safety time range, the electric actuator during the operation stage is normal and no signal is sent out; Step 54: Judge whether the detection time of the second timer is within the preset safety time range; The preset safety time includes a preset safety valve opening time and a preset safety valve closing time. The preset safety time is determined by the valve stem output stroke distance of the electric actuator, the valve motor speed, the transmission ratio of the transmission mechanism, and the valve stem thread pitch, or obtained through multiple valve opening and closing tests; Step 55: If the detection time is within the preset safety time range, the electric actuator is normal; The determination that the state of the electric actuator is normal through the detection time includes: Receive a remote valve opening control instruction and judge whether the detection time is within the preset safety valve opening time range; If the detection time is within the preset safety valve opening time range, the valve opening of the electric actuator is normal; Receive a remote valve closing control instruction and judge whether the detection time is within the preset safety valve closing time range; If the detection time is within the preset safety valve closing time range, the valve closing of the electric actuator is normal; Step 56: If the detection time is not within the preset safety time range, the electric actuator has a fault and a fault alarm is sent; Step 6: After determining the state of the electric actuator through the detection time, send the state signal of the electric actuator to the electric actuator remote controller.

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