Pre-diagnosis-based dismounting and taking-out method and system for valve seat of plunger multi-way valve, storage medium and computing equipment

Abstract

A pre-diagnosis-based dismantling and taking-out method for a plunger multi-way valve seat comprises the following steps that tiny vibration is applied to the inner wall of the valve seat, the adhesion type is judged according to the frequency characteristic of a vibration response signal, and a corresponding tension value Fset and target displacement Starget are preset according to the adhesion type; the real-time tension value Freal and the real-time displacement Sreal in the drawing process are collected; dynamically adjusting the output force F (t) of the execution mechanism through a fuzzy PID algorithm; if the valve seat begins to move, the valve seat is pulled out at a constant speed; and when the tension value Freal and the displacement Sreal are detected to change suddenly, a safety protection mechanism is triggered. The invention further discloses a pre-diagnosis-based dismantling and taking-out system for the plunger multi-way valve seat, the adhesion type and strength are recognized through the pre-diagnosis module, auxiliary measures are selected in a targeted mode through setting of fuzzy self-adaptive PID control, the taking-out success rate is increased, and efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the field of plunger multi-way valve seats, and particularly to a pre-diagnosis-based removal method for a plunger multi-way valve seat, its system, storage medium, and computing device. Background Art

[0002] Due to its high control accuracy and stability, the plunger multi-way valve is widely used in the petroleum, chemical, and fine chemical production processes to ensure the continuity and stability of the production process. When impurities or foreign objects are mixed into the conveying medium and the valve is closed, it may cause damage to the valve seat. At this time, the valve seat needs to be removed for maintenance or replacement of spare parts.

[0003] Since the valve seat is cylindrical and tightly embedded in the valve body, there is no place to apply force when removing it. The conventional method is to use a double-headed bolt of appropriate length to support the inner wall, and fix a rope on the bolt to apply an external force to take out the valve seat.

[0004] This method is likely to cause damage to the inner wall of the valve seat; secondly, the valve seat fits tightly with the valve body. Due to long-term operation, medium erosion, etc., the friction force between the valve seat and the valve body will increase, and it may be difficult to remove the valve seat, or even impossible to remove it; the valve seat jamming is usually caused by corrosion, sediment, or thermal deformation, but the traditional method can only be dealt with after the failure occurs. Existing tools lack the ability to predict the adhesion state, and only use post-treatments such as pickling and heating after the pulling fails, resulting in low efficiency. Summary of the Invention

[0005] In order to overcome the above deficiencies of the prior art, the present invention provides a pre-diagnosis-based removal method for a plunger multi-way valve seat to solve the problem of low efficiency in removing the plunger multi-way valve seat.

[0006] Another object of the present invention is to provide a removal system for a plunger multi-way valve seat.

[0007] Another object of the present invention is to provide a storage medium.

[0008] Another object of the present invention is to provide a computing device.

[0009] The object of the present invention is achieved by the following technical solutions:

[0010] A pre-diagnosis-based removal method for a plunger multi-way valve seat includes the following steps:

[0011] (1) Apply a small vibration to the inner wall of the valve seat, judge the adhesion type according to the frequency characteristics of the vibration response signal, and preset the corresponding pulling force value F set and target displacement S target ;

[0012] (2) Collect the real-time tensile force value F during the pulling process. real and the real-time displacement S real ;

[0013] (3) Dynamically adjust the output force F(t) of the actuator through the fuzzy PID algorithm;

[0014] (4) Gradually increase the tensile force. If the valve seat starts to move, pull it out at a constant speed;

[0015] (5) When the detected tensile force value F real and the displacement S real mutate, trigger the safety protection mechanism.

[0016] Preferably, in step (1), the vibration frequency is 10 - 50 Hz.

[0017] Preferably, in step (3), the calculation formula for controlling the output force F(t) is as follows:

[0018]

[0019] where e(t) = S target - S real .

[0020] Preferably, in step (1), when it is determined as high-risk adhesion, use heating or ultrasonic assistance.

[0021] Preferably, high-risk adhesion means that the adhesion strength coefficient C > 0.8, and the calculation formula for the adhesion strength coefficient C is as follows:

[0022]

[0023] A pre-diagnosis-based removal and extraction system for the valve seat of a plunger multi-way valve, comprising:

[0024] Pre-diagnosis module: used to apply a small vibration to the inner wall of the valve seat, judge the adhesion type, and preset the corresponding tensile force value F according to the adhesion type set ;

[0025] Integrated sensing module: used to collect the tensile force value F in real time during the pulling process real and the displacement S real ;

[0026] Controller: used to dynamically adjust the output force F(t) of the actuator through the fuzzy PID algorithm;

[0027] Actuator: used to gradually increase the tensile force. If the valve seat starts to move, pull it out at a constant speed;

[0028] Safety protection module; used when the detected tensile force value F real and the displacement Sreal When a mutation occurs, the safety protection mechanism is triggered.

[0029] Preferably, the actuator includes a locking screw, a vertical plate and a jack, the jack is located between the vertical plates, the locking screw passes through the vertical plate, the end of the locking screw has a raised top block that is wedged into the notch in the valve seat, and the raised top block is connected to the valve seat.

[0030] Preferably, the prognostic module comprises a vibration responsive sensor.

[0031] Preferably, the integrated sensing module includes a force sensor and a displacement sensor.

[0032] Preferably, the controller receives the feedback signal from the sensor module, has a built-in adaptive control algorithm, and dynamically calculates the target tension adjustment amount ΔF;

[0033] The present invention has the following advantages and beneficial effects compared with the prior art:

[0034] (1) The present invention identifies the adhesion type and strength through a pre-diagnosis module and selects auxiliary measures in a targeted manner, thereby improving not only the removal success rate but also the efficiency.

[0035] (2) Setting of fuzzy adaptive PID control, inputting the diagnosis and pre-diagnosis results into the PID controller, dynamically optimizing the control parameters, and setting the maximum output force to avoid overload damage.

[0036] (3) The safety protection module brakes promptly at the initial stage of slippage (such as within 0.5 mm of sudden displacement) to avoid material waste and equipment idling. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 It is a flow chart of a method for removing and taking out a valve seat of a plunger multi-way valve based on pre-diagnosis according to the present invention;

[0038] Figure 2 It is a structural schematic diagram of the actuator of the present invention;

[0039] Figure 3 It is a schematic diagram of the structure of the raised top block in the actuator of the present invention;

[0040] The markings of the components in the accompanying drawings:

[0041] 1-locking screw, 2-jack, 3-vertical plate, 4-raised top block. DETAILED DESCRIPTION

[0042] The purpose of the present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments. The embodiments cannot be described one by one here, but the implementation mode of the present invention is not therefore limited to the following embodiments.

[0043] Embodiment 1

[0044] A method for removing a plunger multi-way valve seat based on pre-diagnosis, comprising the following steps:

[0045] (1) Apply a small vibration to the inner wall of the valve seat, with a vibration frequency of 10 - 50 Hz and an amplitude < 0.1 mm. Determine the adhesion type according to the frequency characteristics of the vibration response signal, and preset the corresponding tensile force value F set and the target displacement S target ;

[0046] (2) Real-time collect the real-time tensile force value F real and the real-time displacement S real ;

[0047] (3) Dynamically adjust the output force F(t) of the actuator through the fuzzy PID algorithm. The PDI controller monitors the tensile force uniformity throughout the process and automatically corrects it when the deviation is too large; Set the maximum safe tensile force, and the calculation formula for the maximum safe tensile force is:

[0048] Maximum tensile force = 0.7 × material strength × cross-sectional area of the valve seat wall.

[0049] (4) Gradually increase the tensile force. If the valve seat starts to move, pull it out at a constant speed;

[0050] (5) When the tensile force value F real and the displacement S real mutate, trigger the safety protection mechanism

[0051] The specific steps for determining the adhesion type according to the frequency characteristics of the vibration response signal in step (1) are as follows:

[0052] When the main frequency peak is located at 100 - 200 Hz, it is determined as corrosion adhesion;

[0053] When the main frequency peak is located at 300 - 500 Hz, it is determined as sediment adhesion;

[0054] When the adhesion strength coefficient C > 0.8, it is determined as high-risk adhesion, and auxiliary means such as heating or ultrasonic waves are required. The calculation formula for the adhesion strength coefficient C is as follows:

[0055]

[0056] In step (3), the output force F(t) of the actuator is dynamically adjusted through the fuzzy PID algorithm:

[0057]

[0058] Among them, e(t) = S target -S real ;

[0059] According to the tensile force error e(t) = S target -S real and the error change rate dynamically adjust the PID parameters K p , K i , K d

[0060] When the instantaneous speed of S real exceeds the set range, reduce the proportional gain K p and increase the derivative gain K d .

[0061] Embodiment 2

[0062] A plunger multi-way valve seat removal and extraction system, comprising:

[0063] Pre-diagnosis module: including a vibration response sensor, used to apply a small vibration to the inner wall of the valve seat, judge the adhesion type, and preset the corresponding tensile force value F according to the adhesion type sct ;

[0064] Integrated sensing module: containing a force sensor and a displacement sensor, used to collect the tensile force value F real and the displacement S real ;

[0065] The force sensor is a ring array force sensor to monitor the circumferential stress distribution of the valve seat in real time and prevent local overload; the force sensor is a piezoelectric sensor and is installed at the clamping end of the actuator

[0066] Controller: receives the feedback signal of the sensing module, has an adaptive control algorithm built-in, and dynamically calculates the target tensile force adjustment amount ΔF;

[0067] The controller is a fuzzy adaptive PID controller, dynamically adjusts the output force curve according to the stress-displacement feedback, increases the integral weight in the adhesion stage (high friction) to maintain a continuous tensile force, and switches to the derivative-dominated mode at the detachment critical point (displacement mutation) to suppress oscillation;

[0068] Actuator: used to gradually increase the tensile force and pull out at a constant speed if the valve seat starts to move;

[0069] The actuator includes 2 locking screws (1), 2 vertical plates (3) and 2 jacks (2). The 2 jacks (2) are respectively located between the vertical plates (3). The locking screws (1) pass through the vertical plates (3) through the holes opened in the middle of the vertical plates (3). The end of the locking screw (1) has a convex top block (4) that fits the inner notch of the valve seat. The convex top block (4) is connected to the valve seat, and the convex top block (4) contains a vibration response sensor.

[0070] Safety protection module; used to trigger the safety protection mechanism when the detected tensile force value F rea1 and displacement S real mutate.

[0071] The above specific implementation manners are the preferred embodiments of the present invention and cannot limit the present invention. Any other changes or other equivalent replacement manners made without departing from the technical solution of the present invention are included in the protection scope of the present invention.

Claims

1. A method for removing a valve seat of a plunger multi-way valve based on pre-diagnosis, characterized in that, It includes the following steps: (1) Apply a small vibration to the inner wall of the valve seat, judge the adhesion type according to the frequency characteristics of the vibration response signal, and preset the corresponding tensile force value F set and the target displacement S target ; (2) Collect the real-time tensile force value F during the pulling process real and the real-time displacement S real ; (3), Dynamically adjust the output force F(t) of the actuator through the fuzzy PID algorithm; (4), Gradually increase the pulling force. If the valve seat starts to move, pull it out at a constant speed; (5) When the detected tensile force value F real and the displacement S real mutate, trigger the safety protection mechanism.

2. The method for removing the valve seat of the plunger multi-way valve based on pre-diagnosis according to claim 1, wherein In step (1), the vibration frequency is 10 - 50 Hz.

3. The method for removing the multi-way valve seat of the plunger based on pre-diagnosis according to claim 1, characterized in that In step (3), the calculation formula of the output force F(t) is as follows: where e(t) = S target -S real .

4. The method for removing and taking out the plunger multi-way valve seat based on pre-diagnosis according to claim 1, characterized in that In step (1), when it is judged as high-risk adhesion, use heating or ultrasonic assistance.

5. A method for removing and taking out a valve seat of a plunger multi-way valve based on pre-diagnosis according to claim 4, characterized in that, High-risk adhesion means that the adhesion strength coefficient C > 0.

8. The calculation formula of the adhesion strength coefficient C is as follows:

6. A pre-diagnosis-based removal system for a valve seat of a plunger multi-way valve, characterized in that, It includes: Pre-diagnosis module: used to apply a small vibration to the inner wall of the valve seat, determine the adhesion type, and preset the corresponding tensile force value F according to the adhesion type set and the target displacement S target ; Integrated sensing module: used to collect the real-time pulling force value F during the pulling process real and the real-time displacement S real ; Controller: Used to dynamically adjust the output force F(t) of the actuator through the fuzzy PID algorithm; Actuator: Used to gradually increase the pulling force. If the valve seat starts to move, pull it out at a constant speed; Safety protection module; used to trigger a safety protection mechanism when a sudden change in the pulling force value F real and the displacement amount S real is detected.

7. The pre-diagnosis-based removal system for the plunger multi-way valve seat according to claim 6, characterized in that, The actuator includes a locking screw (1), a vertical plate (3) and a jack (2). The jack (2) is located between the vertical plates (3). The locking screw (1) passes through the vertical plate (3). The end of the locking screw (1) has a convex top block (4) that fits with the notch inside the valve seat. The convex top block (4) is connected to the valve seat.

8. A storage medium, characterized in that, It stores a program. When the program is executed by the processor, it realizes a method for removing and taking out the valve seat of a plunger multi-way valve based on pre-diagnosis described in any one of claims 1 - 5.

9. A computing device, characterized in that, It includes a processor and a memory for storing programs executable by the processor. When the processor executes the program stored in the memory, it realizes a method for removing and taking out the valve seat of a plunger multi-way valve based on pre-diagnosis described in any one of claims 1 - 5.

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