Sequence control valve jamming monitoring method and system, electronic equipment and storage medium

Abstract

The invention relates to a program control valve jamming monitoring method and system, electronic equipment and a storage medium. The method comprises the following steps that monitoring data of a valve opening and closing mechanism are obtained; preprocessing the monitoring data to obtain a jam judgment data set; calculating a jerk equivalent corresponding to the data in the jam judgment data set; judging a jerk interval to which the jerk equivalent belongs; and matching the jam grade corresponding to the jerk interval to which the jerk interval belongs. According to the invention, by defining different jamming degree grades, quantitative detection of the smooth degree of the valve action is realized; different processing schemes are provided according to different output jam levels, low-level jam does not need to be concerned, alarm information is sent to high-level jam, and related personnel are reminded to process the jam in time; and in combination with the residual service life prediction model, regarding the jamming level as a key variable of the residual service life prediction model, and calculating the residual service life, so that the residual service life of the valve can be monitored in real time for guiding safe and stable operation of a fluid system.

Description

Technical Field

[0001] The present invention relates to the technical field of valve jamming monitoring, and particularly relates to a method, a system, an electronic device and a storage medium for monitoring the jamming of a programmed valve. Background Art

[0002] As one of the key devices in an industrial system, if an abnormal jam or a fault occurs during the operation of a remotely controlled valve, it will cause a sequential control interlock fault. In severe cases, the valve being jammed will lead to an emergency shutdown of the entire system, which will not only cause economic losses, but may even trigger a safety accident in extreme cases.

[0003] Currently, the method for determining valve jamming is to calculate the signal sending and feedback time through the DCS system and limit switches, and evaluate the degree of valve jamming based on the change in time. The on-off signals transmitted by the limit switches on the market can only represent three physical quantities of the valve: 0 - closed in place, 1 - opened in place, t - time (recorded by the system), and based on this, the operating state of the valve is roughly determined. For example, for a valve of a certain specification at a certain work station, the DCS system requires it to be switched on and off in place within 10S, and the initial switch time of the valve when it leaves the factory is 5S. During use, as the valve performance deteriorates, the switch time will become longer. Relevant personnel determine the operating state and the degree of jamming of the valve based on the change in the valve switch time.

[0004] However, there is no inevitable connection between the extension of the valve switch time and whether the valve is jammed. Changes in pipeline pressure, air source pressure, etc. will all affect the valve switch time. Therefore, the above-mentioned scheme for evaluating the valve fault situation through the overall valve switch time cannot accurately reflect the jamming fault and the severity of the fault in a specific stroke during the valve switching process, and it is easy to miss judging the fault; at the same time, it is impossible to directly monitor the transient changes in the motion characteristics during the valve switching process, and it is not sensitive to the jamming fault occurring at a certain stroke point during the valve switching process, making it difficult to achieve the transient evaluation and rapid diagnostic identification of the valve jamming fault; in addition, it is also difficult to give suggestions for solving the jamming fault and predict the remaining service life, to achieve the early prevention of the jamming fault, insight into the health status of the valve, and timely and accurate maintenance and repair of the fluid system. Summary of the Invention

[0005] In order to achieve the above objects and other advantages of the present invention, the first object of the present invention is to provide a method for monitoring the jamming of a programmed valve, including the following steps:

[0006] Obtain the monitoring data of the valve opening and closing mechanism, where the monitoring data includes the linear displacement and / or angular displacement of the valve opening and closing mechanism;

[0007] Preprocess the monitoring data to obtain a jamming determination data set;

[0008] Calculate the jerk equivalent corresponding to the data in the jamming determination data set;

[0009] Determine the jerk interval to which the jerk equivalent belongs;

[0010] Match the jamming level corresponding to the jerk interval to which it belongs.

[0011] Further, the following steps are also included:

[0012] Input the jamming level and the relevant parameters of the program-controlled valve into the prediction model of the remaining service life of the program-controlled valve to obtain the prediction result of the remaining service life of the program-controlled valve.

[0013] Further, before the step of preprocessing the monitoring data, the following steps are also included:

[0014] Obtain the working process of the program-controlled valve, and the working process includes an opening process and a closing process;

[0015] Judge whether the monitoring data reaches the threshold corresponding to the working process;

[0016] If the monitoring data does not reach the threshold corresponding to the working process, determine the jamming level as the stuck level, and execute the step of inputting the jamming level and the relevant parameters of the program-controlled valve into the prediction model of the remaining service life of the program-controlled valve.

[0017] Further, before the step of preprocessing the monitoring data, the following steps are also included:

[0018] Filter the theoretical monitoring data volume from the monitoring data;

[0019] If the number of the same monitoring data volume in the filtered theoretical monitoring data volume reaches the threshold, determine the jamming level as the stuck level, and execute the step of inputting the jamming level and the relevant parameters of the program-controlled valve into the prediction model of the remaining service life of the program-controlled valve.

[0020] Further, calculating the jerk equivalent corresponding to the data in the jamming determination data set is to perform a third-order differentiation of the data in the jamming determination data set with respect to time to obtain the jerk equivalent.

[0021] Further, the construction of the jerk interval includes the following steps:

[0022] Divide the working process of the program-controlled valve into multiple stages, and the working process includes an opening process and a closing process;

[0023] Set the monitoring data interval for each stage corresponding to the working process;

[0024] Perform a third-order differentiation of the theoretical monitoring data volume with respect to time to calculate the theoretical jerk;

[0025] Divide the theoretical jerk into multiple stage jerks according to the monitoring data intervals corresponding to each stage of the working process;

[0026] Set the jerk threshold corresponding to each stage jerk;

[0027] Calculate the product of the jerk threshold and the initial endpoint values of several jerk intervals to obtain the final endpoint values of the jerk intervals, forming several jerk interval ranges;

[0028] Associate the jerk interval ranges with the jamming levels.

[0029] Further, the steps for determining the jerk interval to which the jerk equivalent belongs include the following:

[0030] Obtain the current working process of the program-controlled valve;

[0031] Determine the stage to which the data in the jamming determination dataset belongs under the current working process of the program-controlled valve;

[0032] Match the stage jerk corresponding to the stage to which the data in the jamming determination dataset belongs;

[0033] Obtain the jerk threshold corresponding to the matched stage jerk;

[0034] Match the several jerk interval ranges corresponding to the obtained jerk threshold;

[0035] Determine the jerk interval range to which the jerk equivalent belongs.

[0036] Further, the steps for matching the jamming level corresponding to the jerk interval to which it belongs include the following;

[0037] Match the corresponding jamming level according to the jerk interval range to which the jerk equivalent belongs;

[0038] Find the number of the maximum jamming levels of each stage jerk;

[0039] If the number of the maximum jamming levels of each stage jerk is greater than or equal to the threshold, determine that the jamming level of the current stage jerk is the maximum jamming level of each stage jerk found;

[0040] If the number of the maximum jamming levels of each stage jerk is less than the threshold, determine that the jamming level of the current stage jerk is the maximum jamming level of each stage jerk found minus one;

[0041] Obtain the maximum value of the jamming levels of all stage jerks as the final jamming level.

[0042] Further, the jamming level includes a completely unjammed level, a slightly jammed level, a micro-jammed level, a moderately jammed level, a severely jammed level, and a jammed-to-death level;

[0043] The recommended treatment plans corresponding to the completely unjammed level, the slightly jammed level, and the micro-jammed level are to be ignored. The recommended treatment plan corresponding to the moderately jammed level is to maintain attention. The recommended treatment plans corresponding to the severely jammed level are to closely monitor, wait for an opportunity to replace or immediately replace, and immediately rush to repair. The recommended treatment plan corresponding to the jammed-to-death level is to urgently rush to repair.

[0044] Further, before inputting the jamming level and the relevant parameters of the programmable control valve into the prediction model of the remaining service life of the programmable control valve, the following steps are also included:

[0045] If the jamming level is the jammed-to-death level, it is determined that the remaining service life of the programmable control valve is 0;

[0046] If the jamming level is a non-jammed-to-death level, execute the step of inputting the jamming level and the relevant parameters of the programmable control valve into the prediction model of the remaining service life of the programmable control valve.

[0047] Further, the relevant parameters of the programmable control valve include the initial service life, the pressure level, the medium hardness, and the corrosion coefficient.

[0048] Further, the construction of the prediction model of the remaining service life of the programmable control valve includes the following steps:

[0049] Obtain the initial service life, the pressure level, the medium hardness, the corrosion coefficient, the jamming level, and the remaining service life in the training set;

[0050] Use the initial service life, the pressure level, the medium hardness, the corrosion coefficient, and the jamming level as inputs and the remaining service life as the output to train the neural network model, and obtain the trained prediction model of the remaining service life of the programmable control valve.

[0051] Further, the following steps are also included:

[0052] Send the GPS positioning information and the jamming warning information to the user; wherein, the jamming warning information includes the equipment name, the jamming level, the recommended treatment plan corresponding to the jamming level, the remaining service life, and the occurrence time.

[0053] Further, the preprocessing of the monitoring data includes resampling the monitoring data.

[0054] The second object of the present invention is to provide an electronic device, including: a memory on which program code is stored; a processor, which is connected to the memory, and when the program code is executed by the processor, the wrist fracture rehabilitation training action recognition method is implemented.

[0055] The third object of the present invention is to provide a computer-readable storage medium, on which program instructions are stored, and when the program instructions are executed, a wrist fracture rehabilitation training action recognition method is implemented.

[0056] The fourth object of the present invention is to provide a program-controlled valve jamming monitoring system for implementing the above method, including a monitoring data collector, a PCB circuit board and an integrated chip, a signal transmitter, and a cloud server;

[0057] The monitoring data collector is used to collect monitoring data of the valve opening and closing mechanism, and the monitoring data includes the linear displacement and / or angular displacement of the valve opening and closing mechanism;

[0058] The PCB circuit board and the integrated chip are used to preprocess the monitoring data to obtain a jamming determination data set; calculate the jerk equivalent corresponding to the data in the jamming determination data set; determine the jerk interval to which the jerk equivalent belongs; match the jamming level corresponding to the belonging jerk interval;

[0059] The signal transmitter is used to send GPS positioning and jamming warning information to the cloud server;

[0060] The cloud server is used to send GPS positioning and jamming warning information to customers.

[0061] Compared with the prior art, the beneficial effects of the present invention are:

[0062] The present invention provides a program-controlled valve jamming monitoring method, system, electronic device and storage medium, which can accurately reflect the jamming fault and the severity of the fault on a specific section of the valve opening and closing process, and there will be no missed judgment of the fault; at the same time, it can directly monitor the transient changes of the motion characteristics during the valve opening and closing process, is sensitive to the jamming fault occurring at a certain stroke point during the valve opening and closing process, and can realize the transient evaluation and rapid diagnosis and identification of the valve jamming fault; in addition, it can also give suggestions for solving the jamming fault and predict the remaining service life, realize the early prevention of the jamming fault, insight into the health status of the valve, and timely and accurately maintain and repair the fluid system.

[0063] The present invention realizes quantitative detection of the smoothness of valve operation by defining different degrees of jamming levels; for different jamming levels output, different treatment schemes are provided. Jamming at a low level does not need to be concerned about, while jamming at a high level sends an alarm message to remind relevant personnel to handle it in time, improving the reliability of the jamming monitoring of the program-controlled valve, contributing to the realization of early real-time monitoring and diagnosis of valve jamming, facilitating popularization and application, and thus ensuring the stable and safe operation of the fluid system, avoiding the occurrence of unplanned shutdown conditions, and can provide advanced warnings of valve jamming to avoid the further development of the severity of accidents; combined with the remaining service life prediction model, regarding the jamming level as a key variable of the remaining service life prediction model, calculating the remaining service life can realize real-time monitoring of the remaining service life of the valve and is used to guide the safe and stable operation of the fluid system; in addition, the remaining service life prediction model of the present invention simultaneously combines the initial service life, pressure level, medium hardness, and corrosion coefficient for calculation, and the reliability of the prediction result is much higher than the calculation method of the remaining service life obtained under the condition of traditional single factors.

[0064] The above description is only an overview of the technical solution of the present invention. In order to be able to understand the technical means of the present invention more clearly and to be implemented in accordance with the content of the description, the following takes the preferred embodiments of the present invention and combines the accompanying drawings to describe in detail as follows. The specific implementation manners of the present invention are given in detail by the following embodiments and their accompanying drawings. Brief Description of the Drawings

[0065] The drawings described herein are used to provide a further understanding of the present invention, form a part of this application, and the illustrative embodiments and descriptions of the present invention are used to explain the present invention and do not constitute an improper limitation to the present invention. In the drawings:

[0066] Figure 1 It is a flowchart of the jamming monitoring method for the program-controlled valve in Embodiment 1;

[0067] Figure 2 It is the initial judgment process of the monitoring data in Embodiment 1 Figure 1 ;

[0068] Figure 3 It is the initial judgment process of the monitoring data in Embodiment 1 Figure 2 ;

[0069] Figure 4 It is a flowchart of the construction of the jerk interval in Embodiment 1;

[0070] Figure 5 It is a flowchart of judging the jerk interval to which the jerk equivalent belongs in Embodiment 1;

[0071] Figure 6 It is a flowchart of matching the jamming level corresponding to the jerk interval to which it belongs in Embodiment 1;

[0072] Figure 7 The initial judgment flowchart for predicting the remaining service life of the program-controlled valve in Embodiment 1;

[0073] Figure 8 The flowchart for constructing the prediction model of the remaining service life of the program-controlled valve in Embodiment 1;

[0074] Figure 9 The schematic diagram of the second-level jamming jerk in Embodiment 1;

[0075] Figure 10 The schematic diagram of the second-level jamming in Embodiment 1;

[0076] Figure 11 The schematic diagram of the third-level jamming jerk in Embodiment 1;

[0077] Figure 12 The schematic diagram of the third-level jamming in Embodiment 1;

[0078] Figure 13 The schematic diagram of the fourth-level jamming jerk in Embodiment 1;

[0079] Figure 14 The schematic diagram of the fourth-level jamming in Embodiment 1;

[0080] Figure 15 The schematic diagram of the user terminal receiving the jamming warning information in Embodiment 1;

[0081] Figure 16 The schematic diagram of the prediction model of the remaining service life of the program-controlled valve in Embodiment 1;

[0082] Figure 17 The schematic diagram of the electronic device in Embodiment 2;

[0083] Figure 18 The schematic diagram of the storage medium in Embodiment 3;

[0084] Figure 19 The schematic diagram of the program-controlled valve jamming monitoring system in Embodiment 4. Detailed implementation manners

[0085] Next, in combination with the accompanying drawings and specific implementation manners, the present invention will be further described. It should be noted that, on the premise of no conflict, any combination can be formed among the following-described embodiments or technical features to form a new embodiment.

[0086] Embodiment 1

[0087] A method for monitoring the jamming of a program-controlled valve, as Figure 1 shown, includes the following steps:

[0088] S1. Obtain the monitoring data of the valve opening and closing mechanism. The monitoring data includes the linear displacement and / or angular displacement of the valve opening and closing mechanism. Among them, the acquisition of the monitoring data adopts the non-electric quantity electrical measurement method, and the linear displacement and / or angular displacement are measured by a linear displacement sensor and / or an angular displacement sensor respectively.

[0089] S2. Preprocess the monitoring data to obtain a sticking judgment data set. Specifically, in order to uniformly judge the sticking level of the valve during different opening or closing processes, the data imbalance problem needs to be solved first.

[0090] Under the same sampling frequency, due to the different opening and closing times of valves under different working conditions and different specifications, there are also differences in the opening and closing times of valves of the same specification. Therefore, the number of elements in the angular displacement data set collected by the angular displacement sensor or the linear displacement data set collected by the linear displacement sensor is different. There may be a situation where the number of elements in one or some data sets is much larger than that in other data sets, that is, data imbalance. In order to make a unified judgment, the imbalance of the data can be reduced by resampling the data set. For example: oversample the data set with fewer elements (such as the number of elements less than N / 2, where N is the number of elements preset according to the actual situation) to increase the number of data in the data set, that is, add copies of some data, and the number of samples is greater than the number of data in this data set; undersample the data set with more elements (such as the number of elements greater than N / 2, where N is the number of elements preset according to the actual situation) to reduce the number of data in the data set, that is, delete some data, and the number of samples is less than the number of data in this data set. The above sampling algorithm is easy to implement, has a fast running speed, and a good data balancing effect. It should be noted that in the above sampling process, two sampling methods of random sampling and non-random sampling can be used, different sampling ratios can also be used for each data set, and oversampling and undersampling can also be used at the same time. By resampling the data set, the sticking judgment method is unified.

[0091] The possible factors for the sticking of the program-controlled valve include: the sealing surface is scoured and eroded, and the friction between the sealing pairs increases locally; the bearing is worn, resulting in local resistance; the valve stem is worn, resulting in local resistance; the structural deformation caused by temperature affects, resulting in local resistance; the medium adheres to the opening and closing parts, resulting in local resistance. Summarizing the above possible factors, it can be concluded that the sudden change of local resistance during the valve opening and closing process causes the valve to stick.

[0092] According to the transient dynamics analysis, the motion acceleration of the programmed control valve is proportional to the resultant force it receives; among them, the resultant force received by the programmed control valve is the resultant force of the driving force and the resistance. From the above analysis, it can be seen that the transient change of the force state of the programmed control valve will be directly reflected in the change of acceleration. For the programmed control valve, the driving force generally does not change suddenly during its opening and closing processes. If the resultant force it receives changes suddenly, it mainly reflects the sudden change of the resistance, which can be monitored by the speed of the acceleration change, that is to say, it can be monitored by the jerk.

[0093] Among them, the jerk, also known as the force change rate, is the change rate of acceleration, that is, the third-order derivative of the position vector with respect to time. The jerk can reflect the smoothness of the force change. The closer the value of the jerk is to zero, the smoother the force change is and the better the stability of the force state is. Therefore, by monitoring the change of the jerk, it is possible to master the speed of the transient resultant force change during the movement of the opening and closing mechanism of the programmed control valve and to identify its motion characteristics more clearly.

[0094] S3. Calculate the jerk equivalent corresponding to the data in the jamming determination dataset; usually, the speed, acceleration, and jerk are obtained by differentiating and calculating the data in the jamming determination dataset respectively. Specifically,

[0095] Perform a first-order differential calculation on the obtained dataset (b1, b2, b3... b q ) with respect to time to obtain the speed equivalent, (c1, c2, c3... c q-1 ): c q-1 = |b q - b q-1 |;

[0096] Perform a second-order differential calculation on the obtained dataset (b1, b2, b3... b q ) with respect to time to obtain the acceleration equivalent, (d1, d2, d3... d q-2 ): d q-2 = |c q-1 - c q-2 |;

[0097] Perform a third-order differential calculation on the obtained dataset (b1, b2, b3... b q ) with respect to time to obtain the jerk equivalent, (e1, e2, e3... e q-3 ): e q-3 = |d q-2 - d q-3 |.

[0098] S4. Determine the jerk interval to which the jerk equivalent belongs.

[0099] Considering that during the opening and closing processes of the valve, the motion characteristics of the valve are different at different stages. For example, the opening speed, stability, pressure difference, etc. are dynamically changing, that is, there are significant differences. For example, in the first stage and the third stage of the opening process of a certain valve, the opening speed is slow, the stability is poor, and the pressure difference is large. In the second stage, the opening speed is fast, the stability is good, and the pressure difference is small. In order to monitor the jamming faults at different stages during the opening and closing processes of the valve more accurately and intelligently. Among them, the construction of the jerk interval includes the following steps:

[0100] S401. Divide the working process of the program-controlled valve into multiple stages, and the working process includes the opening process and the closing process. In this embodiment, the above-mentioned multiple stages include the first stage, the second stage, and the third stage;

[0101] S402. Set the monitoring data interval for each stage corresponding to the working process; the first stage, the second stage, and the third stage can be set respectively during each opening process or closing process of the program-controlled valve. For example, during the opening process, the preset ranges of the monitoring data for the first stage, the second stage, and the third stage are set respectively, and the preset ranges of the monitoring data for each stage can be adjusted at any time according to actual needs. Taking the angle interval as an example, the angle interval of the first stage can be set as A1~A2, the angle interval of the second stage can be set as A2~A3, and the angle interval of the third stage can be set as A3~A4. In this embodiment, A1, A2, A3, and A4 are all non-negative numbers, and A1<A2<A3<A4. During the closing process, the preset ranges of the monitoring data for the first stage, the second stage, and the third stage are set respectively. Taking the angle interval as an example, the angle interval of the first stage can be set as A3~A4, the angle interval of the second stage can be set as A2~A3, and the angle interval of the third stage can be set as A1~A2.

[0102] S403. Perform a third-order differential of the theoretical monitoring data volume with respect to time to calculate the theoretical jerk; among them, the theoretical monitoring data can be several high-frequency monitoring data summarized from experiments or several high-frequency monitoring data simulated by software. Through the theoretical monitoring data volume, the physical process of the valve opening and closing can be reproduced, and data analysis of the jamming faults during the valve opening and closing process can be realized, and the simulation of the jamming change trend is more in line with the actual situation. Among them, taking the theoretical angle as an example, the theoretical angle can be (2.9, 3.6, 4.4, 5.4,..., 85.8), and perform a third-order differential of the theoretical angle with respect to time to calculate the theoretical jerk as (0.2, 0.4, 0.4, 0.1,...,0.0).

[0103] S404. Divide the theoretical jerk into multiple stage jerks according to the monitoring data intervals of each stage corresponding to the working process, that is, there is a corresponding relationship between the stage jerk and the stages divided during the opening process or closing process of the program-controlled valve. In this embodiment, the multiple stage jerks include a first stage jerk, a second stage jerk, and a third stage jerk;

[0104] S405. Set the jerk threshold w corresponding to each stage jerk; for example, the threshold of the first stage jerk can be set to w1, the threshold of the second stage jerk can be set to w2, and the threshold of the third stage jerk can be set to w3. The threshold of each stage jerk can be adjusted at any time according to actual requirements.

[0105] S406. Calculate the product of the jerk threshold and the initial endpoint values of several jerk intervals to obtain the final endpoint values of the jerk intervals, and form several jerk interval ranges. Make the jerk interval ranges of different stages during the opening process and closing process of the valve different, so as to more accurately fit the motion characteristics of the valve in different stages during the opening process and closing process; specifically,

[0106] The jerk interval ranges include a first jerk interval, a second jerk interval, a third jerk interval, a fourth jerk interval, a fifth jerk interval, a sixth jerk interval, and a seventh jerk interval; among them,

[0107] The first jerk interval is (-∞, w*0], the second jerk interval is (w*0, w*0.5], the third jerk interval is (w*0.5, w*1], the fourth jerk interval is (w*1, w*2], the fifth jerk interval is (w*2, w*4], the sixth jerk interval is (w*4, w*8], and the seventh jerk interval is (w*8, +∞).

[0108] S407. Associate the jerk interval ranges with the jamming levels. By defining different jamming level grades, quantitatively detect the smoothness of the valve action. Among them, the jamming levels include a completely non-jamming level, a slightly jamming level, a slightly jamming level, a moderately jamming level, a severely jamming level, and a jammed level;

[0109] The recommended treatment plans corresponding to the completely non-jamming level, the slightly jamming level, and the slightly jamming level are to be not concerned. The recommended treatment plan corresponding to the moderately jamming level is to keep attention. The recommended treatment plan corresponding to the severely jamming level is to closely monitor, and wait for an opportunity to replace (for severe jamming and jerks of the valve) or replace immediately, repair immediately (for the valve with a risk of jamming). The recommended treatment plan corresponding to the jammed level is to carry out emergency repair.

[0110] To represent the jamming level more conveniently and intuitively, the jamming level is represented by level 0, level 1, level 2, level 3, level 4, level 5, and level 6. Among them, level 0 corresponds to the above-mentioned completely unjammed level and the first jerk interval, level 1 corresponds to the above-mentioned slight jamming level (invisible to the naked eye) and the second jerk interval, level 2 corresponds to the above-mentioned micro-jamming level (slight jamming jerks visible to the naked eye) and the third jerk interval. An example of the jerk of level 2 jamming is as shown in Figure 9 shown, and an example of the jamming level of level 2 is as shown in Figure 10 shown. Level 3 corresponds to the above-mentioned medium jamming level (obvious jamming jerks visible to the naked eye) and the fourth jerk interval. An example of the jerk of level 3 jamming is as shown in Figure 11 shown, and an example of the jamming level of level 4 is as shown in Figure 12 shown. Level 4 corresponds to the above-mentioned severe jamming level (severe jamming jerks of the valve) and the fifth jerk interval. An example of the jerk of level 4 jamming is as shown in Figure 13 shown, and an example of the jamming level of level 4 is as shown in Figure 14 shown. Level 5 corresponds to the above-mentioned severe jamming level (risk of valve jamming) and the sixth jerk interval, and level 6 corresponds to the above-mentioned jammed level and the seventh jerk interval, as specifically shown in Table 1.

[0111] Table 1 Valve Jamming Level, Corresponding Description and Suggested Treatment Plan

[0112] Jamming Level Description Suggested Solution 0 No Jamming at All No Attention Required 1 Slight Jamming by Logical Judgment, Invisible to the Naked Eye No Attention Required 2 Slight Jamming by Logical Judgment, Slight Jamming Frustration Visible to the Naked Eye No Attention Required 3 Moderate Jamming by Logical Judgment, Obvious Jamming Frustration Visible to the Naked Eye Keep Attention 4 Severe Jamming by Logical Judgment, Severe Jamming Frustration of the Valve Closely Monitor and Replace Opportunely 5 Severe Jamming by Logical Judgment, Risk of Valve Seizure Replace Immediately and Conduct Emergency Repair Immediately 6 Seized Emergency Repair

[0113] Combined with the above-established jerk interval range and the corresponding jamming level, the steps of the above-mentioned step of determining the jerk interval to which the jerk equivalent belongs include the following steps:

[0114] S41. Obtain the current working process of the program-controlled valve, that is, the opening process and the closing process of the program-controlled valve;

[0115] S42. Determine the stage to which the data in the jamming determination dataset belongs under the current working process of the program-controlled valve, that is, determine whether it belongs to the first stage, the second stage, or the third stage in the opening process or the closing process of the program-controlled valve;

[0116] S43. Match the stage jerk corresponding to the stage to which the data in the jamming determination dataset belongs, that is, match the first-stage jerk, the second-stage jerk, or the third-stage jerk;

[0117] S44. Obtain the jerk threshold w corresponding to the matched stage jerk;

[0118] S45. Match the several jerk interval ranges corresponding to the obtained jerk threshold, that is, match the above-mentioned first jerk interval, second jerk interval, third jerk interval, fourth jerk interval, fifth jerk interval, sixth jerk interval, and seventh jerk interval;

[0119] S46. Determine the jerk interval range to which the jerk equivalent belongs.

[0120] S5. Match the jamming level corresponding to the jerk interval to which it belongs.

[0121] In order to integrate the jamming faults in different stages during the valve opening and closing process and determine the control strategy of the fluid system, it is necessary to determine the final jamming level, and determine the control strategy of the valve according to the final jamming level, so as to carry out maintenance and overhaul control of the fluid system, solve the problem of valve jamming monitoring in the operation of the fluid system, and realize the safe operation of the controlled fluid system. Especially when a valve jamming fault occurs, it can quickly adjust the valve and the fluid system to ensure the safe operation of the fluid system. The specific steps are as follows;

[0122] S51. Match the corresponding jamming level according to the jerk interval range to which the jerk equivalent belongs. For example: if it is determined that the jerk equivalent belongs to the fourth jerk interval, the corresponding jamming level is level 3; if it is determined that the jerk equivalent belongs to the seventh jerk interval, the corresponding jamming level is level 6.

[0123] S52. Find the number m of the maximum jamming levels of the jerk in each stage. For example: the maximum jamming level of the jerk in the first stage is level 3 and the number of the maximum jamming levels is 2, the maximum jamming level of the jerk in the second stage is level 4 and the number of the maximum jamming levels is 1, and the maximum jamming level of the jerk in the third stage is level 5 and the number of the maximum jamming levels is 1;

[0124] S53. Determine whether the number m of the maximum jamming levels of the jerk in each stage is greater than or equal to the threshold p;

[0125] S54. If the number m of the maximum jamming levels of the jerk in each stage is greater than or equal to the threshold p, then determine that the jamming level of the jerk in the current stage is the maximum jamming level m of the jerk in each stage found; assuming that the threshold p is set to 2, then the jamming level of the jerk in the first stage in the above example is level 3.

[0126] S55. If the number of the maximum jamming levels of the jerk in each stage is less than the threshold, then determine that the jamming level of the jerk in the current stage is the maximum jamming level m of the jerk in each stage found minus one; assuming that the threshold p is set to 2, then the jamming level of the jerk in the second stage in the above example is level 3, and the jamming level of the jerk in the third stage is level 4.

[0127] S56. Obtain the maximum value of the jamming levels of the jerk in all stages as the final jamming level; combined with the above illustration, the final jamming level is level 4.

[0128] The service life of valves is one of the core elements in the life cycle assessment of fluid systems. How to reasonably and accurately evaluate the valve life is of great significance for the maintenance and overhaul of fluid systems. Currently, there are generally two ways to describe the service life of isolation valves in industrial systems:

[0129] Frequency of use: For example, the service life of an NPS 6 CLASS 300 hard-sealed ball valve is 2000 times of opening and closing.

[0130] Service time: For example, the service life of an NPS 6 CLASS 300 hard-sealed ball valve is 2 years.

[0131] Life grade classification: The life of a valve of a certain specification under a certain working condition is expressed in scientific notation as ax10 b , that is, it is defined that the life grade of a certain configuration of this valve under this working condition is b.a.

[0132] For example: The life of a 6-300 hard-sealed ball valve under a certain working condition is 2x10 3 times, and the life grade of this valve is defined as 3.2. Among them, the first number 3 is the exponent of 10, representing the order of magnitude, and the second number represents the multiple of this order of magnitude.

[0133] Predicting the remaining useful life (RUL) is one of the core advantages of Industry 4.0 methods. Due to the rapid deployment of Internet of Things (IoT) devices, data sources of variables such as vibration, pressure, current, and temperature are now widespread and readily available. Coupled with digital maintenance records, it provides unprecedented insights into the health status of process control valves.

[0134] S6. Input the jamming level and relevant parameters of the process control valve into the prediction model of the remaining useful life of the process control valve, and obtain the prediction result of the remaining useful life of the process control valve, which can be output in the form of the above life grade b.a, or the corresponding output form can be set according to actual needs.

[0135] To save computing resources and shorten the computing cycle. Before inputting the jamming level and relevant parameters of the process control valve into the prediction model of the remaining useful life of the process control valve, the following steps are also included:

[0136] S501. Judge whether the jamming level is the stuck level;

[0137] S502. If the jamming level is the stuck level, it is determined that the remaining useful life of the process control valve is 0;

[0138] S503. If the jamming level is not the stuck level, execute the step of inputting the jamming level and relevant parameters of the process control valve into the prediction model of the remaining useful life of the process control valve.

[0139] Combined with the development of valves and practical use experience, the lifespan of valves mainly depends on several factors. In a high-pressure environment, valves require more frequent maintenance or replacement, even before considering the nuances of any specific medium. Additionally, since valves are commonly used for the on-off control of gases and liquids, including water, oil, air, and chemicals, media containing suspended particles are abrasive and may cause premature failure of the valve seal, which may manifest as leakage, or depending on the severity of the medium's characteristics, the operating torque of the valve may increase sharply, ultimately leading to drive failure. The corrosion rate of valves depends on the temperature, pressure, and chemical properties of the valve flow path globe valve. Once the valve seal corrodes, it requires maintenance or replacement. The jamming level of the valve is also a major factor affecting the remaining service life of the valve.

[0140] Summarizing the above factors, the relevant parameters of the programmable control valve include the initial service life L, pressure rating p, medium hardness h, corrosion coefficient m.

[0141] Specifically, the construction of the prediction model for the remaining service life of the programmable control valve includes the following steps:

[0142] S61. Obtain the initial service life L, pressure rating p, medium hardness h, corrosion coefficient m, jamming level k, and remaining service life RUL in the training set;

[0143] S62. Use the initial service life, pressure rating, medium hardness, corrosion coefficient, and jamming level as inputs and the remaining service life as the output to train the neural network model, and obtain the trained prediction model for the remaining service life of the programmable control valve, as Figure 16 shown. Among them, the neural network model can adopt a convolutional neural network model, etc., and the prediction accuracy and robustness of the model are better.

[0144] S7. Send the GPS positioning information and jamming warning information of the jammed valve to the user; among them, the jamming warning information includes the device name, jamming level, recommended treatment plan corresponding to the jamming level, remaining service life, and occurrence time, realizing more accurate, clear, and visual monitoring of the valve state. The jamming warning information received by the user terminal is as Figure 15 shown. The push of the GPS positioning information and jamming warning information of the jammed valve saves time for guiding relevant personnel to adjust the valve and system operating conditions in a timely manner, improves the system operating efficiency, and prevents unplanned shutdown events of the system caused by valve jamming failures.

[0145] To save computing resources and improve the efficiency of jamming fault identification. Before the preprocessing step of the monitoring data, the following steps are also included:

[0146] S11. Obtain the working process of the programmable control valve, and the working process includes the opening process and the closing process;

[0147] S12. Determine whether the monitoring data reaches the threshold corresponding to the working process; taking the set angle threshold X as an example, determine whether the actual sampling angle reaches the set angle threshold X during the opening process or the closing process.

[0148] S13. If the monitoring data does not reach the threshold corresponding to the working process, determine that the jamming level is the stuck level, that is, the above-mentioned level 6; S14. Execute the above step of inputting the jamming level and the relevant parameters of the program-controlled valve into the prediction model of the remaining service life of the program-controlled valve.

[0149] To save computing resources and improve the efficiency of jamming fault identification. Before the preprocessing step of the monitoring data, the following steps are also included:

[0150] S101. Filter the theoretical monitoring data volume from the monitoring data; taking the sampling data as the angle as an example, calculate the angle interval number according to the number of actual sampling angles / (default number of sampling points * j); according to the angle interval number, filter out the theoretical angles from the actual sampling angles, and the theoretical angles here are the above-mentioned theoretical angles, for example: the theoretical angles can be (2.9, 3.6, 4.4, 5.4,..., 85.8).

[0151] S102. Determine whether the number of the same monitoring data volume in the filtered theoretical monitoring data volume reaches the threshold n.

[0152] S103. If the number of the same monitoring data volume in the filtered theoretical monitoring data volume reaches the threshold n, determine that the jamming level is the stuck level; S104. Execute the above step of inputting the jamming level and the relevant parameters of the program-controlled valve into the prediction model of the remaining service life of the program-controlled valve.

[0153] The present invention realizes the quantitative detection of the smoothness of the valve action by defining different jamming degree levels; for different output jamming levels, different treatment schemes are provided. Low-level jamming does not need to be concerned, and high-level jamming sends an alarm message to remind relevant personnel to handle it in time, improving the reliability of the jamming monitoring of the program-controlled valve, contributing to the realization of the early real-time monitoring and diagnosis of valve jamming, facilitating popularization and application, and then ensuring the stable and safe operation of the fluid system, avoiding the occurrence of unplanned shutdown conditions, and can provide an advanced warning of valve jamming to avoid the further development of the accident severity; combined with the prediction model of the remaining service life, regarding the jamming level as a key variable of the prediction model of the remaining service life, calculating the remaining service life, can monitor the remaining service life of the valve in real time, and is used to guide the safe and stable operation of the fluid system; in addition, the prediction model of the remaining service life of the present invention combines the initial service life, pressure level, medium hardness, and corrosion coefficient for calculation, and the reliability of the prediction result is much higher than the calculation method of the remaining service life obtained under the condition of traditional single factors.

[0154] Embodiment 2

[0155] An electronic device 200, as Figure 17 shown, includes but is not limited to: a memory 201 on which program code is stored; a processor 202 coupled to the memory, and when the program code is executed by the processor, a monitoring method for sticking of a program-controlled valve is implemented. For a detailed description of the method, reference may be made to the corresponding description in the above method embodiments, which will not be elaborated herein.

[0156] Embodiment 3

[0157] A computer-readable storage medium, as Figure 18 shown, on which program instructions are stored, and when the program instructions are executed, a monitoring method for sticking of a program-controlled valve is implemented. For a detailed description of the method, reference may be made to the corresponding description in the above method embodiments, which will not be elaborated herein.

[0158] Embodiment 4

[0159] A monitoring system for sticking of a program-controlled valve that implements the above monitoring method for sticking of a program-controlled valve, as Figure 19 shown, includes a proximity switch, a monitoring data collector, a PCB circuit board and an integrated chip, a signal transmitter, and a cloud server;

[0160] The proximity switch is used to output switch position information;

[0161] The monitoring data collector is used to collect monitoring data of the valve opening and closing mechanism, and the monitoring data includes the linear displacement and / or angular displacement of the valve opening and closing mechanism;

[0162] The PCB circuit board and the integrated chip are used to preprocess the monitoring data to obtain a sticking determination data set; calculate the jerk equivalent corresponding to the data in the sticking determination data set; determine the jerk interval to which the jerk equivalent belongs; match the sticking level corresponding to the jerk interval to which it belongs;

[0163] The signal transmitter is used to send GPS positioning and sticking warning information to the cloud server; wherein, the sticking warning information includes the device name, the sticking level, the recommended treatment plan corresponding to the sticking level, the remaining service life, and the occurrence time;

[0164] The cloud server is used to send GPS positioning and sticking warning information to the customer.

[0165] For a detailed description of the system, reference may be made to the corresponding description in the above method embodiments, which will not be elaborated herein.

[0166] It should also be noted that the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, commodity or device comprising a series of elements not only includes those elements but also includes other elements not expressly listed, or further includes elements inherent in such process, method, commodity or device. Without further limitation, an element defined by the statement "comprising an..." does not exclude the existence of additional identical elements in the process, method, commodity or device comprising the element.

[0167] Each embodiment in this specification is described in a progressive manner. For the same or similar parts among the embodiments, reference can be made to each other, and the key point of each embodiment is to illustrate the differences from other embodiments.

[0168] The above is only for the embodiments of this specification and is not used to limit one or more embodiments of this specification. For those skilled in the art, one or more embodiments of this specification can have various changes and transformations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of one or more embodiments of this specification shall be included within the scope of the claims of one or more embodiments of this specification.

Claims

1. A method for monitoring the jamming of a program-controlled valve, characterized in that, It includes the following steps: Obtain the monitoring data of the valve opening and closing mechanism, where the monitoring data includes the linear displacement and / or angular displacement of the valve opening and closing mechanism; Preprocess the monitoring data to obtain a sticking determination data set; Calculate the jerk equivalent corresponding to the data in the sticking determination data set; Judge the jerk interval to which the jerk equivalent belongs; Match the sticking level corresponding to the jerk interval to which it belongs.

2. The method for monitoring the jamming of a program-controlled valve according to claim 1, wherein: It further includes the following steps: Input the sticking level and relevant parameters of the program-controlled valve into the prediction model of the remaining service life of the program-controlled valve to obtain the prediction result of the remaining service life of the program-controlled valve.

3. The method for monitoring the jamming of a programmable control valve according to claim 2, characterized in that: Before the step of preprocessing the monitoring data, it further includes the following steps: Obtain the working process of the program-controlled valve, where the working process includes an opening process and a closing process; Judge whether the monitoring data reaches the threshold corresponding to the working process; If the monitoring data does not reach the threshold corresponding to the working process, then determine the sticking level as the stuck level, and execute the step of inputting the sticking level and relevant parameters of the program-controlled valve into the prediction model of the remaining service life of the program-controlled valve.

4. The method for monitoring the jamming of a program-controlled valve according to claim 2, characterized in that: Before the step of preprocessing the monitoring data, it further includes the following steps: Filter the theoretical monitoring data volume from the monitoring data; If the number of the same monitoring data volume in the filtered theoretical monitoring data volume reaches the threshold, then determine the sticking level as the stuck level, and execute the step of inputting the sticking level and relevant parameters of the program-controlled valve into the prediction model of the remaining service life of the program-controlled valve.

5. The method for monitoring the jamming of a programmable control valve according to claim 1, wherein: The calculation of the jerk equivalent corresponding to the data in the sticking determination data set is to perform a third-order differentiation of the data in the sticking determination data set with respect to time to obtain the jerk equivalent.

6. A method for monitoring the jamming of a program-controlled valve according to claim 3 or 4, characterized in that: The construction of the jerk interval includes the following steps: Divide the working process of the program-controlled valve into multiple stages, where the working process includes an opening process and a closing process; Set the monitoring data interval for each stage corresponding to the working process; Perform a third-order differentiation of the theoretical monitoring data volume with respect to time to calculate the theoretical jerk; Divide the theoretical jerk into multiple stage jerks according to the monitoring data interval for each stage corresponding to the working process; Set the jerk threshold corresponding to each stage jerk; Calculate the product of the jerk threshold and the initial endpoint values of several jerk intervals to obtain the final endpoint values of the jerk intervals, forming several jerk interval ranges; Associate the jerk interval ranges with the sticking levels.

7. The method for monitoring the jamming of a programmable control valve according to claim 6, wherein: The judgment of the jerk interval to which the jerk equivalent belongs includes the following steps: Obtain the current working process of the program-controlled valve; Judge the stage to which the data in the sticking determination data set belongs under the current working process of the program-controlled valve; Match the stage jerk corresponding to the stage to which the data in the sticking determination data set belongs; Obtain the jerk threshold corresponding to the matched stage jerk; Match the several jerk interval ranges corresponding to the obtained jerk threshold; Judge the jerk interval range to which the jerk equivalent belongs.

8. The program-controlled valve jamming monitoring method according to claim 7, characterized in that: The matching of the sticking level corresponding to the jerk interval to which it belongs includes the following steps; Match the corresponding sticking level according to the jerk interval range to which the jerk equivalent belongs; Find the number of the maximum sticking levels of each stage jerk; If the number of the maximum jamming levels of the jerk in each stage is greater than or equal to the threshold value, it is determined that the jamming level of the jerk in the current stage is the maximum jamming level of the jerk in each stage found; If the number of the maximum jamming levels of the jerk in each stage is less than the threshold value, it is determined that the jamming level of the jerk in the current stage is the maximum jamming level of the jerk in each stage found minus one; Obtain the maximum value of the jamming levels of the jerk in all stages as the final jamming level.

9. The method for monitoring the jamming of a programmed valve according to claim 6, characterized in that: The jamming levels include a completely non-jamming level, a slightly jamming level, a micro-jamming level, a medium jamming level, a severe jamming level, and a stuck level; The recommended treatment solutions corresponding to the completely non-jamming level, the slightly jamming level, and the micro-jamming level are to be not concerned. The recommended treatment solution corresponding to the medium jamming level is to keep attention. The recommended treatment solutions corresponding to the severe jamming level are to closely monitor, wait for an opportunity to replace or immediately replace, and immediately repair. The recommended treatment solution corresponding to the stuck level is to perform emergency repair.

10. A method for monitoring the jamming of a programmable valve according to claim 9, characterized in that: Before inputting the jamming level and the relevant parameters of the program-controlled valve into the program-controlled valve remaining service life prediction model, the following steps are further included: If the jamming level is the stuck level, it is determined that the remaining service life of the program-controlled valve is 0; If the jamming level is a non-stuck level, perform the step of inputting the jamming level and the relevant parameters of the program-controlled valve into the program-controlled valve remaining service life prediction model.

11. A method for monitoring the jamming of a programmable control valve according to claim 2 or 10, characterized in that: The relevant parameters of the program-controlled valve include the initial service life, the pressure level, the medium hardness, and the corrosion coefficient.

12. The method for monitoring the jamming of a programmable control valve according to claim 11, wherein: The construction of the program-controlled valve remaining service life prediction model includes the following steps: Obtain the initial service life, the pressure level, the medium hardness, the corrosion coefficient, the jamming level, and the remaining service life in the training set; Use the initial service life, the pressure level, the medium hardness, the corrosion coefficient, and the jamming level as inputs and the remaining service life as an output to train the neural network model, and obtain the trained program-controlled valve remaining service life prediction model.

13. A method for monitoring the jamming of a program-controlled valve according to claim 9, characterized in that: The following steps are further included: Send the GPS positioning information and the jamming early warning information to the user; wherein, the jamming early warning information includes the equipment name, the jamming level, the recommended treatment solution corresponding to the jamming level, the remaining service life, and the occurrence time.

14. A method for monitoring the jamming of a programmable control valve according to claim 1, characterized in that: The preprocessing of the monitoring data includes resampling the monitoring data.

15. An electronic device, characterized in that, Include: A memory, on which program code is stored; A processor, which is connected to the memory, and when the program code is executed by the processor, the method according to any one of claims 1 to 14 is implemented.

16. A computer-readable storage medium, characterized in that, Program instructions are stored thereon, and when the program instructions are executed, the method according to any one of claims 1 to 14 is implemented.

17. A program-controlled valve jamming monitoring system for implementing the method according to any one of claims 1 to 14, characterized in that: Include a monitoring data collector, a PCB circuit board and an integrated chip, a signal transmitter, and a cloud server; The monitoring data collector is used to collect the monitoring data of the valve opening and closing mechanism, and the monitoring data includes the linear displacement and / or angular displacement of the valve opening and closing mechanism; The PCB circuit board and the integrated chip are used to preprocess the monitoring data to obtain a jamming determination data set; Calculate the jerk equivalent corresponding to the data in the jamming determination data set; determine the jerk interval to which the jerk equivalent belongs; Match the stick-slip level corresponding to the jerk interval to which it belongs; The signal transmitter is used to send the GPS positioning and stick-slip warning information to the cloud server; The cloud server is used to send the GPS positioning and stick-slip warning information to the customer.

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