Valve drive control method and system

Abstract

The application discloses a valve driving control method and system, and relates to the technical field of industrial device control. The method comprises the following steps: acquiring valve opening position data; if the valve opening position data is in a resistance component separation interval, calculating a friction force reference value; if the valve opening position data is in a sealing force judgment interval, calculating smooth sealing compression stiffness according to the friction force reference value; and controlling a valve driving device according to the smooth sealing compression stiffness. The application can combine the resistance component separation interval and the sealing force judgment interval to analyze data, so as to realize valve driving control, and improve accuracy and reliability.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of industrial device control, and in particular to a valve drive control method and system. BACKGROUND

[0002] In the industrial production process, high-torque valve actuators are usually deployed on key process pipelines to accurately control the on-off or flow of fluids. In order to ensure that these valves can reliably operate under various working conditions, existing control methods usually rely on torque sensors to determine the operating state of the valve. However, in actual applications, the frictional resistance inside the valve drive device will be affected by changes in the ambient temperature or process fluid temperature, resulting in changes in the viscosity of the lubricant, and thus making the composition of the driving torque complex. This complexity often makes it difficult for existing control methods to accurately determine the true closed state of the valve, thereby causing a series of operational difficulties and potential equipment damage risks, low control accuracy, and low reliability.

[0003] To sum up, the technical problems existing in the related art need to be improved. SUMMARY

[0004] The main purpose of the embodiments of the present application is to provide a valve drive control method and system, which can combine resistance component separation intervals and sealing force judgment intervals for data analysis to achieve valve drive control, thereby improving accuracy and reliability.

[0005] In one aspect, the present application provides a valve drive control method, comprising the following steps:

[0006] Obtaining valve opening position data;

[0007] If the valve opening position data is in the resistance component separation interval, calculating a friction force reference value;

[0008] If the valve opening position data is in the sealing force judgment interval, calculating a smooth sealing compression stiffness according to the friction force reference value;

[0009] Controlling the valve drive device according to the smooth sealing compression stiffness.

[0010] In some embodiments, the calculation of the friction force reference value comprises:

[0011] Generating a valve forward movement signal, the valve forward movement signal being used to control the valve drive device to move a preset distance in the valve closing direction, and collecting first valve operating torque data;

[0012] Calculating a forward micro-motion average torque value according to the first valve operating torque data;

[0013] generate a valve reverse movement signal for controlling the valve drive device to move a preset distance in an opening direction of the valve, and collect second valve operation torque data;

[0014] calculate a reverse micro-motion average torque value according to the second valve operation torque data;

[0015] calculate the friction reference value according to the forward micro-motion average torque value and the reverse micro-motion average torque value.

[0016] In some embodiments, the calculating the smooth sealing compression stiffness according to the friction reference value comprises:

[0017] collect third valve operation torque data;

[0018] filter the third valve operation torque data;

[0019] smooth the valve opening position data;

[0020] time-align the filtered third valve operation torque data and the smoothed valve opening position data;

[0021] subtract the time-aligned third valve operation torque data from the friction reference value to obtain net sealing torque data;

[0022] calculate a sealing compression stiffness sequence according to the net sealing torque data and the time-aligned valve opening position data;

[0023] perform a sliding average processing on the sealing compression stiffness sequence to obtain the smooth sealing compression stiffness.

[0024] In some embodiments, the calculating the sealing compression stiffness sequence according to the net sealing torque data and the time-aligned valve opening position data comprises:

[0025] identify key points on a relationship curve between the net sealing torque data and the valve opening position data;

[0026] divide a sealing compression stage into a plurality of sub-intervals according to the key points;

[0027] calculate sealing compression stiffnesses in each sub-interval according to the net sealing torque data and the valve opening position data in the sub-interval;

[0028] combine the sealing compression stiffnesses corresponding to each sub-interval to obtain the sealing compression stiffness sequence.

[0029] In some embodiments, the identifying the key point on the curve of the relationship between the net sealing torque data and the valve opening position data comprises:

[0030] segmenting the net sealing torque data and the valve opening position data to obtain a plurality of data segments;

[0031] calculating a torque change rate corresponding to each data segment;

[0032] identifying an initial significant change point corresponding to each torque change rate;

[0033] detecting continuity of a plurality of the initial significant change points to obtain a target significant change point;

[0034] judging an amplitude threshold value of the target significant change point to obtain the key point.

[0035] In some embodiments, the detecting continuity of a plurality of the initial significant change points to obtain a target significant change point comprises:

[0036] selecting one significant change point from a plurality of the initial significant change points as a to-be-detected significant change point;

[0037] monitoring a fluctuation amplitude of a torque change rate corresponding to the to-be-detected significant change point within a preset time window;

[0038] calculating a mean value and a standard deviation according to the fluctuation amplitude;

[0039] if the mean value is within a preset fluctuation range and the standard deviation is less than a preset fluctuation threshold value, regarding the to-be-detected significant change point as the target significant change point.

[0040] In some embodiments, the judging an amplitude threshold value of the target significant change point to obtain the key point comprises:

[0041] obtaining a cumulative running time of a valve sealing component, a historical sealing compression stiffness change trend, and a current environment temperature;

[0042] determining an amplitude threshold value according to the cumulative running time of the valve sealing component, the historical sealing compression stiffness change trend, and the current environment temperature;

[0043] if a torque change amplitude corresponding to the target significant change point is greater than the amplitude threshold value, regarding the target significant change point as the key point.

[0044] In some embodiments, the determining an amplitude threshold value according to the cumulative running time of the valve sealing component, the historical sealing compression stiffness change trend, and the current environment temperature comprises:

[0045] acquire a medium corrosive parameter and an operating frequency parameter during valve operation;

[0046] correct the cumulative operation time according to the medium corrosive parameter and the operating frequency parameter;

[0047] determine the amplitude threshold according to the corrected cumulative operation time, the historical sealing compression stiffness change trend, and the current environmental temperature.

[0048] In some embodiments, the controlling the valve driving device according to the smoothed sealing compression stiffness comprises:

[0049] if the smoothed sealing compression stiffness is greater than a preset minimum effective sealing stiffness, calculating a growth rate of the smoothed sealing compression stiffness;

[0050] if the growth rate of the smoothed sealing compression stiffness is less than a preset stiffness stability threshold, controlling the valve driving device to stop.

[0051] In another aspect, an embodiment of the present application provides a valve driving control system, comprising:

[0052] a data acquisition module configured to acquire valve opening position data;

[0053] a reference value calculation module configured to calculate a friction force reference value if the valve opening position data is in a resistance component separation interval;

[0054] a sealing compression stiffness calculation module configured to calculate a smoothed sealing compression stiffness according to the friction force reference value if the valve opening position data is in a sealing force judgment interval;

[0055] a driving device control module configured to control a valve driving device according to the smoothed sealing compression stiffness.

[0056] The embodiments of the present application have at least the following beneficial effects: the embodiments of the present application first acquire valve opening position data, calculate a friction force reference value if the valve opening position data is in a resistance component separation interval, calculate a smoothed sealing compression stiffness according to the friction force reference value if the valve opening position data is in a sealing force judgment interval, and then control a valve driving device according to the smoothed sealing compression stiffness, so that data analysis can be performed in combination with the resistance component separation interval and the sealing force judgment interval to achieve valve driving control, and thus the accuracy and reliability are improved.

[0057] Other features and advantages of the present application will be set forth in the description that follows, and in part will be apparent from the description, or can be learned by practice of the application. The purposes and other advantages of the present application will be realized and attained by the structure particularly pointed out in the description and appended claims. BRIEF DESCRIPTION OF DRAWINGS

[0058] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and for those skilled in the art, other drawings can also be obtained from these drawings without creative labor.

[0059] Figure 1 A flow chart of a valve driving control method according to an embodiment of the present application;

[0060] Figure 2 A structural schematic diagram of a valve driving control system according to an embodiment of the present application. DETAILED DESCRIPTION

[0061] In order to make the purposes, technical solutions and advantages of the present application more clear, the present application will be further described in detail below with reference to the drawings and embodiments.

[0062] In the related art, in many industrial production processes, high-torque valve actuators play a crucial role, and are usually deployed on critical process pipelines to accurately control the on-off or flow rate of fluids. In order to ensure that these valves can reliably operate under various working conditions, the existing control method usually relies on a torque sensor to determine the operating state of the valve, especially whether the valve is closed in place. However, in actual applications, the frictional resistance inside the valve driving device will be affected by changes in the ambient temperature or process fluid temperature, resulting in changes in the viscosity of the lubricant, and thus making the composition of the driving torque complex. This complexity often makes it difficult for the existing control method to accurately determine the true closing state of the valve, thereby causing a series of operational difficulties and potential equipment damage risks.

[0063] For example, in many critical industrial production fields, large-scale steam pipeline systems in power plants, fluid transportation pipelines in complex petrochemical plants, or main pipelines in municipal water supply systems, all widely deploy large-diameter, high-pressure industrial valves. These valves need to withstand huge fluid pressure in design, and their opening or closing operations often need to overcome huge mechanical resistance. Therefore, they are usually equipped with specially designed electric valve actuator. A typical actuator core consists of a high-power motor and a multi-stage reduction gearbox, which together can generate enough torque to rotate the valve stem. In order to achieve precise control of the valve position and at the same time protect the valve itself and its actuator from overload damage, a high-precision torque sensor is usually integrated on the output shaft of the actuator.

[0064] In the conventional valve operation process, when the control system issues an instruction to start closing the valve, the motor starts to rotate. Throughout the entire travel of the valve from the fully open position to the fully closed position, the torque sensor continuously monitors and transmits the real-time torque value it detects to the control system. In most stages of the valve closing travel, the fluid resistance encountered by the valve plate moving in the pipeline fluid is relatively stable, so the torque output by the actuator also maintains a relatively low and stable level. However, when the valve plate is about to contact the valve seat and start to squeeze the sealing ring to form a tight seal, the mechanical resistance inside the valve will increase sharply. This sudden increase in resistance will directly cause a significant and rapid rise in driving torque. The control system is pre-set with a "cut-off torque threshold", which is a calibrated upper limit of torque for determining whether the valve has been completely closed in place. Once the sensor measures the torque to reach this preset value, the system will immediately determine that the valve has been completely closed in place, and quickly stop power supply to the motor, thus completing a valve closing operation. This torque feedback-based control method works well under ideal conditions, effectively preventing damage to the valve sealing surface or the actuator gear due to excessive force, and ensuring reliable sealing of the valve.

[0065] However, in some actual and more severe industrial application environments, the situation becomes complex and introduces unexpected challenges. For example, when these valve systems are deployed outdoors, or the process fluid they control has a dramatic temperature fluctuation, the operating temperature of the valve actuator and its internal components will no longer remain constant. This significant fluctuation in environmental or process temperature is the starting point for a series of subsequent problems.

[0066] As the ambient or process fluid temperature drops significantly, the viscosity of the lubricants inside the valve actuator, including the lubricating oil or grease in the reduction gearbox, as well as the lubricants at the valve stem thrust bearing and stuffing box, will increase significantly. This is an inherent physical property of lubricants, which becomes less fluid and more viscous at low temperatures. This increase in viscosity directly results in a substantial increase in the frictional resistance of the mechanical drive train inside the actuator. Greater resistance will be encountered in gear meshing, bearing rolling, and valve stem sliding in the stuffing box.

[0067] This additional internal friction caused by the increased viscosity of the lubricants at low temperatures results in a significant increase in the overall mechanical resistance that the motor has to overcome when driving the valve. This means that a larger portion of the motor's output torque is consumed in overcoming the internal friction of the actuator itself, rather than effectively acting on the movement and sealing of the valve disc. This effect is particularly pronounced in the final stages of the valve closing stroke, as the valve disc contacts and compresses the seat seal, which itself requires overcoming greater static friction and sealing forces. At this point, the additional internal friction resistance further exacerbates the torque demand.

[0068] Due to this abnormally increased mechanical resistance, the torque sensor will detect a sharp rise in torque during the valve closing stroke, and this rise will occur much earlier than when the valve is actually closed in place under normal temperature or ideal operating conditions. In other words, the torque value measured by the sensor will have reached the pre-set "shut-off torque threshold" before the valve disc has fully compressed the seal ring or even reached its designed full-closed position. Although the value and rate of rise of the torque signal may be similar to normal closing, its "position" or "timing" in the overall stroke of the valve has shifted fundamentally.

[0069] For existing control systems, the judgment logic is based on whether the torque value reaches the threshold, and it cannot effectively distinguish the specific reasons for the torque rise. Therefore, when it receives this early torque peak caused by abnormal internal friction at low temperatures, it will mistakenly judge that the valve has been successfully closed in place. The control system will immediately perform the same response as normal closing - cutting off the motor power and sending a "valve closed" status signal to the monitoring interface of the central control room.

[0070] The result of this misjudgment is that the valve is not actually fully sealed. There is still a small physical gap between the valve plate and the valve seat, and the expected zero-leakage closing is not achieved. The process medium in the pipeline will continue to leak from this gap to the downstream. This internal leakage may not be easy to detect at first, but it can cause a series of serious problems. For example, in a chemical reaction area that requires strict isolation, this leakage can cause different materials to flow together, thereby contaminating the product, changing the reaction conditions, and even causing unintended chemical reactions, resulting in huge production losses. In energy systems, the leakage of high-pressure fluids such as steam can cause continuous energy loss and reduce system efficiency.

[0071] More seriously, high-pressure fluids with abrasive or corrosive particles passing through the narrow gap at high speed can cause severe erosion and wear of the valve sealing surface. Over time, even after the temperature rises and the viscosity of the lubricant returns to normal, the valve sealing surface has already been permanently damaged, causing the valve to be unable to close tightly, even under ideal operating conditions, and achieving zero leakage. Eventually, it can only be replaced, resulting in huge economic losses and downtime. In addition, the driving device itself will also bear additional impact load and wear due to repeated premature stopping under abnormal operating conditions, reducing its service life and increasing maintenance costs.

[0072] In industrial high-torque valve drive control, when the internal lubricant viscosity of the driving device abnormally increases due to low-temperature environment or process fluid temperature fluctuations, thereby causing a significant increase in mechanical friction resistance, the existing control method has low control accuracy and low reliability.

[0073] Therefore, the embodiments of the present application calculate a friction force reference value in the resistance component separation interval and separate it from the total driving torque, so as to obtain more pure net sealing torque data in the sealing force judgment interval. The smooth sealing compression stiffness calculated based on the net sealing torque data and the valve opening position data can truly reflect the stress state and health condition of the valve sealing element. Compared with the prior art, the embodiments of the present application no longer simply rely on the absolute value of the torque, but evaluate the sealing compression stiffness, a more essential physical quantity, to judge the sealing state of the valve. This method can effectively distinguish between torque increases caused by friction and torque increases caused by sealing force, avoid misjudgment caused by friction fluctuations, ensure reliable zero-leakage closing of the valve under complex temperature conditions, and prevent premature wear of equipment and potential production risks.

[0074] The embodiments of the present application will be specifically explained below in conjunction with the accompanying drawings:

[0075] Figure 1 is an optional flowchart of a valve drive control method provided by the embodiments of the present application, Figure 1The method in the method can include but not limited to steps S101 to S104.

[0076] Step S101, acquiring valve opening position data;

[0077] Step S102, if the valve opening position data is in the resistance component separation interval, calculating the friction force reference value;

[0078] Step S103, if the valve opening position data is in the sealing force judgment interval, calculating the smooth sealing compression stiffness according to the friction force reference value;

[0079] Step S104, controlling the valve driving device according to the smooth sealing compression stiffness.

[0080] The steps S101 to S104 shown in the embodiments of the application can combine the resistance component separation interval and the sealing force judgment interval for data analysis, so as to realize the valve driving control, and improve the accuracy and reliability.

[0081] In some embodiments, steps S101-S104 can first acquire the valve opening position data. Exemplarily, a rotary encoder installed on the valve driving device can be used to monitor the rotation angle of the valve stem in real time, and the angle data can be converted into the opening position of the valve. In another implementation, a linear displacement sensor can be used to directly measure the linear displacement of the valve plate or the valve stem, so as to obtain the opening position data of the valve. These sensors transmit the collected analog or digital signals to the control system, and after necessary signal processing and conversion, the accurate valve opening position data can be obtained. It can be understood that the valve opening position data refers to the real-time position information used to describe the opening or closing degree of the valve, which is usually collected and output by a valve position sensor (such as a potentiometer, an encoder or a magnetostrictive sensor), and its value can be expressed as a percentage, an angle or a linear displacement, which is used to indicate the relative position of the valve plate relative to the valve seat.

[0082] If the valve opening position data is in the resistance component separation interval, a friction reference value is calculated. Exemplarily, the friction reference value can be calculated by controlling the valve drive device to move a preset small distance in the valve closing direction, and collecting first valve operating torque data during the process. Then, according to the first valve operating torque data, a forward micro-motion average torque value is calculated. Next, the valve drive device is controlled to move the same preset small distance in the valve opening direction, and second valve operating torque data is collected. According to the second valve operating torque data, a reverse micro-motion average torque value is calculated. Finally, the friction reference value is calculated by taking the average or weighted average of the forward micro-motion average torque value and the reverse micro-motion average torque value. For example, the friction reference value can be simply calculated by adding the forward micro-motion average torque value and the reverse micro-motion average torque value and dividing by two. It can be understood that the resistance component separation interval refers to the valve opening range in which the valve plate has not yet contacted the valve seat or has only slightly contacted the valve seat during the closing process, at which time the driving torque is mainly composed of friction resistance, and the sealing force has not yet been significantly generated. In this interval, the friction component can be effectively identified and quantified. The friction reference value refers to the torque reference value required to overcome the internal friction resistance of the valve drive device when there is no sealing force under a specific working condition. The reference value is used to separate the friction component from the total driving torque to obtain a more pure sealing torque.

[0083] If the valve opening position data is in the sealing force judgment interval, the smooth sealing compression stiffness is calculated according to the friction force reference value. For example, the third valve operating torque data reflecting the actual operating torque of the valve in the sealing force judgment interval can be collected. In order to eliminate measurement noise, the third valve operating torque data needs to be filtered, for example, using a low-pass filter or a sliding average filter. At the same time, in order to ensure the consistency of the data, the valve opening position data needs to be smoothed, for example, using a sliding average or a Savitzky-Golay filter. Then, the filtered third valve operating torque data and the smoothed valve opening position data are time-aligned to ensure that the torque value and the corresponding opening position data are synchronized in time. Next, the time-aligned third valve operating torque data is subtracted from the previously calculated friction force reference value to obtain net sealing torque data. The net sealing torque data excludes the influence of friction and more truly reflects the compression force borne by the seal. Finally, the sealing compression stiffness sequence is calculated according to the net sealing torque data and the time-aligned valve opening position data, and the sequence is smoothed to obtain the smooth sealing compression stiffness. It can be understood that the sealing force judgment interval refers to the valve opening range in which the valve plate has contacted the valve seat and started to apply compression force to the seal ring during the closing process, and at this time the sealing force component in the driving torque significantly increases. In this interval, the sealing compression stiffness needs to be accurately evaluated to judge the sealing state. The smooth sealing compression stiffness refers to the sealing compression stiffness value after smoothing in the sealing force judgment interval. The sealing compression stiffness reflects the ability of the valve seal to resist deformation when compressed, and is a key indicator for evaluating the sealing state and the health of the seal. Through smoothing, measurement noise and transient fluctuations can be eliminated, and more stable and reliable stiffness values can be obtained.

[0084] According to the smooth sealing compression stiffness, the valve driving device is controlled. For example, a preset minimum effective sealing stiffness can be set. If the calculated smooth sealing compression stiffness is greater than the preset minimum effective sealing stiffness, it indicates that the valve seal is being effectively compressed. At this time, the system further calculates the growth rate of the smooth sealing compression stiffness. If the growth rate is less than the preset stiffness stability threshold, it indicates that the sealing compression process has stabilized and the sealing force has reached the expected level, at which time the valve driving device can be controlled to stop running to complete the closing operation of the valve. This control method can ensure that the valve is accurately stopped after reaching the effective sealing state, avoiding overpressure or underpressure sealing.

[0085] Traditional methods often rely on a single torque threshold to determine whether the valve is closed to the position, which is prone to misjudgment when the ambient temperature or process fluid temperature fluctuates, causing the friction to change. For example, in a low temperature environment, the viscosity of the lubricant increases, the friction increases, and the valve may not be fully closed to the position, and the torque may reach the preset threshold, causing the drive to stop prematurely, resulting in valve leakage. The present embodiment introduces the calculation of the friction reference value and the evaluation of the smooth sealing compression stiffness, significantly improving the accuracy and reliability of the valve drive control.

[0086] Through the above technical solutions, the present embodiment can dynamically compensate for the influence of environmental changes on friction by calculating the friction reference value, making the subsequent sealing force analysis more accurate. Within the sealing force judgment interval, the torque and opening data are filtered, smoothed and time-aligned, and the sealing compression stiffness sequence is calculated, and then the moving average is performed, to finally obtain a stable and reliable smooth sealing compression stiffness. This detailed processing process makes the judgment of the sealing state more sensitive and accurate. When the smooth sealing compression stiffness reaches the preset value and the growth rate tends to be stable, the valve drive device is controlled to stop, which ensures that the valve stops running only after effective sealing is achieved, avoiding leakage caused by premature stopping, and preventing damage to the seal and the drive device caused by overpressure sealing. Therefore, the present embodiment can significantly improve the reliability and sealing performance of the valve, prolong the service life of the valve and the drive device, and reduce the operation and maintenance cost.

[0087] In some embodiments, in step S102, calculating the friction reference value can include but is not limited to the following steps:

[0088] A valve forward movement signal is generated, which is used to control the valve drive device to move a preset distance in the valve closing direction, and first valve running torque data is collected;

[0089] According to the first valve running torque data, a forward micro-motion average torque value is calculated;

[0090] A valve reverse movement signal is generated, which is used to control the valve drive device to move a preset distance in the valve opening direction, and second valve running torque data is collected;

[0091] According to the second valve running torque data, a reverse micro-motion average torque value is calculated;

[0092] According to the forward micro-motion average torque value and the reverse micro-motion average torque value, a friction reference value is calculated.

[0093] In some embodiments, the calculation of the friction reference value can not be accurate enough or be affected by transient factors, which can cause deviation in the subsequent calculation of the seal compression stiffness and affect the accuracy of the valve drive control. To this end, a forward valve movement signal can be generated to control the valve drive device to move a preset distance in the valve closing direction, and first valve operating torque data can be collected. Based on the first valve operating torque data, a forward micro-motion average torque value can be calculated. For example, a control instruction can be sent to the valve drive device to control the valve drive device to move a preset distance in the valve closing direction in small steps or in a very short time. The preset distance is usually set to be sufficient to overcome the static friction and enter the dynamic friction state, but not enough to cause significant seal compression or medium flow change. At the same time, the first valve operating torque data reflecting the actual resistance of the valve during forward micro-motion is collected. The collected first valve operating torque data can be statistically processed, for example, by taking the average, median or weighted average, etc., to eliminate transient fluctuations and noise, and obtain a stable estimate of the friction during forward micro-motion.

[0094] Then a reverse valve movement signal is generated to control the valve drive device to move a preset distance in the valve opening direction, and second valve operating torque data is collected. Based on the second valve operating torque data, a reverse micro-motion average torque value is calculated. For example, a control instruction can be sent to the valve drive device to control the valve drive device to move the same preset distance in the valve opening direction, while collecting the second valve operating torque data, and the same or similar statistical method as calculating the forward micro-motion average torque value can be used to obtain a stable estimate of the friction during reverse micro-motion.

[0095] Then, based on the forward micro-motion average torque value and the reverse micro-motion average torque value, the friction reference value is calculated, which further offsets system errors, eliminates directional deviations, and improves the accuracy and robustness of the friction reference value by considering the friction in both directions. For example, the final friction reference value can be obtained by taking the arithmetic mean, weighted average or other forms of combination of the two average torque values.

[0096] The embodiment introduces valve forward movement signals and valve reverse movement signals, respectively collects forward and reverse valve operating torque data, and calculates corresponding micro-motion average torque values, so that the friction characteristics of the valve in the micro-motion state can be more comprehensively and accurately captured. Specifically, through forward and reverse micro-motion, one-way measurement deviation caused by factors such as internal structure of the driving device, contact characteristics between the valve sealing component and the valve stem, and medium pressure can be effectively distinguished and offset. The combination of forward micro-motion average torque value and reverse micro-motion average torque value can provide a more balanced and unbiased friction estimate, so that the calculated friction reference value is closer to the pure friction resistance component in the actual operation of the valve, and provides more reliable input for subsequent sealing compression stiffness calculation.

[0097] In order to more clearly illustrate the technical scheme, specific examples are used in the following. When the valve opening position data enters the resistance component separation interval, the control system sends a forward micro-motion instruction to the valve driving device, moves the valve 0.1 millimeter in the closing direction, and collects valve driving torque data at a frequency of 100 Hz during the process to obtain first valve operating torque data. Subsequently, the data is averaged to obtain a forward micro-motion average torque value, for example, 50 Nm. Then, the control system sends a reverse micro-motion instruction to move the valve 0.1 millimeter in the opening direction, collects second valve operating torque data, and calculates a reverse micro-motion average torque value, for example, 48 Nm. Finally, the two average torque values are arithmetically averaged, that is, (50 Nm + 48 Nm) / 2 = 49 Nm, as the current friction reference value. The friction reference value is then used for smooth sealing compression stiffness calculation in the sealing force judgment interval, thereby realizing accurate control of the valve driving device.

[0098] Through the above technical scheme, the embodiment can significantly improve the calculation accuracy and robustness of the friction reference value. Compared with one-way measurement or simple measurement, the embodiment effectively suppresses measurement noise and transient interference through bidirectional micro-motion and average value calculation, and reduces the sealing compression stiffness calculation deviation caused by measurement error. Thus, more reliable basis can be provided for accurate control of the valve driving device, overpressure or underpressure sealing caused by inaccurate friction estimation can be avoided, the service life of the valve sealing component is prolonged, and the stability and safety of the valve operation are improved.

[0099] In some embodiments, in step S103, calculating the smooth sealing compression stiffness according to the friction reference value can include but is not limited to the following steps:

[0100] Step S201, collecting third valve operating torque data;

[0101] Step S202, filtering the third valve operating torque data;

[0102] Step S203, smoothing the valve opening position data;

[0103] Step S204, time aligning the filtered third valve operating torque data and the smoothed valve opening position data;

[0104] Step S205, subtracting the time aligned third valve operating torque data from the friction reference value to obtain net sealing torque data;

[0105] Step S206, calculating a sealing compression stiffness sequence according to the net sealing torque data and the time aligned valve opening position data;

[0106] Step S207, performing a sliding average on the sealing compression stiffness sequence to obtain a smoothed sealing compression stiffness.

[0107] In some embodiments, the third valve operating torque data can be collected first. For example, the torque data generated by the valve driving device can be obtained in real time or periodically when the valve driving device performs sealing compression operation. The third valve operating torque data reflects the total resistance experienced by the valve during the sealing process, including the compression force of the seal and the residual friction force, etc. The third valve operating torque data is filtered to eliminate noise and abnormal fluctuations in the data, to obtain a more stable and true torque change trend. For example, various filtering algorithms such as low-pass filter, median filter or Kalman filter can be used to process the collected third valve operating torque data. At the same time, the valve opening position data is smoothed to eliminate possible small jitter or measurement errors in the valve opening position data during the collection process, to ensure the continuity and accuracy of the position data. For example, methods such as sliding average, Savitzky-Golay filter, etc. can be used to smooth the valve opening position data.

[0108] Then the third valve operating torque data after filtering and the valve opening position data after smoothing are time-aligned, so that the torque data and the corresponding valve opening position data remain synchronized on the time axis for subsequent accurate correlation analysis. This can be achieved through techniques such as timestamp matching, interpolation or resampling. Subtract the third valve operating torque data after time alignment from the friction reference value to obtain the net sealing torque data. By subtracting the friction reference value, the friction component can be effectively stripped, so that the net sealing torque data generated only by the compression of the seal can be more accurately obtained. According to the net sealing torque data and the valve opening position data after time alignment, the sealing compression stiffness sequence is calculated. The sealing compression stiffness reflects the ability of the seal to resist deformation at different compression levels, and is a key parameter for evaluating the performance of the seal. The calculation process usually involves analyzing the relationship between the net sealing torque data and the valve opening position data, such as by taking the derivative of torque with respect to position or piecewise linear fitting. The sliding average processing of the sealing compression stiffness sequence can further eliminate local fluctuations in the sealing compression stiffness sequence, making the trend more stable and representative, thereby providing a more reliable basis for subsequent valve drive control.

[0109] The third valve operating torque data and the valve opening position data are collected to obtain the original operating state information of the valve during the sealing compression process. Subsequently, the original data is filtered and smoothed to effectively remove noise and measurement errors, ensuring the quality and reliability of the data. The key is to subtract the filtered third valve operating torque data from the pre-calculated friction reference value, successfully separating the sealing compression torque from the friction torque, thereby obtaining net sealing torque data that purely reflects the compression state of the seal. This separation of friction components allows the subsequent calculated sealing compression stiffness to more accurately represent the actual performance of the seal. Finally, the sealing compression stiffness sequence is further smoothed by sliding average processing to eliminate possible transient fluctuations in the calculation process, ensuring that the obtained smoothed sealing compression stiffness has good stability and representativeness, laying the foundation for accurate control of the valve drive device.

[0110] Through the above technical solutions, the original torque and position data are preprocessed, and the friction component is effectively separated, significantly improving the accuracy of the sealing compression stiffness calculation. As a result, the smoothed sealing compression stiffness obtained can more truly reflect the actual working state and performance of the valve seal, avoiding false judgments caused by noise, measurement errors or friction interference. This high-precision stiffness information is crucial for fine control of the valve drive device, helping to achieve more accurate sealing force control, prolong the service life of the seal, and improve the reliability and safety of the valve operation.

[0111] In some embodiments, in step S206, calculating the seal compression stiffness sequence according to the net seal torque data and the time-aligned valve opening position data can include, but is not limited to, the following steps:

[0112] Step S301, identifying key points on the relationship curve between the net seal torque data and the valve opening position data;

[0113] Step S302, dividing the seal compression stage into multiple sub-intervals according to the key points;

[0114] Step S303, calculating the seal compression stiffness according to the net seal torque data and the valve opening position data in each sub-interval;

[0115] Step S304, combining the seal compression stiffness corresponding to each sub-interval to obtain the seal compression stiffness sequence.

[0116] In some embodiments, since the seal compression process of the valve is usually nonlinear, involving complex mechanical responses of the sealing material at different compression levels, such as initial contact, elastic deformation, and plastic deformation stages. Without distinguishing these different stages, the calculation results may not accurately reflect the true stiffness characteristics of the seal at each stage, thereby affecting the accuracy of subsequent valve drive control. Therefore, the key points on the relationship curve between the net seal torque data and the valve opening position data can be identified first, which can be determined by analyzing the trend of the net seal torque data changing with the valve opening position data. These key points can represent the transition of the seal in different physical states or mechanical behaviors during compression, such as the initial contact point of the seal with the valve seat, the point at which the seal begins to deform significantly, or the point at which the maximum compression is reached. The purpose is to accurately define different stages in the seal compression process.

[0117] Then, according to the key points, the seal compression stage is divided into multiple sub-intervals, which can use the identified key points as the boundary line to subdivide the entire seal compression process into several continuous sub-stages with relatively uniform mechanical characteristics. For example, one sub-interval may correspond to the elastic deformation stage of the seal, while another sub-interval may correspond to the plastic deformation stage. The purpose is to perform independent stiffness analysis on each sub-interval to more accurately reflect the local characteristics.

[0118] According to the net sealing torque data and the valve opening position data in each sub-interval, the sealing compression stiffness is calculated. In each divided sub-interval, the net sealing torque data and the valve opening position data collected in the sub-interval are analyzed, for example, linear regression, curve fitting or difference calculation method, to obtain the sealing compression stiffness corresponding to the sub-interval. The stiffness value reflects the deformation resistance of the seal in the specific compression stage. The purpose is to obtain segmented and more detailed stiffness information.

[0119] Finally, the sealing compression stiffness corresponding to each sub-interval is combined to obtain a sealing compression stiffness sequence. The sealing compression stiffness values calculated by all sub-intervals can be arranged in order of the corresponding valve opening position to form a sequence reflecting the stiffness change of the entire sealing compression process. The sequence can comprehensively and dynamically describe the stiffness characteristics of the seal under different compression degrees.

[0120] The embodiment can accurately capture the moment or position of the mechanical behavior transition of the seal in the compression process by identifying the key points on the relationship curve between the net sealing torque data and the valve opening position data. Due to the nonlinear characteristics of the sealing compression process, the stiffness in different stages shows significant differences, so the entire sealing compression stage is divided into multiple sub-intervals by the key points, so that the sealing characteristics in each sub-interval can be considered as relatively uniform or have a specific change rule. On this basis, the sealing compression stiffness is calculated independently for each sub-interval, avoiding the simple averaging of the entire complex process, so as to obtain more representative and accurate local stiffness values. Finally, these segmented sealing compression stiffnesses are combined to form a complete sealing compression stiffness sequence, which can reflect the stiffness change of the seal from the initial contact to the complete compression in detail, providing more detailed and reliable basic data for subsequent smoothing and valve drive control.

[0121] To make the technical solution clearer, specific examples are used for explanation below. Assume that during the valve closing process, the collected net sealing torque data and valve opening position data form a curve. First, the system will analyze the curve and identify, for example, that when the valve opening position is X1, the net sealing torque begins to rise significantly, which can be a key point indicating the initial contact of the seal with the valve seat. Subsequently, when the valve opening position is X2, the torque rise slope changes significantly, which can indicate that the seal has entered the plastic deformation stage from the elastic deformation stage and is identified as another key point. Based on these key points, the seal compression stage is divided into three subintervals: [initial position, X1] (no contact or pre-contact), [X1, X2] (elastic compression stage), and [X2, final closing position] (plastic compression or full compression stage). Within each subinterval, for example, in the [X1, X2] interval, a seal compression stiffness value is calculated by performing linear regression analysis on the net sealing torque data and valve opening position data in the interval, which represents the stiffness of the seal in the elastic compression stage. Similarly, in the [X2, final closing position] interval, a corresponding stiffness value is also calculated. Finally, these calculated stiffness values are combined in order of their corresponding valve opening positions to form a sequence reflecting the stiffness changes throughout the seal compression process. For example, the sequence can show that the stiffness is low and stable in the elastic stage and significantly higher in the plastic stage.

[0122] Through the above technical solution, the present embodiment makes the calculation of seal compression stiffness more refined and localized through the identification of key points and the division of subintervals, thereby significantly improving the accuracy and reliability of the seal compression stiffness sequence. This segmented calculation method can more truly reflect the actual mechanical response of the seal at different compression levels, providing more solid data support for the accurate control of the valve driving device and helping to achieve more precise seal force control and longer seal life.

[0123] In some embodiments, in step S301, identifying the key points on the relationship curve between the net sealing torque data and the valve opening position data can include, but is not limited to, the following steps:

[0124] Step S401, segmenting the net sealing torque data and valve opening position data to obtain multiple data segments;

[0125] Step S402, calculating the torque change rate corresponding to each data segment;

[0126] Step S403, identifying the initial significant change point corresponding to each torque change rate;

[0127] Step S404, performing continuity detection on the multiple initial significant change points to obtain a target significant change point;

[0128] Step S405, amplitude threshold judgment is performed on the target significant change point to obtain a key point.

[0129] In some embodiments, due to the possibility of data noise, measurement error or nonlinear characteristics of sealing components during valve operation, simply identifying key points may result in insufficient accuracy or insufficient robustness of the identification result, thereby affecting the accuracy of the sealing compression stiffness sequence. Therefore, the net sealing torque data and valve opening position data can be segmented to obtain multiple data segments. The continuously collected data stream can be divided into several discrete data segments according to a preset time interval, data volume or based on data characteristics (e.g., torque or opening change trend). The purpose is to decompose the complex data curve into local segments that are easier to analyze and process, so as to facilitate subsequent fine analysis of the characteristics of each local region.

[0130] Then, the torque change rate corresponding to each data segment is calculated. Within each data segment, the instantaneous or average change trend of the net sealing torque data with respect to the valve opening position data or time can be calculated by difference, regression analysis or sliding window average, etc. For example, the ratio of the torque difference value to the opening difference value between adjacent data points can be calculated, or the data segment is linearly fitted, and the slope of the fitted straight line is taken as the torque change rate. The purpose is to quantify the degree of change of the torque with the opening, thereby preliminarily identifying the region where the sealing state may change.

[0131] Then, the initial significant change point corresponding to each torque change rate is identified. In the calculated torque change rate sequence, by setting a threshold, a peak detection algorithm or a statistical method, the time or position where the torque change rate changes significantly or suddenly is found. These points usually indicate the change of the contact state of the sealing element and the valve seat, such as from free travel to initial contact, or from elastic deformation to plastic deformation. The purpose is to preliminarily screen out all candidate points that may indicate the transition of the sealing state. The continuity of the multiple initial significant change points is detected to obtain the target significant change point. The initial significant change points can be checked for continuity or aggregation in the time or opening dimension to exclude false significant change points caused by transient noise or accidental fluctuations. The purpose is to improve the robustness of the identification of significant change points and reduce false positives.

[0132] Finally, the target significant change point is subjected to a magnitude threshold judgment to obtain the key point, which can evaluate whether the torque change magnitude corresponding to the target significant change point reaches a preset magnitude threshold. The preset magnitude threshold can be set according to the valve type, sealing material characteristics, operating conditions and historical data experience. The purpose is to ensure that the identified key point not only has a significant change rate, but also has a large enough change magnitude to represent the actual sealing state transition, thereby avoiding misjudgment of small and unimportant fluctuations as key points.

[0133] The present embodiment solves the challenge of accurately identifying the key points on the relationship curve between the net sealing torque data and the valve opening position data under complex operating conditions by introducing segmentation processing, torque change rate calculation, initial significant change point identification, continuity detection and magnitude threshold judgment. First, segmentation processing decomposes continuous data into manageable segments, making local feature analysis possible. Second, the calculation of the torque change rate can sensitively capture the signs of sealing state transition, because the change in the degree of contact or compression of the seal and the valve seat is usually accompanied by a significant change in the torque change rate. The identification of the initial significant change point is based on the preliminary screening of these change rates. More importantly, by performing continuity detection on the initial significant change points, false change points caused by random noise or transient interference can be effectively filtered out, ensuring that the identified points have certain stability and reliability. Finally, the magnitude threshold judgment further ensures that the identified key points have sufficient physical meaning, i.e., their corresponding torque change magnitude is sufficient to represent the actual sealing state transition, rather than insignificant fluctuations. Through this layer-by-layer screening and verification mechanism, the present embodiment can accurately and robustly extract the key turning points that truly reflect the sealing compression process from the original data.

[0134] To make the technical solution clearer, specific examples are used for explanation below. Assume that during the valve closing process, a series of net sealing torque data and valve opening position data are collected. First, these data are processed in segments, for example, every 100 data points as a data segment. For each data segment, the torque change rate is obtained by calculating the ratio of the torque difference between adjacent data points and the opening difference. Then, by setting a change rate threshold (for example, when the change rate exceeds a certain preset value), the initial significant change points are identified. For example, in a certain data segment, if the torque change rate suddenly increases from near zero to a positive value, this point is marked as an initial significant change point. Subsequently, continuity detection is performed on these initial significant change points. For example, if at least 3 initial significant change points appear within a preset time window (for example, 5 consecutive data segments), it is considered that these points have continuity, and the first point among them is taken as the target significant change point. Finally, amplitude threshold judgment is performed on these target significant change points. For example, if the torque change amplitude (for example, the difference between the average values of the torque before and after the point) corresponding to a certain target significant change point is greater than a preset amplitude threshold (for example, 5 Nm), this point is finally determined as a key point. Through this multi-stage screening and verification, false positives caused by individual data point anomalies or slight fluctuations can be effectively avoided, ensuring that the identified key points are important turning points that truly reflect the sealing state transition.

[0135] Through the above technical solution, the embodiment can significantly improve the accuracy and robustness of identifying key points on the relationship curve between the net sealing torque data and the valve opening position data. Specifically, segment processing and torque change rate calculation make the capture of local data features more precise; the identification of initial significant change points provides a basis for subsequent screening; continuity detection effectively suppresses the influence of noise and accidental fluctuations on the identification result, avoiding false positives; amplitude threshold judgment ensures that the identified key points have actual physical meaning, eliminating unimportant minor changes. As a result, the identified key points can more accurately reflect the real physical turning points in the sealing compression stage, thereby providing a more reliable basis for subsequent division of the sealing compression stage into multiple subintervals, further improving the accuracy of sealing compression stiffness sequence calculation, and ultimately enhancing the precision and reliability of valve drive control.

[0136] In some embodiments, in step S404, the continuity detection is performed on the plurality of initial significant change points to obtain target significant change points, which can include but is not limited to the following steps:

[0137] Selecting one significant change point from the plurality of initial significant change points as a to-be-detected significant change point;

[0138] Monitoring the fluctuation amplitude of the torque change rate corresponding to the to-be-detected significant change point within a preset time window.

[0139] According to the fluctuation amplitude, the mean value and the standard deviation are calculated;

[0140] If the mean value is within the preset fluctuation range and the standard deviation is less than the preset fluctuation threshold, the to-be-detected significant change point is taken as the target significant change point.

[0141] In some embodiments, due to factors such as sensor noise, medium fluctuation, or mechanical vibration, the initial significant change point may have transient fluctuations or discontinuities. If these non-continuous and unstable changes are not effectively distinguished, they may be misidentified as target significant change points, thereby affecting the accuracy of subsequent sealing compression stiffness calculation. Therefore, one of the initial significant change points can be selected as a to-be-detected significant change point, which can be selected in a sequential traversal, timestamp-based, or torque change rate amplitude sorting manner. For example, each initial significant change point can be selected in time sequence for detection.

[0142] Then, within a preset time window, the fluctuation amplitude of the torque change rate corresponding to the to-be-detected significant change point is monitored. For example, the numerical range of the torque change rate can be continuously collected and analyzed. The preset time window refers to a continuous time interval before and after the to-be-detected significant change point, which is used to observe the dynamic behavior of the torque change rate near the point. The length of the time window can be adjusted according to the actual application scenario, data sampling frequency, and expected continuity detection sensitivity.

[0143] According to the fluctuation amplitude, the mean value and the standard deviation are calculated;

[0144] To more clearly illustrate the technical solutions, specific examples are used in the following explanations. Assume that during the valve closing process, the system has identified multiple initial significant change points. When one of the initial significant change points is selected as a to-be-detected significant change point, for example, the torque rate corresponding to this point suddenly increases at a certain time. To verify its continuity, the system will continuously collect torque rate data within a preset time window of 100 milliseconds before and after this point. Assume that within this 100 milliseconds, 10 torque rate data points are collected, which are [10, 11, 9, 10, 12, 11, 10, 9, 11, 10] (unit: N·m / mm). The system will calculate the average value and standard deviation from these data. For example, the average value is calculated to be 10.3 N·m / mm, and the standard deviation is calculated to be 0.9 N·m / mm. At this time, the system will compare these calculation results with the preset threshold. Assume that the preset fluctuation range is [9.5, 12.0] N·m / mm, and the preset fluctuation threshold is 1.5 N·m / mm. Since the calculated average value 10.3 N·m / mm is within the preset fluctuation range [9.5, 12.0] N·m / mm, and the standard deviation 0.9 N·m / mm is less than the preset fluctuation threshold 1.5 N·m / mm, the to-be-detected significant change point is confirmed as a target significant change point. Conversely, if another to-be-detected significant change point has a larger torque rate data fluctuation within the preset time window, for example, the calculated standard deviation is 2.0 N·m / mm, which exceeds the preset fluctuation threshold 1.5 N·m / mm, then this point will be determined as a non-continuous change and will not be a target significant change point. In this way, the present embodiment can effectively distinguish between real, continuous sealing compression changes and transient noise or interference, thereby improving the accuracy of key point identification.

[0145] Through the above technical solutions, the present embodiment can significantly improve the accuracy and robustness of key point identification on the relationship curve between the net sealing torque data and the valve opening position data. By strictly detecting the continuity of the initial significant change point and combining the average value and standard deviation judgment, transient noise or non-continuous fluctuation can be effectively avoided from being misidentified as a key point, thereby ensuring the accuracy of subsequent sealing compression stiffness sequence calculation. This not only improves the reliability of the valve drive control system, but also provides a solid data foundation for accurate evaluation of the valve sealing state, which helps to prolong the service life of the valve and optimize the operating efficiency.

[0146] In some embodiments, the step S405 of performing amplitude threshold judgment on the target significant change point to obtain the key point can include but is not limited to the following steps:

[0147] Step S501, acquiring the cumulative running time of the valve sealing component, the historical sealing compression stiffness change trend, and the current environmental temperature;

[0148] In step S502, a threshold of amplitude is determined according to the cumulative running time of the valve sealing component, the historical sealing compression stiffness change trend, and the current environmental temperature.

[0149] In step S503, if the torque change amplitude corresponding to the target significant change point is greater than the threshold of amplitude, the target significant change point is taken as the key point.

[0150] In some embodiments, due to the use of a fixed threshold of amplitude, the actual running condition and environmental changes of the valve sealing component may not be fully considered, resulting in an impact on the identification accuracy of the key point. For example, the wear and aging of the valve sealing component and the fluctuation of the environmental temperature all affect the sealing performance and in turn change the normal change range of the sealing torque. Therefore, the cumulative running time of the valve sealing component, the historical sealing compression stiffness change trend, and the current environmental temperature can be obtained first, wherein the cumulative running time refers to the total length of time that the sealing component of the valve has actually run since the valve was put into use. This time can be used as an important indicator for evaluating the aging degree and wear condition of the sealing component. The historical sealing compression stiffness change trend refers to the change law of the sealing compression stiffness of the valve over time or the number of running cycles in the past running period, such as the stiffness decay curve or fluctuation mode obtained through historical data analysis. The current environmental temperature refers to the real-time temperature of the environment in which the valve is located when the valve drive control system is making a judgment. The environmental temperature directly affects the physical properties of the sealing material, such as the elastic modulus and the friction coefficient.

[0151] Then, a threshold of amplitude is determined according to the cumulative running time of the valve sealing component, the historical sealing compression stiffness change trend, and the current environmental temperature. A torque change amplitude threshold that adapts to the current working condition can be calculated through a pre-set model, algorithm, or table lookup method. For example, as the cumulative running time increases, the sealing component may wear, causing the sealing stiffness to decrease. At this time, the threshold of amplitude may need to be adjusted accordingly to avoid misjudgment. The historical sealing compression stiffness change trend can provide a baseline for predicting future stiffness changes, thereby more accurately setting the threshold. The change of the environmental temperature may cause the thermal expansion and contraction of the sealing material, affecting the sealing force, and therefore also needs to be considered in the determination of the threshold.

[0152] If the torque change amplitude corresponding to the target significant change point is greater than the threshold of amplitude, the target significant change point is taken as the key point. This means that when the torque change amplitude exceeds the threshold dynamically adjusted according to the current actual situation, the point can be considered as a key turning point in the sealing compression process, thereby ensuring the accuracy and reliability of the identification of the key point.

[0153] To make the technical solution clearer, specific examples are used for explanation below. Assume that a valve sealing component has accumulated 5000 hours of operation, and its historical sealing compression stiffness change trend shows slight attenuation, and the current environmental temperature is 30 degrees Celsius. The system will calculate a dynamic amplitude threshold, for example, set to 15 Newton-meters, according to these input parameters through a pre-set machine learning model or empirical formula. When the torque change amplitude corresponding to the target significant change point is detected to be 18 Newton-meters, since 18 Newton-meters is greater than 15 Newton-meters, the point will be identified as a key point. Conversely, if the torque change amplitude corresponding to another target significant change point is 12 Newton-meters, it will not be identified as a key point. This dynamic adjustment mechanism enables the system to adapt to the operating characteristics of the valve under different life cycles and different environmental conditions, ensuring the accuracy of key point identification.

[0154] Through the above technical solution, the embodiment can significantly improve the accuracy and robustness of key point identification in valve sealing compression stiffness calculation. Since the amplitude threshold is dynamically determined according to the actual operating conditions and environmental conditions of the valve sealing component, it can effectively avoid misjudgment caused by factors such as component aging, wear and tear, or changes in environmental temperature, making the calculation of the sealing compression stiffness sequence more accurate. This not only helps to more accurately evaluate the sealing performance of the valve, but also provides a more reliable basis for the control of the valve drive device, thereby prolonging the service life of the valve and improving the operating safety.

[0155] In some embodiments, in step S502, determining the amplitude threshold according to the accumulated operating time of the valve sealing component, the historical sealing compression stiffness change trend and the current environmental temperature can include but is not limited to the following steps:

[0156] Obtaining medium corrosivity parameters and operating frequency parameters during valve operation;

[0157] Correcting the accumulated operating time according to the medium corrosivity parameters and the operating frequency parameters;

[0158] Determining the amplitude threshold according to the corrected accumulated operating time, the historical sealing compression stiffness change trend and the current environmental temperature.

[0159] In some embodiments, since only considering these macroscopic parameters can not fully reflect the complex effects on the valve sealing components in actual operation, such as the corrosiveness of the medium and the operating frequency of the valve, and other factors, which have a significant impact on the wear and aging of the sealing components, if not taken into account, it can cause the determined amplitude threshold to deviate from the actual performance degradation of the sealing components, thereby affecting the accuracy of the key point identification. For this purpose, the medium corrosiveness parameter and the operating frequency parameter during the operation of the valve can be obtained first, wherein the medium corrosiveness parameter refers to the degree of erosion or degradation of the chemical properties of the fluid contacted by the valve to the sealing component material, which can be quantitatively represented, for example, by obtaining indicators such as corrosion rate, corrosion level, or concentration of specific chemical components. The operating frequency parameter refers to the number of times the valve is opened and closed per unit time, reflecting the frequency of mechanical stress on the sealing component. These parameters can be obtained through real-time monitoring by sensors, analysis of historical operation records, or manual input.

[0160] Then, according to the medium corrosiveness parameter and the operating frequency parameter, the cumulative operating time is corrected, and the amplitude threshold is determined according to the corrected cumulative operating time, the historical sealing compression stiffness change trend, and the current environmental temperature. The original cumulative operating time can be weighted or adjusted to more accurately reflect the actual aging degree of the sealing component. For example, in a corrosive medium environment or under high operating frequency, the actual wear and aging speed of the sealing component will accelerate, at this time the corrected cumulative operating time will be greater than the original cumulative operating time, and vice versa. The corrected cumulative operating time can more truly represent the equivalent service life of the sealing component.

[0161] To more clearly illustrate the technical solutions, specific examples are used in the following for explanation. Assume that a valve is running in a strong corrosive medium, and its operating frequency is much higher than the average level. This embodiment first acquires the medium corrosiveness parameter during the operation of the valve, for example, sets a corrosion factor of 1.5 (indicating that the corrosion accelerates 1.5 times the aging), and acquires the operating frequency parameter, for example, sets a frequency factor of 1.2 (indicating that the high-frequency operation accelerates 1.2 times the aging). Then, the original cumulative operating time is multiplied by these correction factors (for example, the corrected cumulative operating time = original cumulative operating time × corrosion factor × frequency factor), to obtain a corrected cumulative operating time. For example, if the original cumulative operating time is 1000 hours, the correction may be 1000 × 1.5 × 1.2 = 1800 hours. Then, the system inputs this corrected 1800 hours, together with the historical sealing compression stiffness change trend and the current environmental temperature, into the amplitude threshold determination model. Thus, the determined amplitude threshold can more accurately reflect the actual aging degree of the valve under the specific severe working condition, so that the system can more timely and accurately identify the key change point of the sealing performance, thereby realizing more accurate valve drive control and maintenance strategy.

[0162] Through the above technical solutions, the amplitude threshold determined by this embodiment can more accurately reflect the actual performance degradation of the valve sealing component, avoiding the evaluation deviation caused by considering only the cumulative operating time. This makes it possible to more accurately determine whether the sealing performance has changed significantly when identifying the key point on the relationship curve between the net sealing torque data and the valve opening position data, thereby improving the reliability and intelligent level of the valve drive control. This embodiment can effectively adapt to the complex aging mechanism of the valve sealing component under different working conditions, prolong the service life of the valve, and reduce the unplanned downtime and maintenance cost.

[0163] In some embodiments, in step S104, controlling the valve drive device according to the smoothed sealing compression stiffness can include but is not limited to the following steps:

[0164] If the smoothed sealing compression stiffness is greater than the preset minimum effective sealing stiffness, the growth rate of the smoothed sealing compression stiffness is calculated.

[0165] If the growth rate of the smoothed sealing compression stiffness is less than the preset stiffness stability threshold, the valve drive device is controlled to stop.

[0166] In some embodiments, since the valve is only roughly controlled according to the smooth sealing compression stiffness, it can not be accurate to determine whether the valve has reached the optimal sealing state, and there is a risk of overdrive or underdrive, thereby affecting the sealing effect and the service life of the equipment. Therefore, the smooth sealing compression stiffness can be determined, and if the smooth sealing compression stiffness is greater than the preset minimum effective sealing stiffness, the growth rate of the smooth sealing compression stiffness is calculated. The preset minimum effective sealing stiffness refers to the minimum sealing compression stiffness value required to ensure that the sealing components of the valve can effectively prevent medium leakage. This value can be determined by experimental testing, theoretical calculation, or according to the type of valve, the characteristics of the medium, the working pressure, and other parameters. The purpose is to ensure that the sealing stiffness reaches a basic effective level during valve driving, and to avoid subsequent growth rate judgment when the stiffness is too low, thereby improving the reliability of control.

[0167] Then the growth rate of the smooth sealing compression stiffness is determined, and if the growth rate of the smooth sealing compression stiffness is less than the preset stiffness stability threshold, the valve driving device is controlled to stop. The growth rate of the smooth sealing compression stiffness refers to the rate of change of the smooth sealing compression stiffness with time or valve opening position when the valve driving device continuously compresses the valve. This growth rate can be calculated by differentiating or regression analyzing the continuously collected smooth sealing compression stiffness data. The purpose is to monitor the trend of the stiffness change to determine whether the sealing compression process is stable. The preset stiffness stability threshold is a critical value for determining whether the sealing compression stiffness growth has stabilized. When the growth rate of the smooth sealing compression stiffness is lower than this threshold, it indicates that the sealing compression process is close to completion, and the sealing stiffness has basically stabilized, and continued driving can cause over-compression or unnecessary energy consumption. This threshold can be set according to the design characteristics of the valve, the elastic modulus of the sealing material, and the actual operation experience.

[0168] To make the technical solution clearer, specific examples are used for explanation below. Assume that a ball valve needs to reach a certain sealing compression stiffness during closing to ensure no leakage. When the valve driving device starts to close the valve, the system continuously acquires the smooth sealing compression stiffness. When the smooth sealing compression stiffness first exceeds the preset minimum effective sealing stiffness (for example, set to 500 N / mm), the system starts to calculate the growth rate of the stiffness. For example, within a certain period of time, the smooth sealing compression stiffness increases from 550 N / mm to 555 N / mm, and the growth rate is 5 N / mm. As the valve further closes, the sealing compression gradually saturates, and the stiffness growth rate gradually decreases. When the calculated growth rate is less than the preset stiffness stability threshold (for example, set to 1 N / mm), the system determines that the valve has reached a stable sealing state, and immediately controls the valve driving device to stop. This control method ensures that the valve reaches effective sealing while avoiding unnecessary over-driving, thereby protecting the seal and optimizing the driving process.

[0169] Through the above technical solution, the embodiment can realize intelligent and refined control of the valve driving device. Compared with control only according to the sealing stiffness, the embodiment can more accurately identify the timing of the valve reaching the best sealing state by combining the judgment of the stiffness growth rate, avoiding the problems of excessive compression or insufficient sealing commonly seen in traditional control. Thus, not only the sealing reliability and stability of the valve are improved, but also the energy consumption of the driving device is significantly reduced, the service life of the valve sealing components is prolonged, and the operation efficiency and economy of the entire valve system are improved.

[0170] The beneficial effects of implementing the embodiment of the application include that the embodiment of the application first acquires valve opening position data, calculates a friction reference value if the valve opening position data is in a resistance component separation interval, calculates a smooth sealing compression stiffness according to the friction reference value if the valve opening position data is in a sealing force judgment interval, and then controls the valve driving device according to the smooth sealing compression stiffness, so that data analysis can be performed in combination with the resistance component separation interval and the sealing force judgment interval to realize valve driving control, thereby improving accuracy and reliability.

[0171] As shown in Figure 2 , the embodiment of the application also provides a valve driving control system, which includes:

[0172] A data acquisition module 601 is configured to acquire valve opening position data.

[0173] A reference value calculation module 602 is configured to calculate a friction reference value if the valve opening position data is in a resistance component separation interval.

[0174] The sealing compression stiffness calculation module 603 is configured to, if the valve opening position data is in the sealing force judgment interval, calculate a smooth sealing compression stiffness according to the friction force reference value;

[0175] The drive device control module 604 is configured to control the valve drive device according to the smooth sealing compression stiffness.

[0176] The contents in the method embodiments are applicable to the system embodiments. The system embodiments specifically implement the same functions as the method embodiments, and achieve the same beneficial effects as the method embodiments.

[0177] The embodiments described in the embodiments of the present application are used to more clearly illustrate the technical solutions of the embodiments of the present application, and do not constitute a limitation on the technical solutions provided by the embodiments of the present application. Those skilled in the art can know that, with the evolution of technology and the appearance of new application scenarios, the technical solutions provided by the embodiments of the present application are also applicable to similar technical problems.

Claims

1. A valve drive control method characterized by, The method comprises the following steps: acquiring valve opening position data; if the valve opening position data is in a resistance component separation interval, calculating a friction reference value; if the valve opening position data is in a sealing force judgment interval, calculating a smooth sealing compression stiffness according to the friction reference value; controlling a valve driving device according to the smooth sealing compression stiffness; the calculation of the smooth sealing compression stiffness according to the friction reference value comprises: collecting third valve operating torque data; filtering the third valve operating torque data; smoothing the valve opening position data; time aligning the filtered third valve operating torque data and the smoothed valve opening position data; subtracting the third valve operating torque data after time alignment from the friction reference value to obtain net sealing torque data; calculating a sealing compression stiffness sequence according to the net sealing torque data and the valve opening position data after time alignment; sliding average processing the sealing compression stiffness sequence to obtain the smooth sealing compression stiffness.

2. The method of claim 1, wherein, the calculation of the friction reference value comprises: generating a valve forward movement signal for controlling the valve driving device to move a preset distance in a valve closing direction and collecting first valve operating torque data; calculating a forward inching average torque value according to the first valve operating torque data; generating a valve reverse movement signal for controlling the valve driving device to move a preset distance in a valve opening direction and collecting second valve operating torque data; calculating a reverse inching average torque value according to the second valve operating torque data; calculating the friction reference value according to the forward inching average torque value and the reverse inching average torque value.

3. The method of claim 1, wherein, the calculation of the sealing compression stiffness sequence according to the net sealing torque data and the valve opening position data after time alignment comprises: identifying key points on a relationship curve between the net sealing torque data and the valve opening position data; dividing a sealing compression stage into multiple subintervals according to the key points; calculating sealing compression stiffness according to the net sealing torque data and the valve opening position data in each subinterval; combining the sealing compression stiffness corresponding to each subinterval to obtain the sealing compression stiffness sequence.

4. The method of claim 3, wherein, the identification of the key points on the relationship curve between the net sealing torque data and the valve opening position data comprises: segmenting the net sealing torque data and the valve opening position data to obtain multiple data segments; calculating a torque change rate corresponding to each data segment; identifying an initial significant change point corresponding to each torque change rate; detecting continuity of multiple initial significant change points to obtain a target significant change point; judging the target significant change point according to an amplitude threshold to obtain the key point.

5. The method of claim 4, wherein, the detection of the target significant change point according to the continuity of multiple initial significant change points comprises: selecting one significant change point from the multiple initial significant change points as a to-be-detected significant change point; Within a preset time window, a fluctuation amplitude of a torque change rate corresponding to the to-be-detected significant change point is monitored; According to the fluctuation amplitude, an average value and a standard deviation are calculated; If the average value is within a preset fluctuation range and the standard deviation is less than a preset fluctuation threshold, the to-be-detected significant change point is taken as the target significant change point.

6. The method of claim 4, wherein, The amplitude threshold judgment on the target significant change point to obtain the key point comprises: Obtaining cumulative running time, historical sealing compression stiffness change trend and current environment temperature of a valve sealing component; According to the cumulative running time, the historical sealing compression stiffness change trend and the current environment temperature of the valve sealing component, an amplitude threshold is determined; If the torque change amplitude corresponding to the target significant change point is greater than the amplitude threshold, the target significant change point is taken as the key point.

7. The method of claim 6, wherein, The determination of the amplitude threshold according to the cumulative running time, the historical sealing compression stiffness change trend and the current environment temperature of the valve sealing component comprises: Obtaining medium corrosivity parameters and operation frequency parameters during valve operation; According to the medium corrosivity parameters and the operation frequency parameters, the cumulative running time is corrected; According to the corrected cumulative running time, the historical sealing compression stiffness change trend and the current environment temperature, the amplitude threshold is determined.

8. The method of claim 1, wherein, The control of the valve driving device according to the smooth sealing compression stiffness comprises: If the smooth sealing compression stiffness is greater than a preset minimum effective sealing stiffness, the growth rate of the smooth sealing compression stiffness is calculated; If the growth rate of the smooth sealing compression stiffness is less than a preset stiffness stability threshold, the valve driving device is controlled to stop.

9. A valve drive control system characterized by, Comprise: A data acquisition module is configured to acquire valve opening position data; A reference value calculation module is configured to calculate a friction force reference value if the valve opening position data is in a resistance component separation interval; A sealing compression stiffness calculation module is configured to calculate a smooth sealing compression stiffness according to the friction force reference value if the valve opening position data is in a sealing force judgment interval; A driving device control module is configured to control a valve driving device according to the smooth sealing compression stiffness; The sealing compression stiffness calculation module is further configured to: Collect third valve operation torque data; Filter the third valve operation torque data; Smooth the valve opening position data; Align the filtered third valve operation torque data and the smoothed valve opening position data in time; Subtract the third valve operation torque data aligned in time from the friction force reference value to obtain net sealing torque data; Calculate a sealing compression stiffness sequence according to the net sealing torque data and the valve opening position data aligned in time; Smoothly average the sealing compression stiffness sequence to obtain the smooth sealing compression stiffness.

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