A method and system for processing opening and closing degree travel data of a hoist

Abstract

The application relates to the technical field of water conservancy engineering control, and discloses a hoist opening degree stroke data processing method and system, which comprises the following steps: continuously acquiring two groups of real-time data of motor load and valve displacement during valve closing; when the motor load data first shows a continuous and background noise-exceeding lifting, marking the moment as an initial contact point; starting from the initial contact point, recording the two groups of real-time data of motor load and valve displacement at a preset sampling frequency, and calculating a resistance change rate = delta load / delta displacement; comparing the resistance change rate with a preset collision threshold to control hoisting and closing; the motor load and valve displacement data are monitored in real time, the resistance change rate is calculated, the contact point of the valve and a water seal or foreign matter is accurately identified during valve closing, the change trend of the resistance change rate is used to effectively distinguish flexible compression and rigid collision, misjudgment is avoided, and the safety and reliability of hoist operation are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of water conservancy engineering control, in particular to a kind of opening and closing machine opening stroke data processing method and system. BACKGROUND

[0002] In water conservancy engineering, the ship lock valve opening and closing machine system is the core equipment to ensure the safe and efficient passage of ships, and the core of its control logic is to accurately convert the signal of the stroke measuring device (such as a rotary encoder) into the vertical actual displacement of the valve body. However, mechanical systems need periodic maintenance and overhaul after long-term operation. For example, when the opening and closing machine system has been in operation for several years and reaches the maintenance period, the steel wire rope, transmission bearing and other components will be replaced. Although the new components meet the design requirements in terms of size and specifications, their physical properties (such as the elasticity and damping of the new steel wire rope, the initial friction and rolling resistance of the new bearing, etc.) differ slightly from those of the old components that have been running for a long time. Although these differences are not significant at the individual component level, they have a cumulative impact on the overall mechanical response of the system when integrated into the transmission chain. The existing opening and closing machine control logic is static and relies on pre-set fixed judgment criteria (such as the stroke measuring device reaching the bottom position threshold or the motor drive current exceeding the load threshold) to determine whether the valve is completely closed and the water seal is fully compressed. Due to changes in the mechanical response of the system, the actual compression state of the water seal corresponding to the original calibrated overload current value is no longer accurate, which may cause the water seal to not be fully compressed when the motor current reaches the old threshold or the water seal to be fully compressed but the current not to reach the threshold, making the system unable to accurately determine the true closing state of the valve.

[0003] In addition, during the closing process of the valve, foreign objects (such as stones and wood) carried by the upstream water flow may be stuck between the door body and the door sill, causing the door body to be blocked from descending prematurely and the motor drive current to rise rapidly. The combined effect of changes in the mechanical response of the system and external foreign object obstruction makes the current signal characteristics (rise rate, peak value, duration) caused by foreign object sticking similar to those of normal water seal compression after component replacement. Since the control system relies on static pre-set logic, it cannot distinguish between increased resistance of a normally compressed water seal and accidental encounter with a hard obstacle based on a single current threshold or stroke data, making it difficult for the control system to make correct and safe decisions: misjudging foreign object sticking as normal compression and continuing to apply pressure may cause damage to the valve, water seal or transmission mechanism due to rigid impact; prematurely stopping the closing process may result in insufficient compression of the water seal, leading to continuous leakage, wasting of water resources and long-term erosion of the lock chamber structure. In view of the above problems, the existing technology needs to be improved. SUMMARY

[0004] To solve the problems of the prior art, the present application provides an opening and closing machine opening stroke data processing method and system, which can accurately distinguish between normal water seal elastic response and foreign object sticking, thereby taking appropriate safety measures and effectively avoiding potential damage to the valve and water seal.

[0005] In a first aspect, the application provides a method for processing opening and closing machine opening stroke data, comprising:

[0006] During valve closing, continuously acquiring real-time data of motor load and valve displacement;

[0007] When the first continuous and background noise-exceeding lifting appears in the motor load data, mark the time as the initial contact point;

[0008] From the initial contact point, record real-time data of motor load and valve displacement at a preset sampling frequency, and calculate the resistance change rate = Δ load / Δ displacement;

[0009] Compare the resistance change rate with a preset collision threshold to control opening and closing.

[0010] The application accurately identifies the contact point of the valve and the water seal or foreign matter during valve closing by monitoring real-time motor load and valve displacement data and calculating the resistance change rate, effectively distinguishes flexible compression and rigid collision according to the change trend of the resistance change rate, avoids misjudgment, and improves the safety and reliability of the operation of the opening and closing machine.

[0011] Further, the application further provides that the method further comprises:

[0012] Acquire the command speed information and the actual speed information of the valve closing;

[0013] Calculate the instantaneous speed deviation in each sampling period, which is the absolute difference between the command speed and the actual speed;

[0014] When the instantaneous speed deviation of continuous multiple sampling periods exceeds the noise threshold of the speed deviation, it is determined that the valve body has sustained physical contact, and the initial contact point is identified, and from the initial contact point, real-time data of motor load and valve displacement are recorded at a preset sampling frequency.

[0015] Through this technical solution, the application introduces the speed deviation as an auxiliary or alternative basis for judging the initial contact point. Especially when the motor load signal is disturbed or not obvious, by monitoring the sustained change of the speed deviation, the initial contact of the valve body and the obstacle can be more sensitive and accurate, further improving the accuracy and robustness of the initial contact point determination.

[0016] Further, the application further provides that the method further comprises:

[0017] Set a continuous lag counter, which increments when the instantaneous speed deviation is continuously greater than the noise threshold;

[0018] When the instantaneous speed deviation is continuously less than or equal to the noise threshold, the continuous lag counter is immediately cleared;

[0019] When the instantaneous speed deviation of a plurality of consecutive sampling periods exceeds the noise threshold, and the value of the continuous lag counter reaches or exceeds the preset sampling point number, it is determined that there is persistent physical contact.

[0020] The present application quantitatively judges the persistence of the instantaneous speed deviation by introducing a continuous lag counter, effectively avoiding the interference of instantaneous noise or accidental fluctuations on the initial contact point determination, ensuring that only when the valve body has stable and persistent physical contact is it confirmed as the initial contact point, thereby improving the accuracy and anti-interference ability of the determination.

[0021] Further, the present application also proposes that, from the initial contact point, recording two groups of real-time data of motor load and valve displacement at a preset sampling frequency, the step of calculating the resistance change rate = Δload / Δdisplacement includes:

[0022] Setting a minimum displacement threshold and a rapid load increase threshold, judging whether Δdisplacement is lower than the minimum displacement threshold and whether Δload exceeds the rapid load increase threshold:

[0023] If both conditions are met, it is determined that there is a rigid collision;

[0024] If not, calculate the resistance change rate;

[0025] Δload is the change amount of the motor load at adjacent sampling times, and Δdisplacement is the change amount of the valve displacement at adjacent sampling times.

[0026] Through this technical solution, the present application introduces a double judgment mechanism for displacement and load change before calculating the resistance change rate, which can quickly and directly identify rigid collision events, avoiding the delay or inapplicability of calculating the resistance change rate in the case of extreme rigid collision, thereby achieving a more rapid and safe response.

[0027] Further, the present application also proposes that the method further includes:

[0028] When the resistance change rate is continuously lower than the preset normal threshold, the closing continues until the water seal is completely compacted;

[0029] When the resistance change rate exceeds the normal threshold but does not reach the collision threshold, the valve is controlled to perform a lifting cycle action, the hysteresis loop area is calculated, and it is judged whether there is a foreign object by comparing with a preset loss threshold.

[0030] By the technical scheme, the application introduces a fine control strategy based on the resistance change rate, which can not only judge normal water seal compaction, but more importantly, when the resistance change rate is between the normal and collision thresholds, the water seal elastic response and foreign object jamming can be effectively distinguished by performing the lifting and lowering cycle action and calculating the hysteresis loop area, so as to avoid over-compaction of the water seal or misjudgment of the foreign object, and improve the intelligent level of the system.

[0031] Further, the application further provides that the step of calculating the hysteresis loop area comprises:

[0032] The motor load and valve displacement recorded in the lifting and lowering cycle action are plotted into a descending process curve and an ascending process curve respectively, and the two curves form a closed area area, that is, the hysteresis loop area.

[0033] By the technical scheme, the application specifies the specific calculation method of the hysteresis loop area, plots the load displacement curve and calculates the closed area area thereof, so as to provide an intuitive and reliable index for quantifying the water seal elastic response or the existence of the foreign object, and make the subsequent judgment more accurate.

[0034] Further, the application further provides that the method further comprises:

[0035] If the hysteresis loop area is less than the loss threshold, it is judged that the water seal is elastically responsive, and the closing is continued until the water seal is completely compacted;

[0036] If the hysteresis loop area is greater than or equal to the loss threshold, it is judged that there is a foreign object and the valve is immediately lifted in reverse.

[0037] Based on the comparison of the hysteresis loop area and the loss threshold, the application provides clear decision logic, which can accurately distinguish between normal water seal elastic response and foreign object jamming, so as to take corresponding safety measures (continue to close or immediately stop / lift in reverse), and effectively avoid potential damage to the valve and the water seal.

[0038] Further, the application further provides that the method further comprises:

[0039] In the process of performing the normal closing operation, the maximum value of the resistance change rate is continuously tracked and recorded to obtain the maximum resistance change rate reference value of the normally compacted water seal.

[0040] By the technical scheme, the application introduces a dynamic learning mechanism, which can obtain the real reference value of the water seal compaction under the current system state by continuously tracking and recording the maximum resistance change rate in the normal closing operation, so that the subsequent threshold setting is more adaptive, and the inaccuracy of the traditional fixed threshold after the change of the system characteristics is overcome.

[0041] Further, the application further provides that the method further comprises:

[0042] Based on the maximum resistance change rate reference value, the normal threshold and the loss threshold are set by a preset scale factor or offset.

[0043] Through the technical scheme, the application realizes adaptive adjustment of the threshold, sets the normal threshold and the loss threshold based on the dynamically obtained maximum resistance change rate reference value, so that the key judgment parameters can be automatically updated with the change of the system running state, greatly improves the adaptability of the system to different working conditions and component wear, and ensures the accuracy and reliability of the judgment.

[0044] In a second aspect, the application also provides a gate opening and closing machine stroke data processing system for executing the gate opening and closing machine stroke data processing method, which comprises:

[0045] The data acquisition unit is used to continuously acquire two groups of real-time data of motor load and valve displacement during valve closing, and mark the time when the first continuous lifting that exceeds background noise appears in the motor load data as the initial contact point; and is also used to record two groups of real-time data of motor load and valve displacement at a preset sampling frequency from the initial contact point;

[0046] The data processing unit is used to calculate the resistance change rate = Δ load / Δ displacement.

[0047] The decision control unit is used to compare the resistance change rate with a preset collision threshold to control the opening and closing.

[0048] In summary, the gate opening and closing machine stroke data processing method and system provided by the application innovatively introduces the identification mechanism of the initial contact point by monitoring the motor load and valve displacement data in real time, and calculates the resistance change rate, so as to accurately identify the contact point of the valve and the water seal or foreign matter during valve closing, and effectively distinguish flexible compression and rigid collision according to the change trend of the resistance change rate, avoid misjudgment, improve the safety and reliability of the operation of the gate opening and closing machine, accurately distinguish the normal water seal elastic response and foreign matter jam, and thus take corresponding safety measures, effectively avoiding potential damage to the valve and the water seal. BRIEF DESCRIPTION OF DRAWINGS

[0049] Figure 1 A flowchart of a gate opening and closing machine stroke data processing method provided by an embodiment of the application is shown.

[0050] Figure 2 A structural schematic diagram of a gate opening and closing machine stroke data processing system provided by an embodiment of the application is shown.

[0051] Label explanation: 210, data acquisition unit; 220, data processing unit; 230, decision control unit. DETAILED DESCRIPTION

[0052] The technical solutions in the present application will be described clearly and completely below in combination with the drawings in the present application. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments. The components of the present application described and shown in the drawings herein can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the claimed present application, but only represents selected embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0053] It should be noted that similar reference numbers and letters represent similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings. Meanwhile, in the description of the present application, the terms "first", "second", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0054] In the field of water conservancy engineering, the opening and closing machine system of ship lock valve is the key equipment to ensure the safe and efficient passage of ships. This system usually relies on a set of precise control logic, the core of which is to accurately convert the signals generated by the stroke measuring device into the actual displacement of the valve body in the vertical direction. This conversion relationship is determined by rigorous measurement and calibration during the factory delivery or the first installation and commissioning stage, and is the basis for the system to accurately control the valve opening and ensure its operation according to the predetermined trajectory, thereby achieving reliable and repeatable valve operation under normal circumstances. However, any mechanical system needs periodic maintenance and overhaul after a long period of operation. Due to the introduction of new components with slight physical property differences in the previous overhaul, the mechanical response characteristics of the entire system have changed during the "loaded compression" stage. This change in mechanical response causes the system to deviate from the behavior mode at the initial calibration at the end of the closing stage. However, the control logic of the opening and closing machine system is usually static, relying on pre-set and fixed judgment criteria to determine whether the valve has been completely closed and the water seal has been compacted. Due to the change in the mechanical response of the system, the "overload" current value calibrated at the factory delivery or before the overhaul no longer accurately corresponds to the actual compacted state of the water seal. When the control system detects a sharp rise in motor drive current, it faces an unclear situation. This is because the current signal characteristics caused by foreign object jamming and the current signal characteristics generated by the system during "normal water seal compression" after replacing components show a high degree of similarity in some key dimensions, which is caused by the combined effect of the change in the mechanical response of the system and the external foreign object obstruction. It is impossible to effectively distinguish between the two completely different situations: "it is the increased resistance caused by the change in the mechanical properties of the system during normal water seal compression", or "it is an accidental encounter with a hard obstacle", due to the lack of ability to analyze and distinguish these complex signal patterns. In this state of ambiguity, it is impossible to make correct and safe decisions.

[0055] To this end, in a first aspect, see Figure 1 The present application proposes a method for processing opening and closing machine opening and stroke data, comprising:

[0056] During valve closing, continuously acquire real-time data of motor load and valve displacement;

[0057] When the first sustained and background noise-exceeding lift appears in the motor load data, mark this time as the initial contact point;

[0058] From the initial contact point, record real-time data of motor load and valve displacement at a pre-set sampling frequency, and calculate the resistance change rate = Δ load / Δ displacement;

[0059] The opening and closing are controlled by comparing the rate of change of resistance with a preset collision threshold.

[0060] The core of this application lies in the refined analysis of the dynamic mechanical response during valve closing to accurately distinguish between normal water seal compaction and abnormal rigid collision. Specifically, during valve closing, the system continuously acquires two sets of real-time data: motor load and valve displacement. These data can be collected in real time by sensors installed on the hoist. Motor load refers to the actual load borne by the hoist's drive motor during operation, which can usually be obtained in real time by measuring parameters such as motor current, power, or torque. For example, a current sensor can be connected in series in the motor circuit to convert the acquired current signal into a digital quantity, thereby reflecting the magnitude of the motor load. Alternatively, a torque sensor installed on the motor output shaft can directly measure the motor's output torque, which can also serve as a direct representation of the motor load. The vertical movement distance of the valve body relative to its initial open position during closing can be achieved using various displacement sensors. For instance, a wire encoder can be used, which is connected to the valve body via a wire. When the valve moves, the wire drives the encoder's internal shaft to rotate, thereby outputting a pulse signal or analog signal proportional to the displacement. In addition, ultrasonic sensors or laser rangefinders can be used to indirectly obtain valve displacement by measuring the change in distance from the sensor to the top of the valve body. Background noise refers to the inherent, random fluctuations in motor load data during normal operation when the valve is not in contact with any object. These fluctuations may originate from the motor's own operating noise, minor friction in the transmission mechanism, sensor accuracy limitations, etc. In practical applications, the typical range of background noise can be determined by collecting motor load data over a long period when the valve is running unloaded or moving slowly, and then performing statistical analysis on this data, such as calculating its root mean square value or standard deviation.

[0061] Subsequently, the continuously acquired motor load data is monitored in real time. When a sustained and background-noise-exceeding lift in the motor load data first appears, the moment is accurately marked as the initial contact point. For example, a dynamic average or a sliding window average can be set, and when the real-time load value exceeds the average plus a preset background noise threshold for a plurality of consecutive sampling points, the initial contact can be determined. This step aims to accurately capture the moment of the initial contact between the valve body and the underwater structure or foreign matter, providing an accurate starting point for subsequent refined analysis. From the initial contact point, the motor load and valve displacement real-time data are continuously recorded at a preset sampling frequency, for example, 100 times per second. These high-frequency data provide sufficient time resolution for calculating the resistance change rate. The formula for calculating the resistance change rate is Δload / Δdisplacement, where Δload is the change in motor load between adjacent sampling times, and Δdisplacement is the change in valve displacement between adjacent sampling times. For example, at time points t1 and t2 (t2 = t1 + 1 / sampling frequency), loads L1, L2 and displacements D1, D2 are collected, then Δload = L2 - L1, and Δdisplacement = D2 - D1. In this way, the dynamic change trend of the resistance experienced by the valve during the closing process can be monitored in real time.

[0062] Finally, the real-time calculated resistance change rate is compared with the preset collision threshold to control the action of the opening and closing machine. If the resistance change rate continues to be lower than the collision threshold, it indicates that the valve is undergoing a normal flexible compaction process, and the closing operation continues until the water seal is completely compacted. Conversely, if the resistance change rate rapidly rises and exceeds the preset collision threshold, it indicates that the valve may have encountered a rigid obstacle, at which point protective measures such as stopping or reversing the valve are immediately taken to avoid damage to mechanical components.

[0063] The application focuses on the dynamic parameter of "resistance change rate" which can more sensitively reflect the instantaneous change trend of the resistance of the valve under unit displacement change. In the normal water seal compaction process, the elastic deformation of the water seal will gradually and smoothly increase the resistance with the increase of displacement, so the resistance change rate will remain in a relatively low and stable range. However, when the valve body collides rigidly with hard foreign matter, even if the displacement change is small, the motor load will rise sharply, causing the resistance change rate to soar instantaneously, far exceeding the value during normal compaction. By accurately identifying the initial contact point and collecting data and calculating the resistance change rate after that, the application can capture this instantaneous and severe change, thereby realizing the rapid and accurate identification of rigid collision. Compared with the prior art, the application has higher robustness and adaptability, is not affected by small changes in the mechanical properties of the system, and can effectively deal with the situation of sudden foreign matter jamming. This dynamic and change rate-based judgment mechanism significantly improves the safety and reliability of the operation of the opening and closing machine, avoids equipment damage and water resource waste caused by misjudgment, and provides a more advanced solution for the safe operation of water conservancy projects.

[0064] The application further proposes to also include obtaining instruction speed information and actual speed information of the valve closing;

[0065] The instantaneous speed deviation in each sampling period is calculated, and the instantaneous speed deviation is the absolute difference between the instruction speed and the actual speed;

[0066] When the instantaneous speed deviation of a plurality of consecutive sampling periods exceeds the noise threshold of the speed deviation, it is determined that the valve body has sustained physical contact, and the initial contact point is identified, and from the initial contact point, the real-time data of the motor load and the valve displacement are recorded at a preset sampling frequency.

[0067] Specifically, during the closing of the valve, in addition to continuously obtaining the real-time data of the motor load and the valve displacement, the instruction speed information and the actual speed information of the valve closing are also obtained. The instruction speed information represents the speed at which the valve should be closed, and the actual speed information is obtained by real-time measurement by displacement sensors or encoders and the like, reflecting the actual movement speed of the valve. Further, in each preset sampling period, the instantaneous speed deviation is calculated. The instantaneous speed deviation is defined as the absolute difference between the instruction speed and the actual speed. By calculating the absolute difference, the deviation between the actual movement and the expected movement of the valve can be quantified, regardless of whether the actual speed is faster or slower than the instruction speed.

[0068] Thus, when the instantaneous speed deviation of the continuous multiple sampling periods exceeds the preset noise threshold of the speed deviation, it is determined that the valve body has sustained physical contact, and the time point is identified as the initial contact point. The noise threshold is used to filter out the instantaneous speed fluctuations caused by system vibration, sensor error or slight friction, etc., to ensure that only when the speed deviation reaches a certain level and persists, it is considered as effective physical contact. The judgment mechanism of continuous multiple sampling periods further enhances the robustness of identification and avoids misjudgment. After the initial contact point is identified, the real-time data of the motor load and the valve displacement are recorded at a preset sampling frequency, so as to perform subsequent resistance change rate calculation and opening and closing control.

[0069] In some preferred embodiments, assuming that the opening and closing machine valve is closing at an instruction speed of 5 mm / s, the actual speed information of the valve is continuously acquired, for example, through a displacement sensor or encoder installed on the valve rod, and data acquisition is performed at a sampling period of every 10 ms. During the closing of the valve, the instantaneous speed deviation in each sampling period is calculated in real time, that is, the absolute difference between the instruction speed and the actual speed. For example, if the instruction speed is 5 mm / s and the actual speed suddenly drops to 4.8 mm / s in a certain sampling period, the instantaneous speed deviation is 0.2 mm / s. The preset noise threshold of the speed deviation is 0.1 mm / s. If the instantaneous speed deviation of the continuous 5 sampling periods (for example, 50 ms) exceeds 0.1 mm / s, for example, 0.2, 0.25, 0.3, 0.28, and 0.22 mm / s, respectively, it is immediately determined that the valve body has sustained physical contact, and the time point is identified as the initial contact point. Once the initial contact point is identified, the recording of the real-time data of the motor load and the valve displacement is immediately started, and the subsequent resistance change rate calculation is performed at a preset sampling frequency (for example, every 50 ms), thereby providing data support for the accurate control of the opening and closing machine. This method can effectively avoid misjudgment caused by fluctuations in motor load data, and ensure that the identification of the initial contact point is more accurate and reliable.

[0070] The application further proposes that the above method further comprises:

[0071] A continuous lag counter is set, which is incremented when the instantaneous speed deviation is continuously greater than the noise threshold;

[0072] The continuous lag counter is immediately cleared when the instantaneous speed deviation is continuously less than or equal to the noise threshold;

[0073] When the instantaneous speed deviation of the continuous multiple sampling periods exceeds the noise threshold, and the value of the continuous lag counter reaches or exceeds the preset sampling point number, it is determined as sustained physical contact.

[0074] Specifically, a continuous lag counter is set as a variable to record the number of sampling periods in which the instantaneous speed deviation continuously exceeds the noise threshold. When the instantaneous speed deviation is greater than the preset noise threshold in the current sampling period, the value of the counter will be incremented. Conversely, once the instantaneous speed deviation is less than or equal to the noise threshold in a certain sampling period, it means that the speed deviation no longer exists continuously or has returned to normal, and the continuous lag counter will be immediately cleared to zero to ensure that only the true continuous deviation is accumulated and calculated. The preset sampling point number is a pre-set threshold value, which can be adjusted according to the actual application scenario and the requirement for detection sensitivity.

[0075] In some preferred embodiments, the noise threshold of the set speed deviation is 0.05 m / s, and the preset sampling point number is 5. During the valve closing process, the command speed and the actual speed are continuously obtained, and the instantaneous speed deviation is calculated. For example, in the continuous sampling period, the instantaneous speed deviation sequence is: 0.06, 0.07, 0.04, 0.08, 0.09, 0.10, 0.11. In the first sampling period, the instantaneous speed deviation 0.06 is greater than the noise threshold 0.05, and the continuous lag counter is incremented to 1. In the second sampling period, the instantaneous speed deviation 0.07 is greater than the noise threshold 0.05, and the continuous lag counter is incremented to 2. In the third sampling period, the instantaneous speed deviation 0.04 is less than the noise threshold 0.05, and the continuous lag counter is immediately cleared to zero. In the fourth sampling period, the instantaneous speed deviation 0.08 is greater than the noise threshold 0.05, and the continuous lag counter is incremented to 1. In the fifth sampling period, the instantaneous speed deviation 0.09 is greater than the noise threshold 0.05, and the continuous lag counter is incremented to 2. In the sixth sampling period, the instantaneous speed deviation 0.10 is greater than the noise threshold 0.05, and the continuous lag counter is incremented to 3. In the seventh sampling period, the instantaneous speed deviation 0.11 is greater than the noise threshold 0.05, and the continuous lag counter is incremented to 4. In this example, since the continuous lag counter has not reached the preset sampling point number 5, it has not been determined as a persistent physical contact.

[0076] If the subsequent instantaneous speed deviation continues to be greater than the noise threshold, for example, the instantaneous speed deviation is 0.12 in the eighth sampling period, the continuous lag counter is incremented to 5. At this time, since the value of the continuous lag counter reaches or exceeds the preset sampling point number 5, it is determined that the valve body has a persistent physical contact, and the moment is identified as the initial contact point. This mechanism effectively avoids the misjudgment caused by the temporary drop of the instantaneous deviation in the third sampling period, and ensures that only the continuous speed deviation is confirmed as a physical contact.

[0077] Further, the application also proposes that the step of recording the motor load and the valve displacement in real time at a preset sampling frequency from the initial contact point to calculate the resistance change rate = Δ load / Δ displacement includes:

[0078] A minimum displacement threshold and a rapid load increase threshold are set, and it is determined whether the displacement difference is lower than the minimum displacement threshold and whether the load difference exceeds the rapid load increase threshold:

[0079] If both conditions are met, it is determined that there is a rigid collision;

[0080] If not, the resistance change rate is calculated;

[0081] The load difference is the change in motor load between adjacent sampling times, and the displacement difference is the change in valve displacement between adjacent sampling times.

[0082] Specifically, the minimum displacement threshold is set to define a small change range of valve displacement, and the purpose is to identify the resistance received by the valve when it is almost stopped or has a very small displacement. For example, when the valve encounters a hard obstacle during closing, its displacement may suddenly become very small, even close to zero. The rapid load increase threshold is set to define the degree of rapid and significant increase in motor load, and the purpose is to identify sudden impact or resistance. For example, when the valve collides with a rigid object, the motor load will increase sharply. Wherein, determining whether the displacement difference is lower than the minimum displacement threshold and whether the load difference exceeds the rapid load increase threshold can be understood as a pre-judgment mechanism. When both conditions are met, i.e. the valve displacement is very small but the motor load increases sharply, it strongly indicates that the valve body has collided with a rigid object, rather than general friction or water seal compaction. Therefore, it can be immediately determined that it is a rigid collision. In practical applications, if the above two conditions are not met, it indicates that the current contact is not a rigid collision, which may be a normal water seal compaction process or contact with a non-rigid foreign object. In this case, the resistance change rate, i.e. the ratio of the load difference to the displacement difference, will continue to be calculated to evaluate the current resistance characteristics. The load difference specifically refers to the difference in motor load between adjacent sampling times, and the displacement difference specifically refers to the difference in valve displacement between adjacent sampling times.

[0083] The application effectively solves the problem that the traditional method may not accurately distinguish different types of contact in time by introducing a pre-judgment mechanism for rigid collision before calculating the resistance change rate. Specifically, when the valve is closing, if its displacement Δdisplacement suddenly becomes very small, while the motor load Δload rapidly and significantly increases, it indicates that the valve may encounter a rigid obstacle that cannot be pushed. In this case, if only the resistance change rate is calculated, although the value may be high, the rigid collision behind it may not be immediately identified. By setting a minimum displacement threshold and a rapid load increase threshold, and judging whether Δdisplacement is below the minimum displacement threshold and Δload exceeds the rapid load increase threshold, the system can quickly and clearly identify the rigid collision event. This mechanism enables the system to identify the rigid collision at the first time it occurs, thereby avoiding damage to the equipment due to delayed judgment. If the conditions for rigid collision are not met, the resistance change rate is calculated to handle other types of contact, such as water seal compaction or contact with flexible foreign matter, thereby achieving fine identification and handling of different contact types.

[0084] In some preferred embodiments, it is assumed that the motor load and valve displacement data are continuously acquired at a sampling frequency of 100 Hz during the closing process of the valve. At a certain time, the valve displacement Δdisplacement suddenly decreases from 0.5 mm to 0.05 mm in the adjacent sampling period, while the motor load Δload increases sharply from 100 N to 300 N. At this time, the preset minimum displacement threshold is set to 0.1 mm, and the rapid load increase threshold is set to 150 N. First, judge whether Δdisplacement (0.05 mm) is lower than the minimum displacement threshold (0.1 mm), the condition is met. Then judge whether Δload (200 N, i.e. 300 N-100 N) exceeds the rapid load increase threshold (150 N), the condition is also met. Since both conditions are met, it is immediately determined that a rigid collision has occurred, and the operation of emergency stop or reverse lifting of the valve can be triggered, thereby effectively preventing the valve body or the structure of the actuator from being damaged due to continuous stress. In contrast, if the valve encounters water seal compaction during closing, Δdisplacement may still be large, and although Δload may gradually increase, it may not exceed the rapid load increase threshold in a short time, at which time the resistance change rate will be calculated to evaluate the degree of water seal compaction, thereby achieving fine control.

[0085] Further, the application also proposes that when the resistance change rate continues to be below the preset normal threshold, the closing continues until the water seal is completely compacted;

[0086] When the resistance change rate exceeds the normal threshold but does not reach the collision threshold, the control valve performs a lifting and lowering cycle, calculates the hysteresis loop area, and compares it with the preset loss threshold to determine whether there is a foreign object.

[0087] The resistance change rate continuously below the preset normal threshold means that the ratio change between the motor load and the valve displacement remains at a low level during the valve closing process, indicating that the valve is approaching the water seal smoothly or is in the normal compaction process without encountering significant resistance. In this case, the valve is allowed to continue to move downward until the water seal is completely compacted to ensure good sealing performance. The normal threshold can be understood as the upper limit of the typical range of the resistance change rate during the normal closing of the valve and the contact with the water seal until the complete compaction process. When the resistance change rate exceeds this normal threshold, it means that the valve may encounter additional resistance beyond that required for normal sealing. The collision threshold represents the critical value of the resistance change rate that may cause a rigid collision leading to equipment damage.

[0088] When the resistance change rate is between the normal threshold and the collision threshold, it indicates that the valve may encounter a non-rigid foreign object or other abnormal conditions, but has not reached the level of rigid collision. In this case, the valve performs a lifting and lowering cycle action. The lifting and lowering cycle action refers to one or more small amplitude downward and upward movements of the valve in a short period of time, which detects and evaluates the properties of the obstacle through such reciprocating motion. During the execution of the lifting and lowering cycle action, the real-time data of the motor load and the valve displacement are continuously recorded, and the hysteresis loop area is calculated based on these data. The hysteresis loop area is an important indicator of energy loss or elastic response of the system. By comparing the calculated hysteresis loop area with the preset loss threshold, it can effectively determine whether there is a foreign object. The loss threshold is a reference value preset according to the elastic response characteristics of the normal water seal, which is used to distinguish between normal elastic deformation and additional energy loss caused by foreign objects.

[0089] By introducing the fine segmentation judgment of the resistance change rate, the problems of sealing not tight and inaccurate foreign object identification in the basic scheme during the valve closing process are effectively solved. Specifically, when the resistance change rate exceeds the normal threshold but has not reached the collision threshold, the scheme no longer directly determines as collision and stops, but performs a lifting and lowering cycle action and calculates the hysteresis loop area to analyze the abnormal situation in depth. This mechanism can effectively distinguish between the elastic response of the normal water seal and the additional resistance caused by foreign objects. The size of the hysteresis loop area directly reflects the energy dissipation during the lifting and lowering cycle. When there is a foreign object, due to the extrusion, friction and other effects of the foreign object, additional energy loss will occur, resulting in an increase in the hysteresis loop area. By comparing this area with the preset loss threshold, it can accurately identify whether there is a foreign object, avoiding the misjudgment of non-rigid foreign objects as normal sealing or rigid collision, thereby improving the intelligence and safety of the operation of the valve.

[0090] Further, the step of calculating the hysteresis loop area includes:

[0091] The motor load and valve displacement data recorded in the lifting cycle are plotted into a descending process curve and an ascending process curve, and the area of the closed region formed by the two curves is the hysteresis loop area.

[0092] Specifically, during the lifting cycle of the valve, the motor load and valve displacement data are continuously recorded. The motor load refers to the load borne by the motor driving the valve movement, which generally reflects the resistance encountered by the valve during movement. The valve displacement refers to the movement distance of the valve body relative to its initial position or a reference point. These real-time data are recorded during the valve descending (closing) process to form a descending process curve, and during the valve ascending (opening) process to form an ascending process curve. The two curves are generally plotted in a coordinate system with the valve displacement as the horizontal axis and the motor load as the vertical axis. When the valve completes a lifting cycle, the descending process curve and the ascending process curve form a closed region. The area of the closed region is defined as the hysteresis loop area. The size of the area reflects the energy loss or resistance characteristics of the valve during the lifting cycle.

[0093] By plotting the motor load and valve displacement data recorded in the lifting cycle into a descending process curve and an ascending process curve, and calculating the area of the closed region formed by the two curves, the friction, resistance, and additional energy loss caused by foreign matter in the valve under specific working conditions can be quantified. When the valve encounters foreign matter during the closing process, the movement trajectory and force condition will be abnormal, resulting in an increase in the difference between the descending and ascending curves, and thus a significant increase in the hysteresis loop area. Conversely, if it is only the normal elastic response of the water seal, the hysteresis loop area will remain in a relatively small range. Therefore, by accurately calculating the hysteresis loop area, a reliable quantitative basis can be provided for subsequent judgment of the presence of foreign matter, making the evaluation of the valve operating state more accurate. This accurate calculation method helps to more accurately identify whether the valve encounters foreign matter during the closing process, thereby avoiding equipment damage or reduced operating efficiency due to misjudgment. In addition, through graphical curve representation and area calculation, the diagnosis of valve operating characteristics and abnormal conditions becomes intuitive and traceable, improving the reliability and diagnostic efficiency of the opening and closing machine opening stroke data processing.

[0094] In this regard, the application further provides that the above method further comprises:

[0095] If the hysteresis loop area is less than the loss threshold, it is judged that it is the elastic response of the normal water seal, and the closing continues until the water seal is completely compacted.

[0096] If the hysteresis loop area is greater than or equal to the loss threshold, it is judged that there is foreign matter and the valve is immediately stopped or lifted in reverse.

[0097] Specifically, when the hysteresis loop area is less than the loss threshold, it indicates that the resistance change experienced by the valve during the closing process is mainly due to the normal elastic deformation of the water seal, at which time the valve can be safely closed until the water seal is completely compacted to ensure the sealing effect. In contrast, when the hysteresis loop area is greater than or equal to the loss threshold, it indicates the presence of abnormal resistance, which is usually due to physical contact between the valve and foreign matter. In this case, in order to avoid damage to the valve or foreign matter, an immediate shutdown operation is performed, or the valve is lifted in reverse to release the foreign matter stuck.

[0098] By introducing the comparison mechanism of the hysteresis loop area and the loss threshold, the limitation that the hysteresis loop area alone cannot directly guide the operation of the valve hoist is solved. When the valve encounters a water seal during the closing process, the water seal will produce a certain elastic deformation, which will be manifested as a smaller hysteresis loop on the motor load and valve displacement curve. However, when the valve encounters foreign matter, the foreign matter will produce additional, inelastic resistance, resulting in a significant increase in the hysteresis loop area. By setting a reasonable loss threshold, the system can accurately distinguish between the two cases. If the hysteresis loop area does not reach the loss threshold, it is confirmed to be the normal elastic response of the water seal, allowing the valve to continue closing to complete the sealing; if the hysteresis loop area reaches or exceeds the loss threshold, it is immediately identified as the presence of foreign matter, triggering the corresponding protective action such as shutdown or reverse lifting, thereby effectively avoiding equipment damage and potential safety risks.

[0099] Through the above technical solution, the resistance encountered by the valve during the closing process can be intelligently judged according to the size of the hysteresis loop area, whether it is due to the elastic deformation of the normal water seal or the presence of foreign matter. This enables the system to take precise subsequent operations, avoiding equipment damage or unnecessary shutdown due to misjudgment. The scheme significantly improves the safety, reliability and intelligent level of the valve hoist operation, ensuring efficient and safe operation of the valve under various working conditions.

[0100] Further, the present application further proposes that during the execution of the normal closing operation, the maximum value of the resistance change rate is continuously tracked and recorded to obtain the maximum resistance change rate reference value of the normally compacted water seal.

[0101] Specifically, during the closing process of the hoist under the ideal working condition that there is no foreign matter, no fault, the valve body is in normal contact with the water seal seat and the water seal is compacted, the resistance change rate calculated during the valve closing process is continuously monitored and recorded. Among them, during the entire normal closing operation period, the data stream of the resistance change rate is collected and stored in real time. Through the analysis of these real-time data, the peak value that the resistance change rate can reach when the valve body is in complete contact with the water seal seat and reaches the final compacted state can be identified. This peak value is determined as the maximum resistance change rate reference value, which represents the maximum resistance change rate that the valve can reach when the water seal is completely compacted under normal and abnormal conditions. The reference value is an important basis for setting related thresholds.

[0102] By dynamically obtaining and recording the maximum value of the resistance change rate during the normal closing operation of the hoist, a maximum resistance change rate reference value for normal compacted water seal based on actual running data is established. Since the reference value is obtained based on the normal operation state of the hoist itself, it can reflect the true performance parameters of the current equipment under abnormal conditions, thereby providing an objective, reliable and adaptive benchmark for the subsequent setting of abnormal judgment thresholds (such as normal threshold and loss threshold). This avoids the disadvantages of relying on fixed empirical values or the need for frequent manual calibration, allowing the system to better adapt to slight wear and tear or environmental changes that may occur during long-term operation of the hoist, ensuring the accuracy and effectiveness of threshold setting.

[0103] Further, based on the above-mentioned maximum resistance change rate reference value, the normal threshold and the loss threshold are set through a pre-set scaling factor or offset.

[0104] Among them, the maximum resistance change rate reference value is obtained by continuously tracking and recording the maximum value of the resistance change rate during the normal closing operation of the hoist, which represents the typical resistance change characteristic of the valve water seal under normal compacted state. The pre-set scaling factor or offset is an adjustable parameter used to convert the reference value into a specific judgment threshold. For example, the normal threshold can be set as the maximum resistance change rate reference value multiplied by a scaling factor less than 1, or subtracted by a pre-set offset; while the loss threshold can be set as the maximum resistance change rate reference value multiplied by a scaling factor greater than 1, or added by a pre-set offset. These factors or offsets can be calibrated and optimized according to the specific model, design parameters and actual operation experience of the hoist, to ensure the accuracy and applicability of the thresholds. Thus, the normal threshold and the loss threshold are no longer fixed values, but dynamic parameters that can be adaptively adjusted according to the running characteristics of the hoist itself.

[0105] By associating the setting of the normal threshold and the loss threshold with the maximum resistance change rate reference value of the normally compacted water seal obtained in the actual operation of the opening and closing machine, adaptive adjustment of the threshold is realized. Specifically, the maximum resistance change rate reference value reflects the real resistance characteristics of the specific opening and closing machine when the water seal is compacted under normal working conditions, thereby providing a reliable benchmark for the setting of the threshold. By introducing a proportion factor or an offset, the reference value can be flexibly converted into a normal threshold and a loss threshold applicable to different judgment scenarios. This way of dynamically adjusting the threshold based on actual operation data can effectively avoid misjudgment or missed judgment caused by fixed thresholds that do not match the actual working conditions, significantly improving the accuracy and robustness of the opening and closing machine opening stroke data processing.

[0106] Through the above technical solution, the normal threshold and the loss threshold of the opening and closing machine opening stroke data processing can be dynamically adjusted according to the operating characteristics and historical data of the opening and closing machine, rather than using fixed values. This makes the system's judgment of the water seal compaction state and the identification of foreign matter more accurate and reliable, effectively avoiding misjudgment caused by equipment aging, working condition changes or individual differences. As a result, the operating safety of the opening and closing machine is significantly improved, the maintenance cost is reduced, and the service life of the equipment can be extended.

[0107] In the second aspect, with reference to Figure 2 The present application proposes an opening and closing machine opening stroke data processing system for executing the above-mentioned opening and closing machine opening stroke data processing method. The system comprises:

[0108] The data acquisition unit 210 is used to continuously acquire two groups of real-time data of motor load and valve displacement during valve closing, and mark the initial contact point when the first lifting of the motor load data that continuously exceeds the background noise occurs; and is also used to record two groups of real-time data of motor load and valve displacement at a preset sampling frequency from the initial contact point;

[0109] The data processing unit 220 is used to calculate the resistance change rate = Δ load / Δ displacement;

[0110] The decision control unit 230 is used to compare the resistance change rate with the preset collision threshold to control the opening and closing.

[0111] Specifically, the data acquisition unit 210 can be understood as a module responsible for obtaining raw operation data from the gate and its driving mechanism. Its main function is to continuously collect motor load data and valve displacement data during the valve closing process. Motor load data can be obtained by force sensors or current sensors installed on the motor driving system, reflecting the real-time load of the motor when driving the valve. Valve displacement data can be obtained by displacement sensors (such as encoders, pull-wire displacement sensors, etc.), indicating the precise position of the valve in the stroke. In addition, after the initial contact point is identified, the data acquisition unit will continue to record these two sets of real-time data with high precision according to the preset sampling frequency, providing basic data for subsequent resistance change rate calculation. When the transmitted motor load data first shows a significant rise that lasts and exceeds the system background noise, the data acquisition unit 210 will accurately mark this moment as the initial contact point, which usually involves filtering, denoising, and trend analysis of the load data.

[0112] One of the key functions of the data processing unit 220 is to calculate the resistance change rate, i.e., Δload / Δdisplacement. This is achieved by calculating the ratio of the change in motor load (Δload) and the change in valve displacement (Δdisplacement) at adjacent sampling times. This change rate directly reflects the trend of the resistance change of the valve during the closing process.

[0113] The decision control unit 230 can be understood as a module that issues corresponding control instructions to adjust the operation state of the gate according to the analysis results of the data processing unit 220. Its main function is to compare the resistance change rate calculated by the data processing unit 220 with the preset collision threshold. When the resistance change rate reaches or exceeds the threshold, the decision control unit 230 will immediately issue control instructions, such as stopping or reversing the valve, to avoid rigid collision or further damage. In addition, according to other logic in the above method, the decision control unit 230 can also decide whether to continue closing the valve until the water seal is completely compacted according to whether the resistance change rate is continuously below the normal threshold, or when the resistance change rate is between the normal threshold and the collision threshold, trigger the lifting and lowering cycle action to detect foreign objects, and according to the comparison result of the hysteresis loop area and the loss threshold, further issue stop or reverse valve lifting instructions.

[0114] The core technical concept of the present application is that instead of relying only on the absolute value or the change rate of a single driving load signal (such as motor current) to determine the condition of the valve closing end, the change of the driving load is ingeniously combined with the small displacement change of the valve stroke, and a "apparent stiffness" value that can directly reflect the "soft and hard" degree of the resistance suffered by the system is calculated in real time. By setting a stiffness threshold based on the physical nature, it can accurately distinguish between the smooth load increase caused by the compaction of flexible water seals (low stiffness) and the load sharply rising and displacement almost unchanged caused by the hard foreign matter jamming (high stiffness) of two completely different physical events, so as to make accurate shutdown decisions.

[0115] The above only describes the embodiments of the present application and is not used to limit the protection scope of the present application. For those skilled in the art, the present application can have various changes and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A method for processing opening and closing machine opening stroke data, characterized in that, The method comprises the following steps: During the closing process of the valve, continuously acquiring real-time data of motor load and valve displacement; When the motor load data first appears a continuous and background noise-exceeding lift, mark the time as the initial contact point; Starting from the initial contact point, record the real-time data of motor load and valve displacement at a preset sampling frequency, and calculate the resistance change rate = Δ load / Δ displacement; Compare the resistance change rate with a preset collision threshold to control opening and closing; The method further comprises the following steps: Acquire the command speed information and actual speed information of the valve closing; Calculate the instantaneous speed deviation in each sampling period, which is the absolute difference between the command speed and the actual speed; When the instantaneous speed deviation of consecutive multiple sampling periods exceeds the noise threshold of speed deviation, it is determined that the valve body has sustained physical contact, and the initial contact point is identified, and the real-time data of motor load and valve displacement is recorded at a preset sampling frequency from the initial contact point. The method further comprises the following steps: Set a continuous lag counter, which increments when the instantaneous speed deviation is continuously greater than the noise threshold; When the instantaneous speed deviation is continuously less than or equal to the noise threshold, the continuous lag counter is immediately cleared; When the instantaneous speed deviation of consecutive multiple sampling periods exceeds the noise threshold, and the value of the continuous lag counter reaches or exceeds the preset number of sampling points, it is determined that there is sustained physical contact. The step of recording the real-time data of motor load and valve displacement at a preset sampling frequency from the initial contact point, and calculating the resistance change rate = Δ load / Δ displacement, comprises the following steps: Set a minimum displacement threshold and a rapid load increase threshold to determine whether the Δ displacement is lower than the minimum displacement threshold and whether the Δ load exceeds the rapid load increase threshold: If both conditions are met, it is determined to be a rigid collision; If not, calculate the resistance change rate; The Δ load is the change amount of the motor load at adjacent sampling times, and the Δ displacement is the change amount of the valve displacement at adjacent sampling times.

2. The method according to claim 1, wherein The method further comprises the following steps: When the resistance change rate continuously falls below a preset normal threshold, continue to close until the water seal is completely compacted; When the resistance change rate exceeds the normal threshold but does not reach the collision threshold, control the valve to perform a lifting and lowering cycle, calculate the hysteresis loop area, and determine whether there is a foreign object by comparing with a preset loss threshold.

3. The method according to claim 2, wherein The step of calculating the hysteresis loop area comprises the following steps: Draw the real-time data of motor load and valve displacement recorded in the lifting and lowering cycle into a descending process curve and an ascending process curve respectively, and the closed area formed by the two curves is the hysteresis loop area.

4. The method of claim 3, wherein, The method further comprises the following steps: If the hysteresis loop area is less than the loss threshold, it is determined to be the elastic response of a normal water seal, and the closing continues until the water seal is completely compacted; If the hysteresis loop area is greater than or equal to the loss threshold, it is determined that there is a foreign object and the valve is immediately stopped or lifted in reverse.

5. The method of claim 4, wherein, The method further comprises the following steps: During the execution of the normal closing operation, the maximum value of the resistance change rate is continuously tracked and recorded to obtain a maximum resistance change rate reference value of the normally compacted water seal.

6. The method of claim 5, wherein, The method further comprises: Based on the maximum resistance change rate reference value, the normal threshold and the loss threshold are set by a preset scale factor or offset.

7. A gate opening stroke data processing system for performing the gate opening stroke data processing method according to any one of claims 1 to 6, characterized by The system comprises: A data acquisition unit is configured to continuously acquire real-time data of motor load and valve displacement during valve closing, and mark the initial contact point when the first lifting of the motor load data that continuously exceeds the background noise occurs; and record the real-time data of the motor load and the valve displacement at a preset sampling frequency from the initial contact point; A data processing unit is configured to calculate the resistance change rate = Δ load / Δ displacement; A decision control unit is configured to compare the resistance change rate with a preset collision threshold to control the opening and closing.

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