Tool for online replacement and maintenance of high-pressure one-way stop valve

Abstract

The invention discloses a tool for on-line replacement and maintenance of a high-pressure one-way stop valve, and relates to the technical field of valve maintenance. The tool comprises a threaded connecting rod assembly, a threaded body and a heavy hammer; a retaining ring is mounted at one end of the threaded connecting rod assembly, and a high-strength alloy steel round rod with external threads is arranged at the other end; the thread body is a hollow cylinder with internal and external threads, and an intelligent torque monitoring system is embedded in the thread body. Through a thread connecting rod and hammer combined structure, a valve element of the stop valve can be rapidly disassembled, meanwhile, the tool can complete disassembly and assembly of the valve element in a non-shutdown state, production interruption caused by equipment shutdown is avoided, and the production efficiency is improved. The continuity of industrial production is guaranteed, the economic loss caused by shutdown is effectively reduced, and the overall production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of valve maintenance technology, specifically to a tool for online replacement and maintenance of high-pressure one-way shut-off valves. Background Technology

[0002] In the production process of steel rolling mills, after the billets are heated and kept warm, a thick layer of iron oxide scale inevitably covers their surface. If this iron oxide scale is not removed in time, it will seriously affect the surface quality of the rolled product. To ensure the surface quality of the rolled product, high-pressure water descaling technology has become a key link. That is, high-pressure water is used to remove the iron oxide scale from the surface of the billet before rolling. The high-pressure shut-off valve of the descaling pump body is the core component of the high-pressure water descaling system and plays a crucial role in the entire descaling process. It is responsible for precisely controlling the flow and shut-off of high-pressure water to ensure that high-pressure water can be sprayed onto the surface of the billet at appropriate pressure and flow rate, thereby effectively removing the iron oxide scale. However, due to the frequent and high-intensity impact of high-pressure water during the descaling process, the valve core of the high-pressure shut-off valve is in a harsh working environment for a long time and is prone to wear and other failures, which poses a challenge to the stable operation of steel rolling production.

[0003] Currently, existing high-pressure check valves have many drawbacks in terms of maintenance. On the one hand, high-pressure check valves are usually large and heavy. When the valve core is worn and needs to be replaced as a whole, the operation is extremely cumbersome and time-consuming. During normal production, the inability to quickly complete the replacement often requires shutdown, which not only seriously affects production efficiency and causes production line interruptions and delays, but also increases the company's production costs, including downtime losses and labor costs. On the other hand, traditional maintenance tools have limited functions and lack intelligent monitoring methods. During the disassembly and installation of the valve core, operators mainly rely on experience and intuition to control the force, making it difficult to accurately grasp the torque. Improper force can easily damage the valve core or other parts of the check valve, further increasing equipment maintenance costs and failure risks. In addition, traditional tools have poor adaptability to different specifications of high-pressure check valves, which cannot meet the needs of diverse industrial scenarios and limits their widespread application in production practice. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a tool for online replacement and maintenance of high-pressure one-way shut-off valves. It employs a unique threaded rod and hammer combination structure, eliminating the need for a complex power source. Through manual operation, it enables rapid, safe disassembly and precise installation of the valve core. Its structure is simple, with few parts, mainly consisting of four parts: a threaded rod assembly, a threaded body, a hammer, and an intelligent torque monitoring system. The threaded rod assembly transmits force, the threaded body connects the tool to the valve core, and the hammer generates the force required for disassembly and installation through inertial impact. Simultaneously, this invention integrates intelligent torque monitoring functionality, embedding a miniature pressure sensor inside the threaded body. Real-time torque data is transmitted to a handheld terminal via Bluetooth. Operators can preset a safe torque threshold; when the monitored torque exceeds the threshold, the handheld terminal immediately issues an audible and visual alarm, effectively preventing equipment damage due to improper force and reducing maintenance costs.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a tool for online replacement and maintenance of high-pressure one-way shut-off valves, the tool comprising: a threaded connecting rod assembly, a threaded body, and a counterweight;

[0006] The threaded connecting rod assembly has a high-strength alloy steel round rod with a backstop ring installed at one end and an external thread at the other end.

[0007] The threaded body is a hollow cylinder with internal and external threads, and an intelligent torque monitoring system is embedded inside.

[0008] Furthermore, a retaining ring is installed at one end of the threaded connecting rod, and the diameter of the retaining ring is larger than the diameter of the rod, thereby restricting the axial displacement of other components. The other end is machined with an external thread, the specification of which matches the internal thread of the threaded body, and the rod is made of high-strength alloy steel.

[0009] Furthermore, the threaded body is a hollow cylindrical structure with threads machined on both its inner and outer sides. The outer thread engages with the outer thread of the threaded connecting rod assembly, and the two are fastened together by rotation. The inner thread is consistent with the thread hole specification of the high-pressure one-way shut-off valve core, which can be tightly screwed into the valve core, so that the tool is firmly connected to the valve core.

[0010] Furthermore, the threaded body is embedded with an intelligent torque monitoring system, which includes a miniature pressure sensor, a built-in micro circuit board, a Bluetooth module, and a small power supply compartment.

[0011] Furthermore, in the intelligent torque monitoring system, a miniature pressure sensor is installed inside the threaded body near the inner thread. The sensor is in contact with the inner wall of the threaded body to accurately sense the changes in torque pressure at the threaded connection. The data collected by the sensor is processed by the built-in micro circuit board.

[0012] Furthermore, in the intelligent torque monitoring system, the micro circuit board uses a dynamic threshold calculation model to dynamically adjust the safety torque threshold considering the actual working condition changes during valve core disassembly and installation. It also corrects the measured torque in real time using a real-time torque correction formula. The micro circuit board is connected to a Bluetooth module, which transmits the real-time monitored torque data to the terminal wirelessly.

[0013] Furthermore, in the intelligent torque monitoring system, the micro-circuit board uses a dynamic threshold calculation model to dynamically adjust the safety torque threshold, taking into account the actual operating condition changes during valve core disassembly and installation. The dynamic adjustment formula is as follows: ,in, It is the first The dynamic safety threshold for secondary torque monitoring is dynamically adjusted according to different stages of valve core disassembly and installation. It is the basic safe torque threshold. It is the torque variation adaptive coefficient, used to adjust the system's sensitivity to historical torque changes. It is the first Next and first The difference between the two torque monitoring values ​​reflects the trend of torque change. This is the current number of torque monitoring readings. This is the environmental factor influence coefficient, used to quantify the impact of environmental factors on the torque threshold. It is a comprehensive environmental impact factor.

[0014] Furthermore, the aforementioned It is a comprehensive environmental impact factor, and its calculation formula is: ,in, Indicates the first Normalized values ​​of environmental parameters For the first The weighting coefficients of each environmental parameter. It refers to the number of environmental parameters.

[0015] Furthermore, in the intelligent torque monitoring system, the measured torque is corrected in real time using a real-time torque correction formula, which is as follows: ,in, This is the corrected actual torque value. It is the torque value measured in real time by a miniature pressure sensor. This is the torque change rate correction coefficient, used to adjust the degree of correction for the torque change rate. It is the rate of change of real-time torque, reflecting how fast the torque changes over time.

[0016] Furthermore, the intelligent torque monitoring system has a small power supply compartment on the outside of the threaded body to power the micro circuit board, sensor and Bluetooth module, and the power supply compartment adopts a waterproof and sealed design.

[0017] Compared with existing technologies, this tool for online replacement and maintenance of high-pressure one-way shut-off valves has the following advantages:

[0018] I. This invention, through a combination structure of threaded connecting rod and hand hammer, enables the quick disassembly of the valve core of a shut-off valve. Furthermore, this tool can complete the disassembly and installation of the valve core without shutting down the machine, avoiding production interruptions caused by equipment downtime, ensuring the continuity of industrial production, effectively reducing economic losses caused by downtime, and improving overall production efficiency.

[0019] Second, this invention integrates an intelligent torque monitoring system. During the disassembly and installation of the valve core, the miniature pressure sensor inside the threaded body can detect changes in torque pressure in real time and transmit the data to a handheld terminal via a Bluetooth module. When the torque exceeds the preset safety threshold or reaches the installation target torque value, the handheld terminal will immediately issue an audible and visual alarm or a prompt signal to remind the operator to adjust the operation and avoid damage to the valve core or other components of the shut-off valve due to improper force. This greatly improves the safety and accuracy of the operation and reduces equipment maintenance costs and failure risks.

[0020] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0022] Figure 1 This is a schematic diagram of the threaded connecting rod in a tool for online replacement and maintenance of a high-pressure one-way shut-off valve.

[0023] Figure 2 This is a schematic diagram of the threaded body in a tool used for online replacement and maintenance of a high-pressure one-way shut-off valve.

[0024] Figure 3 This is a schematic diagram of the intelligent torque monitoring system in a tool for online replacement and maintenance of high-pressure one-way shut-off valves. Detailed Implementation

[0025] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0026] Example 1

[0027] A tool for online replacement and maintenance of high-pressure one-way shut-off valves mainly consists of a threaded connecting rod assembly, a threaded body, a counterweight, and an intelligent torque monitoring system. The threaded connecting rod assembly is made of 42CrMo high-strength alloy steel, with a round rod diameter of 30mm. One end is welded with a 45mm diameter anti-reverse ring, which ensures a firm connection through an annular weld. The anti-reverse ring can effectively limit the axial displacement of the counterweight and threaded body during disassembly and installation, preventing tool parts from accidentally falling off and causing safety hazards. The other end of the round rod is machined with an M24×2 external thread to mate with the threaded body.

[0028] The threaded body is a hollow cylindrical structure made of stainless steel. Its inner side is machined with an M36×2 internal thread that matches the threaded hole of the high-pressure one-way shut-off valve core, while the outer side has an M24×2 external thread adapted to the threaded connecting rod assembly. A miniature pressure sensor is embedded inside the threaded body near the inner thread using a high-precision inlay process. High-strength thermally conductive adhesive is filled between the sensor and the inner wall of the threaded body to ensure a tight fit, enabling the sensor to accurately detect changes in torque and pressure at the threaded connection. The miniature pressure sensor is connected to a Bluetooth module via a micro-circuit board etched inside the threaded body. The Bluetooth module employs a low-power design, enabling it to wirelessly transmit real-time monitored torque data to a handheld terminal. On the outer side of the threaded body, a small power supply compartment with a diameter of 15mm and a depth of 10mm is located, sealed with a waterproof sealing ring and a threaded cap. It can accommodate two CR2032 button batteries to provide stable power to the sensor and Bluetooth module.

[0029] The counterweight is a hollow cylindrical cast iron part with one open end and an inner diameter of 32mm. It can slide freely on the threaded connecting rod assembly. The counterweight weighs 2kg. The outer surface is knurled to form a non-slip texture for easy gripping by the operator. A 5mm diameter hanging ring is welded to one end for convenient tool storage.

[0030] When disassembling the valve core, the threaded body and the valve core are tightly screwed together by the inner thread, and the threaded connecting rod assembly is then screwed together with the outer thread of the threaded body, forming a stable connection structure. The operator pulls the hammer to make it rest against the anti-reverse ring, and then forcefully strikes the hammer towards the valve core. The inertial impact force of the hammer is transmitted to the valve core through the threaded connecting rod assembly and the threaded body, overcoming the friction and residual pressure between the valve core and the valve seat. During this process, the miniature pressure sensor collects the pressure data of the threaded connection in real time, which is processed by the micro circuit board and transmitted to the handheld terminal. When the detected torque exceeds the preset threshold, the handheld terminal immediately issues an audible and visual alarm to remind the operator to stop the operation. The principle is similar when installing the valve core. The valve core is screwed into the valve seat by tapping the hammer lightly. When the torque reaches the preset value, the system prompts that the installation is complete.

[0031] Example 2

[0032] Before replacing the valve core, ensure that the high-pressure shut-off valve of the descaling pump is closed, and completely release the pressure in the pipeline to zero through the pressure relief valve. Use a pressure gauge to check the pressure and ensure that the working environment is safe. At the same time, prepare the new valve core and check whether its model and specifications match the valve to be replaced, and whether there is any damage on its surface.

[0033] Open the handheld terminal and enter the intelligent torque monitoring system's operating interface. Based on the valve manual and historical maintenance data, set the basic safe torque threshold. Due to the high operating temperature and significant vibration of the descaling pump, further environmental parameters were determined: by consulting maintenance data for this type of valve under similar operating conditions, an adaptive coefficient for torque variation was set. =0.3, which enables the system to better adapt to torque fluctuations during disassembly, and the environmental factor influence coefficient. =0.2, taking into account the influence of factors such as temperature and vibration on the torque threshold; torque change rate correction coefficient. =0.1, used to correct sensor measurement errors. Additionally, install the button battery in the power compartment inside the threaded body and test the Bluetooth connection to ensure the intelligent torque monitoring system functions correctly. This includes considering the comprehensive environmental impact factor. It needs to be calculated based on the actual environmental parameters, and the calculation formula is as follows: In this operation, environmental sensors were used to acquire data such as temperature and vibration. After normalization, the data was then weighted according to pre-set coefficients. The calculated value is used for subsequent dynamic threshold calculations.

[0034] Slowly screw the threaded body into the threaded hole of the old valve core of the high-pressure one-way shut-off valve. Use a torque wrench to tighten to the specified torque, ensuring a tight connection between the threaded body and the valve core, with a screw depth of 30mm. Next, screw the external thread of the threaded connecting rod assembly into the external thread of the threaded body, checking the connection's tightness as you screw, until both are fully tightened and there is no looseness. The operator holds the end of the threaded connecting rod assembly closest to the valve core with one hand and a weight with the other, pulling the weight along the threaded connecting rod assembly away from the valve core until it rests against the anti-reverse ring. Then, the weight is quickly struck towards the valve core. During each impact, a miniature pressure sensor collects pressure data from the threaded connection in real time. After processing by a micro-circuit board, a dynamic threshold calculation model is used. Calculate the current dynamic safety torque threshold At the same time, the real-time torque correction formula is used. Torque value measured by sensor Make corrections to obtain the corrected actual torque value. and with To make a comparison, if > The handheld terminal immediately issues an audible and visual alarm to remind the operator to stop. At this time, the operator needs to analyze the cause, which may be that the valve core is stuck or the threshold is set too low. The impact force can be adjusted appropriately or the threshold can be re-evaluated. Repeat the impact operation. When the valve core begins to loosen, continue to impact slowly until the valve core is completely removed from the valve seat. After disassembly, unscrew the threaded connecting rod assembly and the threaded body in sequence, and properly place the disassembled old valve core in the designated container.

[0035] Remove the inspected and qualified new valve core, clean its threaded hole and sealing surface again, and screw the threaded body into the threaded hole of the new valve core, ensuring the same depth and secure connection. Align the new valve core with the threaded body installed with the valve seat and slowly insert it into the valve seat. At the same time, tighten the threaded connecting rod assembly to the threaded body. The operator supports the threaded connecting rod assembly with one hand to maintain the concentricity of the valve core and valve seat, using a level to assist in calibration, ensuring that the valve core is installed vertically and without tilt. With the other hand, hold the weight and gently tap it to gradually screw the valve core into the valve seat. During the tapping process, the intelligent torque monitoring system continues to work, constantly calculating the dynamic threshold. And correct the actual torque value The operator closely monitors the torque data on the handheld terminal. When the valve core approaches the preset installation torque value, reduce the striking force appropriately and slowly tighten it to the specified position. When the installation torque threshold calculated by the formula is reached, the handheld terminal issues a prompt signal, indicating that the valve core has been installed in place and the tapping stops.

[0036] After installation, remove the tools, check the valve for leaks, introduce low-pressure gas into the pipeline, apply soapy water to the valve seal, and observe for any bubbles. If a leak is found, reinstall and adjust the valve core using the tools. Once the valve is confirmed to be properly sealed, clean the work site, wipe all parts of the tools clean, and store them in a dedicated toolbox. Turn off the handheld terminal and remove the battery from the power compartment of the threaded body for safekeeping.

[0037] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A tool for online replacement and maintenance of high-pressure one-way shut-off valves, characterized in that, The tool includes: a threaded connecting rod assembly, a threaded body, and a counterweight; The threaded connecting rod assembly has a high-strength alloy steel round rod with a backstop ring installed at one end and an external thread at the other end. The threaded body is a hollow cylinder with internal and external threads, and an intelligent torque monitoring system is embedded inside.

2. The tool for online replacement and maintenance of high-pressure one-way shut-off valves according to claim 1, characterized in that, One end of the threaded connecting rod is equipped with a backstop ring, and the diameter of the backstop ring is larger than the diameter of the rod, thereby restricting the axial displacement of other components. The other end is machined with an external thread, the specification of which matches the internal thread of the threaded body. The rod is made of high-strength alloy steel.

3. The tool for online replacement and maintenance of high-pressure one-way shut-off valves according to claim 1, characterized in that, The threaded body is a hollow cylindrical structure with threads machined on both its inner and outer sides. The outer thread engages with the outer thread of the threaded connecting rod assembly, and the two are fastened together by rotation. The inner thread is consistent with the thread hole specification of the high-pressure one-way shut-off valve core, which can be tightly screwed into the valve core, so that the tool is firmly connected to the valve core.

4. The tool for online replacement and maintenance of high-pressure one-way shut-off valves according to claim 1, characterized in that, The threaded body is embedded with an intelligent torque monitoring system, which includes a miniature pressure sensor, a built-in micro circuit board, a Bluetooth module, and a small power supply compartment.

5. A tool for online replacement and maintenance of a high-pressure one-way shut-off valve according to claim 4, characterized in that, In the intelligent torque monitoring system, a miniature pressure sensor is installed inside the threaded body near the inner thread. The sensor is in contact with the inner wall of the threaded body to accurately sense the changes in torque pressure at the threaded connection. The data collected by the sensor is processed by the built-in micro circuit board.

6. A tool for online replacement and maintenance of a high-pressure one-way shut-off valve according to claim 4, characterized in that, In the intelligent torque monitoring system, the micro-circuit board uses a dynamic threshold calculation model to dynamically adjust the safety torque threshold considering the actual working condition changes during valve core disassembly and installation. It also corrects the measured torque in real time using a real-time torque correction formula. The micro-circuit board is connected to a Bluetooth module, which transmits the real-time monitored torque data to the terminal wirelessly.

7. A tool for online replacement and maintenance of a high-pressure one-way shut-off valve according to claim 6, characterized in that, In the intelligent torque monitoring system, the micro-circuit board uses a dynamic threshold calculation model to dynamically adjust the safety torque threshold, taking into account the actual operating conditions during valve core disassembly and installation. The dynamic adjustment formula is as follows: ,in, It is the first The dynamic safety threshold for secondary torque monitoring is dynamically adjusted according to different stages of valve core disassembly and installation. It is the basic safe torque threshold. It is the torque variation adaptive coefficient, used to adjust the system's sensitivity to historical torque changes. It is the first Next and first The difference between the two torque monitoring values ​​reflects the trend of torque change. This is the current number of torque monitoring readings. This is the environmental factor influence coefficient, used to quantify the impact of environmental factors on the torque threshold. It is a comprehensive environmental impact factor.

8. A tool for online replacement and maintenance of a high-pressure one-way shut-off valve according to claim 7, characterized in that, The It is a comprehensive environmental impact factor, and its calculation formula is: ,in, Indicates the first Normalized values ​​of environmental parameters For the first The weighting coefficients of each environmental parameter. It refers to the number of environmental parameters.

9. A tool for online replacement and maintenance of a high-pressure one-way shut-off valve according to claim 6, characterized in that, In the intelligent torque monitoring system, the measured torque is corrected in real time using a real-time torque correction formula, which is as follows: ,in, This is the corrected actual torque value. It is the torque value measured in real time by a miniature pressure sensor. This is the torque change rate correction coefficient, used to adjust the degree of correction for the torque change rate. It is the rate of change of real-time torque, reflecting how fast the torque changes over time.

10. A tool for online replacement and maintenance of a high-pressure one-way shut-off valve according to claim 4, characterized in that, The intelligent torque monitoring system has a small power supply compartment on the outside of the threaded body to power the micro circuit board, sensor and Bluetooth module, and the power supply compartment adopts a waterproof and sealed design.

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