Safety valve on-line automatic verification method and verification system

Abstract

The invention relates to the technical field of safety valve verification, in particular to an online automatic verification method and system for a safety valve, and the method comprises the steps: receiving a starting instruction from external equipment through a Bluetooth module; controlling an execution element to drive a push rod to move to a preset position according to the starting instruction; in the moving process of the push rod, force value data generated by the force value sensor and displacement data of the push rod are collected; according to the invention, a wireless transmission function is realized through the Bluetooth module, remote operation and data acquisition with terminals such as a mobile phone or a tablet computer are supported, the convenience and flexibility of use are greatly improved, and more importantly, the force value data are processed to judge the state of the valve. According to the technology, the blank that the threaded safety valve cannot be verified on line in the prior art is filled up, and efficient and accurate state detection and maintenance of the threaded connection safety valve can also be realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of safety valve calibration, in particular to a safety valve online automatic calibration method and calibration system. BACKGROUND

[0002] In industrial production, energy supply, special equipment and daily life, safety valves, as a kind of key safety protection device, are widely installed on various pressure-bearing equipment and pipeline systems. The core function of safety valves is to automatically open and release pressure when the system pressure exceeds the preset value, preventing serious accidents such as explosion and rupture of equipment or system due to overpressure, thereby protecting personnel life and property safety.

[0003] In order to ensure that safety valves can continuously and effectively perform their protection duties, regular calibration and maintenance are essential. Traditional safety valve calibration methods usually require safety valves to be disassembled from equipment or pipelines, then transported to a special calibration laboratory or tested on site using portable calibration equipment. This process not only requires professional technicians to operate, but also involves complex disassembly, transportation and installation processes, often requiring downtime, resulting in production interruption or system shutdown.

[0004] However, in practical applications, a large number of safety valves are installed in locations that are inconvenient to disassemble, such as high altitude, enclosed space, toxic and harmful environment, high temperature and high pressure area, or as an integral part of key systems. For these safety valves, traditional offline calibration methods are not only extremely difficult to operate and costly, but also often cannot be implemented due to the huge economic losses or operational risks caused by downtime.

[0005] Therefore, in order to improve the calibration convenience of safety valves, we propose a safety valve online automatic calibration method and calibration system. SUMMARY

[0006] The purpose of the present application is to solve the problems in the prior art, such as the traditional offline calibration method being extremely difficult to operate, costly, and often unable to be implemented due to the huge economic losses or operational risks caused by downtime, and to propose a safety valve online automatic calibration method and calibration system.

[0007] In order to achieve the above purpose, the present application adopts the following technical solutions: A safety valve online automatic calibration method is designed, which comprises: receiving a start instruction from an external device through a Bluetooth module; controlling an actuator to drive a push rod to move to a preset position according to the start instruction; collecting force value data generated by a force value sensor and displacement data of the push rod during movement of the push rod; The force value data is processed to determine the state of the valve.

[0008] Further, the starting instruction from the external device is received through the Bluetooth module, and the starting instruction comprises: The Bluetooth module is initialized and configured as a slave mode, so that the module is in a state of being discoverable and connectable by the external device; The starting string instruction sent by the external device is received, and after receiving the starting string instruction, a starting instruction is sent to the execution element.

[0009] Further, the execution element is controlled to drive the push rod to move to the preset position according to the starting instruction, and the starting instruction comprises: After receiving the starting instruction, the execution element controls the rod to move to the corresponding position according to the preset speed and target position, wherein the starting instruction comprises an instruction data frame containing a frame header, a control parameter and a checksum; After the execution element receives the starting instruction, a response frame is returned, and displacement data of the push rod is obtained through the response frame, wherein the response frame comprises an instruction data frame containing a frame header, a data frame and a checksum.

[0010] Further, the force value data generated by the force value sensor and the displacement data of the push rod are collected during the movement of the push rod, and the force value sensor comprises: The force value sensor senses the force value based on the parallel plate capacitance change or the strain gauge principle; An AD7190 chip is used to convert an analog signal output by the sensor into a digital signal; The digital signal is transmitted to a processor based on an SPI communication protocol for analysis to obtain the force value data; Whether the force value data and the displacement data of the push rod exceed a threshold value is determined, and if so, the driving of the execution element is stopped and a protection state is entered.

[0011] Further, the force value data is processed to determine the state of the valve, and the processing comprises: The force value data is subjected to Kalman filtering to obtain smoothed force value data; A peak value searching algorithm is applied to the smoothed force value data, and an inflection point value identified by the peak value searching algorithm is used to determine an opening force value; The opening force value is compared with a preset threshold value, and whether the valve is in a qualified state is determined according to a comparison result.

[0012] In addition, the application further provides an online automatic verification system for a safety valve, and the system comprises: A receiving unit is configured to receive a starting instruction from an external device through a Bluetooth module; A control unit is configured to control the driving of the push rod to a preset position according to the start instruction. A collection unit is configured to collect force value data generated by the force value sensor and displacement data of the push rod during the movement of the push rod. A judgment unit is configured to process the force value data to determine the state of the valve.

[0013] Further, the receiving unit comprises: An initialization unit is configured to initialize the Bluetooth module and configure it as a slave mode, so that the module is in a state of being discoverable and connectable by an external device. A receiving sub-unit is configured to receive a start string instruction sent by an external device, and send a start instruction to the execution element after receiving the start string instruction.

[0014] Further, the control unit comprises: A control sub-unit is configured to control the movement of the push rod to a corresponding position according to a preset speed and target position after receiving the start instruction, wherein the start instruction comprises an instruction data frame containing a frame header, a control parameter and a checksum. A response unit is configured to return a response frame after the execution element receives the start instruction, and obtain the displacement data of the push rod through the response frame, wherein the response frame comprises an instruction data frame containing a frame header, a data frame and a checksum.

[0015] Further, the collection unit comprises: A sensing unit is configured to sense the force value based on the principle of parallel plate capacitance change or strain gauge; A conversion unit is configured to convert an analog signal output by the sensor into a digital signal through an AD7190 chip; An analysis unit is configured to transmit the digital signal to a processor for analysis based on an SPI communication protocol to obtain force value data; A protection unit is configured to determine whether the force value data and the displacement data of the push rod exceed a threshold value, and if so, stop the driving of the execution element and enter a protection state.

[0016] Further, the judgment unit comprises: A filtering unit is configured to obtain smoothed force value data by performing Kalman filtering on the real-time collected force value data; A peak searching unit is configured to apply a peak searching algorithm to the smoothed force value data to determine an opening force value identified by the peak searching algorithm. A judgment sub-unit is configured to compare the opening force value with a preset threshold value, and determine whether the valve is in a qualified state according to the comparison result.

[0017] The safety valve online automatic verification method and verification system have the beneficial effects that: the wireless transmission function is realized through the Bluetooth module in the application, remote operation and data collection with a mobile phone or a tablet and the like terminal are supported, and the convenience and flexibility of use are greatly improved; and more importantly, the technology fills the blank that the existing technology cannot perform online verification on a threaded safety valve, so that efficient and accurate state detection and maintenance can also be realized for the threaded safety valve. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 The flowchart is intended for the embodiment one of the application; Figure 2 The flowchart is intended for the embodiment two of the application; Figure 3 The structural diagram is intended for the embodiment three of the application; Figure 4 The structural diagram is intended for the embodiment four of the application; Figure 5 The structural diagram is intended for the embodiment five of the application. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application.

[0020] Embodiment one Reference Figure 1 As one of the embodiments of the application, a safety valve online automatic verification method is disclosed, and the verification method comprises the following steps: 101. The verification system receives a starting instruction from an external device through a Bluetooth module; As an optional implementation manner, in the embodiment of the application, the Bluetooth module is used to realize wireless communication with the external device, and the external device includes but is not limited to a mobile phone, a computer and the like terminal. In addition, the Bluetooth module is set to WH-BLE102-V1.1 in the embodiment. 102. The verification system controls an execution element to drive a push rod to move to a preset position according to the starting instruction; As an optional implementation manner, in the embodiment of the application, the execution element is set to a servo cylinder in the application, and the servo cylinder is connected with the push rod. Of course, the push rod should also be connected with a top rod of the safety valve during testing. The push rod is driven by the servo cylinder to act on the top rod, so as to control the movement of the top rod of the safety valve, and then the opening force value detection of the safety valve is performed. 103. The verification system collects force value data generated by a force value sensor and displacement data of the push rod during the movement of the push rod; As an optional implementation, in the embodiment of the application, the force value sensor uses the capacitance change based on the parallel plate capacitor. During the execution of the element movement control process, the force value sensor generates pressure or tension. The force changes the distance between the plates or the deformation, resulting in a change in the capacitance value. The strain gauge is attached to the elastic body, such as a metal beam or column, to form a Wheatstone bridge. The core principle of the Wheatstone bridge is to measure the unknown resistance value by comparing the ratio of two resistances. When the circuit is connected, the current flows through the four resistances and forms two parallel branches in the circuit. When the bridge reaches the equilibrium state, the potential difference between the galvanometer is zero, that is, no current flows through the galvanometer. At this time, the voltages of the two branches are equal. In strain measurement, the change of the strain gauge resistance will cause the bridge to be unbalanced. By detecting this unbalanced signal, the size of the strain can be calculated. In addition, the external force deforms the elastic body, the resistance of the strain gauge changes, and the bridge outputs a voltage signal. The obtained electrical signal is converted by the AD7190 chip and transmitted to the processor through the SPI communication mode and then parsed to obtain the force value data.

[0021] 104、The verification system processes the force value data to determine the state of the valve.

[0022] As an optional implementation, in the embodiment of the application, the Kalman filtering algorithm is used to filter the received real-time force value data to make the data present a smooth curve. The peak value algorithm is used to find an inflection point value based on the filtered data of the Kalman filtering algorithm. The inflection point value is the opening force value, which is used to determine whether the valve is in a qualified state.

[0023] Embodiment two Please refer to Figure 2 The verification method described in the embodiment includes: 201、The verification system initializes the Bluetooth module and configures it as a slave mode, so that the module is in a state that can be discovered and connected by external devices; As an optional implementation, in the embodiment of the application, the system establishes a connection through the WH-BLE102-V1.1 Bluetooth module. After the module is powered on, a series of AT instructions need to be sent through the serial port to configure it. In some embodiments, for example: first, send AT+DISCONN to disconnect any existing connection, then set the device name to WX-AQFMS (AT+NAME=WX-AQFMS), then set the transmission interval to 8 (AT+TPL=8), and finally set the module to slave mode (AT+MODE=S). After the above configuration is completed, the Bluetooth module will send a data every 100 microseconds (µs) according to the setting, thereby starting communication with external devices.

[0024] 202、the verification system receives a start string instruction sent by the external device, and sends a start instruction to the execution element after receiving the start string instruction; As an optional embodiment, in the embodiment of the application, the verification system first listens to a specific start signal sent by an external device, for example, a user sends the signal through a mobile phone APP operation. In actual application scenarios, this is usually manifested as the user clicking a "start" button on the APP interface. After clicking the button, the APP sends a conventional start string instruction, for example, ":start", to the verification system through a pre-established Bluetooth connection. The processor in the verification system continuously monitors the Bluetooth receiving port. Once the specific start string ":start" is detected, the processor is ready to send a specific motor control start instruction to the execution element to execute the subsequent push rod moving operation.

[0025] 203、the verification system receives the start instruction, and the execution element moves to a corresponding position according to a preset speed and target position, wherein the start instruction includes an instruction data frame containing a frame header, a control parameter and a checksum; As an optional embodiment, in the embodiment of the application, after the verification system receives a string instruction representing a start intention, for example, "start", the system internally generates and sends a start instruction to the execution element. In this embodiment, the instruction data frame is a hexadecimal data frame, for example, the processor sends a hexadecimal data frame 55 AA 0701 31 23 00 80 00 00 34 66. The last bit in this data frame is a checksum, and the previous 55 AA is a data frame header, which is used to judge that this is the data sent to the execution element, and then drive the push rod to move according to the preset speed and target position until it reaches the specified position.

[0026] 204、the verification system returns a response frame after the execution element receives the start instruction, and obtains the displacement data of the current push rod through the response frame, wherein the response frame includes an instruction data frame containing a frame header, a data frame and a checksum.

[0027] As an optional implementation, in the embodiment of the application, in order to ensure that the instruction is correctly received and executed, and to grasp the running state of the push rod in real time, the execution element, after receiving the starting instruction data frame, carries out internal processing and returns a response frame to the verification system. The response frame in this embodiment is also in a hexadecimal data format, such as AA 55 0F 0131 20 00 00 40 00 20 00 10 00 00 00 00 20 00 D0; wherein the last D0 is a check sum, and the preceding AA 55 is a frame header, which tells the processor that this is feedback information from the execution element and needs the processor to parse the middle data frame. After receiving the response frame, the verification system parses the data frame part, especially extracts the displacement data of the current push rod, which not only confirms that the instruction has been successfully received, but also enables the system to monitor the position of the push rod in real time, for subsequent state judgment or closed-loop control.

[0028] 205、The force value sensor of the verification system senses the force value based on the parallel plate capacitance change or the strain gauge principle; As an optional implementation, in the embodiment of the application, the force value sensor uses the capacitance change based on the parallel plate capacitor. During the movement control of the push rod by the execution element, the force value sensor generates pressure or tension. The action of the force changes the distance between the plates or the deformation, resulting in a change in the capacitance value. The strain gauge is pasted on the elastic body, such as a metal beam or column, to form a Wheatstone bridge. The core principle of the Wheatstone bridge is to measure the unknown resistance value by comparing the ratio of two resistances. When the circuit is connected, the current flows through the four resistances and forms two parallel branches in the circuit. When the bridge reaches the balanced state, the potential difference between the galvanometer is zero, that is, no current flows through the galvanometer. At this time, the voltages of the two branches are equal. In strain measurement, the change of the strain gauge resistance will cause the bridge to be unbalanced. By detecting this unbalanced signal, the size of the strain can be calculated.

[0029] 206、The verification system converts the analog signal output by the sensor into a digital signal through the AD7190 chip; As an optional implementation, in this embodiment, the AD7190 chip is used to convert the obtained electrical signal, and then the corresponding electrical signal is converted into a digital signal for subsequent processor analysis and processing.

[0030] 207、The verification system transmits the digital signal to the processor based on the SPI communication protocol for analysis to obtain the force value data; Further, in this embodiment, the external force deforms the elastic body, the resistance of the strain gauge changes, and the bridge outputs a voltage signal. The AD7190 chip is used to convert the obtained electrical signal, which is transmitted to the processor through the SPI communication mode and then analyzed to obtain the force value data.

[0031] 208、Judge whether the force value data and the displacement data of the push rod exceed the threshold value, if yes, stop driving the actuator and enter the protection state.

[0032] As an optional implementation, if the user forgets to manually click the stop button during the test, such as when the force sensor detects that the pulling force reaches the 200N threshold or when the detected displacement exceeds the 2mm threshold, the device will automatically trigger the protection mechanism to stop the movement of the actuator, prevent damage to the device or safety valve due to excessive pulling force, and ensure test safety. When the stop button is clicked subsequently, the actuator is automatically reset.

[0033] 209、Verify the system by Kalman filtering of the real-time collected force value data to obtain smoothed force value data; As an optional implementation, in the embodiment of the application, after the processor sends the start instruction, the force sensor starts to continuously measure the force value on the valve to obtain a series of original force value data points F_raw(t1), F_raw(t2), F_raw(t3),...; these data points may randomly jump around the true value; Kalman filtering: input the collected original force value data F_raw(t i ) into the Kalman filter, the filter predicts the force value at the next time according to a simple model, then the filter compares and weights the predicted value with the actually measured F_raw(t i ), and thereafter the Kalman filter outputs a series of estimated force values F_smooth(t i ) that are smoother and have less noise, and the F_smooth curve better reflects the true trend of force value change.

[0034] 210、The verification system applies a peak finding algorithm to the smoothed force value data to determine the opening force value based on the inflection point value identified by the peak finding algorithm; As an optional implementation, in the embodiment of the application, the smoothed force value data F_smooth(t i ) output by the Kalman filter is taken as input, and the algorithm analyzes the shape of the F_smooth(t i ) curve. It particularly focuses on the rate of change of the force value, that is, the "slope" or "gradient" of the curve. During the opening of the valve, the force value usually changes slowly at first, and then rapidly increases when the valve overcomes the resistance and starts to move. This "rapid increase" stage corresponds to the place where the curve has the largest slope. The goal of the peak finding algorithm is to find this point with the largest slope, which is the "inflection point". The algorithm calculates the F_smooth(t i) the difference between different time points, and find the maximum one, which is the time point t_peak, the inflection point t_peak corresponding to the smooth force value F_smooth(t_peak), that is, determined as the "opening force value".

[0035] 211、The verification system compares the opening force value with a preset threshold value, and judges whether the valve is in a qualified state according to the comparison result.

[0036] As an optional embodiment, in the embodiment of the application, by comparing the above-mentioned determined opening force value with a preset threshold value representing a qualified standard, the verification system can quickly and accurately judge whether a single valve meets the quality requirements, thereby realizing effective quality control.

[0037] In the application, the wireless transmission function is realized through the Bluetooth module, remote operation and data acquisition with terminals such as mobile phones or tablets are supported, and the convenience and flexibility of use are greatly improved. More importantly, the technology fills the gap that the existing technology cannot perform online verification on the threaded safety valve, so that the threaded safety valve can also realize efficient and accurate state detection and maintenance.

[0038] Embodiment three With reference to Figure 3 The application further provides a safety valve online automatic verification system, specifically, the verification system comprises a receiving unit 301, a control unit 302, an acquisition unit 303 and a judgment unit 304, wherein: The receiving unit 301 is used for receiving a starting instruction from an external device through a Bluetooth module; As an optional embodiment, in the embodiment of the application, the Bluetooth module is used to realize wireless communication with an external device, and the external device includes but is not limited to a terminal such as a mobile phone, a computer, etc. In addition, the Bluetooth module in the embodiment is set to WH-BLE102-V1.1. The control unit 302 is used for controlling a driving push rod to move to a preset position according to the starting instruction; As an optional embodiment, in the embodiment of the application, the driving push rod is connected with a servo cylinder, and of course the push rod should also be connected with a top rod of the safety valve during testing. The servo cylinder drives the push rod to act on the top rod, so as to control the movement of the top rod of the safety valve, and then the opening force value detection of the safety valve is performed. The acquisition unit 303 is used for acquiring force value data generated by a force value sensor and displacement data of the push rod during the movement of the push rod; As an optional implementation, in the embodiment of the present application, the force value sensor uses the capacitance change based on the parallel plate capacitor. During the execution of the element control process of the push rod movement, the force value sensor generates pressure or tension. The force changes the distance between the plates or the deformation, which leads to the change of the capacitance value. The strain gauge is pasted on the elastic body, such as a metal beam or column, to form a Wheatstone bridge. The core principle of the Wheatstone bridge is to measure the unknown resistance value by comparing the ratio of two resistances. When the circuit is connected, the current flows through the four resistances and forms two parallel branches in the circuit. When the bridge reaches the balance state, the potential difference between the galvanometer is zero, that is, no current flows through the galvanometer. At this time, the voltages of the two branches are equal. In strain measurement, the change of the strain gauge resistance will cause the bridge to be unbalanced. By detecting this unbalanced signal, the size of the strain can be calculated. In addition, the external force deforms the elastic body, and the resistance of the strain gauge changes. The bridge outputs a voltage signal. The obtained electrical signal is converted by the AD7190 chip, transmitted to the processor through the SPI communication mode, and then analyzed to obtain the force value data.

[0039] The judging unit 304 is used for processing the force value data to judge the state of the valve.

[0040] As an optional implementation, in the embodiment of the present application, the Kalman filtering algorithm is used to filter the received real-time force value data to make the data present a smooth curve. The inflection point value is found on the basis of the data filtered by the Kalman filtering algorithm through the peak searching algorithm. The inflection point value is the opening force value. The opening force value is used to judge whether the valve is in a qualified state.

[0041] Embodiment four Referring to Figure 4 It is another structure diagram of the verification system. Specifically, the receiving unit 301 in the verification system includes: The initial unit 3011 is used for initializing the Bluetooth module and is configured in a slave mode, so that the module is in a state of being discovered and connected by an external device. As an optional implementation, in the embodiment of the application, the system establishes a connection through a WH-BLE 102-V1.1 Bluetooth module. After the module is powered on, a series of AT instructions need to be sent through a serial port to configure it. In some embodiments, for example, first, AT+DISCONN is sent to disconnect any existing connection, then the device name is set to WX-AQFMS (AT+NAME=WX-AQFMS), then the transmission interval is set to 8 (AT+TPL=8), and finally the module is set to slave mode (AT+MODE=S). After the above configuration is completed, the Bluetooth module will send a piece of data every 100 microseconds (µs) according to the settings, thereby starting communication with external devices.

[0042] The receiving subunit 3012 is configured to receive a start string instruction sent by an external device, and send a start instruction to the executing element when the start string instruction is received.

[0043] As an optional implementation, in the embodiment of the application, the verification system first listens to a specific start signal sent by an external device, for example, a user sends a specific start signal through a mobile phone APP. In actual application scenarios, this is usually manifested as the user clicking a “start” button on the APP interface. After clicking the button, the APP sends a conventional start string instruction, for example, “:start”, to the verification system through a pre-established Bluetooth connection. The processor in the verification system continuously monitors the Bluetooth receiving port. Once the specific start string “:start” is detected, the processor is ready to send a specific motor control start instruction to the executing element to execute the subsequent push rod moving operation.

[0044] In addition, the control unit 302 in the embodiment includes: The control subunit 3021 is configured to, after receiving the start instruction, control the executing element to move to a corresponding position according to a preset speed and target position, wherein the start instruction includes an instruction data frame containing a frame header, a control parameter, and a checksum. As an optional implementation, in the embodiment of the application, after the verification system receives a string instruction representing a start intention, for example, “start”, the system internally generates and sends a start instruction to the executing element. The instruction data frame in the embodiment is a hexadecimal data frame, for example, the processor sends a hexadecimal data frame 55 AA 0701 31 23 00 80 00 00 34 66. The last bit in this data frame is a checksum, and the previous 55 AA is a data frame header, which is used to judge that this is data sent to the executing element, thereby driving the push rod to move according to a preset speed and target position until reaching a specified position.

[0045] The response unit 3022 is configured to return a response frame after the execution element receives the start instruction, and the displacement data of the current push rod is obtained through the response frame, wherein the response frame includes an instruction data frame, and the instruction data frame includes a frame header, a data frame and a checksum.

[0046] As an optional implementation, in the embodiment of the application, in order to ensure that the instruction is correctly received and executed, and to grasp the running state of the push rod in real time, the execution element returns a response frame to the verification system after receiving the start instruction data frame, and the response frame is also in the hexadecimal data format in the embodiment, such as AA 55 0F 0131 20 00 00 40 00 20 00 10 00 00 00 00 20 00 D0, wherein the last D0 is the checksum, and the previous AA 55 is the frame header, which is used to tell the processor that it is feedback information from the execution element, and the processor needs to parse the data frame in the middle. After receiving the response frame, the verification system parses the data frame part, especially extracts the displacement data of the current push rod, which not only confirms that the instruction has been successfully received, but also enables the system to monitor the position of the push rod in real time, which is used for subsequent state judgment or closed-loop control.

[0047] On the basis of the above embodiment, the collection unit 303 in the embodiment includes: The sensing unit 3031 is configured to sense the force value based on the parallel-plate capacitance change or the strain gauge principle. As an optional implementation, in the embodiment of the application, the force value sensor uses the capacitance change based on the parallel-plate capacitor. During the movement control of the push rod by the execution element, the force value sensor generates pressure or tension. The action of the force changes the distance between the plates or the deformation, resulting in the change of the capacitance value. The strain gauge is pasted on the elastic body, such as a metal beam or column, to form a Wheatstone bridge. The core principle of the Wheatstone bridge is to measure the unknown resistance value by comparing the ratio of two resistances. When the circuit is connected, the current flows through the four resistances and forms two parallel branches in the circuit. When the bridge reaches the balance state, the potential difference between the galvanometer is zero, that is, no current flows through the galvanometer. At this time, the voltages of the two branches are equal. In the strain measurement, the change of the strain gauge resistance will cause the imbalance of the bridge. The size of the strain can be calculated by detecting the imbalance signal.

[0048] The conversion unit 3032 is configured to convert the analog signal output by the sensor into a digital signal through an AD7190 chip. As an optional implementation, in the embodiment, the AD7190 chip is used to convert the obtained electrical signal, and then the corresponding electrical signal is converted into a digital signal, so as to facilitate the subsequent processor to perform analysis and processing.

[0049] The analysis unit 3033 transmits the digital signal to the processor based on the SPI communication protocol for analysis to obtain force value data; Further, in the embodiment, the external force deforms the elastic body, the strain gauge resistance changes, the bridge output voltage signal changes, the acquired electrical signal is converted by the AD7190 chip, transmitted to the processor through the SPI communication mode, and then analyzed to obtain the force value data.

[0050] The protection unit 3034 judges whether the force value data and the displacement data of the push rod exceed the threshold value, and if so, stops driving the execution element and enters the protection state.

[0051] As an optional implementation, if the user forgets to manually click the stop button during the test, such as when the force value sensor detects that the pulling force reaches the 200N threshold value or when the detected displacement exceeds the 2mm threshold value, the device will automatically trigger the protection mechanism to stop the movement of the execution element, prevent damage to the device or safety valve due to excessive pulling force, and ensure test safety. When the stop button is clicked later, the execution element is automatically reset.

[0052] In addition, the judgment unit 304 in the embodiment includes: The filter unit 3041 obtains smoothed force value data by Kalman filtering on the real-time collected force value data; As an optional implementation, in the embodiment, when the processor sends a start instruction, the force sensor starts continuous measurement of the force value on the valve to obtain a series of original force value data points F_raw(t1), F_raw(t2), F_raw(t3),...; these data points may randomly jump around the true value; The Kalman filter: input the collected original force value data F_raw(t i ) into the Kalman filter, which predicts the force value at the next time according to a simple model, then the filter compares and weights the predicted value with the actually measured F_raw(t i ) to output a series of smoother and less noisy estimated force values F_smooth(t i ). The F_smooth curve better reflects the true trend of force value changes.

[0053] The peak finding unit 3042 applies a peak finding algorithm to the smoothed force value data to determine the opening force value through the inflection point value identified by the peak finding algorithm; As an optional implementation, in the embodiment, the Kalman filter outputs the smoothed force value data F_smooth(t iAs input, the algorithm analyzes F_smooth(t) i The shape of the curve. It pays particular attention to the rate of change of force, that is, the "slope" or "gradient" of the curve. During the valve opening process, the force usually changes slowly at first, and then rises rapidly when the valve overcomes the resistance and begins to move. This "rapid rise" phase corresponds to the point where the slope of the curve is the largest. The goal of the peak finding algorithm is to find this point with the largest slope, which is the "inflection point". The algorithm calculates F_smooth(t i Find the difference between different time points and find the time point t_peak corresponding to the largest difference. The smoothing force value F_smooth(t_peak) corresponding to the inflection point time point t_peak is determined as the "opening force value".

[0054] The judgment subunit 3043 compares the opening force value with a preset threshold and determines whether the valve is in a qualified state based on the comparison result.

[0055] As an optional implementation, in this embodiment of the invention, by comparing the determined opening force value with a preset threshold representing a qualified standard, the verification system can quickly and accurately determine whether a single valve meets the quality requirements, thereby achieving effective quality control.

[0056] This invention utilizes a Bluetooth module to achieve wireless transmission, supporting remote operation and data acquisition with mobile phones or tablets, greatly improving ease of use and flexibility. Most importantly, this technology fills the gap in existing technologies that cannot perform online calibration of threaded safety valves, enabling efficient and accurate status monitoring and maintenance of threaded safety valves.

[0057] Example 5 Please see Figure 5 , Figure 5 This is a schematic diagram of another verification system disclosed in an embodiment of the present invention, as shown below. Figure 5 As shown, the verification system may include: Memory 501 storing executable program code; Processor 502 coupled to memory 501; Specifically, processor 502 calls the executable program code stored in memory 501 and executes it. Figures 1-2 An online automatic calibration method for any type of safety valve.

[0058] This invention discloses a computer-readable storage medium storing a computer program, wherein the computer program causes a computer to execute... Figures 1-2 Any method for online automatic calibration of safety valves.

[0059] The embodiments of the present application also disclose a computer program product, which, when running on a computer, enables the computer to perform part or all of the steps of the method in the above method embodiments.

[0060] Those skilled in the art can understand that all or part of the steps of the above-mentioned method embodiments can be instructed by a program to relevant hardware, and the program can be stored in a computer readable storage medium, including Read-Only Memory (ROM), Random Access Memory (RAM), Programmable Read-Only Memory (PROM), Erasable Programmable Read-Only Memory (EPROM), One-time Programmable Read-Only Memory (OTPROM), Electrically-Erasable Programmable Read-Only Memory (EEPROM), Compact Disc Read-Only Memory (CD-ROM) or other disc storage, magnetic disk storage, magnetic tape storage or any other medium capable of storing data which can be read by a computer.

[0061] The above describes only the preferred embodiments of the present application, but the protection scope of the present application is not limited to this. Any person skilled in the art, according to the technical solution and the inventive concept of the present application, makes equivalent replacement or change within the technical range disclosed by the present application, should be covered within the protection scope of the present application.

Claims

1. A method for online automatic calibration of a safety valve, characterized in that, include: Receive start commands from external devices via Bluetooth module; According to the start command, the actuator is controlled to drive the push rod to move to a preset position; During the movement of the push rod, force data generated by the force sensor and displacement data of the push rod are collected; The force data is processed to determine the valve's state.

2. The method for online automatic calibration of a safety valve according to claim 1, characterized in that: The step of receiving a start command from an external device via the Bluetooth module includes: Initialize the Bluetooth module and configure it to slave mode, so that the module can be discovered and connected to by external devices; It receives a startup string command sent by an external device, and upon receiving the startup string command, sends a startup command to the execution element.

3. The method for online automatic calibration of a safety valve according to claim 1, characterized in that: The step of controlling the actuator to drive the push rod to move to a preset position according to the start command includes: Upon receiving the start command, the actuator controls the lever to move to the corresponding position according to the preset speed and target position. The start command includes an instruction data frame containing a frame header, control parameters, and a checksum. When the actuator receives the start command, it will return a response frame. The displacement data of the current push rod can be obtained through the response frame. The response frame includes a command data frame containing a frame header, a data frame, and a checksum.

4. The method for online automatic calibration of a safety valve according to claim 1, characterized in that: The process of collecting force data from the force sensor and displacement data of the push rod during its movement includes: Force sensors detect force values ​​based on the capacitance change of parallel plates or the principle of strain gauges. The AD7190 chip converts the analog signal output by the sensor into a digital signal. The digital signal is transmitted to the processor for analysis based on the SPI communication protocol to obtain force data. Determine whether the force value data and the displacement data of the push rod exceed the threshold. If so, stop driving the actuator and enter the protection state.

5. The method for online automatic calibration of a safety valve according to claim 1, characterized in that: The process of processing the force data to determine the valve's state includes: Smoothed force data is obtained by performing Kalman filtering on the real-time force data. A peak-finding algorithm is applied to the smoothed force data, and the inflection point value identified by the peak-finding algorithm is used to determine the opening force value. The opening force value is compared with a preset threshold, and the valve is judged to be in a qualified state based on the comparison result.

6. An online automatic calibration system for safety valves, characterized in that... ,include: The receiving unit is used to receive start commands from external devices via the Bluetooth module; The control unit is used to control the actuator to drive the push rod to move to a preset position according to the start command; The acquisition unit is used to acquire force data generated by the force sensor and displacement data of the push rod during the movement of the push rod; The judgment unit is used to process the force value data to determine the state of the valve.

7. The online automatic calibration system for a safety valve according to claim 6, characterized in that: The receiving unit includes: The initialization unit is used to initialize the Bluetooth module and configure it in slave mode, so that the module can be discovered and connected to by external devices. The receiving subunit is used to receive the start string instruction sent by the external device. After receiving the start string instruction, it sends the start instruction to the execution element.

8. The online automatic calibration system for a safety valve according to claim 6, characterized in that: The control unit includes: The control subunit is used to receive the start command and then control the actuator to move the lever to the corresponding position according to the preset speed and target position. The start command includes an instruction data frame containing a frame header, control parameters and a checksum. The response unit is used to return a response frame after the actuator receives a start command, and to obtain the current displacement data of the push rod through the response frame. The response frame includes an instruction data frame containing a frame header, a data frame, and a checksum.

9. The online automatic calibration system for a safety valve according to claim 6, characterized in that: The acquisition unit includes: The sensing unit, a force sensor, senses force based on the capacitance change of a parallel plate or the principle of a strain gauge. The conversion unit converts the analog signal output by the sensor into a digital signal using the AD7190 chip; The parsing unit transmits the digital signal to the processor for parsing based on the SPI communication protocol to obtain force data. The protection unit determines whether the force value data and the displacement data of the push rod exceed the threshold. If so, it stops driving the actuator and enters the protection state.

10. The online automatic calibration system for a safety valve according to claim 6, characterized in that: The determination unit includes: The filtering unit is used to perform Kalman filtering on the real-time force data to obtain smoothed force data; The peak finding unit is used to apply a peak finding algorithm to the smoothed force value data, and determine the opening force value by using the inflection point value identified by the peak finding algorithm; The judgment subunit is used to compare the opening force value with a preset threshold and determine whether the valve is in a qualified state based on the comparison result.

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