Intelligent online monitoring and linkage control method for electric butterfly valve of dust removal system

Abstract

The application discloses a dust removal system electric butterfly valve intelligent online monitoring linkage control method, relates to the field of online monitoring of electric butterfly valves of dust removal system valves, and comprises the following steps: collecting driving torque data and pipeline medium flow data of the electric butterfly valve in real time and synchronously, and extracting the dust deposition distribution characteristics by virtually dividing the circumferential area of the valve plate and the bottom of the valve seat; the circumferential area of the valve plate and the bottom of the valve seat is virtually divided into a plurality of discrete fan-shaped units, the dust deposition distribution characteristics of each area are constructed based on historical data in the initial cleaning state, and the key dust deposition area is located in combination with the torque abnormality characteristics; after cleaning is completed, the torque data of the electric butterfly valve and the flow data of the pipeline medium are monitored again to verify the cleaning effect, and if the torque deviation does not return to the normal interval, secondary cleaning is started, the online perception, intelligent diagnosis and closed-loop linkage control of the dust deposition state of the electric butterfly valve are realized, and the cleaning efficiency and the equipment operation stability are significantly improved.

Description

Technical Field

[0001] This invention belongs to the field of online monitoring technology for electric butterfly valves in dust removal systems, and relates to an intelligent online monitoring and linkage control method for electric butterfly valves in dust removal systems. Background Technology

[0002] In the field of industrial dust removal, electric butterfly valves in dust removal systems are key fluid control devices, mainly used to regulate the flow and on / off state of media in pipelines to ensure stable system operation. However, because dust removal systems are often located in harsh environments with high dust and high humidity, dust easily accumulates on the valve plate and seat of electric butterfly valves, leading to abnormally increased torque, decreased sealing performance, or even jamming, which seriously affects system operating efficiency and equipment lifespan.

[0003] These problems not only disrupt the flow stability of the dust removal system and reduce dust filtration efficiency, but may also cause unplanned system shutdowns due to sudden valve malfunctions, resulting in production losses. Therefore, real-time online monitoring of the operating status of electric butterfly valves is particularly important.

[0004] Currently, there are still many limitations in the maintenance and monitoring technology of electric butterfly valves for dust removal systems in the industrial field: Firstly, most existing technologies adopt the method of periodic shutdown and offline testing, which cannot capture the dynamics of dust accumulation and torque changes during valve operation in real time. This lagging monitoring mode often only discovers the problem after the dust accumulation has caused a significant decline in valve performance or even a failure. This can easily cause fluctuations in the flow rate of the dust removal system, a sharp drop in filtration efficiency, and even serious consequences such as pipeline blockage and overload burnout of the drive motor.

[0005] Secondly, existing dust accumulation detection technologies typically rely on a single parameter to determine the dust accumulation situation, which cannot accurately locate the specific area of ​​dust accumulation. This results in the need to thoroughly blow the entire valve during cleaning operations, which not only wastes a lot of cleaning resources but may also cause unnecessary wear on the sealing surfaces of the valve plate and valve seat due to excessive blowing, thus shortening the valve's service life.

[0006] Third, existing technologies lack the ability to assess cleaning results after cleaning operations are completed, making it impossible to promptly confirm whether the dust inside the valve has been removed to a level that does not affect normal operation. If the dust is not completely removed, it can easily lead to subsequent problems such as obstructed valve movement and reduced sealing performance, resulting in increased maintenance time and costs. Summary of the Invention

[0007] In view of this, in order to solve the problems mentioned in the background art, the present invention provides an intelligent online monitoring and linkage control method for electric butterfly valves in dust removal systems.

[0008] The objective of this invention can be achieved through the following technical solution: a method for intelligent online monitoring and linkage control of electric butterfly valves in dust removal systems, comprising the following steps: S1, real-time synchronous acquisition of the driving torque data of the electric butterfly valve and the real-time flow data of the pipeline medium;

[0009] S2. The circumferential area at the bottom of the butterfly valve plate and seat is virtually divided into multiple discrete areas, and the dust accumulation distribution characteristics of each area are constructed based on historical data under the initial cleaning state.

[0010] S3. Based on the abnormal characteristics of torque data under different flow conditions, and combined with the characteristics of dust accumulation distribution, locate the key areas of dust accumulation.

[0011] S4. For the key dust accumulation areas identified, compare the measured torque data under the current working conditions with the standard torque at the same flow point in real time to obtain the torque deviation value, and trigger the cleaning command by analyzing the growth trend of the torque deviation value.

[0012] S5. Adaptively adjust the blowing angle, pressure, and duration of the blowing device according to the cleaning instructions, and perform the cleaning operation;

[0013] S6. After cleaning, re-monitor the torque data of the electric butterfly valve and the flow data of the medium in the pipeline to verify the cleaning effect. If the torque deviation does not return to the normal range, start the second cleaning.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The present invention collects the driving torque data of the electric butterfly valve and the flow data of the pipeline medium in real time and extracts the ash distribution characteristics by virtually dividing the circumferential area of ​​the bottom of the butterfly valve plate and valve seat, thereby realizing real-time online monitoring and accurate positioning of the ash accumulation status of the valve, avoiding serious consequences such as valve performance degradation, system flow fluctuation, reduced filtration efficiency and motor overload caused by ash accumulation.

[0015] (2) This invention virtually divides the circumferential area of ​​the valve plate and valve seat bottom into multiple discrete sector units, and constructs the dust accumulation distribution characteristics of each area based on historical data under the initial cleaning state. Then, it combines the torque abnormality characteristics to locate the key dust accumulation area, which can accurately locate the key dust accumulation area and avoid the problem of relying on a single parameter and being unable to distinguish the specific dust accumulation location. This achieves targeted cleaning, reduces the waste of cleaning resources, reduces unnecessary wear on the valve sealing surface, and extends the service life of the valve.

[0016] (3) After cleaning, the present invention re-monitors the torque data of the electric butterfly valve and the flow data of the pipeline medium to verify the cleaning effect. If the torque deviation does not return to the normal range, a second cleaning is initiated. This establishes a cleaning effect verification and second cleaning mechanism, avoiding valve movement obstruction and sealing performance degradation due to incomplete cleaning, and improving maintenance efficiency. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a diagram illustrating the implementation steps of the method of the present invention.

[0019] Figure 2 This is a flowchart illustrating the construction of the dust distribution characteristics of the electric butterfly valve in its initial cleaning state according to the present invention.

[0020] Figure 3 This is a flowchart illustrating the key areas for dust accumulation in the electric butterfly valve of this invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figure 1 As shown, the present invention provides an intelligent online monitoring and linkage control method for electric butterfly valves in dust removal systems, including: S1, real-time synchronous acquisition of the driving torque data of the electric butterfly valve and the real-time flow data of the pipeline medium.

[0023] It should be noted that torque data is obtained by installing non-contact torque sensors, such as strain gauge or magnetoelectric torque sensors, on the output shaft of the electric butterfly valve's drive motor or gearbox to monitor the resistance torque experienced by the valve plate during rotation in real time. The sensor amplifies and filters the detected analog signal through a signal conditioning circuit, then converts it into a digital signal via an A / D conversion module, and finally transmits it to the central monitoring system via fieldbus or industrial Ethernet.

[0024] Flow data is collected in real time by installing flow meters, such as orifice plate flow meters, vortex flow meters, or electromagnetic flow meters, on the pipeline where the electric butterfly valve is located. These flow meters detect the volumetric or mass flow rate of the medium flowing through the pipeline. The standard signal output by the flow meter is acquired through an I / O module and transmitted to the central monitoring system via the industrial network.

[0025] Under normal circumstances, the driving torque is relatively stable. When dust, scale, or jamming accumulates in the valve plate or valve seat area, the rotational resistance increases, and the driving torque will rise significantly. Therefore, an abnormal increase in torque is a direct sign of dust accumulation or mechanical failure. Torque data is collected to determine whether cleaning is necessary.

[0026] Flow rate directly affects the impact force of the fluid on the valve plate, and thus the driving torque. Under the same valve opening, the torque at higher flow rates is naturally higher than that at lower flow rates. Simply looking at torque without considering flow rate data can easily lead to misjudgments. For example, high flow rate and slight dust accumulation may result in high torque, which could be mistaken for severe dust accumulation. Therefore, torque data must be synchronized with flow rate data to accurately determine whether the current torque is abnormal.

[0027] S2. The circumferential area at the bottom of the butterfly valve plate and seat is virtually divided into multiple discrete regions, and the dust accumulation distribution characteristics of each region are constructed based on historical data under the initial cleaning state.

[0028] The specific steps for virtually dividing the circumferential area of ​​the bottom of the butterfly valve plate and seat into multiple discrete areas are as follows: Based on the product design drawings or physical measurements of the electric butterfly valve, determine the precise position of the rotation axis of the valve plate and the inner diameter of the bottom of the valve seat, and thereby define the reference center and radius of the virtual division.

[0029] With the valve plate rotation axis as the center and the inner circumference of the valve seat sealing surface as the outer boundary, rays are uniformly drawn from the center to the boundary circumference, virtually dividing the circular area into several sector-shaped monitoring units of equal area.

[0030] Specifically, a two-dimensional plane coordinate system is established with the confirmed rotation axis of the valve plate as the origin of the virtual coordinate system: the direction of the coincidence between the center line of the valve plate and the central axis of the valve body when the valve plate is fully closed is taken as the positive direction of the X-axis, and the positive direction of the Y-axis is taken as the direction perpendicular to the X-axis and pointing towards the opening direction of the valve plate, thus forming a virtual segmented reference coordinate system.

[0031] The inner circumference of the valve seat sealing surface is used as the outer boundary of the virtual division. This circumference is defined as a circle with radius R in the virtual coordinate system. It only covers the sealing surface area where the valve plate and the bottom of the valve seat are in contact and where dust easily accumulates, excluding the non-monitored area outside the valve body. This is defined as the range of the division area.

[0032] Using the positive X-axis of the virtual coordinate system as the starting reference, the angle values ​​of each ray are calculated sequentially according to the center angle α of each sector unit: the first ray has an angle of 0°, the second ray has α, the third ray has 2α, ..., the Nth ray has (N-1)α, forming N rays that are evenly distributed starting from the reference center O. The area formed by two adjacent rays and the inner circle of the valve seat sealing surface constitutes a sector monitoring unit: starting from 0°, the area enclosed by (0°-α) is defined as unit 1, the area enclosed by (α-2α) is defined as unit 2, ..., the area enclosed by ((N-1)α-360°) is defined as unit N.

[0033] The monitoring units, divided into several sector-shaped units of equal area, are divided into different adaptation ranges based on the actual size of the inner circumference radius of the sealing surface of the electric butterfly valve seat. The smaller the radius, the fewer units are selected, and the larger the radius, the more units are selected. This ensures that the unit coverage area matches the valve seat size, avoiding monitoring redundancy due to too many small-radius valve seat units and monitoring omissions due to too few large-radius valve seat units.

[0034] The aforementioned sector-shaped monitoring unit is defined as a discrete region.

[0035] The valve plate rotates around the rotation axis. The inner circumference of the valve seat sealing surface is the core area where the medium contacts the valve plate and where dust easily accumulates. The sector-shaped unit divided based on this can accurately cover the physical space where the valve plate interacts with the medium during operation and may accumulate dust. It will not miss high-dust-accumulation areas such as the edge of the sealing surface, nor will it include redundant areas on the outside of the valve body where there is no risk of dust accumulation.

[0036] See Figure 2 As shown, the specific steps for constructing the dust distribution characteristics of each area based on historical data under the initial cleaning state are as follows: the dust removal system is run under the initial cleaning state of the electric butterfly valve and the driving torque data under multiple flow conditions are collected, while the real-time flow data of the corresponding pipeline medium is recorded.

[0037] For each virtual discrete region, the real-time collected torque value is compared with the standard torque threshold of the corresponding flow point. If the measured torque continuously exceeds the threshold range, a torque anomaly event is recorded.

[0038] It should be noted that the standard torque threshold is obtained by statistically analyzing multiple sets of torque sample data in the same discrete region at each flow point, such as calculating the average and median, to obtain the normal torque benchmark value for that region at that flow point.

[0039] In the initial clean state of the electric butterfly valve, free of dust accumulation, the flow rate of the pipeline medium is the core factor affecting the driving torque. The higher the flow rate, the stronger the impact and friction of the medium on the valve plate, and the higher the normal torque required to drive the valve plate to rotate. Conversely, the lower the flow rate, the lower the corresponding normal torque. Therefore, the normal torque in the same discrete region is not a fixed value, but a dynamic value that varies with the flow rate. It is necessary to use the corresponding flow point as a benchmark to determine whether the torque is abnormal.

[0040] The frequency of abnormal events triggered in each region during the historical operating cycle is statistically analyzed, and the dust accumulation probability weight of that region is initialized accordingly.

[0041] The number of new torque anomaly events associated with each region is counted within each analysis period.

[0042] The number of new entries is compared with a preset threshold range. If the number of new entries falls into a lower range, the probability weight of dust accumulation in that area is increased by one level. If the number of new entries falls into a medium range, it is increased by two levels. If the number of new entries falls into a higher range, it is increased by three levels.

[0043] It should be noted that the more severe the dust accumulation and the faster the dust accumulation rate in a certain discrete area, the more new anomalies will occur in that area per unit time, with the triggered torque continuously exceeding the standard threshold.

[0044] If the number of new occurrences falls into a lower range, it indicates that the region only occasionally experiences torque anomalies during the analysis period. The dust accumulation may be in a state of slight accumulation and slow deterioration, such as a small amount of dust beginning to adhere, but it has not yet significantly affected the operation of the valve plate. Therefore, it is only necessary to increase the weight level by one to match the low-risk deterioration characteristics.

[0045] If the number of new occurrences falls into the medium range, it indicates that the dust accumulation in the area has entered a relatively rapid accumulation stage, and the frequency of abnormal torque has increased significantly. If dust continues to accumulate, the resistance of the valve plate will gradually increase, and the risk of dust accumulation will deteriorate at an accelerated rate. It is necessary to increase the two weight levels to reflect the urgency of the deterioration of the medium risk.

[0046] If the number of new occurrences falls into a high range, it means that the area's dust accumulation has deteriorated rapidly and is seriously affecting the system. For example, if a large amount of dust accumulates, the valve plate's operating resistance will rise sharply, and anomalies will be triggered frequently in a short period of time. The risk of dust accumulation is extremely high. Therefore, it is necessary to increase the weight level by three levels to highlight the urgency of the high-risk deterioration and provide a clear high-risk signal for the subsequent location of key dust accumulation areas.

[0047] The preset threshold range is determined based on the baseline data under the initial cleaning state, combined with the influence of dust accumulation on torque anomalies and the system monitoring accuracy requirements.

[0048] To maintain stable flow conditions under each degree of dust accumulation, the system was run and the number of new anomalies was counted in each analysis period. The experiment was repeated multiple times and the average value was taken. For example, the average number of new anomalies under slight dust accumulation was recorded as N1, the average number of new anomalies under moderate dust accumulation was recorded as N2, and the average number of new anomalies under heavy dust accumulation was recorded as N3. The positive correlation between the degree of dust accumulation and the number of anomalies was verified: it was confirmed that N1 < N2 < N3 formed a corresponding relationship curve between the degree of dust accumulation and the number of new anomalies.

[0049] The probability weight of dust accumulation in this area is defined as the dust accumulation distribution feature.

[0050] S3. Based on the abnormal characteristics of torque data under different flow conditions, and combined with the characteristics of dust accumulation distribution, locate the key areas of dust accumulation.

[0051] See Figure 3 As shown, the steps for locating key areas of dust accumulation are as follows: determine the operating condition range to which the current flow belongs based on real-time flow data, and extract virtual areas within the flow range where historical torque anomaly events occur more frequently as candidate areas.

[0052] The dust accumulation distribution characteristics of each virtual region are retrieved, and regions with high dust accumulation probability weight levels are selected as high-probability dust accumulation regions.

[0053] The candidate region is matched with the high-probability dust accumulation region. If a region belongs to both the candidate region and the high-probability dust accumulation region, then the region is identified as a key dust accumulation region.

[0054] It should be noted that a high weighting of dust accumulation probability means that the region has a high frequency of torque anomalies caused by dust accumulation in its historical operation, and the number of new anomalies is growing rapidly. It is a region with strong dust accumulation susceptibility and a consistently high dust accumulation risk, reflecting the objective law that the region is more prone to dust accumulation.

[0055] High-probability dust accumulation areas exclude occasional anomalies: The determination of high-probability dust accumulation areas is based on long-term historical data statistics, rather than single or short-term anomalies. This can filter out occasional anomaly areas caused by momentary interference, representing areas that truly have the basis for dust accumulation risk.

[0056] If the key area is determined solely based on the current anomaly, occasional anomaly areas caused by momentary interference may be misjudged as dust accumulation areas. For example, a low-risk area may enter the candidate area due to an impurity impact, but if the dust accumulation probability weight is low, it does not belong to the high-probability dust accumulation area and is excluded after matching. By matching with high-probability dust accumulation areas, it can be ensured that the key area to be determined has a historical dust accumulation risk basis, thus excluding interference from non-dust accumulation factors.

[0057] Output the number and location information of key dust accumulation areas to the cleaning control unit.

[0058] S4. For the identified key areas of dust accumulation, compare the measured torque data under the current operating conditions with the standard torque at the same flow point in real time to obtain the torque deviation value. Analyze the growth trend of the torque deviation value to trigger a cleaning command.

[0059] The specific steps to obtain the torque deviation value are as follows: acquire the real-time flow data of the current pipeline medium, and read the number and location information of the key dust accumulation areas that have been located.

[0060] Based on real-time flow data, a preset flow rate and standard torque correspondence table is dynamically queried to extract the standard torque reference curve for the entire operating cycle of the valve plate at that flow rate point.

[0061] Specifically, the extracted discrete data sets of angle and standard torque are processed through linear fitting to fill the torque data gaps between adjacent angle nodes, forming a continuous correspondence between angle and standard torque. Using the valve plate rotation angle as the abscissa and the standard torque value as the ordinate, a standard torque baseline curve for the entire operating cycle of the valve plate at that flow point is generated. This curve reflects the normal law of torque variation with angle during the valve plate's movement from fully closed to fully open and back to fully closed under the initial clean state and flow conditions.

[0062] The actual torque data of the electric butterfly valve is collected synchronously for a complete cycle under the current flow conditions. The torque data segment corresponding to the valve plate passing through the key area is extracted from the complete torque data and marked as the current torque abnormality characteristic component.

[0063] It should be noted that dust accumulation only adheres to specific discrete areas of the valve seat and valve plate, i.e., the dust accumulation focus areas. Its interference with the driving torque does not persist throughout the entire valve plate's operating cycle; rather, it only becomes apparent when the valve plate rotates through these focus areas. When the valve plate is not in the focus area, even if there is no dust accumulation in other areas, the torque remains within the normal range. Only when the valve plate comes into contact with the dust accumulation in the focus area will the additional resistance generated by the dust cause the torque to increase, forming a localized abnormal torque segment. Therefore, after simultaneously collecting the actual torque data for the entire cycle, only the torque data segment when the valve plate passes through the focus area is extracted.

[0064] The actual torque characteristic component data segment is compared point by point with the standard torque value within the same valve plate angle range on the standard torque reference curve, and the absolute value of the deviation between all data points in the characteristic component data segment and the standard value is calculated.

[0065] Determine whether the absolute value sequence continuously exceeds the preset tolerance range. If the determination result is yes, calculate the average value of the absolute value of the deviation within the data segment and define it as the current comprehensive torque deviation value of the dust accumulation key area.

[0066] It should be noted that the preset tolerance range is based on the normal torque fluctuation range under no dust accumulation conditions, and is determined in combination with equipment accuracy and on-site operating conditions. The core benchmark for determining the tolerance range is to statistically analyze the absolute value sequence of deviations for all flow conditions and all key areas, and record the maximum deviation value.

[0067] When dust accumulates in key dust-prone areas, the additional resistance generated by the dust continuously acts on the valve plate throughout its rotation through these areas. This causes the torque within the corresponding angle range to consistently exceed the standard torque at the same flow rate, resulting in a torque deviation sequence that consistently exceeds the normal range. In contrast, non-dust-accumulation interference during field operation only causes a sudden increase in torque deviation at one or two data points, preventing the entire deviation absolute value sequence from continuously exceeding the range. Therefore, by determining whether the absolute value sequence continuously exceeds the preset tolerance range, non-dust-accumulation interference can be effectively filtered out, ensuring that the deviation values ​​calculated subsequently originate solely from dust accumulation.

[0068] The specific triggering process of the cleaning instruction is as follows: continuously acquire the comprehensive torque deviation value of the current key area of ​​dust accumulation, and record the deviation value at fixed time intervals to form a time-series data sequence.

[0069] It should be noted that the fixed time interval is the number of valve plate cycles required to observe the deterioration of dust accumulation from an acceptable state to a state requiring cleaning, based on the initial operating data.

[0070] Short-term fluctuation filtering is applied to the time-series data sequence to identify and remove data points that suddenly increase or decrease due to instantaneous operating condition fluctuations, and a smoothed torque deviation trend curve is generated.

[0071] Extract the data segment from the smoothed torque deviation trend curve within the most recent complete operating cycle, and calculate the average rate of change of the torque deviation value within that data segment.

[0072] Determine whether the average rate of change is consistently positive and whether this consistently positive average rate of change exceeds the system's allowable rate of deterioration. If both conditions are met, it is preliminarily determined that the area has a trend of continuous deterioration in dust accumulation.

[0073] It should be noted that dust accumulation will continuously increase the contact resistance between the valve plate and the valve seat, resulting in an increase in driving torque. This means that the overall torque deviation value increases over time, indicating that the average rate of change is consistently positive. Essentially, this is a direct data reflection of the continuous increase in dust accumulation. If the average rate of change is not positive, such as remaining flat or decreasing, it indicates that the dust accumulation has not increased or has even decreased, and there is no deteriorating trend.

[0074] Even if the average rate of change is positive, if it does not exceed the tolerance limit, it means that the dust accumulation is growing slowly and will not affect the normal operation of the butterfly valve in the short term. Slight dust accumulation can be handled by subsequent routine cleaning. Only when the average rate of change exceeds the tolerance limit does it mean that the dust accumulation is growing too fast. If it is not cleaned in time, it may cause problems such as valve plate jamming and pipeline blockage. Therefore, it is necessary to initially determine that the dust accumulation is continuing to worsen, so as to provide a basis for subsequent confirmation and triggering of cleaning instructions.

[0075] The specific method for determining the tolerance of the deterioration rate through statistical analysis is as follows: based on the long-term operating data of the electric butterfly valve in the initial clean state, calculate the natural fluctuation trend of the torque deviation value under different operating conditions, and take the statistical upper limit of its average rate of change as the tolerance value.

[0076] When it is initially determined that there is a trend of continuous deterioration of dust accumulation, the continuous monitoring timer is started. If the average rate of change of torque deviation remains positive and the value increases over three consecutive operating cycles, the trend of deterioration of dust accumulation is confirmed.

[0077] It should be noted that three consecutive operating cycles can further filter out such short-term, non-continuous interference factors. If it is only a short-term change in operating conditions, the average rate of change in subsequent cycles will decrease or turn negative. However, the increase in resistance caused by dust accumulation is gradual and irreversible, which will keep the average rate of change positive over consecutive cycles. The effect of dust accumulation on torque will increase with the number of operating cycles and the amount of dust accumulation, and the rate of increase in valve plate resistance will accelerate, that is, the average rate of change will increase.

[0078] Once the trend of worsening dust accumulation is confirmed, a cleaning instruction is generated for the key dust-accumulated area.

[0079] S5. Adaptively adjust the blowing angle, pressure, and duration of the blowing device according to the cleaning instructions, and perform the cleaning operation.

[0080] The specific adjustment of the blowing angle is as follows: extract the virtual fan-shaped unit number of the key dust accumulation area in the cleaning instruction, and determine the starting angle and ending angle of the fan-shaped area covered on the circumference of the valve seat according to the number.

[0081] It should be noted that the specific steps for obtaining the starting angle and the ending angle are as follows: First, retrieve the reference data when the electric butterfly valve is virtually divided into discrete regions, including the valve plate rotation axis determined by product design drawings or physical measurements, the inner diameter of the valve seat bottom, and the total number of sector monitoring units in the circumferential region division, to ensure that the angle calculation is based on a unified reference.

[0082] Divide the total circumferential angle by the total number of fan-shaped units virtually divided in the circumferential area at the bottom of the valve seat to obtain the angle range corresponding to a single fan-shaped unit. This angle range is the angle span. For example, when the total number of fan-shaped units is 12, the angle span is 30°.

[0083] Subtract the value 1 from the current sector unit number K, then multiply the result by the angular span of a single sector unit. The final value is the starting angle covered by that sector unit on the valve seat circumference. Alternatively, directly multiply the current sector unit number K by the angular span of a single sector unit to obtain the ending angle covered by that sector unit on the valve seat circumference. For example, with sector unit number 5 and a total of 12 sector units, the starting angle is 120° and the ending angle is 150°.

[0084] The circumferential angle corresponding to the center line is calculated based on the starting and ending angles of the sector region.

[0085] From a plurality of nozzles arranged circumferentially, select the target nozzle whose spray range covers the center line.

[0086] The centerline of the key dust accumulation area is the geometric center of the entire fan-shaped area and the core location where dust is most likely to concentrate. When dust accumulates in the circumferential area of ​​the valve seat, it is usually distributed with the center of the area as the reference. Therefore, the nozzle spray range covers the centerline to ensure that the airflow can directly act on the core area with the most concentrated dust, avoiding the problem of incomplete cleaning caused by nozzle deviation and spraying away from the core dust accumulation area.

[0087] A control signal is generated to open the solenoid valve leading to the one or more target nozzles, while closing the solenoid valves of other non-target nozzles, ensuring that the compressed air jet is only sprayed from the target nozzles that are aligned with or cover the key areas of dust accumulation.

[0088] The pressure is specifically adjusted as follows: extract the torque deviation value of the key dust accumulation area in the cleaning instruction and its recent trend.

[0089] The average rate of change of torque deviation over a complete operating cycle is calculated based on the torque deviation value sequence.

[0090] Specifically, the torque deviation values ​​at the start and end of the cycle are determined from the selected complete cycle deviation data, and the total duration of the complete operating cycle is recorded. The torque deviation value at the start of the cycle is subtracted from the torque deviation value at the end of the cycle to obtain the total change in torque deviation within the complete cycle. A positive result indicates an increasing trend in deviation within the cycle, while a negative result indicates a decreasing trend. The total change in torque deviation is divided by the total duration of the complete operating cycle to obtain the average rate of change of torque deviation within the complete cycle. This result reflects the average rate of increase or decrease in torque deviation within the cycle, providing a quantitative basis for subsequent pressure adjustment and ash accumulation trend judgment.

[0091] If the torque deviation value is less than or equal to the first preset threshold and the torque deviation change rate parameter is less than or equal to the second preset threshold, then the first pressure level is selected.

[0092] It should be noted that in this situation, the dust accumulation is in a low-threat state, with a small amount and slow growth. A small amount of dust can be removed with low pressure, and the slow growth means that there is no need for urgent high-intensity cleaning. Selecting the first pressure level can avoid excessive impact on the valve seat sealing surface from high pressure, thus extending the equipment life, and can also reduce compressed air consumption and save energy.

[0093] If the torque deviation value is greater than the first preset threshold, or the torque deviation change rate parameter is greater than the second preset threshold, then the second pressure level is selected.

[0094] It should be noted that in this situation, there is a single high-threat factor in the dust accumulation. On the one hand, this indicates that the current dust accumulation is high and the deviation value is large, requiring medium pressure for cleaning. On the other hand, it indicates that the dust accumulation is growing rapidly, i.e., the rate of change is high, requiring medium pressure to promptly curb its deterioration. However, since neither indicator exceeds the standard simultaneously, if only the deviation value is high but the growth is slow, or only the growth is rapid but the deviation value is low, the highest pressure is not required. Medium pressure can balance the cleaning effect and resource consumption, avoiding over-cleaning or under-cleaning.

[0095] The specific process for obtaining the first preset threshold is as follows: When the electric butterfly valve is in a known clean state, its drive torque data under different flow conditions are collected, the deviation between the measured torque and the standard torque under each condition is calculated, its normal fluctuation range is statistically analyzed, and the upper limit of the fluctuation range is taken as the first preset threshold to ensure that it is not triggered erroneously during normal operation.

[0096] The second preset threshold is obtained as follows: Based on historical cleaning cycle data, the average growth rate of torque deviation value during each dust accumulation process is calculated. Combined with the allowable deterioration rate of the equipment and maintenance response time, a change rate value that can provide early warning without frequent false alarms is selected. The optimal setting value is then verified and adjusted through on-site tests.

[0097] If the torque deviation value is greater than the first preset threshold and the torque deviation change rate parameter is greater than the second preset threshold, then the third pressure level is selected.

[0098] It should be noted that in this situation, the accumulated dust is in a high-threat state, both in large quantity and growing rapidly. Large amounts of dust require high pressure for effective removal, and the rapid growth means that incomplete cleaning will quickly lead to another malfunction. Selecting the third pressure level allows for one-time removal of the accumulated dust through high-intensity blowing, curbing the deterioration trend and avoiding secondary cleaning due to insufficient cleaning power, thus reducing equipment start-up and shutdown losses.

[0099] The duration is specifically adjusted as follows: the cleaning command is parsed to obtain the torque deviation value of the key dust accumulation area and the historical cleaning record of the area.

[0100] The standard blowing time in the initial clean state of the area is used as the baseline duration.

[0101] If the torque deviation exceeds a first proportion of the standard torque, the reference duration will be extended by a first period.

[0102] It should be noted that when the torque deviation exceeds the first proportion of the standard torque, it indicates that the dust accumulation has reached a certain scale and cannot be completely removed by the standard time period alone. The first time period needs to be extended to ensure initial removal.

[0103] The first ratio is determined based on the statistical relationship between the degree of dust accumulation and the increase in torque during the actual operation of the electric butterfly valve, and is usually obtained through historical data or experimental calibration.

[0104] The first time period is determined based on the additional blowing time required to eliminate this level of dust accumulation in actual cleaning validation tests.

[0105] If the current combined torque deviation exceeds the second proportion of the standard torque, the reference duration will be extended by a second period.

[0106] It should be noted that if the current overall torque deviation value exceeds the second proportion of the standard torque, it indicates that the amount of dust accumulation is greater or the dust accumulation is more stubborn. Simply extending the first time period may not be enough to clean thoroughly, and the second time period needs to be extended to enhance the cleaning effect by spraying for a longer time.

[0107] The second ratio was determined based on measured data showing a significant increase in torque deviation under severe dust accumulation conditions.

[0108] The second time period is determined based on the verification results of the blowing time required to remove severe ash accumulation, and its value is greater than that of the first time period.

[0109] If the torque deviation after cleaning is not up to standard, the third time period will be extended based on the adjusted duration mentioned above.

[0110] It should be noted that if the deviation value decreases after cleaning but still continues to exceed the preset tolerance range, it is determined that the torque deviation does not meet the standard.

[0111] If the torque deviation of a certain area does not meet the standard after the last two cleanings, it indicates that the dust accumulation in that area may be more stubborn, or that the initial cleaning parameters were not fully adapted to the dust accumulation state. Adjusting the duration based solely on the torque deviation value or rate of change may not be sufficient to completely remove the dust accumulation. It is necessary to extend the third time period by using a longer blowing time to enhance the flushing effect of the airflow on the dust accumulation, thereby avoiding triggering the cleaning command again in the short term due to incomplete cleaning, and reducing equipment start-up and shutdown losses and resource waste.

[0112] During system debugging or actual operation verification, for areas where the torque still does not meet the standard after cleaning with conventional parameters, gradually increase the blowing time to conduct compensation tests, record the minimum additional time required for the torque deviation to return to normal, statistically analyze the data of multiple such cases, and take its reasonable upper limit, such as the average value plus one standard deviation, as the setting value for the third time period.

[0113] S6. After cleaning, re-monitor the torque data of the electric butterfly valve and the flow data of the medium in the pipeline to verify the cleaning effect. If the torque deviation does not return to the normal range, start the second cleaning.

[0114] The specific content of the secondary cleaning is as follows: receiving the judgment result that the cleaning effect does not meet the standard, and locking the original dust accumulation key area as the target area for secondary cleaning.

[0115] Retrieve the blowing parameters during the first cleaning of the area and the torque deviation before and after cleaning.

[0116] Increase the blowing pressure by one level based on the initial cleaning pressure level, and increase the blowing duration by a preset compensation time based on the initial cleaning duration.

[0117] It should be noted that the preset compensation time is calibrated based on the initial cleaning parameters and the degree of non-compliance. If the initial cleaning time is shorter and the torque deviation value is larger when the standard is not met, the compensation time needs to be appropriately increased based on the benchmark compensation time. If the initial cleaning time is close to the standard value and the non-compliance deviation is small, the compensation time should be set according to the benchmark compensation time to ensure that the compensation time matches the degree of defect in the initial cleaning.

[0118] Based on the original spray angle coverage, the range is expanded to the angle area corresponding to the adjacent virtual sector unit, and the nozzles corresponding to the newly added angle area are enabled.

[0119] A secondary cleaning control command is generated to drive the blowing device to perform the cleaning operation according to the adjusted parameters.

[0120] After cleaning, re-monitor the torque deviation value of the area using the same verification method as the first cleaning.

[0121] If the deviation value returns to the normal range, the secondary cleaning is deemed effective, and the cleaning parameters and results are recorded.

[0122] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, in the form of a computer program product.

[0123] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0124] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0125] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0126] Finally, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for intelligent online monitoring and linkage control of electric butterfly valves in a dust removal system, characterized in that: Includes the following steps: S1. Real-time synchronous acquisition of the driving torque data of the electric butterfly valve and the real-time flow data of the pipeline medium; S2. The circumferential area at the bottom of the butterfly valve plate and seat is virtually divided into multiple discrete areas, and the dust accumulation distribution characteristics of each area are constructed based on historical data under the initial cleaning state. S3. Based on the abnormal characteristics of torque data under different flow conditions, and combined with the characteristics of dust accumulation distribution, locate the key areas of dust accumulation. S4. For the key dust accumulation areas identified, compare the measured torque data under the current working conditions with the standard torque at the same flow point in real time to obtain the torque deviation value, and trigger the cleaning command by analyzing the growth trend of the torque deviation value. S5. Adaptively adjust the blowing angle, pressure, and duration of the blowing device according to the cleaning instructions, and perform the cleaning operation; S6. After cleaning, re-monitor the torque data of the electric butterfly valve and the flow data of the medium in the pipeline to verify the cleaning effect. If the torque deviation does not return to the normal range, start the second cleaning.

2. The intelligent online monitoring and linkage control method for electric butterfly valves in a dust removal system according to claim 1, characterized in that: The specific steps for virtually dividing the circumferential area of ​​the bottom of the butterfly valve plate and valve seat into multiple discrete regions are as follows: Based on the product design drawings or physical measurements of the electric butterfly valve, determine the precise position of the valve plate rotation axis and the inner diameter of the bottom of the valve seat, thereby defining the virtual dividing reference circle center and radius; With the valve plate rotation axis as the center and the inner circumference of the valve seat sealing surface as the outer boundary, rays are uniformly drawn from the center to the boundary circumference to virtually divide the circular area into several sector-shaped monitoring units of equal area. The aforementioned sector-shaped monitoring unit is defined as a discrete region.

3. The intelligent online monitoring and linkage control method for electric butterfly valves in a dust removal system according to claim 1, characterized in that: The specific steps for constructing the dust accumulation distribution characteristics of each region based on historical data under initial cleaning conditions are as follows: The dust removal system was operated under the initial cleaning state of the electric butterfly valve, and drive torque data under multiple flow conditions were collected. At the same time, the real-time flow data of the corresponding pipeline medium was recorded. For each virtually divided discrete region, the real-time collected torque value is compared with the standard torque threshold of the corresponding flow point. If the measured torque continuously exceeds the threshold range, a torque anomaly event is recorded. The frequency of abnormal events triggered in each region during the historical operating cycle is counted, and the dust accumulation probability weight of that region is initialized accordingly. The number of new torque anomaly events associated with each region is counted within each analysis period; The number of new entries is compared with the preset threshold range. If the number of new entries falls into the lower range, the probability weight of dust accumulation in that area is increased by one level. If the number of new entries falls into the middle range, it is increased by two levels. If the number of new entries falls into the higher range, it is increased by three levels. The probability weight of dust accumulation in this area is defined as the dust accumulation distribution feature.

4. The intelligent online monitoring and linkage control method for electric butterfly valves in a dust removal system according to claim 3, characterized in that: The steps for locating key areas of dust accumulation are as follows: The operating condition range to which the current flow belongs is determined based on real-time flow data, and virtual regions with a high frequency of historical torque anomaly events within this flow range are extracted as candidate regions. The dust accumulation distribution characteristics of each virtual region are retrieved, and regions with high dust accumulation probability weight levels are selected as high-probability dust accumulation regions. The candidate area is matched with the high probability of dust accumulation area. If an area belongs to both the candidate area and the high probability of dust accumulation area, then the area is identified as the key area for dust accumulation. Output the number and location information of key dust accumulation areas to the cleaning control unit.

5. The intelligent online monitoring and linkage control method for electric butterfly valves in a dust removal system according to claim 4, characterized in that: The torque deviation value is obtained through the following steps: Obtain real-time flow data of the current pipeline medium, and read the identification number and location information of the key areas of ash accumulation that have been located; Based on real-time flow data, a preset flow rate and standard torque correspondence table is dynamically queried to extract the standard torque reference curve for the entire operating cycle of the valve plate at that flow rate point. Synchronously collect the actual torque data of the electric butterfly valve running for a complete cycle under the current flow conditions, extract the torque data segment corresponding to the valve plate passing through the key area from the complete torque data, and mark the data segment as the current torque abnormal characteristic component; The actual torque characteristic component data segment is compared point by point with the standard torque value within the same valve plate angle range on the standard torque reference curve, and the absolute value of the deviation between all data points in the characteristic component data segment and the standard value is calculated. Determine whether the absolute value sequence continuously exceeds the preset tolerance range. If the determination result is yes, calculate the average value of the absolute value of the deviation within the data segment and define it as the current comprehensive torque deviation value of the dust accumulation key area.

6. The intelligent online monitoring and linkage control method for electric butterfly valves in a dust removal system according to claim 1, characterized in that: The specific triggering process of the cleaning command is as follows: Continuously acquire the comprehensive torque deviation value of the current key dust accumulation area, and record the deviation value at fixed time intervals to form a time series data sequence; Short-term fluctuation filtering is applied to the time series data sequence to identify and remove data points that suddenly increase or decrease due to instantaneous operating condition fluctuations, and a smoothed torque deviation trend curve is generated. Extract the data segment from the smoothed torque deviation trend curve within the most recent complete operating cycle, and calculate the average rate of change of the torque deviation value within that data segment. Determine whether the average rate of change is continuously positive and whether the continuously positive average rate of change exceeds the system's allowable rate of deterioration. If both conditions are met, it is preliminarily determined that there is a trend of continuous deterioration of dust accumulation in the area. When it is initially determined that there is a trend of continuous deterioration of dust accumulation, the continuous monitoring timer is started. If the average rate of change of torque deviation value remains positive and the value increases in three consecutive operating cycles, the trend of deterioration of dust accumulation is confirmed. Once the trend of worsening dust accumulation is confirmed, a cleaning instruction is generated for the key dust-accumulated area.

7. The intelligent online monitoring and linkage control method for electric butterfly valves in a dust removal system according to claim 2, characterized in that: The specific adjustment of the blowing angle is as follows: Extract the virtual sector unit number of the dust accumulation key area in the cleaning instruction, and determine the starting angle and ending angle of the sector area corresponding to the virtual sector unit on the valve seat circumference based on the number; Calculate the circumferential angle corresponding to the center line of the sector based on the starting and ending angles of the sector area; From a plurality of nozzles arranged circumferentially, select the target nozzle whose spray range covers the center line; A control signal is generated to open the solenoid valve leading to the one or more target nozzles, while closing the solenoid valves of other non-target nozzles, ensuring that the compressed air jet is only sprayed from the target nozzles that are aligned with or cover the key areas of dust accumulation.

8. The intelligent online monitoring and linkage control method for electric butterfly valves in a dust removal system according to claim 1, characterized in that: The pressure is adjusted as follows: Extract the torque deviation values ​​and their recent trends in the key dust-accumulating areas from the cleaning instructions; Calculate the average rate of change of torque deviation value over the complete operating cycle based on the torque deviation value sequence; If the torque deviation value is less than or equal to the first preset threshold and the torque deviation change rate parameter is less than or equal to the second preset threshold, then the first pressure level is selected. If the torque deviation value is greater than the first preset threshold, or the torque deviation change rate parameter is greater than the second preset threshold, then the second pressure level is selected. If the torque deviation value is greater than the first preset threshold and the torque deviation change rate parameter is greater than the second preset threshold, then the third pressure level is selected.

9. The intelligent online monitoring and linkage control method for electric butterfly valves in a dust removal system according to claim 1, characterized in that: The duration is adjusted as follows: Analyze cleaning commands to obtain torque deviation values ​​in key dust-accumulating areas and historical cleaning records for those areas; The standard blowing time in the initial clean state of the area is used as the baseline duration; If the torque deviation exceeds a first proportion of the standard torque, the reference duration will be extended by a first period. If the current overall torque deviation exceeds the second proportion of the standard torque, the reference duration will be extended by a second period. If the torque deviation after cleaning is not up to standard, the third time period will be extended based on the adjusted duration mentioned above.

10. The intelligent online monitoring and linkage control method for electric butterfly valves in a dust removal system according to claim 1, characterized in that: The specific details of the secondary cleaning are as follows: Upon receiving the judgment that the cleaning effect has not met the standard, the original key areas of dust accumulation are identified as the target areas for secondary cleaning; Retrieve the blowing parameters during the first cleaning of this area and the torque deviation before and after cleaning; Increase the blowing pressure by one level based on the initial cleaning pressure level, and increase the blowing duration by a preset compensation time based on the initial cleaning duration; Based on the original spray angle coverage, it is expanded to the angle area corresponding to the adjacent virtual sector unit, and the nozzles corresponding to the newly added angle area are enabled. Generate secondary cleaning control commands to drive the blowing device to perform cleaning operations according to the adjusted parameters; After cleaning, re-monitor the torque deviation value of the area using the same verification method as the first cleaning; If the deviation value returns to the normal range, the secondary cleaning is deemed effective, and the cleaning parameters and results are recorded.

Images