Intelligent valve sensing and control terminal and implementation method thereof

Abstract

The application discloses a valve intelligent sensing and control terminal and an implementation method thereof, and belongs to the field of industrial valve maintenance automation. The device comprises a connecting shaft, a displacement module, a strain module, a control module, a pneumatic amplification module, a communication module, an alarm module and a power module arranged in a box body; the displacement module is used for collecting signals based on the Hall principle to detect the number of rotations of a valve rod and infer the forward and reverse rotation directions of the valve rod; the strain module is used for collecting the electric signal values of strain gauges arranged on the connecting shaft and performing torque calculation; the control module is used for receiving the data signals collected by the displacement module and the strain module, feeding back the gas output size of the pneumatic amplification module, and then adjusting the output torque of the pneumatic actuator. The application realizes automatic monitoring, early warning and dynamic adjustment of the valve state, solves the problems of low efficiency of traditional manual recording and post-fault maintenance, and improves the safety and economy of industrial system operation.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of industrial valve maintenance automation, and particularly relates to a valve intelligent sensing and control terminal and an implementation method thereof, which are used for predicting, sensing and dynamically controlling a valve. BACKGROUND

[0002] In the field of industrial production, during the long-term operation of various types of valves, the valve stem needs to be repeatedly rotated to realize the opening and closing control of the valve. However, this process inevitably causes wear of the related components of the valve stem assembly. With the passage of time, the wear of the components gradually intensifies, which easily leads to problems such as jamming, malfunction or sealing failure of the valve, thereby affecting the normal operation accuracy of the valve and bringing safety hazards to the stable operation of the entire industrial system.

[0003] At present, the evaluation of the valve state mainly relies on manual recording of the valve stem operation times, which is not only inefficient but also requires a large amount of labor cost, and it is difficult to accurately grasp the actual working condition of the valve in real time. In practical applications, maintenance is often carried out only after the valve fails, which not only increases the maintenance cost but also may cause production interruption due to failure downtime, further increasing the operation burden of the industrial system. The above problems are common in various application scenarios of valves.

[0004] Therefore, in the industrial field, there is an urgent need for a technical solution that can automatically monitor the state of the valve. Through the valve state sensing intelligent terminal, the displacement rotation angle of the valve stem is monitored in real time, the running state of the valve is predicted in advance, and when the number of valve stem operations reaches a preset threshold, an alarm is automatically triggered so that the staff can timely maintain. At the same time, based on the monitored valve stem displacement rotation angle information, the gas input is increased or decreased adaptively, so as to dynamically adjust the opening angle of the valve, ensure that the valve always maintains accurate running state, avoid failure problems caused by component wear, and ensure stable and efficient operation of the industrial system. SUMMARY

[0005] The purpose of the present application is to overcome the defects in the prior art, solve the problem that current industrial valves cannot be automatically diagnosed and adjusted, and provide a valve intelligent sensing and control terminal and an implementation method thereof.

[0006] The specific technical solutions adopted by the present application are as follows:

[0007] In a first aspect, the application provides a valve intelligent sensing and control terminal, comprising a connecting shaft, a displacement module, a strain module, a control module, a pneumatic amplification module, a communication module, an alarm module and a power module arranged inside a box body; the connecting shaft is vertically installed in the middle of the box body, the bottom is connected with the valve stem of the valve through a shaft coupling, and the top penetrates through the box body and is connected with the rotating shaft of the angular stroke pneumatic actuator;

[0008] The displacement module is used to collect signals based on the Hall principle to detect the number of rotations of the valve stem and infer the forward and reverse directions of the valve stem;

[0009] The strain module is used to collect the electrical signal values of the strain gauges arranged on the connecting shaft and calculate the torque;

[0010] The control module is used to accept the data signals collected by the displacement module and the strain module, feedback control the air output size of the pneumatic amplification module, and then adjust the output torque of the pneumatic actuator; in addition, the control module monitors and diagnoses faults according to the data signals collected by the displacement module and the strain module, uploads the fault signals to the upper computer through the communication module, and simultaneously outputs the fault signals to the alarm module;

[0011] The power module is used to power the remaining modules.

[0012] As a preferred, the connecting shaft, the shaft coupling, the valve stem and the rotating shaft of the angular stroke pneumatic actuator are coaxially connected.

[0013] As a preferred, the displacement module comprises a Hall circuit board and a Hall element; the Hall circuit board is an integrated ring structure, coaxially sleeved and fixed on the outside of the connecting shaft; two Hall elements are arranged on the Hall circuit board in an orthogonal manner, and the two Hall elements have an angle difference of 90° with respect to the shaft body of the connecting shaft.

[0014] As a preferred, the box body comprises an upper shell and a lower shell; the upper part of the connecting shaft penetrates out of the upper shell, an oil seal is arranged at the connection between the two, and the bottom of the upper shell is detachably connected with the top of the lower shell to form an overall sealed structure, and the lower shell is fixed on the valve seat.

[0015] As a preferred, the strain module comprises a strain gauge; the strain gauge is pasted on the shaft body of the connecting shaft, the pins thereof are arranged in a circumferential direction along the shaft body, and the strain gauge is connected to the control module through a wire.

[0016] As a preferred, the control module comprises a data acquisition interface of the displacement module and the strain module, an input interface of the power module, a control interface of the pneumatic amplification module, a communication module interface and an alarm module interface.

[0017] As a preferred, the pneumatic amplification module is installed on the lower shell, the air inlet thereof is connected with an air source, and the air outlet thereof is connected with the pneumatic actuator.

[0018] As preferred, the communication module has both wired and wireless transmission modes.

[0019] As preferred, the alarm module includes two LED light groups, which present green, yellow or red light according to the valve health status; when the control module determines that the valve status is normal, the green light is always on; when the control module determines that the valve is stuck, the yellow light is always on; when the control module determines that the valve is faulty, the red light is always on.

[0020] In the second aspect, the application provides an implementation method of the valve intelligent sensing and control terminal, and the implementation method is specifically as follows:

[0021] S1: connect the connecting shafts with the valve rod and the rotating shaft of the pneumatic actuator respectively, fix the box body on the valve seat, and connect the air source and the wires and signal lines among the modules;

[0022] S2: when the control module is given an opening signal, the control module controls the output of the pneumatic amplification module so as to reach the initial set air volume required for opening the valve, and the air volume is sufficient to open the corresponding valve to reach the opening state; when the control module is given a closing signal, the control module controls the pneumatic amplification module to discharge the air pressure in the pneumatic actuator to reach the full-closed state of the valve;

[0023] S3: in the opening and closing process of the valve, the sensors of the displacement module and the strain module sense the angle, number of times and tension change of the rotation of the connecting shaft, and transmit the data to the control module; the control module monitors the rotation angle, number of times, time and torque size of the valve, and calculates the rotation speed of the valve and the friction force borne by the valve rod;

[0024] S4: when the valve is matched, the initial value is set according to the required output torque of the valve, including the initial torque M 0 and the initial speed V 0 =90 / T 0 ; wherein, T 0 is the initial time required for rotating 90° under the torque;

[0025] S5: when the given opening and closing signal, the friction force borne by the valve rod suddenly increases or the valve position almost does not change in the action process of the valve, that is, the torque value M >80% M 0 or the valve speed V ≈0, the control module outputs the fault alarm information, and the red light of the alarm module is always on;

[0026] S6: When the given opening and closing signal, the valve in the process of action, monitoring the friction force value of the valve rod is less than 50% of the initial torque, or the speed drops to 50% of the initial speed, indicating that the valve is normal action, the control module controls the alarm module green light always on;

[0027] S7: When the given opening and closing signal, the valve in the process of action, monitoring the friction force value of the valve rod is 50%~80% of the initial torque, or the speed drops to 50%~80% of the initial speed, indicating that the valve is stuck, through the control module output warning information, and through the alarm module display yellow light always on;

[0028] When the valve is stuck, the next time the opening and closing signal is sent, the control module controls the gas output of the pneumatic amplification module according to the detected fault condition Q m , to ensure that the increased friction can be overcome, and the opening speed is comparable to the initial speed; the output dynamic gas volume of the opening process Q mi The calculation formula is as follows:

[0029] ;

[0030] In the formula: x i The current recorded valve position, V i The speed corresponding to the current valve position, p t The pneumatic actuator cylinder pressure, A t The effective area of the pneumatic actuator diaphragm, K The spring stiffness of the pneumatic actuator, d The diameter of the spring pneumatic actuator shaft, R The gas constant, T The temperature, c v The flow coefficient, a The gain coefficient (determined by experiment at factory).

[0031] The present application has the following beneficial effects relative to the prior art:

[0032] 1) The present application has higher precision and stability: In the current industrial valve maintenance monitoring field, most of the valve health conditions are still determined by manual counting. Especially in high-intensity working conditions, the valve is continuously opened and closed for work, which inevitably causes problems such as missed recording, misrecorded, low efficiency, and the inability to determine the valve stem rotation amplitude and the valve rotation state, making it difficult to achieve accurate perception of the valve state. The device provided by the present application can accurately measure the valve stem through the built-in sensor and transmit external signal warnings and transmissions through the alarm and communication modules. In addition, the functional modules of the device are independently encapsulated, supporting flexible replacement and expansion, such as adapting to different types of sensors to achieve the desired value.

[0033] 2) The maintenance strategy of the present application is more accurate and has self-adaptive dynamic adjustment capability: In the past, valves were usually manually inspected and repaired after internal components were damaged and could not work normally, which belonged to "after-the-fact remedy" and easily caused system sudden shutdown, medium leakage, and even safety accidents. The device provided by the present application can update the valve stem cumulative rotation number in real time through electronic counting, and when the preset threshold is reached, the LED flickering prompt for manual detection and maintenance is given through the alarm module, and remote reminders are given through the communication module to avoid faults. The parallel design of the alarm module and the communication module ensures double response (local alarm + remote early warning) in abnormal state, meeting the high reliability requirements of industrial safety scenarios. On the other hand, the device can rely on the integrated pneumatic amplifier module to realize self-adaptive dynamic adjustment: when the sensor detects abnormal valve stem rotation amplitude, tension fluctuation, and other factors affecting valve operation, the pneumatic amplifier controls its gas output size by receiving the signal given by the control module, and then accurately adjusts the valve opening angle to correct the valve stem operating state. The above two aspects not only solve the passivity of traditional "after-the-fact repair", but also improve the working conditions of the valve stem through real-time dynamic adjustment, reduce component wear caused by operating parameter deviation, prolong the service life of the valve, and realize "early warning + adjustment" double protection. BRIEF DESCRIPTION OF DRAWINGS

[0034] The drawings needed in the following embodiment or related technical description will be briefly introduced as follows:

[0035] Figure 1 It is a perspective view of the combination of the box body and the valve in the preferred embodiment of the present application and the angular travel pneumatic actuator;

[0036] Figure 2 It is a perspective view of the internal structure of the box body in the preferred embodiment of the present application;

[0037] Figure 3 It is a longitudinal section structure schematic view of the internal connecting shaft of the box body in the preferred embodiment of the present application;

[0038] Figure 4Fig. 1 is a schematic diagram of the transverse section structure of the connecting shaft inside the box body in the preferred embodiment of the present application;

[0039] Figure 5 Fig. 2 is a system architecture diagram of the preferred embodiment of the present application;

[0040] In the figure, the reference signs are: 1 box body; 1000 angular stroke pneumatic actuator; 2000 valve; 11 upper shell; 12 lower shell; 2 connecting shaft; 21 coupling; 3 displacement module; 31 Hall circuit board; 32 Hall element; 4 strain module; 5 control module; 6 pneumatic amplification module; 7 communication module; 8 alarm module; 9 power module. DETAILED DESCRIPTION

[0041] In order to make the above-mentioned objects, features and advantages of the present application more apparent and easy to understand, the specific embodiments of the present application will be described in detail below with reference to the accompanying drawings. In the following description, a large number of specific details are set forth in order to facilitate a full understanding of the present application. However, the present application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without departing from the scope of the present application, so the present application is not limited to the specific embodiments disclosed below. The technical features in each embodiment of the present application can be combined accordingly without conflict.

[0042] In the description of the present application, it should be understood that when an element is considered to be "connected" to another element, it can be directly connected to the other element or indirectly connected to the other element with an intermediate element. In contrast, when an element is considered to be "directly" connected to another element, there is no intermediate element.

[0043] The present application provides a valve intelligent sensing and control terminal, which mainly comprises a connecting shaft 2, a displacement module 3, a strain module 4, a control module 5, a pneumatic amplification module 6, a communication module 7, an alarm module 8 and a power module 9 arranged inside a box body 1.

[0044] Among them, the connecting shaft rotates coaxially with the valve stem, and the magnetic powder above the shaft shoulder cooperates with the orthogonally arranged Hall sensor in the displacement module to accurately record the number and direction of valve stem rotation; the strain gauge of the strain module is attached to the shaft body of the connecting shaft to detect the change in torsion; the control module receives, outputs signals and drives other modules; the pneumatic amplification module adjusts the air output to correct the opening angle of the valve according to the control signal; the communication module supports wired and wireless transmission in two ways to meet the data interaction needs in different environments; the alarm module is equipped with LED lamp groups to realize the local warning function, when the number of rotations or force value monitored by the equipment reaches the preset threshold, the local alarm and remote alarm will be triggered at the same time to ensure that abnormal conditions are discovered and handled in time.

[0045] The structure, connection mode and function of each module will be described in detail below.

[0046] In the terminal device of the present application, the connecting shaft 2 is vertically installed in the middle of the box body 1, the bottom is connected with the valve rod of the valve 2000 through the shaft coupling 21, and the top penetrates through the box body 1 and is located outside the box body 1 and connected with the rotating shaft of the angular stroke pneumatic actuator 1000, as shown in Figure 1 and 2 .

[0047] As a preferred embodiment of the present application, the valve 2000 is a pneumatic valve (such as a ball valve), which is an industrial valve and includes a valve body, a valve rod, a valve seat and a pneumatic actuator. The valve uses the prior art, and its specific structure is not described here.

[0048] As a preferred embodiment of the present application, the connecting shaft 2, the shaft coupling 21, the valve rod of the valve 2000 and the rotating shaft of the angular stroke pneumatic actuator 1000 are coaxially connected. The connecting shaft is used to connect the valve rod and keep coaxial rotation, and the shaft shoulder is provided with uniformly sprayed magnetic powder to form a ring-shaped area with magnetism.

[0049] As a preferred embodiment of the present application, as shown in Figure 2 , the box body 1 includes two parts of an upper shell 11 and a lower shell 12. The upper shell 11 is connected with the pneumatic actuator 1000, and the lower shell 12 is connected with the valve seat of the valve 2000. The bottom of the upper shell 11 is detachably (such as screw connection) connected with the top of the lower shell 12 to form an overall sealed structure. The upper part of the connecting shaft 2 penetrates out of the upper shell 11, and an oil seal is arranged at the contact position to ensure the overall sealing of the box body.

[0050] As a preferred embodiment of the present application, the pneumatic actuator can use an AT pneumatic actuator.

[0051] In the terminal device of the present application, the displacement module 3 can collect signals based on the Hall principle to detect the number of rotations of the valve rod and infer the forward and reverse directions of the valve rod.

[0052] As a preferred embodiment of the present application, the displacement module 3 includes a Hall circuit board 31 and a Hall element 32. As shown in Figure 2 and 4As shown, the Hall circuit board 31 is an integrated annular structure, coaxially sleeved and fixed on the outside of the connecting shaft 2, and the inner annular surface is opposite to the magnetic powder spraying surface of the connecting shaft. The circuit board can adopt an annular rigid circuit board, and the PCB is integrated with a signal processing circuit and an interface circuit (for electrical connection with the control module). In addition, the Hall circuit board 31 is provided with (for example, welded) two Hall elements 32 (that is, two Hall sensors A and B) arranged orthogonally, and the two Hall elements 32 have an angle difference of 90° with respect to the shaft body of the connecting shaft 2, that is, the central axes of the two Hall sensors A and B are arranged orthogonally in the PCB plane, and the angle difference is 90°. The detection surfaces of the two Hall sensors are both opposite to the position above the shaft shoulder where the magnetic powder is sprayed, and the detection surfaces are kept at a fixed distance of 5 mm from the surface of the shaft where the permanent magnetic powder is sprayed.

[0053] When the valve is opened and closed, the valve rod drives the connecting shaft to rotate to the corresponding position, and the Hall sensors A and B arranged on the circuit board can detect the number of rotations of the valve rod through the Hall effect. Because the Hall sensors A and B have a position difference of 90°, the forward and reverse rotation of the valve rod can also be inferred according to the sequence of the pulse signals collected by the Hall sensors A and B.

[0054] As a preferred embodiment of the present application, the Hall circuit board can be fastened to the base support by screws and arranged concentrically with the connecting shaft.

[0055] In the terminal device of the present application, the strain module 4 is used to collect the electrical signal value of the strain gauge arranged on the connecting shaft 2 and calculate the torque.

[0056] As a preferred embodiment of the present application, the strain module 4 includes a strain gauge, which can be located at the upper end of the displacement module. As shown in Figure 2 and 3 The strain gauge is stably pasted on the surface of the shaft body by glue, the pins thereof are arranged in the circumferential direction of the shaft body (corresponding to the torque detection direction), and the strain gauge is connected to the control module by wires. When the shaft body is displaced and rotated, the strain gauge senses the small tension of the shaft body and generates a change in resistance value, which is output to the control module by wires. The control module calculates the corresponding torque change value according to the built-in algorithm.

[0057] In actual use, in order to ensure that the strain gauge is in full contact with the surface of the shaft body, fine sandpaper is used to polish the bonding position of the shaft body before bonding, and an alcohol wipe is used to wipe the bonding surface to ensure that the bonding surface is free of impurities. When bonding the strain gauge, the epoxy resin glue is evenly applied to the contact surface of the strain gauge, and then the surface is pressed against the polished area of the shaft body. During the pressing process, the surfaces should be in full contact.

[0058] In the terminal device of the present application, as shown in Figure 5As shown, the control module 5 is used to accept the data signals collected by the displacement module 3 and the strain module 4, feedback control the air output size of the pneumatic amplification module 6, and then adjust the output torque of the pneumatic actuator 1000. In addition, the control module 5 monitors and diagnoses faults according to the data signals collected by the displacement module 3 and the strain module 4, and uploads the fault signals to the upper computer through the communication module 7 and outputs them to the alarm module 8.

[0059] As a preferred embodiment of the present application, as shown in Figure 4 The control module 5 is an integrated circuit board, which includes a data acquisition interface of the displacement module 3 and the strain module 4, an input interface of the power module 9, a control interface of the pneumatic amplification module 6, a communication module 7 interface and an alarm module 8 interface. In actual use, the control module receives state data such as valve rod torque, rotation angle and rotation frequency through wired connection, receives valve action signals of the upper computer through the communication module, controls the air output size of the pneumatic amplification module in combination with the collected state data, adjusts the output torque of the pneumatic actuator, monitors and diagnoses faults, uploads the fault signals to the upper computer system through the communication module, and outputs them to the alarm module.

[0060] As a preferred embodiment of the present application, the pneumatic amplification module 6 can be rigidly fixed and installed on the upper surface of the lower shell 12, connected with the side wall, and supported by the device lower shell top column at the bottom to form double positioning of top fixation + bottom support. It is provided with an air inlet and an air outlet, the air inlet is connected with the air source, and the air outlet is connected with the pneumatic actuator 1000, as shown in Figure 3 and 4 In actual use, the pneumatic amplification module can be turned on to a certain position by the switch signal given by the control module to reach the current required full opening level; at the same time, the control module can control the air output size of the pneumatic amplification module in combination with the collected torque and angle data, and then adjust the output torque of the pneumatic actuator. When the valve rod is working, the control module 5 accepts the data collected by the displacement module 3 and the strain module 4, and when the valve sticking is detected, the control module 5 will dynamically control the gas output of the pneumatic amplifier 6 Q m to ensure that the increased friction can be overcome, and the opening speed is comparable to the initial speed.

[0061] As a preferred embodiment of the present application, the communication module can be provided with two types of signal transmission modes: one is wired transmission through external interface for wired connection; and the other is wireless transmission, which can push the valve health status in real time on the PC end and the mobile APP end.

[0062] As a preferred embodiment of the present application, the alarm module 8 comprises a circuit board and two LED lamp groups, which are connected to the control module by wire and controlled by the control module to emit warning light, i.e. green, yellow or red light according to the health status of the valve 2000. For example, when the control module 5 determines that the valve 2000 is in normal state, the green light is always on; when the control module 5 determines that the valve 2000 is stuck, the yellow light is always on; when the control module 5 determines that the valve 2000 is in failure, the red light is always on.

[0063] As a preferred embodiment of the present application, as shown in Figure 4 The communication module 7, the alarm module 8 and the communication module 9 can be fixed on one side of the upper surface of the lower shell 12, respectively.

[0064] In the terminal device of the present application, the power module 9 is used to supply power to the remaining modules.

[0065] As a preferred embodiment of the present application, the power module 9 provides a pluggable mobile power supply for the power output of the control module, which comprises a mobile battery and can supply power to the displacement module 3, the strain module 4, the control module 5, the pneumatic amplification module 6, the communication module 7, the alarm module 8 and the communication module 9. The power module provides DC power for each module through a conversion circuit, and the power interface is connected to the input interface of the built-in power module 9 of the control module 5, so as to realize stable output of power current.

[0066] By using the above-mentioned valve intelligent sensing and control terminal, the present application further provides an implementation method, and each step of the method is specifically as follows:

[0067] S1: The connecting shaft 2 is connected with the valve rod of the valve 2000 and the rotating shaft of the pneumatic actuator 1000, respectively, the box body 1 is fixed on the valve seat of the valve 2000, and the air source and the wires and signal lines between the modules are connected.

[0068] As a preferred embodiment of the present application, the step is specifically as follows:

[0069] The lower shell 12 is fixed on the valve seat of the valve body by bolts, the valve rotating shaft coupling 21 is axially connected with the valve rod and fastened by a set screw, the connecting shaft 2 is axially connected to the upper end of the valve rotating shaft coupling 21, then the upper shell 11 is installed on the lower shell 12 by screws, an oil seal is installed at the opening of the upper end of the upper shell 11 to ensure the overall sealing property of the box body 1. Subsequently, the AT pneumatic actuator 2 is installed and fixed on the upper end surface of the upper shell 11 by a connecting bracket and fastening bolts; in terms of air path connection, the air source pipeline joint is connected at the air inlet of the pneumatic amplification module 6, one end of the air outlet pipeline is connected at the air outlet of the pneumatic amplification module 6, and the other end is correspondingly inserted into the pneumatic quick connector of the pneumatic actuator 1000, so as to complete the assembly of the entire device.

[0070] S2: When the control module 5 is given an opening signal, the control module 5 controls the output of the pneumatic amplification module 6 to reach the initial set air volume required for the valve 2000 to open, which is sufficient to open the corresponding valve 2000 to reach the open state. When the control module 5 is given a closing signal, the control module 5 controls the air pressure in the pneumatic actuator 1000 to be discharged to reach the fully closed state of the valve 2000.

[0071] S3: During the opening and closing of the valve 2000, the displacement module 3 and the strain module 4 sense the angle, number of rotations and tension changes of the connecting shaft, and transmit the data to the control module 5. The control module 5 monitors the rotation angle, number of rotations, time and torque of the valve 2000, and calculates the rotation speed of the valve 2000 and the friction force on the valve stem.

[0072] S4: When the valve 2000 is matched, the initial value is set according to the required output torque of the valve 2000, including the initial torque M 0 and the initial speed V 0 =90 / T 0 . Among them, T 0 is the initial time required to rotate 90° at this torque.

[0073] S5: When the given opening and closing signal, the valve 2000 in the process of action, the friction force on the valve stem increases suddenly (i.e. the value of the torque M >80% M 0 ) or the valve position has little change (i.e. the valve speed V ≈0) of the next time, then output the fault alarm information through the control module 5, and display the red light always on through the alarm module 8.

[0074] S6: When the given opening and closing signal, the valve 2000 in the process of action, the friction force on the valve stem is less than 50% of the initial torque, or the speed drops to 50% of the initial speed, indicating that the valve 2000 is operating normally, and the control module 5 controls the alarm module 8 to always light green.

[0075] S7: When the given opening and closing signal, the valve 2000 in the process of action, the friction force on the valve stem is 50% to 80% of the initial torque, or the speed drops to 50% to 80% of the initial speed, indicating that the valve 2000 is stuck, and the control module 5 outputs a warning message and displays the yellow light always on through the alarm module 8.

[0076] When the valve 2000 is detected to be stuck, the next time the opening and closing signal is sent, the control module 5 controls the gas output of the pneumatic amplification module 6 according to the detected fault condition Q m , so as to ensure that the increased friction can be overcome, and the opening speed is equivalent to the initial speed. The output dynamic gas amount of the opening process Q mi The calculation formula is as follows:

[0077] ;

[0078] In the formula, x i is the current recorded valve position, V i is the speed corresponding to the current valve position, p t is the pneumatic actuator cylinder pressure, A t is the effective area of the pneumatic actuator diaphragm, K is the spring stiffness of the pneumatic actuator, d is the diameter of the spring pneumatic actuator shaft, R is the gas constant, T is the temperature, c v is the flow coefficient, a is the gain coefficient.

[0079] In a preferred embodiment of the present application, as shown in Figure 5 The block diagram is a device system architecture diagram of the present application, which is used to intuitively show the composition architecture, connection relationship and interaction logic of each functional module in the system. In the figure, a rectangular box represents an independent functional module, and an arrow represents the information and signal flow between modules. The power module 9 is used to provide stable power for the system, including lithium battery pack, voltage conversion circuit and overcharge and overdischarge protection unit, and the output voltage is adapted to the working requirements of each module. The control module 50 is the core of the system, which receives the collected signals from the strain module 4 and the displacement module 3, generates control instructions after processing, drives the alarm module 8 and coordinates the communication module to realize data interaction, and outputs control signals to the pneumatic amplification module 6; the strain module 4 collects the strain signals of the connecting shaft 2 in real time and transmits them to the control module 5 through wired transmission; the displacement module 3 synchronously obtains the position change data and inputs the control module 5; the pneumatic amplification module 6 receives the signals output by the control module 5, controls the gas output, and then acts on the pneumatic actuator; after logical judgment, the control module 5 sends a trigger signal such as an indicator light blinking to the alarm module 8, and uploads the state data to the cloud or terminal device through the communication module 9.

[0080] All the modules form a closed-loop cooperative system. Through the innovative sensor integration scheme, the intelligent control algorithm and the dynamic adjustment capability of the pneumatic amplification module, a high-precision and high-reliability valve state sensing system and active adjustment system are constructed, a complete technical solution is provided for the predictive maintenance of the industrial valve, and the safety and economy of industrial manufacturing are significantly improved.

[0081] The application realizes automatic monitoring, early warning and dynamic adjustment of the valve state, solves the problems of low efficiency of traditional manual recording and post-fault maintenance, and improves the safety and economy of industrial system operation.

[0082] The above-mentioned embodiments are only a preferred scheme of the application, and are not intended to limit the application. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the application. Therefore, any technical solution obtained by equivalent replacement or equivalent transformation falls within the protection scope of the application.

Claims

1. A valve intelligent sensing and control terminal, characterized in that, The utility model relates to a valve shaft torque real-time monitoring system, including the connection axle (2), displacement module (3), strain module (4), control module (5), pneumatic amplification module (6), communication module (7), alarm module (8) and power module (9) set up inside the box (1), the connection axle (2) vertical installation in the middle part of box (1), bottom is connected with the valve stem of valve (2000) through the shaft coupling (21), top passes through the box (1) and is connected with the pivot of angular stroke pneumatic actuator (1000), The displacement module (3) is used for collecting signals based on the Hall principle to detect the number of rotations of the valve stem and infer the forward and reverse rotation directions of the valve stem. The strain module (4) is used for collecting the electrical signal values of strain gauges placed on the connection axle (2) and performing torque calculation. The control module (5) is used for receiving the data signals collected by the displacement module (3) and the strain module (4), feedback controlling the gas output size of the pneumatic amplification module (6), and then adjusting the output torque of the pneumatic actuator (1000). In addition, the control module (5) monitors and diagnoses faults according to the data signals collected by the displacement module (3) and the strain module (4), uploads the fault signals to the upper computer through the communication module (7), and simultaneously outputs the fault signals to the alarm module (8). The power module (9) is used for powering the remaining modules. When the valve (2000) is detected to be stuck, the control module (5) controls the gas output of the pneumatic amplification module (6) according to the detected fault condition when the next opening and closing signal is sent Q m , so as to ensure that the increased friction can be overcome, and the opening speed is equivalent to the initial speed. The output dynamic volume of its opening process Q mi The calculation formula is as follows: ； wherein: x i is the current recorded valve position, V i is the speed corresponding to the current valve position, K is the pneumatic actuator spring stiffness, d is the spring pneumatic actuator shaft diameter, R is the gas constant, T is the temperature, c v is the flow coefficient, a is the gain coefficient, initial torque M 0 , initial speed V 0 .

2. The valve intelligence sensing and control terminal according to claim 1, characterized in that, The connection axle (2), the shaft coupling (21), the valve stem of the valve (2000), and the pivot of the angular stroke pneumatic actuator (1000) are coaxially connected.

3. The valve intelligence sensing and control terminal according to claim 1, wherein The displacement module (3) includes a Hall circuit board (31) and Hall elements (32). The Hall circuit board (31) is an integrated ring-shaped structure and is fixed coaxially outside the connection axle (2). Two Hall elements (32) are arranged orthogonally on the Hall circuit board (31), and the two Hall elements (32) have a 90° angle difference relative to the shaft body of the connection axle (2).

4. The valve intelligence sensing and control terminal according to claim 1, wherein The box (1) includes an upper shell (11) and a lower shell (12). The upper part of the connection axle (2) penetrates the upper shell (11), an oil seal is arranged at the connection between the two, the bottom of the upper shell (11) is detachably connected to the top of the lower shell (12) to form a whole sealed structure, and the lower shell (12) is fixed on a valve seat.

5. The valve intelligence sensing and control terminal according to claim 1, wherein The strain module (4) includes strain gauges. The strain gauges are pasted on the shaft body of the connection axle (2), the pins thereof are arranged circumferentially along the shaft body, and the strain gauges are connected to the control module through wires.

6. The valve intelligence sensing and control terminal according to claim 1, wherein The control module (5) includes data acquisition interfaces of the displacement module (3) and the strain module (4), an input interface of the power module (9), a control interface of the pneumatic amplification module (6), a communication module (7) interface, and an alarm module (8) interface.

7. The valve intelligence sensing and control terminal of claim 1, wherein The pneumatic amplification module (6) is installed on the lower shell (12), the gas inlet thereof is connected to a gas source, and the gas outlet thereof is connected to the pneumatic actuator (1000).

8. The valve intelligence sensing and control terminal of claim 1, wherein The communication module (7) has both wired and wireless transmission modes.

9. The valve intelligence sensing and control terminal of claim 1, wherein The alarm module (8) includes two LED lamp groups, which present green, yellow or red light according to the health state of the valve (2000); when the control module (5) determines that the state of the valve (2000) is normal, the green light is always on; when the control module (5) determines that the valve (2000) is stuck, the yellow light is always on; when the control module (5) determines that the valve (2000) is faulty, the red light is always on.

10. A method for implementing the valve intelligent sensing and control terminal according to any one of claims 1-9, characterized in that, The specific implementation is as follows: S1: connect the connecting shaft (2) with the valve stem of the valve (2000) and the rotating shaft of the pneumatic actuator (1000) respectively, fix the box body (1) on the valve seat of the valve (2000), and connect the air source and the wires and signal lines between the modules; S2: when the control module (5) is given an opening signal, the control module (5) controls the output of the pneumatic amplification module (6) to reach the initial set air volume required for opening the valve (2000), which is sufficient to open the corresponding valve (2000) to reach the opening state; when the control module (5) is given a closing signal, the control module (5) controls the pneumatic amplification module (6) to discharge the air pressure in the pneumatic actuator (1000) to reach the full-closed state of the valve (2000); S3: during the opening and closing process of the valve (2000), the sensors of the displacement module (3) and the strain module (4) sense the angle, number of rotations and tension change of the connecting shaft, and transmit the data to the control module (5); the control module (5) monitors the rotation angle, number of rotations, time and torque of the valve (2000), and calculates the rotation speed of the valve (2000) and the friction force acting on the valve stem; S4: When matching the valve (2000), set the initial value according to the required output torque of the valve (2000), including the initial torque M 0 and the initial speed V 0 =90 / T 0 ; wherein, T 0 is the initial time required for rotating 90° at the torque. S5: When the on-off signal is given, the friction force on the valve stem suddenly increases or the valve position hardly changes during the action of the valve (2000), that is, when the next torque value M >80% M 0 or when the next valve speed V ≈0, the control module (5) outputs a fault alarm information, and the alarm module (8) displays a red light constantly on; S6: when the given opening and closing signal, the valve (2000) is in motion, and the friction force acting on the valve stem is less than 50% of the initial torque, or the speed is reduced to 50% of the initial speed, it indicates that the valve (2000) is in normal operation, and the control module (5) controls the alarm module (8) to always turn on the green light; S7: when the given opening and closing signal, the valve (2000) is in motion, and the friction force acting on the valve stem is 50%~80% of the initial torque, or the speed is reduced to 50%~80% of the initial speed, it indicates that the valve (2000) is stuck, the control module (5) outputs a warning information, and the alarm module (8) displays a yellow light always on. When the valve (2000) is detected to be stuck, the control module (5) controls the gas output of the pneumatic amplification module (6) according to the detected fault condition when the next opening and closing signal is sent Q m , so as to ensure that the increased friction can be overcome, and the opening speed is equivalent to the initial speed; the output dynamic gas volume of the opening process Q mi The calculation formula is as follows: ； where: x i is the current recorded valve position, V i is the velocity corresponding to the current valve position, p t is the pneumatic actuator cylinder pressure, A t is the pneumatic actuator diaphragm effective area, K is the pneumatic actuator spring stiffness, d is the spring pneumatic actuator shaft diameter, R is the gas constant, T is the temperature, c v is the flow coefficient, a is the gain coefficient.

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