Pneumatic full-bore plug valve

Abstract

The invention relates to the technical field of plug valves, and provides a pneumatic full-bore plug valve, and a control method of the pneumatic full-bore plug valve comprises the steps that real-time environment information is obtained in response to an adjustment trigger signal; obtaining predicted environment information based on the real-time environment information and the target opening degree; adjusting control information is obtained based on the real-time opening degree and the target opening degree; wherein the adjustment control information is used for controlling the driving part to drive the cock to rotate to the target opening degree; state analysis information is obtained based on the predicted environment information and the adjustment control information; wherein the state analysis information reflects the state of the pneumatic full-bore plug valve. According to the pneumatic full-bore plug valve control method provided by the invention, the technical problem that the leakage risk may be increased due to the fact that the hysteresis of the sealing performance of the plug cock is passively found and analyzed through maintenance after leakage in the related technology can be solved.

Description

Technical Field

[0001] This application relates to the field of plug valve technology, and more particularly to a pneumatic full-bore plug valve. Background Technology

[0002] A pneumatic plug valve is an automated valve that uses compressed air as a power source and a pneumatic actuator to drive the rotation of the core opening and closing element (plug) inside the valve, thereby realizing the on / off control or flow regulation of fluids (liquids, gases, powders).

[0003] However, traditional pneumatic plug valves usually use a preset fixed opening degree or adjust the opening degree only according to the air source pressure. When abnormal situations such as plug seal wear or excessive air source pressure fluctuation occur, it is impossible to add sealing compensation air pressure during the adjustment process. The leak can only be passively discovered and repaired after the leak occurs, which easily increases the risk of leakage. Summary of the Invention

[0004] This application provides a pneumatic full-bore plug valve, which can improve the technical problem in related technologies where the analysis of plug sealing performance is delayed due to passive maintenance after leakage, which may increase the risk of leakage.

[0005] In a first aspect, embodiments of this application provide a pneumatic full-bore plug valve, comprising: The valve body has a medium passage for conveying fluid; The drive unit is disposed on the valve body; A stopcock, located within the medium passage and rotatably mounted on the valve body, is drive-connected to the drive unit; the stopcock has an adjustment channel; and The control unit is communicatively connected to the drive unit; The control unit is used to control the drive unit to drive the plug to rotate so as to change the overlapping area of ​​the adjustment channel and the medium channel, and to drive the plug to approach and abut against the valve body; The pneumatic full-bore plug valve also includes: At least two flow meters are installed on the valve body and located at both ends of the medium channel, respectively. The flow meters are used to monitor the flow rate of the fluid passing through both ends of the medium channel in real time. At least one angle acquisition device is disposed on the cock or the drive shaft of the cock, for real-time monitoring of the rotation angle of the cock; The two flow meters and the angle acquisition device are respectively connected to the control unit in communication.

[0006] The technical solutions described in this application embodiment have at least the following technical effects: The pneumatic full-bore plug valve provided in this embodiment provides a stable installation reference for the plug and drive unit through the valve body. The full-bore medium channel enables unobstructed transport of easily clogged fluids such as powders and slurries. The sealing surface, in conjunction with the plug, withstands axial pressure to form a reliable seal. The drive unit rotates the plug, changing the overlap area between the regulating channel and the medium channel to achieve flow control. The drive unit also moves the plug closer to and against the valve body, ensuring the plug's sealing surface adheres to the valve body's sealing surface under the axial pressure of the drive unit, further preventing fluid leakage. The drive unit receives commands from the control unit, driving the plug to rotate and regulate flow. The drive unit also moves the plug axially closer to and against the valve body, applying a preset pressure to enhance the plug's sealing performance and providing real-time feedback of operating status signals, providing data support for the control unit's dynamic adjustments. The control unit receives real-time signals from the drive unit, determines the sealing status and adjustment accuracy, and automatically controls the drive unit to move the plug to increase the axial pressure, achieving dynamic pressure compensation.

[0007] Secondly, embodiments of this application provide a pneumatic full-bore plug valve control method, applied to the pneumatic full-bore plug valve described in the first aspect above, the method comprising: The system acquires real-time environmental information in response to an adjustment trigger signal; wherein the real-time environmental information includes the real-time opening degree of the valve, the real-time upstream flow rate and the real-time downstream flow rate of the medium channel, and the adjustment trigger signal is used to instruct the drive unit to adjust the real-time opening degree to the target opening degree; Predicted environmental information is obtained based on the real-time environmental information and the target opening; wherein, the predicted environmental information includes the predicted upstream flow and the predicted downstream flow of the medium channel; Adjustment control information is obtained based on the real-time opening degree and the target opening degree; wherein, the adjustment control information is used to control the drive unit to drive the valve to rotate to the target opening degree; State analysis information is obtained based on the predicted environmental information and the regulation and control information; wherein, the state analysis information reflects the state of the pneumatic full-bore plug valve.

[0008] The technical solutions described in this application embodiment have at least the following technical effects: First, by responding to the adjustment trigger signal (used to instruct the drive unit to adjust the real-time opening of the cock to the target opening), real-time environmental information, including the real-time opening of the cock and the real-time upstream and downstream flow rates of the medium channel, is accurately acquired, providing basic data support for subsequent analysis and control. Next, by combining the real-time environmental information with the target opening, predicted upstream and downstream flow rates (predicted environmental information) reflecting the flow state of the medium channel after adjustment are generated, allowing for advance prediction of the adjustment effect and providing a reference benchmark for subsequent state analysis such as sealing performance. Finally, based on the difference between the real-time opening and the target opening, adjustment control information is generated to control the drive unit to rotate the cock to the target opening, ensuring precise execution of the opening adjustment. Finally, by integrating predicted environmental information and regulation and control information, the system outputs status analysis information reflecting the overall status of the pneumatic full-bore plug valve, providing a basis for plug valve performance evaluation and abnormal handling. This enables real-time monitoring and proactive analysis of the valve status, improving upon the traditional passive mode of discovering problems only after leakage. It allows abnormalities such as sealing performance to be identified in a timely manner during regulation, providing data support for subsequent targeted handling such as sealing compensation, reducing leakage risks, and addressing the technical problem of delayed sealing performance analysis. Attached Figure Description

[0009] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0010] Figure 1 This is a schematic diagram of the structure of the pneumatic full-bore plug valve provided in the embodiments of this application; Figure 2 A cross-sectional view of a pneumatic full-bore plug valve provided in an embodiment of this application; Figure 3 A schematic flowchart illustrating the pneumatic full-bore plug valve control method provided in this application embodiment; Figure 4 A flowchart illustrating step S200 in the pneumatic full-bore plug valve control method provided in this application embodiment; Figure 5 This is a flowchart illustrating step S300 in the pneumatic full-bore plug valve control method provided in the embodiments of this application.

[0011] The following are the labeling elements in the figure: 100. Pneumatic full-bore plug valve; 10. Valve body; 20. Drive unit; 21. Drive connector; 22. Rotating component; 23. Pressing drive device; 24. Rotating drive device; 30. Plug; 40. Control unit. Detailed Implementation

[0012] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0013] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application. The terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0014] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0015] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0016] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0017] In this application, "and / or" is merely a way of describing the relationship between related objects, indicating that three relationships can exist; for example, A and / or B can represent three cases: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0018] It should be noted that in this application, the words "in some embodiments," "exemplarily," and "for example" are used to indicate examples, illustrations, or descriptions. Any embodiment or design described in this application as "in some embodiments," "exemplarily," or "for example" should not be construed as being more preferred or advantageous than other embodiments or design solutions. Specifically, the use of words such as "in some embodiments," "exemplarily," and "for example" is intended to present related concepts in a specific manner, meaning that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of this application. The appearance of the above words in various places in the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment that is mutually exclusive with other embodiments. Those skilled in the art will explicitly and implicitly understand that the embodiments described herein can be combined with other embodiments.

[0019] A pneumatic plug valve is an automated valve that uses compressed air as a power source and a pneumatic actuator to drive the rotation of the core opening and closing element (plug) inside the valve, thereby realizing the on / off control or flow regulation of fluids (liquids, gases, powders).

[0020] However, traditional pneumatic plug valves usually use a preset fixed opening degree or adjust the opening degree only according to the air source pressure. When abnormal situations such as plug seal wear or excessive air source pressure fluctuation occur, it is impossible to add sealing compensation air pressure during the adjustment process. The leak can only be passively discovered and repaired after the leak occurs, which easily increases the risk of leakage.

[0021] Based on this, in order to improve the technical problem in the related technology that the analysis of plug sealing performance is delayed due to post-leakage maintenance, which may increase the risk of leakage, the embodiments of this application provide the following solution.

[0022] Please see Figure 1 and Figure 2 This application provides a pneumatic full-bore plug valve 100, which includes a valve body 10, a drive unit 20, a plug 30, and a control unit 40, wherein: The valve body 10 has a medium passage 11 for conveying fluid.

[0023] The drive unit 20 is disposed on the valve body 10.

[0024] The stopcock 30 is located in the medium channel 11 and is rotatably mounted on the valve body 10 and is connected to the drive unit 20. The stopcock 30 has an adjustment channel 31.

[0025] The control unit 40 is communicatively connected to the drive unit 20.

[0026] The control unit 40 is used to control the drive unit 20 to drive the valve 30 to rotate so as to change the overlapping area of ​​the adjustment channel 31 and the medium channel 11, and to drive the valve 30 to approach and abut against the valve body 10. The pneumatic full-bore plug valve 100 also includes: At least two flow meters are installed on the valve body 10 and located at both ends of the medium channel 11 respectively. The flow meters are used to monitor the flow rate of the fluid passing through both ends of the medium channel 11 in real time. At least one angle acquisition device is disposed on the valve 30 or the drive shaft of the valve 30 for real-time monitoring of the rotation angle of the valve 30; The two flow meters and the angle acquisition device are respectively connected to the control unit 40 for communication.

[0027] It is understood that the valve body 10 provides an installation reference for the plug 30 and the drive unit 20, while also constructing a fluid transport channel, allowing fluid to move from one end of the medium channel 11 to the other. For example, the valve body 10 can be a tubular structure made of high-strength carbon steel or stainless steel. The area where the valve body 10 contacts the plug 30 can be provided with a rubber bushing. The plug 30 contacts the rubber bushing when it is near the valve body 10 or when the opening is adjusted, thereby improving the sealing performance and preventing the plug 30 from directly rubbing against the valve body 10, thus avoiding increased wear on the plug 30.

[0028] The stopcock 30 changes the overlap area between the regulating channel 31 and the medium channel 11 by rotation, and at the same time relies on the sealing surface to cooperate with the valve body 10 to achieve fluid sealing and flow regulation. For example, the stopcock 30 can be a cylindrical or conical structure made of stainless steel or aluminum alloy, and the surface of the stopcock 30 can be covered with a rubber layer to improve sealing performance.

[0029] The drive unit 20 is the power source that drives the rotary valve 30 to rotate or move. It also provides the torque for the rotation of the rotary valve 30 and the axial pressure, and feeds back the pressure, rotation angle and torque signals to the control unit 40 in real time. For example, the drive unit 20 can be a double-acting cylinder, a servo motor, etc., but is not limited to these.

[0030] A flow meter is a device that can monitor the flow rate of a medium within a medium channel 11 in real time. For example, a flow meter can be an electromagnetic flow meter, a turbine flow meter, etc., but is not limited to these.

[0031] An angle acquisition device is a device that can monitor the rotation angle of the valve 30 in real time. For example, the angle acquisition device can be an encoder (when the valve 30 rotates, it drives the encoder shaft to rotate, and the pulse signal output by the encoder is used to calculate the opening degree by counting or decoding), a Hall angle sensor (which receives the electrical signal output by the Hall angle sensor that is proportional to the angle of the valve 30), etc., but is not limited to these.

[0032] The control unit 40 is a control device capable of controlling the drive unit 20 to drive the rotary valve 30 to rotate or move based on data transmitted from the drive unit 20. For example, the control unit 40 may be a programmable logic controller, a programmable automation controller, etc., but is not limited thereto. The control unit 40 may be mounted on the drive connector 21.

[0033] As can be seen from the above, the pneumatic full-bore plug valve 100 provided in this application embodiment provides a stable installation reference for the plug 30 and the drive unit 20 through the valve body 10. It enables unobstructed transport of easily clogged fluids such as powders and slurries through the full-bore medium channel 11, and forms a reliable seal by cooperating with the plug 30 through the sealing surface to withstand axial pressure. The drive unit 20 drives the plug 30 to rotate, changing the overlapping area of ​​the adjustment channel 31 and the medium channel 11 to achieve flow control. It also drives the plug 30 closer to and against the valve body 10 so that the sealing surface of the plug 30 fits against the sealing surface of the valve body 10 under the axial pressure of the drive unit 20, further preventing fluid leakage. The drive unit 20 receives commands from the control unit 40 to drive the plug 30 to rotate, achieving flow regulation, and drives the plug 30 to approach and against the valve body 10 axially, applying a preset pressure to enhance the sealing performance of the plug 30. It also provides real-time feedback of the operating status signal, providing data support for the dynamic adjustment of the control unit 40. The control unit 40 receives real-time signals from the drive unit 20, determines the sealing status and adjustment accuracy, and automatically controls the drive unit 20 to move the piston 30 to increase the axial pressure and achieve dynamic pressure compensation based on the transmitted data.

[0034] In some embodiments, please refer to the following: Figure 1 and Figure 2 The drive unit 20 includes a drive connector 21, a rotating member 22, a pressing drive device 23, and at least two rotating drive devices 24.

[0035] The drive connector 21 is disposed on the valve body 10.

[0036] The rotating component 22 is rotatably mounted on the drive connector 21.

[0037] The pressure driving device 23 is disposed on the rotating member 22 and connected to the stopcock 30, and is used to drive the stopcock 30 to approach and abut against the valve body 10 in a direction perpendicular to the rotation surface of the rotating member 22.

[0038] A rotary drive device 24 is disposed on the drive connector 21 and connected to the rotating member 22. One rotary drive device 24 is used to drive the rotating member 22 to rotate in a first direction, and the other rotary drive device 24 is used to drive the rotating member 22 to rotate in a second direction, the first direction being opposite to the second direction.

[0039] The control unit 40 is communicatively connected to the pressure drive device 23 and the rotation drive device 24.

[0040] It is understood that the drive connector 21 is responsible for fixing the pressure drive device 23 and the rotation drive device 24 to the valve body 10, while providing stable rotational support for the rotating component 22 to ensure the accuracy of power transmission. For example, the drive connector 21 can be a flange structure made of aluminum alloy or stainless steel, but is not limited to these.

[0041] The rotating component 22 is responsible for receiving the torque of the rotary drive device 24 and driving the valve 30 to rotate. At the same time, it supports the pressure drive device 23, realizing the transfer and coordination of rotation and pressure power. For example, the rotating component 22 can be a cylindrical structure made of stainless steel or aluminum alloy, but it is not limited to this. The rotating component 22 can be rotatably connected to the drive connector 21 through a bearing. The outer periphery of the rotating component 22 can be provided with an angle limiting protrusion, which, in conjunction with the limit switch of the drive connector 21, limits the maximum rotation angle of the rotating component 22 (which can be 0-90°, adapting to the flow adjustment range of the valve 30), to avoid excessive rotation and damage to the components.

[0042] The pressure-driving device 23 is responsible for driving the valve 30 to approach and abut against the valve body 10 along the axial direction (perpendicular to the rotation surface of the rotating component 22), applying controllable pressure to ensure a tight seal between the sealing surfaces. For example, the pressure-driving device 23 can be a double-acting cylinder, a servo motor, etc., but is not limited to these.

[0043] Two rotary drive devices 24 drive the rotating component 22 to rotate in a first direction (e.g., clockwise) and a second direction (e.g., counterclockwise), respectively, to achieve bidirectional opening adjustment of the valve 30. Furthermore, if one rotary drive device 24 fails, the other rotary drive device 24 can also be used to adjust the opening, ensuring flexible and redundant adjustment. For example, the rotary drive device 24 can be a pneumatic rack and pinion cylinder, a servo motor, etc., but is not limited to these.

[0044] This configuration provides a stable mounting reference for the rotating component 22 and the rotary drive device 24 via the drive connector 21, preventing structural misalignment during power transmission. The rotating component 22 receives the torque from the rotary drive device 24, driving the valve 30 to rotate synchronously, thereby achieving flow regulation (opening adjustment) and supporting the pressure drive device 23. This ensures that the push rod of the pressure drive device 23 is coaxial with the valve 30, avoiding eccentric force during axial pressure. Furthermore, the angle limit ensures that the rotation of the valve 30 remains within a safe adjustment range, improving operational reliability. When the push rod of the pressure-reducing drive device 23 extends, it pushes the valve plug 30 towards the valve body 10 in a direction perpendicular to the rotation surface of the valve plug 30, so that the sealing surface of the valve plug 30 and the sealing surface of the valve body 10 are tightly fitted to form an initial seal. When the sealing surface of the valve plug 30 or the valve body 10 is worn, the pressure-reducing drive device 23 increases the output pressure under the control command sent by the control unit 40 to increase the pressure, thereby compensating for the sealing gap (active compensation). When the valve plug 30 needs to be rotated for adjustment, the push rod can be retracted appropriately (reducing the pressure), thereby reducing the rotation resistance and avoiding excessive wear of the sealing surface. The two rotary drive devices 24 receive commands from the control unit 40 respectively, and drive the rotating part 22 and the valve plug 30 to rotate bidirectionally through individual or coordinated actions to realize the adjustment of flow (opening degree) and reduce the flow adjustment error. Through the redundant design of the dual rotary drive devices 24, the adjustment failure caused by the failure of a single rotary drive device 24 is avoided, and the reliability of the drive unit 20 is improved.

[0045] Please see Figure 3 This application also provides a pneumatic full-bore plug valve control method, applied to the pneumatic full-bore plug valve 100 described above. The pneumatic full-bore plug valve control method includes: The system acquires real-time environmental information in response to an adjustment trigger signal. The real-time environmental information includes the real-time opening degree of the valve, the real-time upstream flow rate of the medium channel, and the real-time downstream flow rate. The adjustment trigger signal is used to instruct the drive unit to adjust the real-time opening degree to the target opening degree. Predicted environmental information is obtained based on real-time environmental information and target opening; the predicted environmental information includes the predicted upstream flow and predicted downstream flow of the medium channel. The adjustment control information is obtained based on the real-time opening degree and the target opening degree; wherein, the adjustment control information is used to control the drive unit to drive the cylinder to rotate to the target opening degree; State analysis information is obtained based on predicted environmental information and regulation and control information; among which, the state analysis information reflects the state of the pneumatic full-bore plug valve.

[0046] As described above, the pneumatic full-bore plug valve control method provided in this application firstly acquires real-time environmental information, including the real-time plug opening, the real-time upstream flow rate, and the real-time downstream flow rate of the medium channel, by responding to the adjustment trigger signal (used to instruct the drive unit to adjust the real-time plug opening to the target opening), providing basic data support for subsequent analysis and control. Next, by combining the real-time environmental information and the target opening, predicted upstream and downstream flow rates (predicted environmental information) reflecting the flow state of the medium channel after adjustment are generated, allowing for early prediction of the adjustment effect and providing a reference benchmark for subsequent state analysis such as sealing performance. Finally, based on the difference between the real-time opening and the target opening, adjustment control information is generated to control the drive unit to rotate the plug to the target opening, ensuring accurate execution of the opening adjustment. Finally, by integrating predicted environmental information and regulation and control information, the system outputs status analysis information reflecting the overall status of the pneumatic full-bore plug valve, providing a basis for plug valve performance evaluation and abnormal handling. This enables real-time monitoring and proactive analysis of the valve status, improving upon the traditional passive mode of discovering problems only after leakage. It allows abnormalities such as sealing performance to be identified in a timely manner during regulation, providing data support for subsequent targeted handling such as sealing compensation, reducing leakage risks, and addressing the technical problem of delayed sealing performance analysis.

[0047] To better understand the pneumatic full-bore plug valve control method provided in the embodiments of this application, the specific implementation process of the pneumatic full-bore plug valve control method provided in the embodiments of this application will be described by way of example below.

[0048] Figure 3 A schematic flowchart of a pneumatic full-bore plug valve control method provided in an embodiment of this application is shown. The pneumatic full-bore plug valve control method includes: S100, in response to the adjustment trigger signal, acquires real-time environmental information; wherein, the real-time environmental information includes the real-time opening degree of the valve, the real-time upstream flow rate and the real-time downstream flow rate of the medium channel, and the adjustment trigger signal is used to instruct the drive unit to adjust the real-time opening degree to the target opening degree.

[0049] It is understandable that the real-time opening degree of the plug can be obtained by receiving data transmitted from an encoder mounted on the rotating shaft of the plug. As the plug rotates, it drives the encoder shaft to rotate, and the pulse signal output by the encoder is used to calculate the opening degree through counting or decoding. Alternatively, it can be obtained by measuring the rotation angle of the valve core using a Hall angle sensor mounted on the rotating shaft of the plug, and receiving an electrical signal proportional to the angle output by the Hall angle sensor, etc., but not limited to these methods. The real-time upstream and downstream flow rates can be obtained by receiving real-time data transmitted from two flow meters (electromagnetic flow meters, turbine flow meters, etc.) located at opposite ends of the medium channel and mounted on the valve body, but not limited to these methods. By responding to a trigger signal (which instructs the drive unit to adjust the current real-time opening degree of the plug to a preset target opening degree), real-time environmental information is collected, including the real-time opening degree of the plug (reflecting the current opening and closing state of the valve), the real-time upstream and downstream flow rates of the medium channel (reflecting the actual transmission state of the fluid through the valve), providing comprehensive and accurate raw data support for subsequent flow prediction, precise opening adjustment, and valve status analysis, thus overcoming the limitations of traditional pneumatic plug valves that rely solely on air source pressure or preset parameters.

[0050] S200 obtains predicted environmental information based on real-time environmental information and target opening; the predicted environmental information includes the predicted upstream flow and predicted downstream flow of the medium channel.

[0051] It is understandable that the method of obtaining predicted environmental information based on real-time environmental information and target opening degree can be to combine the real-time opening degree of the plug, the real-time upstream flow rate and the real-time downstream flow rate of the medium channel contained in the real-time environmental information with the target opening degree corresponding to the adjustment target and input them into a pre-built flow prediction model. Through the model's correlation calculation between the current operating state (real-time parameters) and the adjustment target (target opening degree), the predicted upstream flow rate and predicted downstream flow rate matching the adjusted operating condition are output. Finally, the predicted upstream flow rate and predicted downstream flow rate output by the model are confirmed as the predicted environmental information. Alternatively, it can be data transmitted by the user, but it is not limited to these methods. Obtaining predicted environmental information based on real-time environmental information and target opening degree can predict the fluid transmission state after the opening degree is adjusted in advance, providing a basis for subsequent sealing performance analysis and adjustment effect verification. This improves the limitation of traditional pneumatic plug valves that only perform adjustment without predictive analysis. By comparing the predicted flow rate with the subsequent actual adjusted flow rate, abnormalities such as sealing leakage can be identified (e.g., if the difference between the actual flow rate and the predicted flow rate exceeds the prediction range, it indicates that the seal may fail), thus improving the lag of traditional valves that only passively detect problems after leakage occurs.

[0052] In one possible implementation, please refer to Figure 4 S200, based on real-time environmental information and target opening, obtains predicted environmental information, including: S210, input the real-time opening degree, target opening degree, real-time upstream flow and real-time downstream flow into the flow prediction model to obtain the predicted upstream flow and predicted downstream flow output by the flow prediction model.

[0053] It is understandable that the flow prediction model is trained using machine learning on multiple sets of data. Each set of data includes: real-time opening degree, target opening degree, real-time upstream flow, and real-time downstream flow, as well as predicted upstream and downstream flow calculated and provided manually in real time. Flow prediction is achieved through model-based computation, ensuring that the prediction results match actual adjustment needs, and providing a basis for subsequent comparative verification of adjustment effects and identification of sealing anomalies.

[0054] S220 identifies the predicted upstream and downstream flows as predicted environmental information.

[0055] It is understandable that identifying the predicted upstream and downstream flow rates from the flow prediction model as predicted environmental information can provide a basis for subsequent analysis of the sealing performance and verification of the regulating effect of pneumatic full-bore plug valves through standardized result definition.

[0056] S300 obtains adjustment control information based on real-time opening degree and target opening degree; wherein, the adjustment control information is used to control the drive unit to drive the cylinder to rotate to the target opening degree.

[0057] It is understandable that the method of obtaining adjustment control information based on real-time opening and target opening can be as follows: first, subtract the real-time opening from the target opening to obtain the opening difference; then, determine whether the absolute value of the difference is less than or equal to the minimum single drive angle of the drive unit. If the absolute value of the difference is less than or equal to the minimum single drive angle, a dual drive method is used to generate adjustment control information (i.e., first, control the pressure drive device to drive the cylinder to move a preset contact distance along the unlocking direction; then, control the two counter-rotating drive devices to synchronously increase torque and monitor the first and second torques in real time; finally, based on the torque change and the cylinder rotation angle, generate opening control information containing the action commands of each device). If the absolute value of the difference is greater than the minimum single drive angle, adjustment control information is directly generated to instruct the drive unit to drive the cylinder to rotate to the target opening, ensuring that the opening adjustment is suitable for both small-angle high-precision adjustment needs and large-angle efficient adjustment scenarios, achieving precise drive control under different opening differences. Alternatively, the real-time opening and target opening can be sent to the user and then the user-transmitted data can be received, but this is not limited to these methods. Based on the current real-time opening degree of the cock and the preset target opening degree, the system generates adjustment control information by quantifying the difference between the two and matching the operating characteristics of the drive unit to control the drive unit to rotate the cock to the target opening degree. This improves the limitations of traditional valves that rely solely on preset fixed parameters or single air source pressure adjustment. By matching the current state with the target requirements, the system ensures the accuracy and relevance of the opening degree adjustment.

[0058] In one possible implementation, please refer to Figure 4 and Figure 5 S300 obtains regulation and control information based on real-time opening degree and target opening degree, including: S310, the value obtained by subtracting the real-time opening from the target opening is confirmed as the opening difference.

[0059] It is understandable that the value obtained by subtracting the real-time opening from the target opening can be used as the opening difference to provide a basis for judging the driving mode of the drive unit (whether it adopts a dual driving method or direct driving).

[0060] For example, assuming the target opening is 10° and the real-time opening is 15°, then the opening difference = 10 - 15 = -5° (a negative opening difference indicates a decrease in opening, while a positive opening difference indicates an increase in opening).

[0061] S320 determines whether the absolute value of the opening difference is less than or equal to the minimum single drive angle.

[0062] It is understandable that the minimum single-drive angle can be 0.5°, 1°, etc., but is not limited to this. Determining whether the absolute value of the opening difference is less than or equal to the minimum single-drive angle involves comparing the absolute value of the quantified opening difference with the minimum single-drive angle of the drive unit. This clarifies the amount of opening adjustment required and distinguishes different adjustment scenarios (if the absolute value of the difference does not exceed the minimum single-drive angle, a dual-drive method must be used to ensure the accuracy of small-angle adjustment; if it exceeds, the valve can be directly driven to rotate). This provides a clear decision-making basis for subsequent generation of adjustment control information for different scenarios, ensuring that the drive method adapts to the opening difference.

[0063] S330, if the opening difference is less than or equal to the minimum single drive angle, adjustment control information is obtained based on the dual drive method; if the opening difference is greater than the minimum single drive angle, adjustment control information is obtained to indicate the drive unit to rotate the drive cylinder to the target opening.

[0064] It is understandable that the way to obtain adjustment and control information based on the dual-drive method can be as follows: first, control the pressure drive device to drive the cylinder to move a preset contact distance to release the contact constraint; then, control the two rotating drive devices with opposite driving directions to synchronously increase the torque, and monitor the first torque corresponding to the opening difference and the second torque of the other device in real time. Then, dynamically generate opening control information based on the changes of the two torques. When the two torques reach the friction value required to drive the cylinder to rotate, keep the second torque unchanged, let the first torque increase at a preset rate and monitor the rotation angle of the cylinder. When the rotation angle reaches half of the absolute value of the opening difference, the first torque decreases at a preset rate until it is equal to the friction value again. At this time, control the two rotating drive devices to synchronously unload the torque to 0, and then drive the cylinder to move a preset contact distance through the pressure drive device (in the opposite direction of the previous movement) to complete the locking. It can also be based on receiving data transmitted by the user, but is not limited to this. If the opening difference is less than or equal to the minimum single drive angle, it means that when driving the cylinder to rotate via a unidirectional drive device, the high static friction of the cylinder sealing surface may cause an impact-type start (leading to inertial overshoot) as the single drive needs to overcome the static friction, resulting in the actual rotation angle of the cylinder being greater than the required rotation angle. Therefore, multiple devices need to work together to ensure accuracy under small angle adjustments. If the opening difference is greater than the minimum single drive angle, adjustment control information is directly generated to instruct the drive unit to drive the cylinder to rotate to the target opening, achieving efficient drive under large angle adjustments.

[0065] In one possible implementation, please refer to Figure 4 and Figure 5 In S330, the regulation and control information is obtained based on the dual-drive method, including: S331, step a, control the pressure driving device to drive the cylinder to move a preset contact distance along the unlocking direction; wherein, the unlocking direction is the direction perpendicular to the rotation surface of the cylinder and opposite to the direction of gravity.

[0066] It is understood that the preset contact distance can be 1cm, 2cm, etc., but is not limited to this. The unlocking direction is the direction in which the driving plug moves away from the valve body, perpendicular to the fluid delivery direction in the medium channel. Controlling the pressure drive device to move the driving plug along the unlocking direction by the preset contact distance can release the contact constraint between the plug and the sealing surface through directional and quantitative displacement operation, laying the operational foundation for subsequent torque adjustment of the rotary drive device and precise angle adjustment of the plug.

[0067] S332, step b, control the two rotary drive devices to increase torque synchronously, and monitor the first torque and the second torque in real time; wherein, the two rotary drive devices drive the valve to rotate in opposite directions, the first torque is the torque generated by the rotary drive device corresponding to the opening difference, and the second torque is the torque generated by the other rotary drive device.

[0068] It is understandable that by synchronously increasing the torque through the reverse drive device to establish an initial torque balance, a stable torque benchmark is provided for subsequent precise control of the rotary valve rotation angle. At the same time, the real-time monitoring of dual torque data can provide timely feedback on the drive status, avoiding adjustment deviations caused by torque fluctuations in a single drive mode, and providing reliable torque data support for small-angle adjustments.

[0069] For example, suppose there are two rotary drive devices, A and B. Rotary drive device A drives the valve to rotate clockwise, and rotary drive device B drives the valve to rotate counterclockwise. When the valve rotates clockwise, the opening increases, and when it rotates counterclockwise, the opening decreases. If the difference in opening is 5°, then rotary drive device A corresponds to the difference in opening. If the difference in opening is -5°, then rotary drive device B corresponds to the difference in opening.

[0070] S333, step c, obtaining opening control information based on the first torque and the second torque; wherein, the opening control information is used to control the two rotary drive devices and the pressing drive device.

[0071] It is understandable that the method of obtaining the opening control information based on the first torque and the second torque can be as follows: when the real-time monitored first torque (corresponding to the opening difference) and second torque (reverse drive) both reach the friction value required to drive the cylinder to rotate, first control the rotary drive device corresponding to the second torque to maintain the torque to maintain balance, and at the same time control the rotary drive device corresponding to the first torque to increase the torque by a preset speed, and track the rotation angle of the cylinder in real time; when the rotation angle reaches half of the absolute value of the opening difference, control the first torque to decrease by a preset speed to avoid cylinder overshoot; when the first torque falls back to the friction value, control the two rotary drive devices to synchronously reduce the torque to 0, and then instruct the pressure drive device to drive the cylinder to move a preset contact distance to complete the fixation in the locking direction opposite to the unlocking direction. At the same time, record the torque difference (the difference between the first torque and the second torque) and rotation angle at each node on the time axis to form a torque-angle correspondence. Finally, integrate the above-mentioned action flow instructions of "torque increase / decrease control, rotation angle monitoring, and pressure drive locking" into opening control information. Alternatively, the first torque and the second torque can be sent to the user and then the data transmitted by the user can be received, but it is not limited to these methods. By dynamically feeding back dual torque data, the torque balance and angle control requirements in small-angle adjustment scenarios are adapted. This ensures that the torque output of the rotary drive device matches the rotational resistance of the valve in real time, avoiding problems such as wear on the sealing surface due to excessive torque or failure to drive due to insufficient torque. It also provides timing instructions for the subsequent action of the pressure drive device, ensuring high precision and stability of small-angle opening adjustment.

[0072] In one possible implementation, please refer to Figure 4 and Figure 5 In S333, opening control information is obtained based on the first torque and the second torque, including: S3331, when the first torque and the second torque are equal to the friction value, the rotary drive device controlling the second torque maintains the torque, and controls the rotary drive device corresponding to the first torque to gradually increase the torque according to the preset torque increase rate, and monitors the rotation angle of the cylinder in real time; wherein, the friction value reflects the torque value required to drive the cylinder to rotate.

[0073] It is understandable that the preset torque increase rate can be 0.5 N·m / s, 2 N·m / s, etc., but is not limited to these. When the real-time monitored first torque (corresponding to the opening difference) and second torque (reverse drive) both reach the friction value (reflecting the basic torque required for the driving cylinder to overcome the contact surface resistance and achieve rotation), on the one hand, the rotary drive device outputting the second torque is controlled to maintain the current torque to maintain the torque balance on both sides of the cylinder and avoid cylinder offset due to sudden torque changes on one side; on the other hand, the rotary drive device outputting the first torque is controlled to gradually increase the torque according to the preset torque increase rate to ensure that the driving force increases smoothly to achieve slow rotation of the cylinder; at the same time, the rotation angle of the cylinder is monitored in real time to provide dynamic feedback for subsequent judgment of whether the angle meets the standard and timely adjustment of torque, reducing the possibility of cylinder overshoot or sealing surface wear caused by sudden torque increase, accurately capturing the cylinder rotation trajectory, and providing a basis for precision control of small angle adjustment.

[0074] S3332, when the rotation angle is equal to half the absolute value of the opening difference, the rotation drive device corresponding to the first torque is controlled to gradually reduce the torque according to the preset torque increase rate.

[0075] It is understandable that when the rotation angle is equal to half the absolute value of the opening difference, the rotation drive device corresponding to the first torque gradually reduces the torque according to the preset torque increase rate. Based on the high precision requirement of small angle adjustment, the inertial effect of the cylinder rotation is used to achieve a smooth transition from speed increase to deceleration by reducing the torque in advance. This avoids overshooting of the cylinder rotation (exceeding the target opening) due to continuous torque loading. At the same time, it reserves buffer space for the subsequent torque to fall back to the friction value and complete the positioning, ensuring that the cylinder angle adjustment fits the target difference and the accuracy and stability of small angle adjustment.

[0076] S3333, when the first torque is equal to the friction value again, control the two rotary drive devices to reduce the torque synchronously, and after the torque of the two rotary drive devices is reduced to 0, control the pressure drive device to drive the cylinder to move a preset contact distance along the locking direction, and obtain the torque angle correspondence based on the real-time monitored torque difference and rotation angle; wherein, the locking direction is opposite to the unlocking direction, the torque difference is the difference between the first torque and the second torque, and the torque angle correspondence includes the torque difference and rotation angle corresponding to each time node on a time axis.

[0077] It is understandable that the two rotary drive devices are first controlled to synchronously reduce torque until the torque value drops to 0, thus terminating the rotary drive force. After the torque is completely removed, the pressure drive device is controlled to move the cylinder a preset contact distance along the locking direction opposite to the unlocking direction, achieving precise fixing of the cylinder position. Simultaneously, based on the torque difference value (i.e., the difference between the first torque and the second torque) and the cylinder rotation angle monitored in real time during the adjustment process, a torque-angle correspondence relationship is constructed, including the torque difference value and rotation angle corresponding to each time node on the time axis. The timing design of first releasing torque and then locking avoids cylinder displacement due to residual torque, ensuring the final accuracy of small angle adjustment. At the same time, the generated torque-angle correspondence relationship provides core data support for subsequent analysis of the friction state between the cylinder and the sealing surface and the determination of the degree of wear.

[0078] S334, steps a, b and c are confirmed as adjustment and control information.

[0079] It is understandable that identifying steps a, b, and c as adjustment and control information can transform scattered single-step action commands into a standardized and executable complete control scheme, ensuring precise coordination of the action timing and parameter settings of the pressure drive device and the dual rotary drive device. This provides a closed-loop controllable execution basis for small-angle adjustment scenarios and also provides a basis for subsequent valve wear performance analysis by integrating the torque-angle correspondence.

[0080] S400 obtains state analysis information based on predicted environmental information and regulation and control information; among which, the state analysis information reflects the state of the pneumatic full-bore plug valve.

[0081] It is understandable that obtaining state analysis information based on predicted environmental information and regulation and control information can be achieved by using the predicted upstream and downstream flow rates from the predicted environmental information as the core benchmarks. First, the difference between these predicted and downstream flow rates is calculated and compared with the actual upstream and downstream flow rates after the opening adjustment. If the deviation between the actual flow rate difference and the predicted flow rate difference exceeds a preset sealing threshold, a seal leak is determined. Then, the torque-angle correspondence (torque difference and rotation angle at each node on the time axis) contained in the regulation and control information is extracted. This is compared with historical torque data under the same operating conditions. If the friction value required for the same opening adjustment (the basic torque driving the piston rotation) increases significantly, or the torque difference fluctuation range is large... If the readings exceed the normal range, it is determined that there is accelerated wear between the plug and the sealing surface. Simultaneously, the accuracy of the actions in the regulation and control information is verified, including whether the torque loading / unloading sequence of the dual rotary drive device, the unlocking / locking displacement of the pressure drive device meet the preset standards, and whether the deviation between the actual rotation angle and the opening degree is within the allowable range, to determine the accuracy of the drive execution. Finally, the results of multi-dimensional assessments, including seal integrity, mechanical wear, and drive execution accuracy, are integrated to form a comprehensive state analysis information reflecting the operating status of the pneumatic full-bore plug valve. This can also involve sending predicted environmental information and regulation and control information to the user and receiving data transmitted by the user, but is not limited to these methods. The state analysis information obtained based on predicted environmental information and regulation and control information can overcome the limitations of traditional valves that rely solely on a single parameter to determine their status. Through the synergistic analysis of the relationship between predicted environmental information and torque angle, the core states of the valve, such as seal integrity, mechanical wear, and drive execution accuracy, can be assessed, providing a basis for subsequent anomaly warnings and maintenance decisions.

[0082] In one possible implementation, please refer to Figure 4 S400 obtains state analysis information based on predicted environmental information and regulation and control information, including: S410, First analysis information is obtained based on predicted environmental information; wherein, the first analysis information reflects the sealing performance of the plug.

[0083] It is understandable that the method of obtaining the first analysis information based on the predicted environmental information can be as follows: first, extract core data (predicted upstream flow and predicted downstream flow) from the predicted environmental information, calculate the difference between the two to obtain the predicted flow difference (i.e., predicted upstream flow minus predicted downstream flow), and use this as the benchmark for judging the sealing performance; after the pneumatic full-bore plug valve completes the opening adjustment (rotates to the target opening) according to the regulation control information, collect the actual upstream flow and actual downstream flow of the medium channel at this time, and simultaneously calculate the actual flow difference; then, quantitatively analyze the deviation value between the actual flow difference and the predicted flow difference (i.e., actual flow difference minus predicted flow difference), and compare this deviation value with the preset sealing threshold (the allowable leakage flow difference range preset based on valve design sealing standards and medium characteristics); if the deviation value is within the preset sealing threshold, it is determined that the plug and the sealing surface are tightly fitted and the sealing performance is good; if the deviation value exceeds the preset sealing threshold, it is determined that there is a sealing leak (the larger the deviation value, the more serious the corresponding leakage). Finally, the sealing performance judgment result is determined as the first analysis information. Alternatively, it can be that the predicted environmental information is sent to the user and then the data transmitted by the user is received, etc., but it is not limited to these methods. The first analysis information obtained based on the predicted environmental information can be used to assess the integrity of the plug seal by comparing the predicted benchmark with the actual verified flow rate, providing key sealing performance data support for the condition analysis information.

[0084] In one possible implementation, please refer to Figure 4 S410, Based on the predicted environmental information, the first analysis information is obtained, including: S411 After the adjustment and control information is executed, the value obtained by subtracting the predicted downstream flow from the predicted upstream flow is confirmed as the prediction difference. The range obtained by adjusting the predicted difference by a preset range ratio is confirmed as the flow judgment range.

[0085] It is understandable that the preset range ratio can be 1%, 5%, etc., but is not limited to this. By first determining the predicted difference and then leaving room for fluctuation redundancy, a basis for judgment is provided for subsequent comparison of whether the actual flow difference meets the sealing requirements (it both anchors the ideal flow difference benchmark under the predicted operating conditions and accommodates the small fluctuations of the actual operating conditions through the preset ratio floating, avoiding misjudgment of sealing leakage due to normal fluctuations).

[0086] For example, assuming the prediction difference is 1.0 m³ / h and the preset range ratio is 1%, then the flow judgment range = (1*0.99, 1*1.01) = (0.99 m³ / h, 1.01 m³ / h).

[0087] S412, step d: obtain the adjusted upstream flow rate and adjusted downstream flow rate of the medium channel, and confirm the value obtained by subtracting the adjusted downstream flow rate from the adjusted upstream flow rate as the adjusted difference value.

[0088] It is understandable that by capturing the flow loss data under the actual operating conditions of the valve, a precise actual reference benchmark is provided for the subsequent comparison with the flow judgment range (generated based on the predicted difference fluctuation). The adjusted difference reflects the difference in the flow of the medium through the valve under actual working conditions and is the key data for judging whether there is leakage on the sealing surface. This provides actual data support for the generation of the first analysis information.

[0089] S413, step e: If the adjusted difference is greater than the maximum value within the flow judgment range, the value obtained by adding the preset contact distance to the step contact distance is confirmed as the new preset contact distance, and a contact sealing command is obtained to control the pressure drive device to drive the cylinder to move the step contact distance along the locking direction. After the contact sealing command is executed, steps d and e are repeated. If the adjusted difference is within the flow judgment range, the value obtained by subtracting 1 from the number of times step e is executed is confirmed as the number of contact adjustments, and the value obtained by dividing the number of contact adjustments by the maximum number of adjustments is confirmed as the sealing response value. The maximum number of adjustments is the value obtained by dividing the maximum adjustable distance by the step contact distance, and the maximum adjustable distance reflects the maximum moving distance that the pressure drive device can drive the cylinder to move.

[0090] It is understandable that the step contact distance can be 2mm, 5mm, etc., but it is not limited to this. If the adjusted difference is greater than the maximum value within the flow rate judgment range (indicating insufficient sealing and leakage risk), the original preset contact distance is first added to the step contact distance to obtain a new preset contact distance. At the same time, a contact sealing command is generated (controlling the pressure drive device to drive the cylinder to move an additional step contact distance along the locking direction to enhance the contact pressure between the cylinder and the sealing surface). After the contact sealing command is executed, step d (obtaining the adjusted upstream and downstream flow rates and calculating the adjusted difference) and this step are repeated until the adjusted difference meets the requirements. If the adjusted difference is within the flow rate judgment range (indicating that the sealing performance meets the standard), the total number of times this step is executed is reduced by 1 to obtain the actual number of contact adjustments (excluding the invalid count of the final meeting). Then, the actual number of contact adjustments is divided by the maximum number of adjustments to obtain the sealing response value. The maximum number of adjustments is calculated by dividing the maximum adjustable distance (reflecting the maximum stroke that the pressure drive device can drive the cylinder to move) by the step contact distance. The sealing response value quantifies the adjustment range required to achieve the sealing standard. The sealing leakage problem is improved by using dynamic pressure adjustment and cyclic verification. At the same time, the sealing performance is transformed into a quantifiable indicator by the sealing response value (the fewer the number of adjustments and the smaller the sealing response value, the better the initial sealing condition or the lower the wear). This provides data support for subsequent comprehensive condition analysis.

[0091] S414, if the sealing response value is less than or equal to the preset sealing ratio, the first analysis information reflecting good sealing performance of the plug is obtained; if the sealing response value is greater than the preset sealing ratio, the first analysis information reflecting abnormal sealing performance of the plug is obtained.

[0092] It is understandable that the preset sealing ratio can be 0.5, 0.7, etc., but is not limited to these. The sealing response value (the ratio of the actual number of adjustment attempts to the maximum number of adjustments, where the maximum number of adjustments is calculated by dividing the maximum adjustable distance by the step contact distance) is used as a quantitative indicator. This is precisely compared with the preset sealing ratio (a critical threshold set based on valve design sealing standards, media characteristics, and operating conditions). If the sealing response value is less than or equal to the preset sealing ratio, it indicates that only a small amount (or no need) of contact adjustment is required to achieve the required seal, and the plug's sealing performance is judged to be good, generating the corresponding first analysis information. If the sealing response value is greater than the preset sealing ratio, it indicates that multiple contact adjustments are required to achieve the sealing requirements, suggesting potential problems such as increased wear and decreased fit accuracy between the plug and the sealing surface, and the plug's sealing performance is judged to be abnormal, generating the corresponding first analysis information.

[0093] S420, the second analysis information is obtained based on the torque angle correspondence; the second analysis information reflects the wear performance of the plug.

[0094] It is understandable that the method of obtaining the second analysis information based on the torque-angle correspondence can be as follows: First, take the torque-angle correspondence under the same historical operating conditions of the valve (same opening adjustment range, same medium characteristics, and same predicted environmental information) as a benchmark, and extract the benchmark friction value (the basic torque required to drive the cylinder to rotate at that time), the benchmark torque difference fluctuation range (the normal fluctuation range of the difference between the first torque and the second torque under the same angle adjustment), and the benchmark synchronization parameter (the time difference threshold between torque loading / unloading and rotation angle change) as a reference for judgment; then, from the torque-angle correspondence generated by the current adjustment and control information, accurately extract three core features: first, the current friction value (the basic torque that drives the cylinder to overcome contact resistance and rotate under the current operating conditions); second, the fluctuation amplitude of the torque difference (the difference between the first torque and the second torque) within the same rotation angle range; and third, the torque increase / decrease change and the cylinder. The synchronization of rotation angle changes (i.e., the time lag between torque and angle changes) is assessed. The current characteristics are then quantitatively compared with benchmark parameters: if the current friction value exceeds a preset wear threshold, it indicates increased contact resistance between the plug and the sealing surface, signifying intensified wear; if the torque difference fluctuation exceeds the benchmark range, it suggests uneven sealing surface wear or increased plug surface roughness; if the lag between torque and angle changes exceeds the benchmark synchronization parameter, it indicates abnormal contact gap between the plug and the sealing surface due to wear. Finally, by synthesizing the above comparison results, key conclusions such as wear degree (slight / moderate / severe) and wear type (uniform wear / localized wear / sealing surface damage) are determined and integrated into a second analytical information comprehensively reflecting the plug's wear performance. This could also involve sending the torque-angle correspondence to the user and receiving user-transmitted data, but is not limited to these methods. Obtaining the second analytical information based on the torque-angle correspondence transforms the wear state into quantifiable torque-angle characteristic indicators, avoiding the subjectivity and lag of traditional wear detection. This enables the assessment of the wear degree and uniformity of the plug and sealing surface, providing data support for state analysis information.

[0095] In one possible implementation, please refer to Figure 4 S420, based on the torque-angle correspondence, the second analysis information is obtained, including: S421, based on the torque-angle correspondence, obtains at least two rotational rates corresponding to the torque difference.

[0096] It is understandable that the rotational rate can be calculated by selecting torque differences from at least two different time periods (characteristic node data from the increasing, stable, or decreasing torque difference stages can be selected), and calculating the ratio of the change in the rotation angle of the cylinder to the corresponding change in time within each time period (i.e., rotational rate v = Δθ / Δt). This ensures that each rotational rate accurately matches its corresponding torque difference, forming multiple sets of corresponding data for torque difference and rotational rate. Based on the torque-angle correspondence (including torque differences at each node on the time axis, the difference between the first and second torques, and the corresponding rotation angle data), at least two rotational rates corresponding to the torque differences are calculated through time-different data extraction. The correlation between rotational rate and torque difference reflects the frictional resistance state of the cylinder. Obtaining multiple sets of corresponding data avoids the randomness of single data, providing data support for subsequent analysis of the variation law of torque difference and rotational rate, and for determining wear performance.

[0097] S422, the value obtained by subtracting the corresponding ideal speed from each rotation speed and then dividing it by the corresponding ideal speed is confirmed as the wear analysis value; wherein, the torque difference between the rotation speed and the corresponding ideal speed is the same.

[0098] It can be understood that the ideal speed is the rotational speed of the cock under ideal conditions (when the cock is newly manufactured) when the torque and rotational speed correspond to the same torque. Based on the benchmark that the same torque difference corresponds to the same ideal working condition, each rotational speed is first matched with its corresponding ideal speed (the torque difference between the two is consistent to ensure the uniformity of the comparison conditions); then, through standardized deviation calculation, each rotational speed is subtracted from the corresponding ideal speed to obtain the speed deviation value, and then divided by the corresponding ideal speed. Finally, the calculation result is confirmed as the wear analysis value (i.e., wear analysis value = (rotational speed - corresponding ideal speed) / corresponding ideal speed). The larger the deviation and the larger the absolute value of the wear analysis value, the more significant the deviation between the actual rotational state and the ideal state, indirectly reflecting the abnormal frictional resistance between the cock and the sealing surface (caused by wear).

[0099] S423, if the wear analysis value is within the preset wear range, then a second analysis information reflecting good wear performance of the cock is obtained; if the wear analysis value is not within the preset wear range, then a second analysis information reflecting abnormal wear performance of the cock is obtained.

[0100] It is understandable that the preset wear range can be (0, 0.6), (0, 0.7), etc., but is not limited to these. If the wear analysis value is within the preset wear range, it indicates that the deviation between the actual rotation speed and the ideal speed is within the allowable range, and the frictional resistance between the plug and the sealing surface has not become abnormal due to wear. The wear performance of the plug is judged to be good, and corresponding second analysis information is generated. If the wear analysis value exceeds the preset wear range (especially when it is negative and the absolute value is large, it indicates that the actual rotation speed is significantly lower than the ideal speed under the same torque difference, and the frictional resistance increases significantly due to wear), the wear performance of the plug is judged to be abnormal, and corresponding second analysis information is generated.

[0101] S430, if both the first analysis information and the second analysis information reflect good performance, then the state analysis information reflecting the good condition of the pneumatic full-bore plug valve is obtained; if the first analysis information and / or the second analysis information do not reflect good performance, then the state analysis information reflecting the abnormal condition of the pneumatic full-bore plug valve is obtained.

[0102] Understandably, if the first analysis clearly indicates good plug sealing performance, and the second analysis confirms good plug wear performance (i.e., both core performance indicators meet preset standards), then integrated status analysis information reflecting the overall good operating condition of the pneumatic full-bore plug valve is generated. Conversely, if the first analysis indicates abnormal sealing performance, the second analysis indicates abnormal wear performance, or either of these performance indicators is abnormal (i.e., at least one core performance indicator has a potential problem), then status analysis information reflecting an abnormal overall condition of the pneumatic full-bore plug valve is generated. By comprehensively verifying both sealing integrity and mechanical wear—two key performance indicators—the omission of potential problems caused by judging only one performance indicator is avoided, ensuring the comprehensiveness and reliability of the status analysis information.

[0103] The pneumatic full-bore plug valve 100 provided in this application embodiment has a control unit 40 that may include at least one processor, at least one memory, and a computer program stored in at least one memory and executable on at least one processor. When the processor executes the computer program, it causes the pneumatic full-bore plug valve 100 to implement the steps in any of the above-described pneumatic full-bore plug valve control method embodiments.

[0104] For example, a computer program can be divided into one or more modules / units, one or more of which are stored in memory and executed by a processor to complete this application. One or more modules / units can be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program in the control unit.

[0105] The control unit can be a computing device such as an embedded integrated controller, a programmable logic controller, or a control box. This control unit may include, but is not limited to, a processor and memory. Those skilled in the art will understand that the above embodiments are merely examples of control units and do not constitute a limitation on the control unit. It may include more or fewer components, or combine certain components, or different components, such as input / output devices, network access devices, buses, etc.

[0106] The processor can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. A general-purpose processor can be a microprocessor or any conventional processor.

[0107] In some embodiments, the memory may be an internal storage unit of the control unit, such as the hard disk or RAM of the control unit. In other embodiments, the memory may be an external storage device of the control unit, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the control unit. Furthermore, the memory may include both internal storage units and external storage devices of the control unit. The memory is used to store the operating system, applications, bootloader, data, and other programs, such as program code for computer programs. The memory can also be used to temporarily store data that has been output or will be output.

[0108] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps in any of the above method embodiments.

[0109] This application provides a computer program product that, when run on a control unit, causes the control unit to implement the steps in any of the above-described method embodiments.

[0110] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the methods of the above embodiments of this application can be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include at least: any entity or device capable of carrying the computer program code to the control unit, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium. Examples include USB flash drives, portable hard drives, magnetic disks, or optical disks.

[0111] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0112] Those skilled in the art will recognize that the units 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.

[0113] In the embodiments provided in this application, it should be understood that the disclosed pneumatic full-bore plug valve and method can be implemented in other ways. For example, the embodiments of the pneumatic full-bore plug valve and method described above are merely illustrative. Furthermore, the couplings or direct couplings or communication connections shown or discussed may be indirect couplings or communication connections through some interfaces, devices, or units, and may be electrical, mechanical, or other forms.

[0114] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0115] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A pneumatic full-bore plug valve, characterized in that, include: The valve body has a medium passage for conveying fluid; The drive unit is disposed on the valve body; A stopcock is located within the medium channel and is rotatably mounted on the valve body, and is connected to the drive unit in a driving manner; the stopcock has an adjustment channel. as well as The control unit is communicatively connected to the drive unit; The control unit is used to control the drive unit to drive the plug to rotate so as to change the overlapping area of ​​the adjustment channel and the medium channel, and to drive the plug to approach and abut against the valve body; The pneumatic full-bore plug valve also includes: At least two flow meters are installed on the valve body and located at both ends of the medium channel, respectively. The flow meters are used to monitor the flow rate of the fluid passing through both ends of the medium channel in real time. At least one angle acquisition device is disposed on the cock or the drive shaft of the cock, for real-time monitoring of the rotation angle of the cock; The two flow meters and the angle acquisition device are respectively connected to the control unit in communication.

2. The pneumatic full-bore plug valve as described in claim 1, characterized in that, The drive unit includes: A drive connector is disposed on the valve body; A rotating component is rotatably mounted on the drive connector; A pressure-driving device, disposed on the rotating member and connected to the stopcock, is used to drive the stopcock to approach and abut against the valve body in a direction perpendicular to the rotation plane of the rotating member; and At least two rotary drive devices are disposed on the drive connector and connected to the rotary member, wherein one rotary drive device is used to drive the rotary member to rotate in a first direction and the other rotary drive device is used to drive the rotary member to rotate in a second direction, wherein the first direction is opposite to the second direction; The control unit is communicatively connected to the pressure drive device and the rotation drive device, respectively.

3. A control method for a pneumatic full-bore plug valve, characterized in that, The method, applied to the pneumatic full-bore plug valve as described in any one of claims 1 to 2, comprises: The system acquires real-time environmental information in response to an adjustment trigger signal; wherein the real-time environmental information includes the real-time opening degree of the valve, the real-time upstream flow rate and the real-time downstream flow rate of the medium channel, and the adjustment trigger signal is used to instruct the drive unit to adjust the real-time opening degree to the target opening degree; Predicted environmental information is obtained based on the real-time environmental information and the target opening; wherein, the predicted environmental information includes the predicted upstream flow and the predicted downstream flow of the medium channel; Adjustment control information is obtained based on the real-time opening degree and the target opening degree; wherein, the adjustment control information is used to control the drive unit to drive the valve to rotate to the target opening degree; State analysis information is obtained based on the predicted environmental information and the regulation and control information; wherein, the state analysis information reflects the state of the pneumatic full-bore plug valve.

4. The pneumatic full-bore plug valve control method as described in claim 3, characterized in that, The process of obtaining predicted environmental information based on the real-time environmental information and the target opening includes: The real-time opening, the target opening, the real-time upstream flow, and the real-time downstream flow are input into the flow prediction model to obtain the predicted upstream flow and the predicted downstream flow output by the flow prediction model. The predicted upstream flow and the predicted downstream flow are confirmed as the predicted environmental information.

5. The pneumatic full-bore plug valve control method as described in claim 3, characterized in that, The process of obtaining adjustment and control information based on the real-time opening degree and the target opening degree includes: The value obtained by subtracting the real-time opening from the target opening is confirmed as the opening difference. Determine whether the absolute value of the opening difference is less than or equal to the minimum single drive angle; If the opening difference is less than or equal to the minimum single drive angle, the adjustment control information is obtained based on the dual drive method; if the opening difference is greater than the minimum single drive angle, the adjustment control information is obtained to instruct the drive unit to drive the valve to rotate to the target opening.

6. The pneumatic full-bore plug valve control method as described in claim 5, characterized in that, The regulation and control information obtained based on the dual-drive method includes: Step a: Control the pressure driving device to drive the valve to move a preset contact distance along the unlocking direction; wherein, the unlocking direction is a direction perpendicular to the rotation surface of the valve and opposite to the direction of gravity; Step b: Control the two rotary drive devices to increase torque synchronously, and monitor the first torque and the second torque in real time; wherein, the two rotary drive devices drive the valve to rotate in opposite directions, the first torque is the torque generated by the rotary drive device corresponding to the opening difference, and the second torque is the torque generated by the other rotary drive device; Step c: Obtain opening control information based on the first torque and the second torque; wherein, the opening control information is used to control the two rotary drive devices and the pressing drive device; Steps a, b, and c are confirmed as the adjustment and control information.

7. The pneumatic full-bore plug valve control method as described in claim 6, characterized in that, The process of obtaining opening control information based on the first torque and the second torque includes: When the first torque and the second torque are equal to the friction value, the rotary drive device controlling the second torque maintains the torque, and controls the rotary drive device corresponding to the first torque to gradually increase the torque according to a preset torque increase rate, and monitors the rotation angle of the cylinder in real time; wherein, the friction value reflects the torque value required to drive the cylinder to rotate; When the rotation angle is equal to half the absolute value of the opening difference, the rotation drive device corresponding to the first torque is controlled to gradually reduce the torque according to the preset torque increase rate. When the first torque is equal to the friction value again, the two rotary drive devices are controlled to reduce the torque synchronously. After the torque of the two rotary drive devices is reduced to 0, the pressing drive device is controlled to drive the plug to move the preset contact distance along the locking direction. The torque angle correspondence is obtained based on the real-time monitored torque difference and the rotation angle. The locking direction is opposite to the unlocking direction, the torque difference is the difference between the first torque and the second torque, and the torque angle correspondence includes the torque difference and the rotation angle corresponding to each time node on a time axis.

8. The pneumatic full-bore plug valve control method as described in claim 7, characterized in that, The state analysis information obtained based on the predicted environmental information and the regulation and control information includes: First analysis information is obtained based on the predicted environmental information; wherein, the first analysis information reflects the sealing performance of the plug; The second analysis information is obtained based on the torque angle correspondence; wherein, the second analysis information reflects the wear performance of the plug; If both the first analysis information and the second analysis information reflect good performance, then the state analysis information reflecting that the pneumatic full-bore plug valve is in good condition is obtained; if the first analysis information and / or the second analysis information do not reflect good performance, then the state analysis information reflecting that the pneumatic full-bore plug valve is in abnormal condition is obtained.

9. The pneumatic full-bore plug valve control method as described in claim 8, characterized in that, The first analysis information obtained based on the predicted environmental information includes: After the adjustment and control information is executed, the value obtained by subtracting the predicted downstream flow from the predicted upstream flow is confirmed as the prediction difference. The range obtained by floating the prediction difference up and down by a preset range ratio is confirmed as the flow judgment range. Step d: Obtain the adjusted upstream flow rate and adjusted downstream flow rate of the medium channel, and confirm the value obtained by subtracting the adjusted downstream flow rate from the adjusted upstream flow rate as the adjusted difference value; Step e: If the adjusted difference is greater than the maximum value within the flow rate judgment range, the value obtained by adding the preset contact distance to the step contact distance is confirmed as the new preset contact distance, and a contact sealing command is obtained to control the pressure driving device to drive the valve to move the step contact distance along the locking direction. After the contact sealing command is executed, steps d and e are repeated. If the adjusted difference is within the flow rate judgment range, the value obtained by subtracting 1 from the number of times step e is executed is confirmed as the number of contact adjustments, and the value obtained by dividing the number of contact adjustments by the maximum number of adjustments is confirmed as the sealing response value. The maximum number of adjustments is the value obtained by dividing the maximum adjustable distance by the step contact distance, and the maximum adjustable distance reflects the maximum moving distance that the pressure driving device can drive the valve to move. If the sealing response value is less than or equal to the preset sealing ratio, the first analysis information reflecting good sealing performance of the plug is obtained; if the sealing response value is greater than the preset sealing ratio, the first analysis information reflecting abnormal sealing performance of the plug is obtained.

10. The pneumatic full-bore plug valve control method as described in claim 8, characterized in that, The second analysis information obtained based on the torque angle correspondence includes: Based on the torque-angle correspondence, at least two rotational rates corresponding to the torque difference are obtained; The wear analysis value is determined by subtracting the corresponding ideal speed from each rotational speed and then dividing the result by the corresponding ideal speed; wherein the torque difference between the rotational speed and the corresponding ideal speed is the same. If the wear analysis value is within the preset wear range, then the second analysis information reflecting good wear performance of the valve is obtained; if the wear analysis value is not within the preset wear range, then the second analysis information reflecting abnormal wear performance of the valve is obtained.

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