Check valve fault early warning method and device

Abstract

The invention discloses a check valve fault early warning method and device. The method comprises the steps that process adjustment information related to a fluid medium flowing through a check valve is obtained; on the basis of the process adjustment information, obtaining the physical property change of the fluid medium; based on the physical property change of the fluid medium, evaluating the lateral force borne by the valve clack of the check valve; and the lateral force of the valve clack is tracked continuously, and early-stage abrasion early warning of the check valve is conducted according to the lateral force of the valve clack. According to the method, the influence of process adjustment on the physical characteristics of a fluid medium is deeply analyzed, and the effect of the influence on the lateral force of the valve clack is further quantified, so that early-stage wear signs which cannot be effectively recognized by a traditional method can be captured, automatic and intelligent prediction and early warning of early-stage wear of the check valve are realized, and the early-stage wear of the check valve can be accurately and rapidly predicted. And sufficient intervention time is provided for maintenance personnel, so that potential equipment damage and production interruption are avoided, and the reliability of equipment operation and the production safety are remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of check valve fault identification, in particular to a check valve fault early warning method and device. BACKGROUND

[0002] In the industrial production environment, check valves play a crucial role in fluid conveying pipe networks, and their main function is to prevent medium backflow and ensure the stable operation of the production process in one direction. In order to grasp the running state of the pipe network in real time, high-precision pressure sensors are usually deployed upstream of the check valve to collect the original pressure data in the pipeline and transmit them to the central control system for real-time monitoring of process parameters and basic anomaly detection. However, in the context of pursuing production efficiency and product quality optimization, the production process department may fine-tune the formula of the fluid medium, such as adding a small amount of surfactant or adjusting the medium temperature curve, which may cause subtle but continuous changes in the physical properties of the medium, such as viscosity, density, and even surface tension. These changes are usually within the normal fluctuation range of the process parameters and do not reach the threshold value to trigger the conventional process alarm, so these potential changes often do not arouse the attention of the operators and are not identified as anomalies by the existing monitoring system based on fixed thresholds.

[0003] Due to these subtle changes in the physical properties of the fluid medium, when the fluid passes through the inside of the check valve, the original flow field distribution will produce a slight deviation, causing the valve disc of the check valve to additionally bear a weak but continuous lateral force during the opening and closing process. Although the lateral force is not strong, its continuous existence has a long-term, subtle influence on the movement trajectory and stress state of the valve disc. This weak lateral force, in the cycle of each opening and closing of the valve disc, will cause the contact stress distribution between the valve disc and the pin shaft connected to it to be no longer uniform. This long-term, concentrated stress action will cause a small amount of uneven wear at the connection between the pin shaft and the valve disc. The characteristics of this wear are slow occurrence and very small wear amount in the early stage, usually in the micron level.

[0004] The accumulation process of this uneven wear is extremely slow, so that in the early stage, it has almost no perceptible direct impact on the opening and closing performance of the check valve. More importantly, the mechanical property changes caused by this small amount of wear are reflected in the signal characteristics of the upstream pressure sensor data, which are almost indistinguishable from the normal fluctuation signal characteristics of the fluid in the pipeline. Traditional monitoring methods, which mainly rely on pre-set fixed thresholds or simple statistical analysis, cannot effectively identify this extremely weak and nonlinear precursor signal of failure from these background noises. Therefore, this potential, slowly developing wear problem is difficult to be discovered under the existing monitoring system.

[0005] In this context, when transient pressure fluctuations occur occasionally in the pipeline system, the check valve will respond quickly to perform its closing function. However, due to the long-term uneven wear of the pin shaft, the valve disc may deviate slightly in its movement trajectory during the rapid reset closing process, which may cause the valve disc to not fully and quickly and stably cut into the valve seat, resulting in a transient slight leakage in a very short time, or the valve disc may have one or more "secondary rebounds" after closing. This transient abnormal phenomenon lasts for a very short time, and the pressure signal anomaly caused by it is significantly attenuated and smoothed by the fluid damping effect of the pipeline system itself before being transmitted to the upstream pressure sensor. At the same time, the response speed and data sampling frequency of the existing pressure sensor may also have limitations, and it is difficult to accurately capture and analyze such extremely short and weak pressure fluctuations. Therefore, this failure phenomenon is difficult to be captured and used as an effective failure warning signal in the existing monitoring system. SUMMARY

[0006] In order to solve the problem that the early wear of the check valve in the prior art is difficult to be effectively identified and warned, the application provides a check valve failure warning method and device.

[0007] The application is implemented by the following technical solutions:

[0008] A check valve failure warning method, comprising:

[0009] Obtaining process adjustment information related to the fluid medium flowing through the check valve;

[0010] Based on the process adjustment information, obtaining the change in physical properties of the fluid medium;

[0011] Based on the change in physical properties of the fluid medium, evaluating the lateral force borne by the valve disc of the check valve;

[0012] Continuously tracking the lateral force of the valve disc and warning the early wear of the check valve according to the lateral force of the valve disc.

[0013] In some embodiments, the continuously tracking the lateral force of the valve disc and warning the early wear of the check valve according to the lateral force of the valve disc comprises:

[0014] Converting the continuously tracked lateral force of the valve disc into a local equivalent contact stress at the connection between the valve disc and the pin shaft;

[0015] Identifying the stress cycle in the local equivalent contact stress and extracting the stress amplitude of the stress cycle;

[0016] According to the fatigue characteristics of the material at the connection between the valve disc and the pin shaft and the stress amplitude, calculating the number of failure cycles caused by each stress cycle;

[0017] accumulating the number of failure cycles to obtain accumulated damage;

[0018] According to the accumulated damage value reaching a preset critical value, early wear and tear warning is given.

[0019] In some embodiments, the early wear and tear warning given according to the accumulated damage value reaching a preset critical value comprises:

[0020] According to the operation criticality of the check valve in the production process, the impact of potential failure on production, and the current production plan, the risk level of the check valve is calculated;

[0021] According to the risk level and the accumulated damage value, differentiated warning information containing maintenance priority suggestion and predicted critical failure time is generated;

[0022] The differentiated warning information is sent.

[0023] In some embodiments, the risk level of the check valve is calculated according to the operation criticality of the check valve in the production process, the impact of potential failure on production, and the current production plan, comprising:

[0024] Production mode switching information is obtained;

[0025] Upstream / downstream equipment operation state is obtained;

[0026] According to the production mode switching information and the upstream / downstream equipment operation state, a running criticality rule library is queried to obtain the corresponding criticality weight; wherein the running criticality rule library contains the criticality weight of the check valve under different production modes and different equipment state combinations;

[0027] According to the criticality weight, the impact of potential failure on production, and the current production plan, the risk level of the check valve is calculated.

[0028] In some embodiments, the differentiated warning information containing maintenance priority suggestion and predicted critical failure time is generated according to the risk level and the accumulated damage value, comprising:

[0029] The type of the warning information receiver is identified;

[0030] According to the identified type of the receiver, a corresponding warning information template is selected from a preset warning information template library; wherein the warning information template defines the content, format and detail level for the corresponding receiver;

[0031] filling the accumulated damage value, the risk level, and the maintenance priority suggestion and the predicted critical failure time generated according to the risk level and the accumulated damage value into the selected early warning information template to generate customized differentiated early warning information;

[0032] sending the customized differentiated early warning information.

[0033] In some embodiments, the generating of the customized differentiated early warning information comprises:

[0034] parsing the structure of the selected early warning information template to identify preset content areas and dynamic data placeholders of the early warning information template;

[0035] evaluating the current production scene and specific needs of the recipient for the early warning information according to the accumulated damage value and the risk level;

[0036] selecting a supplementary information module matching the specific needs from a preset supplementary information module library according to the evaluation result; wherein the supplementary information module contains additional text descriptions, charts or operation instructions for specific scene or recipient needs;

[0037] filling the accumulated damage value, the risk level, the maintenance priority suggestion, the predicted critical failure time, and the content of the supplementary information module into the corresponding areas of the early warning information template to generate the customized differentiated early warning information.

[0038] In some embodiments, the evaluating of the current production scene and specific needs of the recipient for the early warning information according to the accumulated damage value and the risk level comprises:

[0039] obtaining real-time SCADA data; the real-time SCADA data includes fluid pressure, temperature, flow rate, and on-off state of the check valve;

[0040] obtaining historical production batch records; the historical production batch records include fluid medium formula, process parameter adjustment records, and corresponding production results;

[0041] obtaining equipment maintenance logs; the equipment maintenance logs include repair, replacement records, and fault descriptions of the check valve;

[0042] obtaining operator feedback experience; the operator feedback experience includes operator descriptions of the check valve abnormalities and processing suggestions;

[0043] aligning the real-time SCADA data, the historical production batch records, the equipment maintenance logs, and the operator experience feedback by time stamp and performing data format standardization processing;

[0044] According to the cumulative damage value and risk level, in combination with the real-time SCADA data after standardization processing, the running condition of the current production scene is identified;

[0045] According to the historical production batch records and equipment maintenance logs after standardization processing, the historical running mode and potential failure correlation of the check valve are analyzed;

[0046] According to the operator experience feedback after standardization processing, the experiential demand for specific running conditions or failure modes is extracted;

[0047] Comprehensive analysis of the running condition, historical running mode, potential failure correlation and experiential demand, the urgency of the current production scene and the detailed demand of the receiver for the early warning information are determined.

[0048] In some embodiments, the comprehensive analysis of the running condition, historical running mode, potential failure correlation and experiential demand, the urgency of the current production scene and the detailed demand of the receiver for the early warning information are determined, including:

[0049] The confidence level of the real-time SCADA data, historical production batch records, equipment maintenance logs and operator experience feedback is set; the confidence level reflects the reliability of the information source in providing accurate information under different running conditions;

[0050] Detect whether there is information conflict between the real-time SCADA data, historical production batch records, equipment maintenance logs and operator experience feedback;

[0051] When the information conflict is detected, according to the confidence level of the conflict information source, the information source with high confidence level is preferred;

[0052] If the confidence levels of the conflict information sources are the same, according to the preset conflict resolution strategy, the conflict information is judged;

[0053] According to the judged information, the urgency of the current production scene and the detailed demand of the receiver for the early warning information are determined.

[0054] In some embodiments, the generation of customized differentiated early warning information further includes:

[0055] Obtain the historical operation records and training records of the receiver;

[0056] According to the historical operation records and training records, the understanding proficiency of the receiver for specific professional terms and operation processes is identified;

[0057] If the emergency degree of the current production scene is relatively high and the understanding proficiency of the receiving party for specific professional terms and operation processes is relatively low, the professional terms in the early warning information are replaced by popular descriptions, the operation processes are decomposed into step-by-step guides, and an animation demonstration or a diagrammatic illustration of the related operation is provided.

[0058] In another aspect, the application provides a check valve failure early warning device, comprising:

[0059] An information acquisition unit is configured to acquire process adjustment information related to fluid media flowing through the check valve.

[0060] A characteristic analysis unit is configured to obtain a physical characteristic change of the fluid media based on the process adjustment information.

[0061] A side force evaluation unit is configured to evaluate a side force borne by the valve disc of the check valve based on the physical characteristic change of the fluid media.

[0062] In addition, an analysis early warning unit is configured to continuously track the side force of the valve disc and perform early wear warning of the check valve according to the side force of the valve disc.

[0063] The application provides a check valve failure early warning method. By deeply analyzing the influence of process adjustment on the physical characteristics of fluid media and further quantifying the influence of the process adjustment on the side force of the valve disc, early wear signs that cannot be effectively identified by traditional methods can be captured, automatic and intelligent prediction and early warning of early wear of the check valve are realized, sufficient intervention time is provided for maintenance personnel, potential equipment damage and production interruption are avoided, and the reliability and safety of equipment operation are significantly improved.

[0064] Correspondingly, the check valve failure early warning device provided by the application also has the same technical effects as described above. BRIEF DESCRIPTION OF DRAWINGS

[0065] The accompanying drawings, which are included to provide a further understanding of the embodiments of the application and constitute a part of the application, do not limit the embodiments of the application. In the drawings:

[0066] Figure 1 A check valve failure early warning method flowchart is provided for the embodiments of the application.

[0067] Figure 2 A check valve failure early warning device principle block diagram is provided for the embodiments of the application.

[0068] Figure 3 A check valve failure early warning system architecture schematic diagram is provided for the embodiments of the application.

[0069] Figure 4An electronic device schematic diagram proposed by an embodiment of the present application;

[0070] Figure 5 A computer readable storage medium schematic diagram proposed by an embodiment of the present application;

[0071] Reference signs and corresponding component names:

[0072] 200 - early warning device, 201 - information acquisition unit, 202 - characteristic analysis unit, 203 - lateral force evaluation unit, 204 - analysis early warning unit, 300 - early warning system, 301 - input device, 302 - output device, 303 - processor A, 304 - memory A, 400 - electronic device, 410 - memory B, 420 - processor B, 411 - computer program A, 500 - computer readable storage medium, 511 - computer program B. DETAILED DESCRIPTION

[0073] In order to make the purpose, technical solutions and advantages of the present application clearer, further detailed description of the present application is made below in combination with embodiments and drawings, the schematic embodiments of the present application and the description thereof are only used to explain the present application, and do not limit the present application.

[0074] In view of the problem that early wear of the check valve in the prior art is difficult to be effectively identified and warned, especially when the physical characteristics of the fluid medium change slightly, the traditional monitoring method cannot capture the slight uneven wear at the connection between the valve disc and the pin shaft, thus causing instantaneous slight leakage or "secondary rebound" phenomenon, thereby causing fault warning lag, affecting production safety and efficiency. An early warning method for check valve is proposed in an embodiment of the present application, which obtains the physical characteristic change of the fluid medium from the process adjustment information, and then evaluates the lateral force of the valve disc, and accumulates the lateral force for early wear warning, thereby solving the problem that the prior art cannot effectively identify the early wear of the check valve caused by slight change of the fluid medium, and realizing early fault warning of the check valve.

[0075] As shown in Figure 1 The early warning method proposed by the embodiment of the present application includes the following steps:

[0076] Step 1, obtaining process adjustment information related to the fluid medium flowing through the check valve;

[0077] Step 2, obtaining the physical characteristic change of the fluid medium based on the process adjustment information;

[0078] Step 3, evaluating the lateral force borne by the valve disc of the check valve based on the physical characteristic change of the fluid medium;

[0079] Step 4, continuously tracking the lateral force of the valve disc and performing early wear warning of the check valve according to the lateral force of the valve disc.

[0080] The reverse valve failure early warning method provided by the embodiments of the present application can capture subtle changes that cannot be captured by a traditional monitoring system by obtaining process adjustment information related to the fluid medium. Based on the process adjustment information, the physical property changes of the fluid medium, such as changes in viscosity, density or surface tension, can be obtained. These changes in physical properties, even within the normal process parameter fluctuation range, will cause a slight flow field deviation when the fluid flows through the check valve, so that the valve disc bears a weak but persistent lateral force. Based on this, the embodiments of the present application evaluate the lateral force change borne by the valve disc according to the changes in the physical properties of the fluid, and can timely and reliably realize early warning of the wear of the check valve based on the lateral force, avoiding failures such as instantaneous leakage or “second rebound” caused by accumulated wear, and significantly improving the reliability and production safety of the equipment operation.

[0081] In the embodiments of the present application, the fluid medium refers to various liquids, gases or slurries transported through a pipeline system in an industrial production process, and the physical properties such as viscosity, density and surface tension of the fluid medium will directly affect the interaction between the fluid and the valve disc of the check valve. The process adjustment information covers any modification or optimization of the fluid medium formula, temperature, pressure and other parameters in the production process, and these adjustments are the root cause of the changes in the physical properties of the fluid. The valve disc of the check valve is the core component of the check valve, responsible for closing the passage when the fluid flows backward, and its movement state and force condition are directly related to the normal operation and service life of the check valve.

[0082] Further, in step 1 of the embodiments of the present application, the acquisition method of the process adjustment information includes:

[0083] Automatically reading process parameter adjustment records from a production control system (such as a DCS or SCADA system). These records usually include the time of adjustment, the type of adjusted parameter (such as temperature set value, component ratio, etc.), the adjustment range and the confirmation information of the operator.

[0084] Manually inputting detailed information of process adjustment by process engineers or operators. This method is suitable for some non-automated or temporary process adjustment scenarios.

[0085] Obtaining information such as medium formula changes and additive usage by combining production planning systems and material management systems. For example, when the production plan requires switching product batches or using new chemical additives, the system will automatically record these changes.

[0086] Further, step 2 of the embodiments of the present application converts abstract process adjustments into specific fluid physical property parameters, and the specific implementation method includes:

[0087] Establish a physical model or empirical formula: For example, by consulting a fluid mechanics manual or conducting laboratory tests, a functional relationship between medium temperature and viscosity, density is established. When the process adjustment information shows that the medium temperature rises, the changes in physical properties such as viscosity and density can be obtained according to the functional relationship.

[0088] Use machine learning model: By collecting a large amount of historical process adjustment data and corresponding fluid physical property measurement data, a machine learning model (such as neural network or support vector machine) is trained to predict the changes in fluid physical properties according to new process adjustment information.

[0089] Retrieve the pre-set medium property database: This database stores the physical property parameters of various fluid media under different process conditions. When the process adjustment information is obtained, the system can automatically retrieve the corresponding fluid physical properties from the database according to the adjusted process parameters.

[0090] Further, in step 3 of the embodiments of the present application, the lateral force change evaluation method includes:

[0091] Adopt computational fluid dynamics (CFD) simulation evaluation: The changes in physical properties of fluid medium are input into the CFD model to simulate the flow field distribution when the fluid flows through the check valve, and then calculate the lateral force on the valve disc under the action of the fluid.

[0092] Establish a simplified mechanical model for evaluation: Based on the geometric shape of the valve disc, fluid flow rate, density, viscosity and other parameters, a simplified mechanical model is established to calculate the lateral force on the valve disc. For example, the lateral component force generated by the asymmetric impact or vortex effect of the fluid on the valve disc can be considered.

[0093] Indirect evaluation using sensor data: Micro pressure sensors or vibration sensors are installed near the check valve. By analyzing the correlation between sensor data and changes in fluid physical properties, the trend of lateral force change on the valve disc is indirectly evaluated.

[0094] Further, in step 4 of the embodiments of the present application, the continuously tracked lateral force of the valve disc can be directly accumulated and early warning of check valve wear can be performed according to the accumulated lateral force and threshold, wherein the accumulation method can include:

[0095] Real-time monitoring and data storage: Through steps 1 to 3, the instantaneous value of the valve disc lateral force is obtained in real time, and it is stored in the database together with the time stamp;

[0096] Periodic sampling and average accumulation: In order to reduce the amount of data and computational burden, a sampling period (such as every minute or every hour) can be set. The average value of the lateral force in the sampling period is calculated, and then the average value is accumulated.

[0097] Integral accumulation: Integrate the valve disc lateral force over time to obtain a cumulative lateral force value, which reflects the total lateral force experienced by the valve disc over a period of time.

[0098] The early warning method for check valve wear can include:

[0099] Fixed threshold method: According to the design life of the check valve, material properties and historical failure data, one or more thresholds are set, and when the cumulative lateral force exceeds the threshold, a wear warning is issued.

[0100] Dynamic threshold method: Considering that the operating load of the check valve is different under different working conditions, the threshold can be dynamically adjusted according to the current production mode, fluid medium type and other factors, for example, in heavy load conditions, the threshold can be appropriately reduced to improve the sensitivity of the warning.

[0101] Threshold combined trend analysis method: The trend of the cumulative lateral force can be analyzed. For example, if the cumulative lateral force shows a rapid growth trend in a short period of time, even if the threshold has not been reached, an early warning can be issued.

[0102] In practical applications, the wear of key parts such as the connection between the valve disc and the pin shaft is often caused by fatigue damage due to long-term alternating loads, and simply accumulating the lateral force cannot accurately reflect the fatigue accumulation process of the material, which may result in insufficient accuracy and timeliness of the warning. In view of this, step 4 of the embodiments of the present application further converts the valve disc lateral force varying with time into local equivalent contact stress and performs fatigue damage accumulation to achieve more accurate early wear warning, and the specific implementation process is as follows:

[0103] The valve disc lateral force is converted into local equivalent contact stress at the connection between the valve disc and the pin shaft; specifically, the macroscopic lateral force acting on the valve disc is mapped and calculated to obtain the microscopic stress state inside the connection between the valve disc and the pin shaft by using mechanical models or finite element analysis methods. The local equivalent contact stress can be understood as the comprehensive stress at the connection due to the lateral force, which can more accurately reflect the stress condition of the material at the microscopic level and provide a data basis for subsequent fatigue damage assessment;

[0104] Identify the stress cycles in the local equivalent contact stress and extract the stress amplitude of the stress cycles; specifically, by processing the local equivalent contact stress data varying with time, such as using standard algorithms such as the rainflow counting method, independent stress cycle events are identified from the data, each stress cycle usually contains a stress amplitude, which is a key parameter for measuring wear loss, thereby converting irregular stress history into a series of discrete stress cycle events that can be used for fatigue calculation;

[0105] According to the fatigue characteristics and stress amplitude of the material at the connection between the valve disc and the pin shaft, the failure cycle number caused by each stress cycle is calculated; specifically, the fatigue data of the material such as the S-N curve (stress-life curve) or the E-N curve (strain-life curve) are combined with the Miner linear cumulative damage theory or other nonlinear cumulative damage theories to quantify the fatigue damage caused by each identified stress cycle, and the failure cycle number caused by each stress cycle can be understood as the reciprocal of the theoretically acceptable cycle number (i.e. the theoretical failure cycle number) of the material under the current stress amplitude, thereby numerically representing the damage of a single stress cycle to the material life;

[0106] The cumulative failure cycle number is obtained to obtain the cumulative damage; specifically, the cumulative damage value is obtained by summing up all the calculated failure cycle numbers caused by each stress cycle, which reflects the fatigue damage degree of the material at the connection between the valve disc and the pin shaft during the entire operation cycle, and is used to evaluate the remaining life of the component;

[0107] In addition, an early wear warning is issued according to whether the cumulative damage value reaches a preset critical value; specifically, when the cumulative damage value reaches the preset critical value, it is judged that the connection between the valve disc and the pin shaft has reached or is close to its fatigue life limit, thereby triggering an early wear warning; the preset critical value is usually set based on the fatigue limit of the material, the safety factor and the actual operation experience. The early wear warning occurs before the actual failure occurs, providing sufficient warning time for preventive maintenance.

[0108] Compared with the scheme based only on the cumulative lateral force, the embodiment of the application can more accurately reflect the actual fatigue load borne by the material at the connection between the valve disc and the pin shaft by converting the macroscopic lateral force of the valve disc into microcosmic local equivalent contact stress and further identifying stress cycles and extracting stress amplitudes, thereby significantly improving the accuracy and timeliness of failure prediction. This enables maintenance personnel to obtain more sufficient warning time before fatigue failure occurs, thereby effectively avoiding sudden failures, reducing the risk of unplanned downtime, optimizing maintenance resource allocation, prolonging the service life of equipment, and ensuring the continuity and safety of the production process.

[0109] In practical applications, only issuing a single early warning message may not fully reflect the actual risk level of potential failure and its potential impact on production operation, and it also fails to provide customized information according to the specific needs of the recipient, which may lead to untimely maintenance response or unreasonable allocation of resources. In view of this, the embodiments of the present application further calculate the risk level of the check valve by comprehensively considering the operation criticality of the check valve in the production process, the impact of potential failure on production, and the current production plan, and generate and send differentiated early warning information containing maintenance priority suggestions and predicted critical failure time based on the risk level and the cumulative damage value, in the step of issuing an early wear warning according to the cumulative damage reaching a preset threshold. The specific implementation process includes:

[0110] According to the operation criticality of the check valve in the production process, the impact of potential failure on production, and the current production plan, the risk level of the check valve is calculated. The operation criticality refers to the importance of the check valve in the entire production line, for example, whether its failure will cause the entire production line to stop production. The impact of potential failure on production refers to the economic loss, safety risk or environmental impact that may be caused by the failure of the check valve. The current production plan takes into account factors such as production load and production priority. By comprehensively considering these factors, a comprehensive level reflecting the current risk of check valve failure can be obtained.

[0111] According to the risk level and the cumulative damage value, differentiated early warning information containing maintenance priority suggestions and predicted critical failure time is generated. According to the calculated risk level and cumulative damage value, early warning information with different content, format and detail level is generated. This information not only contains traditional failure warning, but also further provides specific maintenance priority suggestions to guide maintenance personnel when and how to intervene, and estimates the time for the check valve to reach the critical failure state, providing data basis for maintenance plan designation. For example, for high-risk level failure, the early warning information emphasizes its urgency and serious impact on production, and gives the suggestion of immediate maintenance. For lower-risk failure, a longer predicted failure time may be provided to allow maintenance personnel to plan maintenance without affecting production.

[0112] In addition, the differentiated early warning information is sent. The differentiated early warning information can be sent to the corresponding recipient through various ways (such as SMS, email, SCADA system interface, mobile application notification, etc.), to ensure that the information can be timely and accurately conveyed to the personnel who need to know.

[0113] Compared with the scheme of issuing a warning only based on accumulated damage, the embodiments of the present application introduce the calculation of risk levels, so that the warning information can fully consider the actual importance of the check valve in production, the degree of harm of potential failure and the current production arrangement, thereby avoiding excessive response to non-critical failure or insufficient response to critical failure. And generate differentiated warning information containing maintenance priority suggestion and predicted critical failure time, so that maintenance personnel can more clearly understand the urgency of failure and the necessity of maintenance, thereby optimizing the allocation of maintenance resources, improving maintenance efficiency and reducing the risk of unplanned downtime. In addition, customized warning information helps managers and operators of different levels to make quick decisions according to their own responsibilities, thereby effectively ensuring the continuity and safety of the production process and minimizing the economic losses caused by potential failure.

[0114] In actual application process, the operation criticality of check valve will be dynamically adjusted with the switching of production mode, the change of upstream or downstream equipment running state. If these dynamic factors are not fully considered, and only the static or generalized criticality is used for risk assessment, the risk level calculation may not be accurate enough, thereby affecting the accuracy of maintenance priority suggestion and the effectiveness of warning information, and even causing resource waste or failing to avoid potential production risks in time. In view of this, the embodiments of the present application further optimize the risk level calculation process of check valve, considering the above dynamic factors, and the specific implementation process includes:

[0115] Obtain production mode switching information; the production mode switching information refers to information about the change of the current running mode of the production line, which can include but is not limited to product type switching, batch production and continuous production mode conversion, major adjustment of process parameters, device start / stop instruction or production plan update, etc., used to represent the macro production state change affecting the running environment and importance of check valve;

[0116] Obtain upstream / downstream equipment running state; the upstream / downstream equipment running state refers to the real-time running data of the equipment directly or indirectly associated with the target check valve, located upstream or downstream of the fluid path of the check valve. These data can include but are not limited to running / stop state, failure alarm, maintenance state, load condition or abnormal fluctuation of key parameters (such as pressure, flow, temperature, etc.) of the equipment, used to represent the stability and potential risk of the local process environment of the check valve;

[0117] According to the production mode switching information and the upstream / downstream equipment running state, a running criticality rule library is queried to obtain a corresponding criticality weight; the running criticality rule library contains criticality weights of the check valve under different production modes and different equipment state combinations; the running criticality rule library is a pre-established knowledge base or database, in which criticality weights of the check valve under different production modes and different equipment state combinations are stored, for example, when the check valve is in a high-pressure conveying mode and the upstream pump fails, the criticality weight of the check valve is relatively high, and when the check valve is in a low-pressure cleaning mode and all related equipment is normal, the weight is relatively low. The construction of the rule library can be based on historical operation data, expert experience, risk assessment matrix or simulation model, and provides a quantitative basis for dynamically evaluating the criticality of the check valve;

[0118] In addition, according to the criticality weight, the influence degree of potential failure on production, and the current production plan, the risk level of the check valve is calculated; specifically, the criticality weight, the negative influence degree (such as downtime, economic loss, safety risk, etc.) that the potential failure may cause to the overall production process, and the current production plan (such as whether it is in a critical production stage, whether there is a standby production line, etc.) are comprehensively considered, and these factors can be calculated through a preset algorithm model (such as weighted average, fuzzy logic reasoning or decision tree model, etc.), so as to obtain a comprehensive risk level value.

[0119] Compared with the scheme of relying only on static criticality evaluation, the embodiments of the present application can more sensitively respond to changes in the production environment by introducing production mode switching information and upstream / downstream equipment running states, and using a pre-set running criticality rule library to query the criticality weight of the check valve that matches the current working condition and calculate the risk level based on the criticality weight, so as to ensure that the risk assessment result is highly consistent with the actual running condition. This not only significantly improves the accuracy and reliability of fault prediction, but also makes the maintenance priority suggestion more targeted, which helps production managers and maintenance engineers make more intelligent decisions in complex and variable production environments, thereby effectively reducing the risk of unplanned downtime, optimizing maintenance resource allocation, and ultimately improving overall production efficiency and safety.

[0120] In practical applications, if the early warning information does not fully consider the specific needs and concerns of different recipients, it may lead to low efficiency of information transmission, and even delay the failure response due to information overload or insufficient information. For example, operators may need concise and clear operation instructions, while maintenance engineers need detailed diagnostic data and maintenance recommendations, and production managers are more concerned about the impact on production plans and costs. If the above problems are not solved, the early warning information cannot effectively guide the decision-making and action of different levels. In view of this, the embodiments of the present application further optimize the generation process of differentiated early warning information, which identifies the type of early warning information recipient and uses a preset template for customization to ensure accurate transmission and efficient use of early warning information. The generation process of differentiated early warning information specifically includes:

[0121] Identify the type of early warning information recipient; for example, the types of recipients include operators, maintenance engineers and production managers; among them, operators are usually responsible for daily monitoring and preliminary response of equipment; maintenance engineers are responsible for detailed diagnosis, maintenance plan development and execution of equipment; production managers are concerned about the overall operation of the production line, resource allocation and production plan adjustment; identifying these different types of recipients facilitates the provision of a basis for subsequent information customization;

[0122] According to the type of the recipient, select the corresponding early warning information template from the preset early warning information template library; the early warning information template defines the content, format and detail level for the recipient; the early warning information template library can pre-store multiple targets designed for different recipients, for example, the template for operators may focus on concise instructions for emergency shutdown or switching operations, the template for maintenance engineers may include detailed fault codes, sensor data trend charts and recommended inspection steps, and the template for production managers may include analysis of the impact of the fault on the production plan, estimated downtime and alternative solution suggestions;

[0123] Fill the cumulative damage value, risk level, and maintenance priority recommendation and estimated critical failure time generated according to the risk level and cumulative damage value into the selected early warning information template to generate customized differentiated early warning information; in this step, dynamic data such as cumulative damage value, risk level, maintenance priority recommendation and estimated critical failure time are accurately inserted into the corresponding placeholders of the preset template, thereby forming a complete content and standardized format customized early warning information;

[0124] And send the customized differentiated early warning information to the recipient; the sending method can include but is not limited to email, SMS, mobile application push notification or message interface integrated into the SCADA / MES system.

[0125] The embodiments of the present application introduce the identification mechanism of the type of the receiver of the early warning information and the preset early warning information template library, realize providing customized early warning information according to the specific needs of different receivers, which not only improves the pertinence and readability of the early warning information, enables the operator to quickly understand and perform the preliminary response, enables the maintenance engineer to efficiently perform fault diagnosis and maintenance planning, enables the production manager to accurately assess the production impact and make decisions, thereby significantly improving the efficiency and accuracy of fault response; in addition, it also avoids information overload, reduces the time of the receiver to process irrelevant information, optimizes the information transmission process, and finally helps to reduce the production interruption risk and maintenance cost caused by the failure of the check valve, and ensures the continuity and safety of the production process.

[0126] In actual application, only relying on the filling of the preset template and the core data, the dynamic changes of the current production scene and the specific needs of different receivers for the early warning information in the specific scene may not be fully met, thereby causing the early warning information to lack sufficient context, detailed operation instructions or targeted supplementary instructions, affecting the effectiveness of the early warning and the decision efficiency of the receiver. In view of this, the embodiments of the present application further optimize the filling process of the early warning information template, generate more targeted and applicable differentiated early warning information by dynamically evaluating the needs and introducing the supplementary information module, and the specific implementation process is as follows:

[0127] The structure of the selected early warning information template is analyzed, and the preset content area and dynamic data placeholder of the early warning information template are identified; specifically, the early warning information template is defined in XML, JSON or other structured format, and these formats are processed by the parser, so that it is clear which part is static descriptive text and which part is variable that needs to be replaced according to real-time data, thereby providing accurate positioning and interface for subsequent dynamic data filling and integration of the supplementary information module;

[0128] According to the cumulative damage value and the risk level, the specific needs of the current production scene and the receiver for the early warning information are evaluated; specifically, according to the current cumulative damage value and the risk level, in combination with the real-time status of the production environment and the role and responsibility of the receiver, it is judged which additional information the early warning information needs to contain to more effectively support the decision, for example, when the risk level is high, more detailed fault diagnosis information may be needed; when the receiver is an operator, more intuitive operation instructions may be needed;

[0129] According to the evaluation result, a supplementary information module matching the specific requirement is selected from a preset supplementary information module library, the supplementary information module contains additional text description, chart or operation instruction for specific scene or receiver requirement; in actual application, the supplementary information module library can pre-store various types of supplementary content, for example, detailed diagnostic process for specific failure mode, valve structure schematic diagram, safety operation procedure, historical failure case analysis, maintenance tool list or emergency shutdown steps, etc.; according to the above evaluation result, one or more supplementary information modules most suitable for the current requirement and the role of the receiver are selected from the library, these modules can be pure text, embedded chart, animation link or interactive operation guide;

[0130] And the cumulative damage value, risk level, maintenance priority suggestion, predicted critical failure time and the content of the supplementary information module are filled into the corresponding area of the early warning information template to generate customized differentiated early warning information; after filling the core cumulative damage value, risk level, maintenance priority suggestion and predicted critical failure time into the response placeholder of the early warning information template, the content of the selected supplementary information module will also be integrated into the preset content area or dynamic insertion area of the template, in this way, the finally generated early warning information not only contains core data, but also contains auxiliary information customized for the current scene and receiver requirement, thereby forming highly customized differentiated early warning information.

[0131] Compared with the scheme of selecting a template according to the type of receiver and filling core data, the embodiment of the application introduces an evaluation mechanism for the current production scene and the specific requirement of the receiver, and dynamically integrates a supplementary information module, so that the generated early warning information is more contextually relevant, more comprehensive and more operationally instructive, which not only ensures that the receiver obtains the most relevant and detailed information at the critical moment, avoids misjudgment or delay due to insufficient information, but also effectively reduces the complexity of failure handling and improves the accuracy and efficiency of maintenance decision-making, thereby further ensuring the stable operation of the production process and the reliability of the equipment assets.

[0132] Further, according to the cumulative damage value and the risk level, the specific requirement of the early warning information for the current production scene and the receiver is evaluated, and the specific implementation process is as follows:

[0133] Real-time SCADA data is obtained, the real-time SCADA data includes fluid pressure, temperature, flow and on-off state of the check valve; these data are key parameters related to the operation of the check valve, among which the fluid pressure, temperature and flow directly reflect the working condition load borne by the check valve, and the on-off state of the check valve indicates the current working mode, the above data are the basis for evaluating the current scene operation condition;

[0134] Obtain historical production batch records, including fluid medium formulation, process parameter adjustment records, and corresponding production results; these records are used to reflect the long-term behavior patterns and potential wear mechanisms of the check valve under different production conditions;

[0135] Obtain equipment maintenance logs, including repair, replacement records, and fault descriptions of the check valve; the equipment maintenance logs are used to analyze the inherent weaknesses, maintenance cycles, and fault evolution trends of the check valve;

[0136] Obtain operator experience feedback, including operator descriptions of check valve abnormalities and handling suggestions; used to supplement field experience and intuitive judgments that cannot be covered by quantitative data;

[0137] Timestamp alignment and data format standardization processing of real-time SCADA data, historical production batch records, equipment maintenance logs, and operator experience feedback; to ensure the comparability and analyzability of data from different sources, timestamp alignment ensures that all data points can be accurately associated with a specific time point, and data format standardization processing allows these heterogeneous data to be processed by a unified data analysis model;

[0138] According to the cumulative damage value and risk level, combined with the standardized real-time SCADA data, identify the operating conditions of the current production scene; for example, whether it is in a stable operation, high load impact, or abnormal fluctuation state;

[0139] According to the standardized historical production batch records and equipment maintenance logs, analyze the historical operation patterns and potential fault correlations of the check valve; for example, whether a specific process adjustment has ever caused a fault, or whether there is a periodic wear;

[0140] According to the standardized operator experience feedback, extract experiential needs for specific operating conditions or fault patterns; for example, under what conditions does the operator want to obtain what type of warning information;

[0141] And, based on the operating conditions, historical operation patterns, potential fault correlations, and experiential needs, determine the urgency of the current production scene and the detailedness of the warning information required by the recipient.

[0142] Compared with the limitations of the traditional early warning scheme in information evaluation, i.e. not fully considering the influence of multi-source heterogeneous data on the demand for early warning information, the embodiments of the present application can more accurately identify the current production scene running condition, historical running mode, potential fault association and experiential demand of the operator by means of comprehensive acquisition, standardized processing and comprehensive analysis of real-time SCADA data, historical production batch records, equipment maintenance logs and operator experience feedback. Therefore, the emergency degree of the current production scene and the detailed degree demand of the receiver for the early warning information can be more accurately judged, thereby providing a solid data foundation and decision basis for generating highly customized and differentiated early warning information, significantly improving the practicability and effectiveness of the early warning information, avoiding the problems of information overload or insufficient information, and further improving the efficiency of fault handling and the safety of production operation.

[0143] In actual application process, multi-source information may have data conflicts or reliability differences, if not effectively processed, may lead to inaccurate judgment of the production scene, and further affect the effectiveness of the early warning information. In view of this, the embodiments of the present application optimize the steps of judging the emergency degree of the current production scene and the detailed degree demand of the receiver for the early warning information based on the above comprehensive running condition, historical running mode, potential fault association and experiential demand, and the specific implementation process is as follows:

[0144] The confidence levels of real-time SCADA data, historical production batch records, equipment maintenance logs and operator experience feedback are set, which reflect the reliability of information sources in providing accurate information under different running conditions; optionally, the confidence levels can also be dynamically adjusted according to historical data analysis, expert experience or machine learning model;

[0145] Detect whether there is information conflict between real-time SCADA data, historical production batch records, equipment maintenance logs and operator experience feedback; specifically, by comparing the data from different information sources, whether there is mutual contradiction or inconsistency is identified, for example, real-time SCADA data shows that the check valve is in normal running state, but the operator experience feedback indicates that there is abnormal vibration or abnormal sound, such conflict can be identified by pre-set logical rules or abnormal detection algorithm;

[0146] When detecting information conflict, according to the confidence level of the conflict information source, the information source with high confidence level is preferentially adopted; for example, if real-time SCADA data is given a higher emergency degree judgment confidence, even if the operator feedback shows that the situation is not urgent, it may still tend to adopt the higher emergency degree indicated by the SCADA data;

[0147] If the confidence levels of the conflict information sources are the same, the conflict information is judged according to a preset conflict resolution strategy, and the conflict resolution strategy includes: in the emergency degree judgment, the real-time SCADA data is preferentially adopted, because it reflects the instantaneous and objective physical parameter change, and has higher timeliness and accuracy for the judgment of the emergency; in the detailed degree requirement judgment, the operator experience feedback is preferentially adopted, so that the experience of the operator can better reflect the demand and understanding ability of the information details in the actual operation.

[0148] According to the judged information, the emergency degree of the current production scene and the detailed degree requirement of the receiver for the early warning information are judged.

[0149] The embodiments of the application can more finely evaluate the value of each information source by introducing the confidence level, avoid the deviation that may be caused by simply superimposing information, adopt the detection and resolution mechanism of information conflict, especially preferentially adopt according to the confidence level and adopt the differentiated strategy for different judgment dimensions, and ensure that even in complex and variable or inconsistent information working conditions, a stable and actual demand conforming judgment can be made, which not only reduces the risk of false positives or false negatives, but also makes the differentiated early warning information generated subsequently more accurately match the actual situation and the demand of the receiver, thereby effectively guiding the maintenance decision and production management, and improving the overall efficiency of the check valve fault prediction.

[0150] In actual application, even if the content and detailed degree of the early warning information are reasonably determined, if the receiver is insufficient in the understanding proficiency of the professional terms or complex operation processes contained therein, especially in the emergency, the information transmission efficiency may be reduced, and even the fault processing is delayed. In view of this, the embodiments of the application further optimize the generation process of the early warning information to ensure that the early warning information can be effectively understood and responded by the receiver, and the specific implementation process is as follows:

[0151] The historical operation records and training records of the receiver are obtained; the historical operation records of the receiver can include the records of the receiver in the past in processing similar faults or performing related maintenance tasks, such as operation logs, fault handling reports and the like; the training records can cover the professional skill training, safety training and related equipment operation certification and the like information accepted by the receiver; by obtaining these records, the knowledge reserve and practical experience of the receiver on the specific technical field and operation process can be comprehensively evaluated;

[0152] According to historical operation records and training records, the understanding proficiency of the receiver to specific professional terms and operation processes is identified, and the understanding proficiency refers to the mastery of the receiver to the professional terms, technical parameters, failure modes and recommended operation steps that may appear in the early warning information, for example, for an experienced engineer, the understanding proficiency is high, and the early warning information containing detailed technical parameters can be directly processed, and for a newly hired operator, the understanding proficiency may be low, and more intuitive and simplified information is needed;

[0153] If the emergency level of the current production scene is high and the understanding proficiency of the receiver to specific professional terms and operation processes is low, the professional terms in the early warning information are replaced by popular descriptions, the operation process is decomposed into step-by-step instructions, and animation demonstration or illustration of related operations is provided; wherein the replacement of professional terms refers to converting complex engineering terms or industry terms into daily understandable language, for example, replacing the lateral force of the valve disc with the lateral pressure on the internal components of the valve; the decomposition of the operation process into step-by-step instructions refers to decomposing a complex maintenance or emergency operation into a series of clear, short and sequential steps; in order to further enhance the understanding and operation accuracy, animation demonstration or illustration of related operations can be provided, for example, through short videos or flowcharts to visually show key operations such as valve closing and component inspection, thereby reducing the cognitive load of the receiver and improving the response speed and operation accuracy of the receiver in emergency situations.

[0154] The embodiments of the present application comprehensively consider the emergency level of the current production scene and the understanding proficiency of the receiver to the early warning information, when the emergency situation is identified and the receiver may have difficulty in understanding complex information, by replacing professional terms with popular descriptions, decomposing operation processes into step-by-step instructions, and providing animation demonstration or illustration, the understanding threshold and cognitive load of the receiver are greatly reduced, especially in high-pressure and emergency production environments, which helps to reduce secondary failures or production accidents caused by information understanding deviation or improper operation, thereby ensuring the continuity and safety of the production process, and improving the overall fault response efficiency and maintenance quality.

[0155] Based on the same technical concept as above, the embodiments of the present application also propose a check valve fault early warning device, as shown in Figure 2 The early warning device 200 includes:

[0156] The information acquisition unit 201 is configured to acquire process adjustment information related to the fluid medium flowing through the check valve. The specific information acquisition method is as described in the above method, which will not be repeated here.

[0157] The characteristic analysis unit 202 is configured to obtain the physical characteristic change of the fluid medium based on the process adjustment information. The specific implementation process is as described in the above method, which will not be repeated here.

[0158] The lateral force evaluation unit 203 is configured to evaluate the lateral force borne by the valve disc of the check valve based on the change in the physical property of the fluid medium. The specific evaluation manner is as described above, and will not be repeated here.

[0159] In addition, the analysis and early warning unit 204 is configured to continuously track the lateral force of the valve disc and perform early wear warning of the check valve according to the lateral force of the valve disc. The specific implementation manner is as described above, and will not be repeated here.

[0160] Based on the same technical concept, the embodiment of the present application further provides a check valve fault early warning system, as shown in the following table. Figure 3 The early warning system 300 provided by the embodiment of the present application includes:

[0161] An input device 301, an output device 302, a processor A 303 and a memory A 304; wherein the number of the processor A 303 and the memory A 304 can be one or more, Figure 3 For example, one processor A 303 and one memory A 304 are taken as an example for description. The input device 301, the output device 302, the processor A 303 and the memory A 304 can be connected through a bus or other means, Figure 3 For example, the connection through the bus is taken as an example.

[0162] The processor A 303 is configured to execute the following steps by calling the operation instructions stored in the memory A 304:

[0163] Obtain process adjustment information related to the fluid medium flowing through the check valve;

[0164] Based on the process adjustment information, obtain the change in the physical property of the fluid medium;

[0165] Evaluate the lateral force borne by the valve disc of the check valve based on the change in the physical property of the fluid medium;

[0166] Continuously track the lateral force of the valve disc and perform early wear warning of the check valve according to the lateral force of the valve disc.

[0167] Optionally, the processor A 303 is further configured to execute any of the implementation manners in the corresponding embodiments of the early warning method by calling the operation instructions stored in the memory A 304.

[0168] Based on the same technical concept, the embodiment of the present application further provides an electronic device, as shown in the following table. Figure 4 The electronic device 400 includes a memory B 410, a processor B 420 and a computer program A 411 stored in the memory B 410 and executable on the processor B 420, and the processor B 420 implements the following steps when executing the computer program A 411:

[0169] Obtain process adjustment information related to the fluid medium flowing through the check valve;

[0170] Based on process adjustment information, the changes in the physical properties of the fluid medium are obtained;

[0171] Based on the changes in the physical properties of the fluid medium, evaluate the lateral force borne by the check valve disc.

[0172] Continuously track the lateral force of the valve disc and provide early warning of check valve wear based on the lateral force of the valve disc.

[0173] Optionally, when processor B420 executes computer program A411, it can implement any of the embodiments in the corresponding examples of the above-described early warning method.

[0174] It should be noted that the electronic device proposed in this application embodiment is a device used to implement the above-mentioned early warning method. Therefore, based on the above-mentioned early warning method proposed in this application embodiment, those skilled in the art can understand the specific implementation method and various variations of the electronic device in this application embodiment. Therefore, how the electronic device specifically implements the above-mentioned early warning method will not be described in detail here. Any electronic device used by those skilled in the art to implement the above-mentioned early warning method is within the scope of protection of this application.

[0175] Based on the same technical concept described above, embodiments of this application also propose a computer-readable storage medium, such as... Figure 5 As shown, the computer-readable storage medium 500 stores a computer program B511, which, when executed by a processor, performs the following steps:

[0176] Obtain process adjustment information related to the fluid medium flowing through the check valve;

[0177] Based on process adjustment information, the changes in the physical properties of the fluid medium are obtained;

[0178] Based on the changes in the physical properties of the fluid medium, evaluate the lateral force borne by the check valve disc.

[0179] Continuously track the lateral force of the valve disc and provide early warning of check valve wear based on the lateral force of the valve disc.

[0180] Optionally, when the computer program B511 is executed by the processor, it can implement any of the embodiments corresponding to the above-described early warning method.

[0181] It should be noted that the descriptions of each embodiment in the above embodiments have different focuses. For parts that are not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0182] Those skilled in the art will appreciate that embodiments of the application can be readily used as software, hardware, or a combination of software and hardware. In one

[0183] The computer program instructions can also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart block or blocks. Figure 1 one or more flowcharts and / or blocks in the flowcharts and / or a combination of flowcharts and / or blocks in the flowcharts can be implemented by computer program instructions. Figure 1 means for carrying out functions specified in the flowchart block or blocks.

[0184] These computer program instructions can also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instructions which implement the flowchart block or blocks. Figure 1 one or more flowcharts and / or blocks in the flowcharts and / or a combination of flowcharts and / or blocks in the flowcharts can be implemented by computer program instructions. Figure 1 means for carrying out functions specified in the flowchart block or blocks.

[0185] These computer program instructions can also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart block or blocks. Figure 1 one or more flowcharts and / or blocks in the flowcharts and / or a combination of flowcharts and / or blocks in the flowcharts can be implemented by computer program instructions. Figure 1 means for carrying out functions specified in the flowchart block or blocks.

[0186] The above detailed description has shown, described, and pointed out the aspects of the application in sufficient detail that others skilled in the art can, by applying the knowledge of those skilled in the art, readily make and use the application. Those skilled in the art will further appreciate that the present application can be practiced with embodiments other than those described, which will occur to those skilled in the art, having the benefit of the present disclosure. What is claimed is:

Claims

1. A method for early warning of check valve malfunction, characterized in that, include: Obtain process adjustment information related to the fluid medium flowing through the check valve; Based on the process adjustment information, the changes in the physical properties of the fluid medium are obtained; The lateral force borne by the check valve disc is evaluated based on the changes in the physical properties of the fluid medium. The valve disc lateral force is continuously tracked, and early wear warnings for the check valve are provided based on the valve disc lateral force.

2. The method for early warning of check valve failure according to claim 1, characterized in that, The method of continuously tracking the lateral force of the valve disc and providing early warning of wear of the check valve based on the lateral force of the valve disc includes: The lateral force of the valve disc obtained through continuous tracking is converted into local equivalent contact stress at the connection between the valve disc and the pin. Identify the stress cycles in the local equivalent contact stress and extract the stress amplitude of the stress cycles; Based on the fatigue characteristics of the material at the connection between the valve disc and the pin and the stress amplitude, calculate the number of failure cycles caused by each stress cycle; Accumulate the number of failure cycles to obtain the cumulative damage; An early wear warning is issued when the cumulative damage value reaches a preset critical value.

3. The method for early warning of check valve failure according to claim 2, characterized in that, The method of issuing an early wear warning based on the cumulative damage value reaching a preset critical value includes: Calculate the risk level of the check valve based on its criticality in the production process, the impact of potential failures on production, and the current production plan. Based on the risk level and the cumulative damage value, generate differentiated early warning information that includes maintenance priority recommendations and estimated critical failure time; Send the differentiated early warning information.

4. The method for early warning of check valve failure according to claim 3, characterized in that, The calculation of the risk level of the check valve based on its operational criticality in the production process, the impact of potential failures on production, and the current production plan includes: Obtain production mode switching information; Obtain the operating status of upstream / downstream equipment; Based on the production mode switching information and the operating status of the upstream / downstream equipment, the criticality rule base is queried to obtain the corresponding criticality weight; wherein the criticality rule base includes the criticality weight of the check valve under different production modes and different equipment status combinations. The risk level of the check valve is calculated based on the criticality weight, the impact of potential failures on production, and the current production plan.

5. The method for early warning of check valve failure according to claim 3, characterized in that, The process of generating differentiated early warning information, including maintenance priority recommendations and estimated critical failure times, based on the risk level and the cumulative damage value, includes: Identify the type of recipient of the early warning information; Based on the type of the identified recipient, a corresponding warning information template is selected from a preset warning information template library; wherein the warning information template defines the content, format and level of detail for the corresponding recipient. The cumulative damage value, risk level, maintenance priority recommendations and estimated critical failure time generated based on the risk level and cumulative damage value are filled into the selected early warning information template to generate customized and differentiated early warning information. Send the customized, differentiated early warning information.

6. The method for early warning of check valve failure according to claim 5, characterized in that, The generation of customized and differentiated early warning information includes: The structure of the selected warning information template is analyzed, and the preset content area and dynamic data placeholders of the warning information template are identified. Based on the cumulative damage value and risk level, assess the specific needs of the current production scenario and the recipient for early warning information; Based on the evaluation results, select supplementary information modules that match the specific needs from the preset supplementary information module library; wherein the supplementary information modules include additional text descriptions, charts or operation instructions for specific scenarios or recipient needs; The cumulative damage value, risk level, maintenance priority recommendation, expected critical failure time, and the content of the supplementary information module are filled into the corresponding area of ​​the early warning information template to generate customized and differentiated early warning information.

7. The method for early warning of check valve failure according to claim 6, characterized in that, The assessment of the specific needs of the current production scenario and the recipient for early warning information based on the cumulative damage value and risk level includes: Acquire real-time SCADA data; the real-time SCADA data includes fluid pressure, temperature, flow rate, and the on / off status of check valves; Obtain historical production batch records; the historical production batch records include fluid medium formulations, process parameter adjustment records, and corresponding production results; Obtain the equipment maintenance log; the equipment maintenance log includes the repair and replacement records of the check valve and the fault description; Obtain operator feedback experience; the operator feedback experience includes the operator's description of the check valve malfunction and handling suggestions; The real-time SCADA data, historical production batch records, equipment maintenance logs, and operator experience feedback are timestamped and their data formats are standardized. Based on the cumulative damage value and risk level, and combined with the standardized real-time SCADA data, the operating conditions of the current production scenario are identified. Based on the standardized historical production batch records and equipment maintenance logs, analyze the historical operating modes and potential fault associations of the check valve; Based on standardized operator experience feedback, extract experiential requirements for specific operating conditions or failure modes. Based on the aforementioned operating conditions, historical operating modes, potential fault correlations, and empirical requirements, the urgency of the current production scenario and the recipient's requirement for detailed early warning information are determined.

8. A method for early warning of check valve failure according to claim 7, characterized in that, The aforementioned assessment of the urgency of the current production scenario and the recipient's requirement for detailed early warning information, based on a comprehensive consideration of operating conditions, historical operating modes, potential fault correlations, and empirical needs, includes: The confidence levels of the real-time SCADA data, historical production batch records, equipment maintenance logs, and operator experience feedback are set; the confidence levels reflect the reliability of the information sources in providing accurate information under different operating conditions. Detect whether there are any information conflicts among the real-time SCADA data, historical production batch records, equipment maintenance logs, and operator experience feedback; When the information conflict is detected, the information source with the higher confidence level is given priority based on the confidence level of the conflicting information source; If the confidence levels of conflicting information sources are the same, the conflicting information will be adjudicated according to the preset conflict resolution strategy. Based on the information following the ruling, determine the urgency of the current production scenario and the recipient's requirement for a high level of detail in the early warning information.

9. A method for early warning of check valve failure according to any one of claims 6-8, characterized in that, The generation of customized and differentiated early warning information also includes: Obtain the recipient's historical operation records and training records; Based on the historical operation records and training records, identify the recipient's level of understanding and proficiency with specific professional terms and operating procedures; If the urgency of the current production scenario is relatively high and the recipient's understanding and proficiency with specific technical terms and operating procedures is relatively low, the technical terms in the warning information will be replaced with common descriptions, and the operating procedures will be broken down into step-by-step instructions, while providing animated demonstrations or illustrated explanations of the relevant operations.

10. A check valve malfunction early warning device, characterized in that, include: The information acquisition unit is used to acquire process adjustment information related to the fluid medium flowing through the check valve; The characteristic analysis unit is used to obtain the changes in the physical properties of the fluid medium based on the process adjustment information; A lateral force assessment unit is used to assess the lateral force borne by the check valve disc based on changes in the physical properties of the fluid medium. In addition, an analysis and early warning unit is used to continuously track the lateral force of the valve disc and provide early warning of early wear of the check valve based on the lateral force of the valve disc.

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