Multi-stage over-torque protection system of intelligent electric actuating mechanism

Abstract

The invention discloses a multi-stage over-torque protection system of an intelligent electric actuating mechanism. The multi-stage over-torque protection system comprises a torque acquisition module, a grading judgment module, a protection execution module, a parameter configuration module and a fault recording module, the torque acquisition module acquires output torque data of the intelligent electric actuating mechanism and transmits the output torque data to the grading judgment module; the parameter configuration module is used for setting a torque protection threshold value; the grading judgment module judges the protection grade according to the output torque data and transmits a judgment result to the protection execution module; the protection execution module executes a corresponding protection action according to the judgment result; the fault recording module records fault information. According to the invention, a multi-stage over-torque protection strategy is adopted, different protection actions can be flexibly executed according to the severity of over-torque, the problem of false shutdown or untimely protection caused by single threshold protection is avoided, and the equipment safety and the production continuity are balanced.

Description

Technical Field

[0001] This invention relates to the field of electric actuator technology, and in particular to a multi-stage over-torque protection system for an intelligent electric actuator. Background Technology

[0002] In the field of industrial automation control, intelligent electric actuators, as core equipment for driving valves, are of paramount importance in terms of operational safety and reliability. Excessive torque is a common potential malfunction in electric actuators, typically caused by valve jamming, abnormal medium pressure, or blockages in pipelines. Failure to address excessive torque issues promptly and effectively can lead to motor burnout, gearbox damage, valve sealing surface wear, and even serious safety accidents such as pipeline rupture and medium leakage.

[0003] Currently, most electric actuators on the market use a single-threshold over-torque protection method. This involves setting a fixed torque threshold; when the output torque exceeds this threshold, the motor power is directly cut off, stopping operation. This protection method has significant drawbacks: firstly, it cannot flexibly adjust the protection strategy according to the actual operating needs of the valve under different working conditions. For example, if the valve is slightly stuck, single-threshold protection may directly shut down the machine, affecting normal production processes. Secondly, it lacks a graded diagnosis and handling system for over-torque faults, making it difficult to distinguish the severity of the fault. This results in maintenance personnel being unable to quickly locate the root cause of the fault, increasing maintenance costs and downtime.

[0004] Therefore, there is an urgent need for an over-torque protection system that can provide graded protection based on the degree of over-torque, and has flexible parameter configuration and fault tracing functions, in order to improve the operational safety and maintainability of intelligent electric actuators. Summary of the Invention

[0005] To address the aforementioned problems in existing technologies, this invention provides a multi-stage over-torque protection system for intelligent electric actuators, enabling graded detection, graded processing, and full traceability of over-torque faults, thereby ensuring the safe and stable operation of the actuator and valve system.

[0006] The technical solution of the present invention is as follows: A multi-stage over-torque protection system for an intelligent electric actuator, characterized in that: The multi-level over-torque protection system is implemented based on an STM32H743 MCU, hereinafter referred to as MCU; it includes a torque acquisition module, a graded judgment module, a protection execution module, a parameter configuration module, and a fault recording module; The torque acquisition module acquires the output torque of the intelligent electric actuator and transmits it to the graded judgment module. The parameter configuration module is connected to the graded judgment module and is used to set the protection threshold and bypass delay time of the output torque. The bypass delay time refers to the duration after the output torque data reaches the protection threshold. The graded judgment module sets at least one over-torque protection level, determines which over-torque protection level the output torque belongs to based on the protection threshold, and transmits the determination result to the protection execution module. The protection execution module executes the corresponding protection action according to the determination result of the graded judgment module. The fault recording module is connected to both the graded judgment module and the protection execution module and is used to record fault information.

[0007] Furthermore, the torque acquisition module uses multiple resistance strain gauges to form a torque sensor with a range of 0~1500Nm and an accuracy of ±0.1% FS. The linearity of the full-range measurement is ensured to be ≤1% FS through 16-point segmented calibration. The torque acquisition module is connected to the MCU via SPI or I2C interface with a communication rate of 250kbps and a sampling rate of 5ms. The data collected by the torque acquisition module includes: (1-1) Output torque, with an accuracy of 0.1 Nm; (1-2) Valve position, accuracy 0.1%; (1-3) Sampling timestamp, with a precision of milliseconds.

[0008] Furthermore, the classification determination module is implemented based on the core 1 of the MCU. The classification determination algorithm is written through embedded software. The protection level threshold and bypass delay time are stored in the FRAM of model FM25W256, and the reading time is ≤100ns.

[0009] Furthermore, the protection execution module includes a motor drive circuit, a relay module, and an ESD linkage interface; the motor drive circuit receives PWM control signals from the MCU to realize motor speed regulation and start / stop control; the relay module is used to disconnect the motor drive power supply from the main power supply; the ESD linkage interface adopts a passive dry contact design for connecting to an external ESD system.

[0010] Furthermore, the grading determination module determines the over-torque protection level based on the following conditions: (2-1) When the output torque is ≥40% of the rated torque, it is a first-level protection; (2-2) When the output torque is ≥60% of the rated torque, it is a secondary protection; (2-3) When the output torque is ≥80% of the rated torque, it is a level three protection; (2-4) When the output torque is ≥100% of the rated torque, it is a level four protection; (2-5) When the output torque is ≥150% of the rated torque, it is a level 5 protection.

[0011] Furthermore, the protection actions of the protection execution module are as follows: (3-1) When the first-level protection is activated, the over-torque alarm is triggered, but the motor does not stop running; (3-2) When the secondary protection is activated, the over-torque alarm is triggered, and the motor speed is reduced to 50% of the rated speed. If the output torque drops below 40% of the rated torque within 10 seconds, the normal speed is restored. If the output torque is still higher than 40% of the rated torque after 10 seconds, the motor is stopped. (3-3) When the three-level protection is triggered, the over-torque alarm will be triggered immediately, the motor will be stopped and locked for 5 minutes, during which electric operation is prohibited; after 5 minutes, it will be automatically unlocked. If the output torque is still higher than 80% of the rated torque, it will remain locked. (3-4) When the fourth level protection is triggered, the over-torque emergency alarm is triggered, the motor drive power is cut off, the motor stops running, the local LED red light stays on, and the emergency alarm pop-up window of the remote system appears; the lock can only be released by manual reset via local knob or remote command. (3-5) When the level 5 protection is triggered, the serious over-torque alarm will be triggered, the motor drive power supply and the main power supply of the actuator will be cut off, and all actions will be stopped. The equipment can only be restored to operation after the administrator performs the fault investigation and manually resets it.

[0012] Furthermore, the graded judgment module calculates the torque change rate of 100 consecutive output torque sampling points. If the torque change rate exceeds 0.5 Nm / ms, it is judged as a torque mutation and a higher level of protection warning is triggered in advance.

[0013] Furthermore, the protection execution module has a fault self-recovery function. When the secondary and tertiary protection is triggered and then returns to normal, it automatically records the recovery time, the torque value and valve position value at the time of recovery, and uploads the recovery information to the remote system.

[0014] Furthermore, the workflow is as follows: S1. System initialization, i.e.: the parameter configuration module automatically loads the parameters of the torque protection level, the torque acquisition module completes sensor self-test and zero-point calibration, and the classification judgment module and protection execution module enter standby mode; S2. The torque acquisition module acquires the output torque every 5ms and transmits it to the grading judgment module; S3. The graded judgment module determines the over-torque protection level of the output torque. If the output torque reaches the threshold of the over-torque protection level and the duration reaches the bypass delay time of the over-torque protection level, a signal for triggering the protection action of the over-torque protection level is sent to the protection execution module. S4. Protection action execution: After receiving the signal from the graded judgment module, the protection execution module immediately triggers the protection action of the over-torque protection level. S5. Fault Recording and Export: After a fault is triggered, the fault recording module automatically records the fault information and stores it in FRAM and eMMC; maintenance personnel can export the fault records as CSV format through the local infrared maintenance port, or view historical fault data through the cloud platform.

[0015] The beneficial technical effects of this invention are as follows: By adopting a multi-level over-torque protection strategy, different protection actions can be flexibly executed according to the severity of the over-torque, avoiding the problems of accidental shutdown or untimely protection caused by single threshold protection, and balancing equipment safety and production continuity. It supports personalized configuration of protection parameters, adapting to the needs of different types of valves (gate valves, globe valves, ball valves, butterfly valves) and different working conditions (high pressure, high temperature, corrosive media), and has strong versatility; It has comprehensive fault recording and tracing functions, and records key parameters in detail during the fault process, providing data support for maintenance personnel to quickly locate the root cause of the fault (such as valve jamming, abnormal medium pressure), thereby reducing maintenance costs and downtime. By integrating torque trend analysis and fault self-recovery functions, the system's intelligence level is improved, potential faults are warned in advance, the risk of fault escalation is reduced, and the fault recovery process is simplified. Attached Figure Description

[0016] Figure 1 This is a system structure diagram of an embodiment; Figure 2 This is a flowchart of an embodiment. Detailed Implementation

[0017] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0018] The system structure of the embodiment is as follows Figure 1 As shown, it includes a torque acquisition module, a classification judgment module, a protection execution module, a parameter configuration module, and a fault recording module. The hardware configuration of each module is as follows: 1. Torque Acquisition Module: The torque sensor is composed of multiple resistance strain gauges, with a range of 0~1500Nm and an accuracy of ±0.1% FS. The linearity of the full-range measurement is ensured to be ≤1% FS through 16-point segmented calibration. The sensor is connected to the dual-core lockstep MCU (STM32H743) of the actuator via SPI or I2C interface, with a communication rate of 250kbps and a sampling rate of 5ms.

[0019] 2. Classification Decision Module: Implemented based on STM32H743 core 1, the classification decision algorithm is written through embedded software, the protection level threshold and bypass delay time are stored in FRAM (model FM25W256), and the read time is ≤100ns.

[0020] 3. Protection Execution Module: Includes motor drive circuit (using IR2233 driver chip), relay module and ESD linkage interface; motor drive circuit receives PWM control signal from MCU to realize motor speed regulation and start / stop control; relay module is used to cut off motor drive power supply and main power supply; ESD linkage interface adopts passive dry contact design and supports docking with external ESD system.

[0021] 4. Parameter configuration module: Local parameter configuration is achieved through a 5-inch IPS display (800×480 resolution) and an infrared remote control receiver circuit. Remote configuration commands are received through the Modbus protocol or a 4G communication module. Configuration permission management is achieved through the MCU's hardware encryption module (AES-256) to prevent unauthorized modification.

[0022] 5. Fault Recording Module: FRAM (FM25W256) is used to store the most recent 100 fault records, eMMC is used to store historical fault data, and data compression adopts LZ77 algorithm with a compression rate of about 40%.

[0023] The functions of each module are as follows: 1. Torque Acquisition Module: Employs a 16-point segmented calibrated torque sensor to acquire the output torque data of the actuator in real time. The sampling rate is 1~10ms. The acquired data includes the real-time torque value (accuracy 0.1Nm), the corresponding valve position value (accuracy 0.1%), and the sampling timestamp (accurate to milliseconds). The torque sensor communicates with the dual-core lockstep MCU of the actuator through an SPI / I2C interface to ensure the real-time performance and accuracy of data transmission.

[0024] 2. Grading Module: Five over-torque protection levels are pre-designed, each corresponding to a different torque threshold (based on the rated torque of the actuator), specifically: Level 1 protection (40% of rated torque), Level 2 protection (60% of rated torque), Level 3 protection (80% of rated torque), Level 4 protection (100% of rated torque), and Level 5 protection (150% of rated torque). The grading module receives real-time torque data transmitted from the torque acquisition module, compares it with the threshold values ​​for each level, and combines this with a preset bypass delay time (0~60s, set independently for each level) to determine whether to trigger a protection action. If the real-time torque exceeds a certain level threshold and the duration reaches the bypass delay time for that level, then the protection for that level is triggered.

[0025] The classification judgment module also has a torque trend analysis function. By calculating the torque change rate (ΔT / Δt) of 100 consecutive sampling points, if the change rate exceeds 0.5Nm / ms, it is judged as a torque change and a higher level of protection warning is triggered in advance. For example, when the real-time torque is within the third protection range (80% of the rated torque) but the change rate exceeds 0.5Nm / ms, the fourth protection warning signal is triggered in advance, giving time for fault handling.

[0026] 3. Protection Execution Module: Executes corresponding protection actions based on the judgment results of the hierarchical judgment module. The specific action strategies are as follows: (1) Level 1 protection (40% rated torque): Only triggers the over-torque warning signal, displays the warning information on the local IPS display screen, and uploads the warning data to the remote DCS / cloud platform without stopping the motor operation; (2) Secondary protection (60% rated torque): Triggers over-torque alarm and controls the motor to run at reduced speed (down to 50% of rated speed). If the torque drops below the threshold within 10 seconds, the normal speed is restored; if the torque is still higher than the threshold after 10 seconds, the motor stops running. (3) Level 3 protection (80% rated torque): If the over-torque alarm is triggered, the motor will be stopped immediately and locked for 5 minutes. During this period, electric operation is prohibited. After 5 minutes, the motor will be unlocked automatically. If the torque is still higher than the threshold, the locked state will be maintained. (4) Level 4 protection (100% rated torque): Triggering an over-torque emergency alarm, cutting off the motor drive power supply, stopping the motor operation, and simultaneously triggering the local LED red light of the actuator to stay on and the emergency alarm pop-up of the remote system; manual reset (local knob or remote command) is required to unlock; (5) Level 5 protection (150% rated torque): Triggering a severe over-torque alarm will cut off the motor drive power supply and the main power supply of the actuator, stop all actions, and trigger the ESD linkage signal (if connected to the ESD system); the equipment can only be restored to operation after the administrator performs fault diagnosis and manual reset.

[0027] 4. Parameter Configuration Module: Supports personalized configuration of over-torque protection threshold and bypass delay time via local infrared remote control or remote DCS / cloud platform; the configuration process requires user permission verification (engineer or administrator permission), and the configuration parameters are stored in FRAM memory and are not lost when power is off; at the same time, the parameter configuration module has a parameter verification function. If the configured threshold exceeds the reasonable range (0~200% rated torque) or the bypass delay time exceeds the range of 0~60s, the configuration will be automatically rejected and an error message will be displayed.

[0028] 5. Fault Recording Module: When any level of over-torque protection is triggered, fault information is automatically recorded, including the fault level, trigger timestamp (accurate to milliseconds), real-time torque value at the time of triggering, valve position value, motor current, motor temperature, and protection action type. The fault information is stored in binary format in dual storage media: FRAM and eMMC. FRAM stores the most recent 100 fault records (FIFO cyclic overwrite), and eMMC stores compressed historical fault data (retained for ≥10 years). Fault records can be exported (CSV / PDF format) via local USB interface or remote communication interface for easy fault tracing and analysis.

[0029] The protection execution module also has a fault self-recovery function. When the secondary and tertiary protection is triggered and then returns to normal, it automatically records the recovery time, torque value and valve position value at the time of recovery, and uploads the recovery information to the remote system to form a complete fault handling closed loop.

[0030] Taking the triggering of Level 3 protection as an example, the workflow of the embodiment is as follows: Figure 2 As shown: 1. System initialization: After the device is powered on, the parameter configuration module automatically loads the over-torque protection parameters (level threshold, bypass delay time) stored in the FRAM, the torque acquisition module completes sensor self-test and zero-point calibration, and the level judgment module and protection execution module enter standby mode.

[0031] 2. Torque Acquisition and Judgment: During equipment operation, the torque acquisition module collects and outputs torque data every 5ms and transmits it to the graded judgment module. The graded judgment module compares the real-time torque with the threshold of each level. If the real-time torque is 70% of the rated torque (assuming the rated torque is 100Nm and the real-time torque is 70Nm), it corresponds to the third-level protection (80% of the rated torque, i.e., 80Nm). Since the threshold is not reached, the protection is not triggered. If the real-time torque rises to 85Nm (exceeding the third-level protection threshold of 80Nm) and the duration reaches the third-level protection bypass delay time (assuming it is set to 5s), then the third-level protection is determined to be triggered.

[0032] 3. Protection Action Execution: After receiving the Level 3 protection trigger signal, the protection execution module immediately triggers the over-torque alarm (the local IPS display shows "Level 3 Over-Torque Alarm", and the remote DCS platform pops up an alarm window). At the same time, it cuts off the motor drive signal, stops the motor, and locks the motor for 5 minutes. After 5 minutes, if the torque acquisition module detects that the torque has dropped below 80 Nm, it automatically unlocks the motor and allows normal operation. If the torque is still higher than 80 Nm, the motor remains locked until it is manually reset.

[0033] 4. Fault Recording and Export: After a fault is triggered, the fault recording module automatically records the fault information (e.g., level: three, trigger time: 2024-05-20 15:30:22.123, real-time torque: 85Nm, valve position: 50.2%, motor current: 8.5A, motor temperature: 65℃, protection action: stop motor and lock for 5 minutes), and stores it to FRAM and eMMC; maintenance personnel can export the fault records to CSV format through the local infrared maintenance port, or view historical fault data through the cloud platform.

[0034] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, and for those of ordinary skill in the art, various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. Therefore, the present invention is not limited to the specific details without departing from the general concept defined by the claims and their equivalents.

Claims

1. A multi-stage over-torque protection system for an intelligent electric actuator, characterized in that: The multi-stage over-torque protection system is implemented based on an STM32H743 MCU, hereinafter referred to as MCU; It includes a torque acquisition module, a classification judgment module, a protection execution module, a parameter configuration module, and a fault recording module; The torque acquisition module acquires the output torque of the intelligent electric actuator and transmits the output torque to the graded judgment module; the parameter configuration module is connected to the graded judgment module and is used to set the protection threshold and bypass delay time of the output torque. The bypass delay time refers to the duration after the output torque data reaches the protection threshold of the output torque; the graded judgment module is set with no less than one over-torque protection level, and determines which over-torque protection level the output torque belongs to based on the protection threshold of the output torque, and transmits the judgment result to the protection execution module. The protection execution module executes the corresponding protection action according to the judgment result of the hierarchical judgment module; The fault recording module is connected to the graded judgment module and the protection execution module respectively, and is used to record fault information.

2. The multi-stage over-torque protection system for an intelligent electric actuator according to claim 1, characterized in that: The torque acquisition module uses multiple resistance strain gauges to form a torque sensor with a range of 0~1500Nm and an accuracy of ±0.1% FS. The linearity of the full-range measurement is ensured to be ≤1% FS through 16-point segmented calibration. The torque acquisition module is connected to the MCU via SPI or I2C interface with a communication rate of 250kbps and a sampling rate of 5ms. The data collected by the torque acquisition module includes: (1-1) Output torque, with an accuracy of 0.1 Nm; (1-2) Valve position, accuracy 0.1%; (1-3) Sampling timestamp, with a precision of milliseconds.

3. The multi-stage over-torque protection system for an intelligent electric actuator according to claim 1, characterized in that: The classification determination module is implemented based on the core 1 of the MCU. The classification determination algorithm is written through embedded software. The protection level threshold and bypass delay time are stored in the FRAM of model FM25W256, and the reading time is ≤100ns.

4. The multi-stage over-torque protection system for an intelligent electric actuator according to claim 1, characterized in that: The protection execution module includes a motor drive circuit, a relay module, and an ESD linkage interface; the motor drive circuit receives PWM control signals from the MCU to realize motor speed regulation and start / stop control; the relay module is used to disconnect the motor drive power supply from the main power supply; the ESD linkage interface adopts a passive dry contact design for connecting to an external ESD system.

5. A multi-stage over-torque protection system for an intelligent electric actuator according to claim 2, characterized in that, The grading determination module determines the over-torque protection level based on the following criteria: (2-1) When the output torque is ≥40% of the rated torque, it is a first-level protection; (2-2) When the output torque is ≥60% of the rated torque, it is a secondary protection; (2-3) When the output torque is ≥80% of the rated torque, it is a level three protection; (2-4) When the output torque is ≥100% of the rated torque, it is a level four protection; (2-5) When the output torque is ≥150% of the rated torque, it is a level 5 protection.

6. The multi-stage over-torque protection system for an intelligent electric actuator according to claim 1, characterized in that, The protection actions of the protection execution module are as follows: (3-1) When the first-level protection is activated, the over-torque alarm is triggered, but the motor does not stop running; (3-2) When the secondary protection is activated, the over-torque alarm is triggered, and the motor speed is reduced to 50% of the rated speed. If the output torque drops below 40% of the rated torque within 10 seconds, the normal speed is restored. If the output torque is still higher than 40% of the rated torque after 10 seconds, the motor is stopped. (3-3) When the three-level protection is triggered, the over-torque alarm will be triggered immediately, the motor will be stopped and locked for 5 minutes, during which electric operation is prohibited; after 5 minutes, it will be automatically unlocked. If the output torque is still higher than 80% of the rated torque, it will remain locked. (3-4) When the fourth level protection is triggered, the over-torque emergency alarm is triggered, the motor drive power is cut off, the motor stops running, the local LED red light stays on, and the emergency alarm pop-up window of the remote system appears; the lock can only be released by manual reset via local knob or remote command. (3-5) When the level 5 protection is triggered, the serious over-torque alarm will be triggered, the motor drive power supply and the main power supply of the actuator will be cut off, and all actions will be stopped. The equipment can only be restored to operation after the administrator performs the fault investigation and manually resets it.

7. A multi-stage over-torque protection system for an intelligent electric actuator according to claim 1, characterized in that: The graded judgment module calculates the torque change rate of 100 consecutive output torque sampling points. If the torque change rate exceeds 0.5 Nm / ms, it is judged as a torque mutation and a higher level of protection warning is triggered in advance.

8. A multi-stage over-torque protection system for an intelligent electric actuator according to claim 1, characterized in that: The protection execution module has a fault self-recovery function. When the secondary and tertiary protection is triggered and then returns to normal, it automatically records the recovery time, the torque value and valve position value at the time of recovery, and uploads the recovery information to the remote system.

9. A multi-stage over-torque protection system for an intelligent electric actuator according to claim 1, characterized in that, The workflow is as follows: S1. System initialization, i.e.: the parameter configuration module automatically loads the parameters of the torque protection level, the torque acquisition module completes sensor self-test and zero-point calibration, and the classification judgment module and protection execution module enter standby mode; S2. The torque acquisition module acquires the output torque every 5ms and transmits it to the grading judgment module; S3. The graded judgment module determines the over-torque protection level of the output torque. If the output torque reaches the threshold of the over-torque protection level and the duration reaches the bypass delay time of the over-torque protection level, a signal for triggering the protection action of the over-torque protection level is sent to the protection execution module. S4. Protection action execution: After receiving the signal from the graded judgment module, the protection execution module immediately triggers the protection action of the over-torque protection level. S5. Fault Recording and Export: After a fault is triggered, the fault recording module automatically records the fault information and stores it in FRAM and eMMC; Maintenance personnel can export fault records as CSV format via the local infrared maintenance port, or view historical fault data through the cloud platform.

Images