Gas filling process anomaly detection and automatic control valve

Abstract

This invention discloses a valve for abnormal detection and automatic control during gas filling, relating to the field of valve technology. The device encompasses a gas control section, a valve structure, and a gas abnormality detection section. The gas control section utilizes a hollow sphere and internal absorbent cotton to adsorb moisture in the gas, and the gas flow can be adjusted by rotating the hollow sphere. The valve structure is driven by a servo motor that drives the valve stem to move the valve core, changing the coupling degree with the valve seat to adjust the valve opening. The gas abnormality detection section is equipped with flow rate, gas pressure, and moisture sensors to monitor gas parameters in real time. When abnormalities in flow rate, gas pressure, or moisture are detected, the external control system, based on sensor data, controls the servo motor to adjust the valve opening. Simultaneously, it can control a small motor in the gas control section to rotate the hollow sphere, assisting in adjusting gas flow rate and pressure and enhancing moisture adsorption, ensuring a stable and safe gas filling process and preventing abnormalities from affecting filling quality and equipment safety.

Description

Technical Field

[0001] This invention relates to the field of valve technology, specifically to a valve for detecting and automatically controlling abnormalities during gas filling processes. Background Technology

[0002] Traditional gas filling processes rely primarily on manual monitoring and valve adjustment. Operators must periodically check data from pressure gauges, flow meters, and other instruments, relying on experience to judge the gas filling status and manually controlling gas flow and pressure. However, this method has significant drawbacks. Manual monitoring is difficult to achieve in real-time and with high precision, and is prone to misjudgment or omission of abnormalities due to negligence or fatigue, failing to promptly detect potential problems such as excessively high gas flow rates, excessively high pressures, or excessive moisture content. Manual valve adjustment has a slow response time, making it difficult to quickly address sudden anomalies, potentially exacerbating the situation and causing serious accidents such as equipment damage, gas leaks, or even explosions. Regarding gas detection, existing gas detection devices have certain limitations. Some devices can only detect a single gas parameter, failing to comprehensively monitor multi-dimensional information such as flow rate, pressure, and moisture content during the gas filling process, making it difficult to accurately determine the gas filling status. Some detection devices have sensors with insufficient stability, easily affected by environmental factors such as temperature, humidity, and impurities, leading to inaccurate detection data and affecting the correct assessment of the gas filling process. For example, although semiconductor sensors are low in cost and fast in response, they have poor selectivity, are easily affected by ambient temperature and humidity, and have relatively low accuracy, making it difficult to meet the high-precision detection requirements of industrial gas filling.

[0003] Furthermore, existing technologies lack an effective linkage mechanism between anomaly detection and valve control during the gas filling process. The detection device and valve control device operate independently. When the detection device detects an anomaly, it cannot promptly transmit the signal to the valve control device to achieve automatic valve adjustment. This results in untimely handling of abnormal situations, increasing production risks. For example, if the valve opening degree is not reduced in time to decrease gas flow and pressure when the gas flow rate or pressure is too high, it may lead to equipment failure or safety accidents. Therefore, developing a device capable of real-time detection of anomalies during the gas filling process and automatic valve control to adjust gas parameters is of significant practical importance. Summary of the Invention

[0004] In view of the deficiencies mentioned above in the background technology, a technical solution is provided for an abnormal detection and automatic control valve in the gas filling process.

[0005] The device includes a valve structure, with a gas control section connected to the left air inlet port and a gas anomaly detection section connected to the right air outlet port. The valve structure includes a housing, a valve seat fixedly connected to the bottom of the housing cavity, and a support base fixedly connected to the top end face of the housing. Two support columns are fixedly connected to the top of the support base, and a fixing plate is fixedly connected to the top of the support columns. A servo motor is fixedly connected to the top surface of the fixing plate, and a valve stem is fixedly connected to the output shaft of the servo motor, penetrating the fixing plate and extending into the housing cavity. A valve core coupled to the valve seat is fixedly connected to the bottom end of the valve stem inside the housing.

[0006] The gas anomaly detection section includes a flange and an air inlet pipe fixed to the right end face of the flange. A flow rate sensor, a pressure sensor and a moisture sensor are embedded and fixed in a ring array on the outer surface of the air inlet pipe.

[0007] The gas control section includes a connecting plate and a gas delivery pipe fixed to the left end face of the connecting plate. A hollow sphere is rotatably disposed in the inner cavity of the gas delivery pipe. A small motor is fixedly connected to the top surface of the gas delivery pipe, and the output shaft of the small motor is connected to a rotating column that passes through the gas delivery pipe. The bottom end of the rotating column is fixedly connected to the outer wall of the hollow sphere.

[0008] In the above technical solution, preferably: the top section of the valve stem is provided with a threaded section, and the inside of the support seat is provided with a threaded hole that matches the threaded section at the top of the valve stem.

[0009] In the above technical solution, preferably, the left port of the housing is the air intake port and the right port of the housing is the exhaust port.

[0010] In the above technical solution, preferably, the left end face of the flange is fixedly connected to the right port of the housing by bolts.

[0011] In the above technical solution, preferably, the outer surface of the air intake pipe has three openings arranged in a ring array for embedding and fixing the flow rate sensor, air pressure sensor and moisture sensor.

[0012] In the above technical solution, preferably, the flow rate sensor, air pressure sensor and moisture sensor are used to monitor the moisture content, gas flow rate and gas pressure of the gas about to flow out of the air intake pipe.

[0013] In the above technical solution, preferably, the right end face of the connecting plate is fixedly connected to the left port of the housing by bolts.

[0014] In the above technical solution, preferably: a circular hole is provided on the top surface of the gas delivery pipe for the rotating column to pass through and rotate, and a dynamic sealing ring adapted to the rotating column is installed inside the circular hole.

[0015] In the above technical solution, preferably: the hollow sphere is filled with absorbent cotton balls to absorb moisture from the gas inside the gas delivery pipe, and the outer surface of the hollow sphere is in contact with the inner wall of the gas delivery pipe.

[0016] In the above technical solution, preferably: the hollow sphere has through channels on its left and right sidewalls for gas flow under normal conditions, and the hollow sphere has multiple fine holes on its front and rear sidewalls to slow down the flow when the flow rate and air pressure exceed a set threshold.

[0017] As can be seen from the above technical solution, the present invention provides a gas filling process abnormality detection and automatic control valve. Compared with the prior art, the present invention has the following beneficial effects:

[0018] The gas control section of this technical solution features a hollow sphere and absorbent cotton balls, which effectively adsorb moisture from the gas during filling, reducing gas humidity and improving gas quality. A small motor drives the hollow sphere to rotate, flexibly adjusting the gas flow cross-sectional area for initial control of gas flow. The valve structure uses a servo motor to drive the valve stem and valve core, precisely changing the valve opening degree for further fine control of gas flow. The gas anomaly detection section is equipped with multiple sensors to comprehensively monitor gas flow rate, pressure, and moisture content in real time. In the event of an anomaly, the external control system responds quickly, simultaneously controlling the valve structure and gas control section to work together rapidly, adjusting gas flow and pressure and enhancing moisture adsorption. This effectively prevents damage to the filling process and equipment caused by abnormal flow rate, pressure, or excessive moisture, ensuring stable and safe gas filling. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments of the present invention or the prior art will be briefly introduced and explained below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 Schematic diagram of a gas filling valve;

[0021] Figure 2 This is a schematic diagram of the valve body's internal structure.

[0022] Figure 3 This is a schematic diagram of the gas anomaly detection section;

[0023] Figure 4 This is a schematic diagram of the gas control section;

[0024] Figure 5 This is a schematic diagram of the internal structure of the gas control section.

[0025] Appendix Figure 1 - Appendix Figure 5 The correspondence between the components is as follows:

[0026] 1. Valve Structure; 1-1. Shell; 1-2. Support Base; 1-3. Fixing Plate; 1-4. Servo Motor; 1-5. Valve Stem; 1-6. Valve Seat; 1-7. Support Column; 1-8. Valve Core; 2. Gas Anomaly Detection Section; 2-1. Inlet Pipe; 2-2. Moisture Sensor; 2-3. Flange; 2-4. Pressure Sensor; 2-5. Flow Rate Sensor; 3. Gas Control Section; 3-1. Gas Delivery Pipe; 3-2. Rotating Column; 3-3. Small Motor; 3-4. Connecting Plate; 3-5. Hollow Sphere; 3-6. Channel; 3-7. Fine Orifice. Detailed Implementation

[0027] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the embodiments described below are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. In order to provide a clearer explanation and description of the technical solutions and implementation methods of the present invention, the following describes specific embodiments that implement the preferred technical solutions of the present invention.

[0028] In an embodiment of a gas filling process anomaly detection and automatic control valve, refer to the attached document. Figure 1 The valve comprises three core parts: valve structure 1, gas anomaly detection section 2, and gas control section 3. Each part, through a specific structure, achieves anomaly detection and automatic control functions during the gas filling process. (See attached document) Figure 2In valve structure 1, the housing 1-1 serves as the main frame, with its left port as the air inlet and its right port as the air outlet, connecting the gas control section 3 and the gas anomaly detection section 2, respectively. A valve seat 1-6 is fixedly connected to the bottom of the inner cavity of the housing 1-1, and a support seat 1-2 is fixedly connected to its top end. The top of the support seat 1-2 is connected to a fixed plate 1-3 via two support columns 1-7, forming a stable support structure. A servo motor 1-4 is fixedly connected to the top surface of the fixed plate 1-3, with its output shaft penetrating the fixed plate 1-3 to the inner cavity of the housing 1-1 and fixedly connected to the top of the valve stem 1-5. The top section of the valve stem 1-5 has a threaded section, and the support seat 1-2 has a matching threaded hole, allowing axial movement of the valve stem 1-5 through threaded engagement. A valve core 1-8 is fixedly connected to the bottom end of the valve stem 1-5 inside the housing 1-1, coupling the valve core 1-8 to the valve seat 1-6. The movement of the valve stem 1-5 controls the opening and closing of the valve. (See attached diagram) Figure 3 The gas anomaly detection section 2 is fixedly connected to the right port of valve structure 1 via flange 2-3. The left end face of flange 2-3 is tightly connected to the right port of housing 1-1 via bolts. The inlet pipe 2-1 is fixed to the right end face of flange 2-3, and its outer surface has three openings arranged in a ring array, each housing a flow rate sensor 2-5, a pressure sensor 2-4, and a moisture sensor 2-2. Flow rate sensor 2-5 monitors the flow rate of gas about to flow out of inlet pipe 2-1, pressure sensor 2-4 monitors gas pressure, and moisture sensor 2-2 monitors the moisture content of the gas. These three sensors collect data in real time, providing key parameters for anomaly detection during the gas filling process.

[0029] Reference Appendix Figure 4 and attached Figure 5The gas control section 3 is fixedly connected to the left port of the valve structure 1 via a connecting plate 3-4. The right end face of the connecting plate 3-4 is fixed to the left port of the housing 1-1 with bolts. The gas delivery pipe 3-1 is fixed to the left end face of the connecting plate 3-4, and a hollow sphere 3-5 is rotatably installed in its inner cavity. The outer surface of the hollow sphere 3-5 contacts the inner wall of the gas delivery pipe 3-1 to ensure sealing during gas flow. The hollow sphere 3-5 is filled with absorbent cotton balls to absorb moisture from the gas inside the gas delivery pipe 3-1 and reduce gas humidity. Through channels 3-6 are provided on the left and right side walls of the hollow sphere 3-5 for gas flow under normal conditions, ensuring the continuity of the gas filling process. At the same time, multiple fine holes 3-7 are provided on the front and rear side walls of the hollow sphere 3-5. When the gas flow rate and pressure exceed the set threshold, the fine holes 3-7 act as a flow slower to prevent gas impact from damaging the valve structure. A small motor 3-3 is fixedly connected to the top surface of the gas delivery pipe 3-1, and its output shaft is connected to a rotating column 3-2 that passes through the gas delivery pipe 3-1. A circular hole is provided on the top surface of the gas delivery pipe 3-1 for the rotating column 3-2 to pass through and rotate. A dynamic sealing ring adapted to the rotating column 3-2 is installed inside the circular hole to ensure sealing during rotation. The bottom end of the rotating column 3-2 is fixedly connected to the outer wall of the hollow sphere 3-5. The small motor 3-3 drives the rotating column 3-2 to rotate, thereby causing the hollow sphere 3-5 to rotate within the cavity of the gas delivery pipe 3-1. The rotation of the hollow sphere 3-5 adjusts the relative position of the channel 3-6 and the cavity of the gas delivery pipe 3-1, thereby controlling the cross-sectional area of ​​gas flow and regulating the gas flow rate.

[0030] In practical applications, when gas enters valve structure 1 from gas delivery pipe 3-1, it first passes through hollow sphere 3-5. The absorbent cotton inside hollow sphere 3-5 absorbs moisture from the gas, reducing its humidity. Simultaneously, small motor 3-3 drives hollow sphere 3-5 to rotate according to a control signal, adjusting the relative position of channel 3-6 and the inner cavity of gas delivery pipe 3-1, thus controlling the gas flow rate. After entering valve structure 1, the coupling state between valve core 1-8 and valve seat 1-6 controls the opening and closing of the valve. When the valve is open, gas enters gas anomaly detection section 2 through valve structure 1. Flow rate sensor 2-5, pressure sensor 2-4, and moisture sensor 2-2 collect real-time data on gas flow rate, pressure, and moisture content, and transmit this data to the control system. The control system uses the collected data to determine if there are any abnormalities in the gas filling process, such as excessively high flow rate, excessively high pressure, or excessive moisture content. When an anomaly is detected, the control system sends a control signal to servo motor 1-4, driving valve stem 1-5 to move and adjusting the coupling state between valve core 1-8 and valve seat 1-6, thereby controlling the valve opening degree and regulating the gas flow rate to ensure the safety and stability of the gas filling process. Simultaneously, the control system can also send a control signal to small motor 3-3 based on the type of anomaly, adjusting the rotation angle of hollow sphere 3-5 to further optimize the gas flow control effect.

[0031] Based on the above description, the workflow of this technical solution is explained as follows:

[0032] When gas filling begins, the gas first enters the gas delivery pipe 3-1 of the gas control section 3. At this time, the hollow sphere 3-5 is in its initial position, and the channels 3-6 on its left and right side walls are aligned with the inner cavity of the gas delivery pipe 3-1. The gas flows normally through the channels 3-6. At the same time, the absorbent cotton balls inside the hollow sphere 3-5 absorb the moisture in the gas, reducing the gas humidity. If the gas flow rate and pressure are within the normal range, the gas continues to enter the inner cavity of the housing 1-1 through the air inlet port of the valve structure 1 via the channels 3-6. At this time, the servo motor 1-4 does not receive any abnormal signals, and the valve stem 1-5... In the initial position, valve core 1-8 and valve seat 1-6 are in normal coupling state, and the valve maintains the set opening degree. Gas flows out from the exhaust port after passing through valve structure 1 and enters the intake pipe 2-1 of gas anomaly detection section 2. Flow velocity sensor 2-5, air pressure sensor 2-4, and moisture sensor 2-2 monitor the flow velocity, pressure, and moisture content of the gas in intake pipe 2-1 in real time and transmit the monitoring data to the external control system. When the gas flow velocity and air pressure are within the normal range and the moisture content does not exceed the standard, the external control system does not issue an abnormal signal, and each component maintains its current working state. Under normal conditions, the gas is continuously and stably filled. If the flow rate sensor 2-5 detects that the gas flow rate is too high, it transmits the flow rate data to the external control system. After analyzing the data, the external control system determines that the flow rate is abnormal and then sends a control signal to the servo motor 1-4. Upon receiving the signal, the servo motor 1-4 starts, and its output shaft drives the valve stem 1-5 to move upward. The valve stem 1-5 drives the valve core 1-8 to move upward, changing the coupling degree between the valve core 1-8 and the valve seat 1-6, reducing the valve opening degree, thereby reducing the gas flow rate and lowering the flow velocity. At the same time, the external control system can also send control signals to the small motor 3-3. After the small motor 3-3 starts, its output shaft drives the rotating column 3-2 to rotate. The rotating column 3-2 drives the hollow sphere 3-5 to rotate, causing the relative position of the channel 3-6 on the hollow sphere 3-5 and the inner cavity of the gas delivery pipe 3-1 to change. This further adjusts the gas flow cross-sectional area and assists in controlling the gas flow rate. When the flow rate drops to the normal range, the flow rate sensor 2-5 transmits the normal data to the external control system. The external control system stops sending signals to the servo motor 1-4 and the small motor 3-3, and all components stop operating. The valve maintains its current opening degree, and the gas continues to be filled stably.

[0033] If the pressure sensor 2-4 detects excessively high gas pressure, it transmits the pressure data to the external control system. The external control system analyzes the data and determines the pressure is abnormal. It then sends a control signal to the servo motor 1-4. The servo motor 1-4 drives the valve stem 1-5 and valve core 1-8 to actuate, reducing the valve opening and decreasing the gas flow to lower the pressure. Simultaneously, it can control the small motor 3-3 to rotate the hollow sphere 3-5. By adjusting the position of the channel 3-6 and utilizing the small holes 3-7 on the front and rear side walls of the hollow sphere 3-5 to slow the flow, it further assists in reducing the pressure. Once the pressure drops to the normal range, the pressure sensor 2-4 transmits normal data to the external control system. The external control system then stops sending signals, all components cease operation, and the valve... The current state is maintained, and gas filling continues. If the moisture sensor 2-2 detects that the gas moisture content exceeds the standard, it transmits the moisture data to the external control system. After the external control system determines that the moisture content is abnormal, it can control the small motor 3-3 to drive the hollow sphere 3-5 to rotate, so that the absorbent cotton balls filled inside the hollow sphere 3-5 can better contact the gas and enhance the adsorption effect on moisture. At the same time, it can also control the servo motor 1-4 to adjust the valve opening degree according to the actual situation and control the gas flow. When the moisture content drops to the normal range, the moisture sensor 2-2 transmits normal data to the external control system, the external control system stops sending signals, all components stop operating, the valve maintains the current opening degree, and the gas continues to complete the filling process.

[0034] This invention is not limited to the preferred embodiments described above. Anyone should understand that structural changes made under the guidance of this invention, and any technical solutions that are the same as or similar to this invention, fall within the protection scope of this invention. Finally, it should be noted that the structures, proportions, sizes, etc., illustrated in the accompanying drawings are only for illustrative purposes to aid those skilled in the art and are not intended to limit the implementation of this application. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effects and objectives of this application, should still fall within the scope of the technical content disclosed in this application.

Claims

1. A gas filling process anomaly detection and automatic control valve comprising a valve structure (1), characterized in that: A gas control section (3) is connected to the left air inlet port of the valve structure (1), and a gas abnormality detection section (2) is connected to the right exhaust port of the valve structure (1). The valve structure (1) includes a housing (1-1), a valve seat (1-6) fixedly connected to the bottom of the inner cavity of the housing (1-1), and a support seat (1-2) fixedly connected to the top end face of the housing (1-1). Two support columns (1-7) are fixedly connected to the top of the support seat (1-2). A fixing plate (1-3) is fixedly connected to the top of the support column (1-7). A servo motor (1-4) is fixedly connected to the top surface of the fixing plate (1-3). A valve stem (1-5) is fixedly connected to the output shaft of the servo motor (1-4) through the fixing plate (1-3) to the inner cavity of the housing (1-1). A valve core (1-8) coupled to the valve seat (1-6) is fixedly connected to the bottom end of the valve stem (1-5) inside the housing (1-1). The gas anomaly detection section (2) includes a flange (2-3) and an air inlet pipe (2-1) fixed on the right end face of the flange (2-3). A flow rate sensor (2-5), a pressure sensor (2-4) and a moisture sensor (2-2) are embedded and fixed in a ring array on the outer surface of the air inlet pipe (2-1). The gas control section (3) includes a connecting plate (3-4) and a gas delivery pipe (3-1) fixed to the left end face of the connecting plate (3-4). A hollow sphere (3-5) is rotatably disposed in the inner cavity of the gas delivery pipe (3-1). A small motor (3-3) is fixedly connected to the top surface of the gas delivery pipe (3-1), and the output shaft of the small motor (3-3) is connected to a rotating column (3-2) that penetrates the gas delivery pipe (3-1). The bottom end of the rotating column (3-2) is fixedly connected to the outer wall of the hollow sphere (3-5). The hollow sphere (3-5) is filled with absorbent cotton balls to absorb moisture from the gas inside the gas delivery pipe (3-1). The outer surface of the hollow sphere (3-5) is in contact with the inner wall of the gas delivery pipe (3-1). The hollow sphere (3-5) has through channels (3-6) on its left and right sidewalls for gas flow under normal conditions. The hollow sphere (3-5) has multiple fine holes (3-7) on its front and rear sidewalls to slow down the flow when the flow rate or air pressure exceeds the threshold.

2. The gas filling process abnormality detection and automatic control valve according to claim 1, characterized in that: The top section of the valve stem (1-5) is provided with a threaded section, and the inside of the support base (1-2) is provided with a threaded hole that matches the threaded section at the top of the valve stem (1-5).

3. The gas filling process abnormality detection and automatic control valve according to claim 1, characterized in that: The left port of the housing (1-1) is the air intake port, and the right port of the housing (1-1) is the exhaust port.

4. The gas filling process abnormality detection and automatic control valve according to claim 1, characterized in that: The left end face of the flange (2-3) is fixedly connected to the right port of the housing (1-1) by bolts.

5. The gas filling process abnormality detection and automatic control valve according to claim 1, characterized in that: The outer surface of the air intake pipe (2-1) has three openings arranged in a ring array for the flow rate sensor (2-5), air pressure sensor (2-4), and moisture sensor (2-2) to be embedded and fixed.

6. The gas filling process abnormality detection and automatic control valve according to claim 1, characterized in that: The right end face of the connecting plate (3-4) is fixedly connected to the left port of the housing (1-1) by bolts.

7. The gas filling process abnormality detection and automatic control valve according to claim 1, characterized in that: The top surface of the gas delivery pipe (3-1) is provided with a circular hole for the rotating column (3-2) to pass through and rotate, and a dynamic sealing ring adapted to the rotating column (3-2) is installed inside the circular hole.

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