Ball valve state detection device and method

Abstract

The application discloses a ball valve state detection device and method, the device comprises: a motor module, the motor module is integrated with a coaxial output shaft and a motor angle rod, one end of the output shaft is provided with a connecting hole and is connected with a ball valve stem, when the output shaft is driven by a motor in the motor module, the ball valve stem can be synchronously driven to rotate, one end of the motor angle rod is inserted into a hole position groove of an angle position sensor; a control unit, specifically a circuit board, connected with the motor module and the angle position sensor; a shell, the motor module and the control unit are arranged in the shell, and a hole is formed in one side of the shell, one end of the output shaft provided with the connecting hole is connected with the ball valve stem through the hole. The ball valve can be more conveniently disassembled and the stall state detection is realized, the dependence on manual work is reduced, and the existing ball valve does not need to be upgraded.

Description

Technical Field

[0001] This invention belongs to the field of ball valve control technology, specifically relating to a ball valve status detection device and method. Background Technology

[0002] In modern buildings, various media such as water and gas need to be transported to various locations through pipelines. Ball valves are important tools for controlling the flow rate and on / off state of these media. Currently, ball valves are mainly mechanical ball valves, which are divided into two types: mechanical ball valves and electric ball valves. Mechanical ball valves require manual operation using tools, while electric ball valves can be operated electrically. However, in some cases, ball valves may be illegally disassembled for use, or they may become stuck. Mechanical ball valves do not have the function of detecting status, while some electric ball valves have status detection functions, detecting forward, reverse, and stop states. When an abnormality occurs, a stuck state may occur, requiring shutdown and maintenance. There are also cases where the ball valve body is disassembled from the electric actuator. This situation requires detection and alarm functions, including three detection methods: Metal contact detection method: Specifically, the ball valve body and the electric actuator are physically connected directly through two spring-loaded metal contacts. Because these are metal contacts, a pressure difference exists between the system ground and the earth, which can easily lead to abnormal equipment detection.

[0003] Limit switch detection method: It is necessary to drill a hole in the connection position of the electric actuator to embed the limit switch. Drilling a hole weakens the waterproof performance of the equipment and makes the structure more complicated.

[0004] Hall effect detection: This method generally requires embedding a magnet in the ball valve body to work with a Hall sensor for detection. This requires modification of the valve body and has poor versatility.

[0005] Therefore, how to more conveniently perform status detection on ball valves, reduce reliance on manual labor, or avoid the poor versatility of traditional electric detection methods is a technical problem that needs to be solved by those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to solve the technical problem that the existing technology for monitoring the condition of ball valves relies on manual and electric detection, which has poor versatility.

[0007] To achieve the above-mentioned technical objectives, in one aspect, the present invention provides a ball valve status detection device, characterized in that the device comprises: The motor module integrates a coaxial output shaft and a motor angle rod. One end of the output shaft has a connection hole for connecting to the ball valve stem. When the output shaft is driven by the motor in the motor module, it can synchronously drive the ball valve stem to rotate. One end of the motor angle rod is inserted into the slot of the angle position sensor. The control unit, specifically a circuit board, is connected to the motor module and the angle position sensor; The housing contains both the motor module and the control unit, and a hole is provided on one side of the housing. The end of the output shaft with a connection hole is connected to the ball valve stem through the hole.

[0008] Furthermore, the circuit board specifically integrates a power module, a main control module, a wireless communication module, a motor drive module, a sampling module, and an angle feedback module. The angle feedback module includes an angle position sensor and is connected to the main control module.

[0009] Furthermore, the angle position sensor includes a sliding rheostat, wherein the resistance of the sliding rheostat has a linear relationship with the angle of the motor angle rod.

[0010] On the other hand, the present invention also provides a ball valve condition detection method, applied in the ball valve condition detection device as described above, the method comprising: The motor module is controlled by a control unit. The current voltage of the pin connected to the angle position sensor in the main control module is continuously collected a preset number of times according to a preset time period; If the current voltage obtained from the preset number of times is less than the preset first voltage threshold, it is determined that the ball valve has been disassembled. If the current voltage obtained from the preset number of times is greater than the preset second voltage threshold, it is determined that the ball valve is stuck. If the current voltage obtained from the preset number of times is greater than the preset first voltage threshold and less than the preset second voltage threshold, then the ball valve is determined to be operating normally.

[0011] Furthermore, the method also includes adjusting the opening degree of the ball valve, specifically including: The opening to be adjusted is obtained, and the target resistance value is determined based on the opening to be adjusted and the first correspondence relationship. The target resistance value is specifically the target resistance value transmitted from the angle position sensor to the main control module. The first correspondence relationship is specifically the linear relationship between the resistance value output by the angle position sensor and the rotation angle of the ball valve. The opening to be adjusted is specifically the target rotation angle of the ball valve. The target voltage of the pin connected to the angle position sensor in the main control module is determined based on the target resistance value. The main control module drives the motor module to work, thereby driving the output shaft and motor angle rod to rotate; When the current voltage of the pin connected to the angle position sensor in the main control module is equal to the target voltage, the drive motor module is stopped.

[0012] Furthermore, the first correspondence is specifically shown in the following formula: ; In the formula, The rotation angle of the ball valve. This represents the resistance value.

[0013] Furthermore, the range of the ball valve rotation angle is specifically 0° to 90°, and the range of the resistance value is specifically determined based on the resistance range of the angle position sensor itself and the range of the ball valve rotation angle.

[0014] Furthermore, the operation of the motor module via the main control module specifically includes: The current resistance is determined based on the current voltage, the power supply voltage of the angle position sensor, and the first correspondence. Specifically, the current resistance is the resistance value output by the angle position sensor at the current moment. The rotation direction of the motor module is determined based on the target resistance and the current resistance; The motor module operates according to the rotation direction.

[0015] This invention provides a ball valve status detection device and method. Compared with existing technologies, this device includes: a motor module, which integrates a coaxial output shaft and a motor angle rod. One end of the output shaft has a connecting hole for connecting to the ball valve stem. When the output shaft is driven by the motor in the motor module, it can synchronously drive the ball valve stem to rotate. One end of the motor angle rod is inserted into the slot of an angle position sensor; a control unit, specifically a circuit board, connected to the motor module and the angle position sensor; and a housing, in which both the motor module and the control unit are housed. A hole is provided on one side of the housing, through which the end of the output shaft with the connecting hole connects to the ball valve stem. This method enables more convenient status detection of ball valves, reduces reliance on manual labor, and eliminates the need to upgrade existing ball valves. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments or prior art of this specification, the drawings used in the description of the embodiments or prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this specification. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 The diagram shown is a structural schematic of the ball valve status detection device provided in the embodiments of this specification. Figure 2 The diagram shown is a schematic flowchart of the ball valve status detection method provided in the embodiments of this specification. Figure 3 The diagram shown is a circuit diagram of the angle feedback module in an embodiment of this specification. exist Figure 2 In the diagram, the correspondence between component names or lines and the drawing numbers is as follows: Motor module 3, output shaft 4, motor angle rod 5, circuit board 7, angle position sensor 8, lower shell 21, upper shell 22, nut buckle 23. Detailed Implementation

[0018] To enable those skilled in the art to better understand the technical solutions in this specification, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0019] like Figure 1 The diagram shows the structure of a ball valve status detection device, which includes: The motor module integrates a coaxial output shaft and a motor angle rod. One end of the output shaft has a connection hole for connecting to the ball valve stem. When the output shaft is driven by the motor in the motor module, it can synchronously drive the ball valve stem to rotate. One end of the motor angle rod is inserted into the slot of the angle position sensor. The control unit, specifically a circuit board, is connected to the motor module and the angle position sensor; The housing contains both the motor module and the control unit, and a hole is provided on one side of the housing. The end of the output shaft with a connection hole is connected to the ball valve stem through the hole.

[0020] Specifically, the circuit board integrates a power module, a main control module, a wireless communication module, a motor drive module, and an angle feedback module. The angle feedback module includes an angle position sensor and is connected to the main control module. The angle position sensor includes a sliding rheostat, wherein the resistance of the sliding rheostat has a linear relationship with the angle of the motor angle rod.

[0021] Specifically, the circuit board integrates at least a power module, a main control module, a wireless communication module, a motor drive module, a sampling module, and an angle feedback module. The angle feedback module is connected to both the main control module and the angle position sensor. It may also integrate buttons, indicator lights, a storage module, etc.

[0022] The power module converts the DC24V input voltage to a low voltage of 3.3V to provide power to each module.

[0023] The main control module is responsible for interacting with the motor drive module, motor detection and feedback module, wireless communication module, storage module, indicator lights, and buttons. It performs functions such as motor drive, motor position feedback, display, local storage, and network data transmission.

[0024] The buttons are used for self-test function control of the valve's local switch and are connected to the main control module via the GPIO interface.

[0025] Indicator lights are used to indicate power supply, valve switching information, and alarm information, and are connected to the main control module via GPIO interface.

[0026] The storage module is used to store valve status and equipment information locally, and is connected to the main control module via the SPI interface.

[0027] The motor drive module is connected to the main control module via GPIO, enabling control functions such as forward rotation, reverse rotation, and stopping of the motor.

[0028] The motor detection feedback is connected to the main control module via GPIO. The main control module can parse the position and angle information to determine the current opening degree. When the ball valve reaches the fully open or fully closed position, the main control module detects the limit switch signal to complete the switch position determination.

[0029] The wireless communication module connects to the main control module via a serial port, enabling 4G network registration and remote transmission of valve information to the platform. It can also send remote commands to the device.

[0030] Based on the above-mentioned regulating device, this application also provides a method for detecting the state of a ball valve, such as... Figure 2 The diagram shown is a flowchart of a ball valve condition detection method, which includes: Step S101: Control the motor module to work through the control unit.

[0031] Step S102: Collect the current voltage of the pin connected to the angle position sensor in the main control module for a preset number of times according to the preset time period.

[0032] Step S103: If the current voltage obtained by the preset number of times is less than the preset first voltage threshold, then it is determined that the ball valve has been disassembled.

[0033] Step S104: If the current voltage obtained by the preset number of times is greater than the preset second voltage threshold, it is determined that the ball valve is stuck.

[0034] Step S105: If the current voltages obtained from the preset number of acquisitions are all greater than the preset first voltage threshold and all less than the preset second voltage threshold, then the ball valve is determined to be operating normally.

[0035] Specifically, such as Figure 3 The diagram shows the circuit diagram of the angle feedback module. U6 is the angle position sensor. Pin 3 is powered by 3.3V and filtered by ferrite bead FB2 and capacitor C24. Pins 2 and 4 are filtered by resistor R27 and capacitor C30 and then output to the ADC pin of the main control module.

[0036] Table 1 below shows the current and ADC pin voltage values ​​of existing motor a under different states. The ADC pin voltage is the current voltage of the pin connected to the main control module in the angle feedback signal circuit. If other motor models are used, the current and voltage values ​​need to be retested.

[0037] Table 1 ; As shown in the table above, the ADC sampling voltage varies under different conditions. The disassembly state can be identified based on the ADC sampling voltage results. To ensure stability, the software design requires comprehensive judgment based on approximately 200 ADC voltage sampling points. First, the valve and ADC detection are started, and after stabilization, the sampling voltage is collected. If all collected voltage values ​​are below a preset first voltage threshold, the ball valve is determined to be in a disassembled state. Alternatively, if a single collected voltage value is below the first voltage threshold, a disassembly state is triggered. If three consecutive checks show a disassembled state, a disassembly state alarm is triggered. Similarly, if all collected voltage values ​​are below the preset first voltage threshold, the ball valve is determined to be in a disassembled state. Alternatively, if a single collected voltage value is above a preset second voltage threshold, a stall state is triggered. If three consecutive checks show a stall state, a stall fault is triggered. If the voltage value is above the preset first voltage threshold but below the second voltage threshold, the ball valve is considered to be in normal working condition.

[0038] In this embodiment of the application, the method further includes adjusting the opening degree of the ball valve, wherein the opening adjustment specifically includes: The opening to be adjusted is obtained, and the target resistance value is determined based on the opening to be adjusted and the first correspondence relationship. The target resistance value is specifically the target resistance value transmitted from the angle position sensor to the main control module. The first correspondence relationship is specifically the linear relationship between the resistance value output by the angle position sensor and the rotation angle of the ball valve. The opening to be adjusted is specifically the target rotation angle of the ball valve. The target voltage of the pin connected to the angle position sensor in the main control module is determined based on the target resistance value. The main control module drives the motor module to work, thereby driving the output shaft and motor angle rod to rotate; When the current voltage of the pin connected to the angle position sensor in the main control module is equal to the target voltage, the drive motor module is stopped.

[0039] Specifically, the adjustment degree, i.e. the target rotation angle of the ball valve, is first obtained. Then, the target resistance value is determined according to the adjustment degree and the first correspondence. Then, the target voltage of the ADC pin is determined according to the target resistance value. Then, the main control module drives the motor module to work, thereby driving the output shaft and the motor angle rod to rotate. The output shaft drives the ball valve stem to rotate. The motor angle rod changes the resistance value output by the angle position sensor in real time, so the voltage of the ADC pin changes in real time. When the current voltage of the ADC is consistent with the target voltage, it means that the ball valve opening degree is consistent with the adjustment degree.

[0040] In specific application scenarios, the resistance value of U6 is 0~10kΩ, and the ball valve rotation angle is 90°, so the corresponding U6 angle variation is 5 kΩ~7.5 kΩ. That is, the resistance at 0° (fully closed position) is 5 kΩ, and the resistance at 90° (fully open position) is 7.5 kΩ. In other words, the ball valve rotation angle range is specifically from 0° to 90°. The resistance range is determined based on the resistance range of the angle position sensor itself and the range of the ball valve rotation angle. The relationship between the ball valve rotation angle and the resistance value is linear, calculated using the formula y=36x-180. The rotation angle of the ball valve. This represents the resistance value, which is the first correspondence. PA5 is the ADC pin of the main control module. After acquiring the voltage of the ADC pin, the resistance value can be calculated, and then the angle value can be deduced according to the calculation formula.

[0041] For example, if the voltage acquired by the ADC is 2V, substitute 2V into (z / 3.3). From z in step 10, the reverse resistance value is approximately 6.061kΩ. Based on the calculation formula, the angle value is then estimated to be approximately 38.2°. When adjusting the opening degree, such as a 45° opening degree control issued remotely, the motor drive chip performs corresponding PID switching control. After calculation, the 45° opening degree control is achieved when the ADC sampling voltage is approximately 2.0625V.

[0042] In this embodiment of the application, the step of driving the motor module through the main control module specifically includes: The current resistance is determined based on the current voltage, the power supply voltage of the angle position sensor, and the first correspondence. Specifically, the current resistance is the resistance value output by the angle position sensor at the current moment. The rotation direction of the motor module is determined based on the target resistance and the current resistance; The motor module operates according to the rotation direction.

[0043] Specifically, the current resistance can be determined based on the current voltage of the ADC pin, the power supply voltage of the angle position sensor, and the first correspondence. For example, if the voltage acquired by the ADC is 2V, substitute 2V into (z / 3.3). The z in 10=p gives the reverse resistance value p as 6.061kΩ. 3.3 is the power supply voltage of the angle position sensor. Assuming the target resistance value is 7kΩ, it means that the resistance value output by the angle sensor needs to be increased. At the same time, substitute the target resistance value into (z / 3.3). The target voltage is obtained from 10=p. Then, according to the first correspondence, the larger the rotation angle of the ball valve, the larger the resistance value. Therefore, the rotation direction of the motor module can be determined according to the first correspondence, which is the direction in which the ball valve opening increases. Then, the motor module is driven to work according to the rotation direction.

[0044] In summary, after determining the target voltage through the above steps, the main control module sends a start command to the motor module. When the motor module drives the output shaft to rotate, since the motor angle rod is coaxial with the output shaft, it will drive the motor angle rod to rotate synchronously. At this time, the signal detected by the angle position sensor will also change, resulting in a change in the voltage of the pin connected to the main control module in the angle feedback signal circuit. When the motor angle rod rotates, the current voltage of the pin connected to the main control module in the angle feedback signal circuit is sampled and detected in real time. When the current voltage equals the target voltage, it indicates that the rotation angle of the ball valve stem is the opening to be adjusted, thus completing the process of intelligent remote adjustment of the mechanical ball valve opening.

[0045] The controller can be implemented in any suitable manner. For example, it can take the form of a microprocessor or processor and a computer-readable medium storing computer-readable program code (e.g., software or firmware) executable by the (micro)processor, logic gates, switches, application-specific integrated circuits (ASICs), programmable logic controllers, and embedded microcontrollers. Examples of controllers include, but are not limited to, microcontrollers such as STM32, HC32F460, and MSP430. Memory controllers can also be implemented as part of the control logic of the memory. Those skilled in the art will also recognize that, in addition to implementing the controller in purely computer-readable program code form, the same functionality can be achieved by logically programming the method steps to make the controller take the form of logic gates, switches, ASICs, programmable logic controllers, and embedded microcontrollers. Therefore, such a controller can be considered a hardware component, and the means included therein for implementing various functions can also be considered as structures within the hardware component. Alternatively, the means for implementing various functions can be considered as both software modules implementing the method and structures within the hardware component.

[0046] The device embodiments described above are merely illustrative. For example, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or plug-ins may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces, indirect coupling or communication connection between devices or units, and may be electrical, mechanical, or other forms.

[0047] These computer program instructions can also be loaded onto a computer or other programmable resource data updating device, causing a series of operational steps to be performed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable device for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0048] The various embodiments in this specification are described in a progressive manner. Similar or identical parts between embodiments can be referred to mutually. Each embodiment focuses on describing the differences from other embodiments. In particular, system embodiments are basically similar to method embodiments, so the description is relatively simple; relevant parts can be referred to the descriptions in the method embodiments. In the description of this specification, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this specification. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0049] Those skilled in the art will recognize that the embodiments described herein are intended to help the reader understand the principles of the invention, and should be understood that the scope of protection of the invention is not limited to such specific statements and embodiments. Those skilled in the art can make various other specific modifications and combinations based on the technical teachings disclosed in this invention without departing from the spirit of the invention, and these modifications and combinations are still within the scope of protection of this invention.

Claims

1. A method for detecting the condition of a ball valve, characterized in that, An application to a ball valve condition detection device, the device comprising: The motor module integrates a coaxial output shaft and a motor angle rod. One end of the output shaft has a connection hole for connecting to the ball valve stem. When the output shaft is driven by the motor in the motor module, it can synchronously drive the ball valve stem to rotate. One end of the motor angle rod is inserted into the slot of the angle position sensor. The control unit, specifically a circuit board, is connected to the motor module and the angle position sensor; The housing contains both the motor module and the control unit, and a hole is provided on one side of the housing. One end of the output shaft with a connection hole is connected to the ball valve stem through the hole. The ball valve status detection method includes: The motor module is controlled by a control unit. The current voltage of the pin connected to the angle position sensor in the main control module is continuously collected a preset number of times according to a preset time period; If the current voltage obtained from the preset number of times is less than the preset first voltage threshold, it is determined that the ball valve has been disassembled. If the current voltage obtained from the preset number of times is greater than the preset second voltage threshold, it is determined that the ball valve is stuck. If the current voltage obtained by the preset number of times is greater than the preset first voltage threshold and less than the preset second voltage threshold, then the ball valve is judged to be operating normally. The resistance value of the angle position sensor is 0~10kΩ. The ball valve rotates at an angle of 90°. When the ball valve rotates between 0° and 90°, the resistance value of the corresponding angle position sensor is 5kΩ~7.5kΩ. The resistance value corresponding to 0° (fully closed) is 5kΩ, and the resistance value corresponding to 90° (fully open) is 7.5kΩ.

2. The ball valve condition detection method as described in claim 1, characterized in that, The circuit board specifically integrates a power module, a main control module, a wireless communication module, a motor drive module, a sampling module, and an angle feedback module. The angle feedback module is connected to both the main control module and the angle position sensor.

3. The ball valve condition detection method as described in claim 1, characterized in that, The angle position sensor includes a sliding rheostat, wherein the resistance of the sliding rheostat has a linear relationship with the angle of the motor angle rod.

4. The ball valve condition detection method as described in claim 1, characterized in that, The method further includes adjusting the opening degree of the ball valve, wherein the opening adjustment specifically includes: The opening to be adjusted is obtained, and the target resistance value is determined based on the opening to be adjusted and the first correspondence relationship. The target resistance value is specifically the target resistance value transmitted from the angle position sensor to the main control module. The first correspondence relationship is specifically the linear relationship between the resistance value output by the angle position sensor and the rotation angle of the ball valve. The opening to be adjusted is specifically the target rotation angle of the ball valve. The target voltage of the pin connected to the angle position sensor in the main control module is determined based on the target resistance value. The main control module drives the motor module to work, thereby driving the output shaft and motor angle rod to rotate; When the current voltage of the pin connected to the angle position sensor in the main control module is equal to the target voltage, the drive motor module is stopped.

5. The ball valve condition detection method as described in claim 4, characterized in that, The first correspondence is shown in the following formula: ； In the formula, The rotation angle of the ball valve. This represents the resistance value.

6. The ball valve condition detection method as described in claim 5, characterized in that, The specific range of the ball valve rotation angle is 0° to 90°, and the specific range of the resistance value is determined based on the resistance range of the angle position sensor itself and the range of the ball valve rotation angle.

7. The ball valve condition detection method as described in claim 6, characterized in that, The operation of the motor module via the main control module specifically includes: The current resistance is determined based on the current voltage, the power supply voltage of the angle position sensor, and the first correspondence. Specifically, the current resistance is the resistance value output by the angle position sensor at the current moment. The rotation direction of the motor module is determined based on the target resistance and the current resistance; The motor module operates according to the rotation direction.

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