Mobile diagnostic device and diagnostic method for actuator

Abstract

A mobile diagnostic device (20) for an actuator (1), in particular for a valve, comprises an interface (21) for establishing a preferably wireless data connection (30) between the diagnostic device (20) and the actuator (1), and at least one sensor (26). The diagnostic device (20) is designed to acquire diagnostic data of the actuator (1) via the interface (21) and to acquire additional time-dependent information data by means of the at least one sensor (26). According to the invention, the diagnostic data comprises data or values of a manipulated or controlled variable (s) of the actuator (1), and the information data comprises data or values of a quantity acquired by the sensor (26) on the actuator (1). By means of such a diagnostic device (20) and by combining the acquired diagnostic data and information data, new diagnostic possibilities can be obtained in the field of the actuator, in particular with respect to the parameterization of the actuator.

Description

Technical Field

[0001] This invention relates to a motion diagnostic apparatus for an actuator according to the preamble of claim 1, and a diagnostic method for an actuator according to the preamble of claim 9. For example, DE 10 2016 117 813 A1 discloses such a motion diagnostic apparatus and / or such a diagnostic method. Background Technology

[0002] Process execution technology, or actuator technology, focuses on measures for the continuous and discontinuous regulation of material and energy flows, in conjunction with process control and sensing technologies. Here, the term "actuator" is generally understood as a system comprising a regulating element, an actuating drive, and components or auxiliary equipment for signaling, regulating, or controlling the regulating element. Therefore, an actuator is essentially an actuator comprising a complex mechatronic unit consisting of multiple components. Examples of actuators for flowing materials include control valves (e.g., lift valves, ball valves, gate valves, butterfly valves) and regulating machines (e.g., pumps). In more recent literature, the term "asset" is also used to refer to a system comprising a regulating element, an actuating drive, and its associated components / auxiliary equipment (i.e., a mechatronic unit), for example, referring to a control valve as a "valve asset."

[0003] A regulating element is a mechanical component that comes into direct contact with a material flow, and includes regulating members for the actual mechanical regulation of the material flow. In the case of a valve, the regulating element includes a valve body with a valve seat, and a closing element, typically a valve cone, that acts in conjunction with the valve seat as the regulating member.

[0004] The task of the actuating drive is to convert the adjustment signal from the automation device into motion, thereby enabling the adjusting member of the adjusting element to obtain a position corresponding to the adjustment signal. This motion can be, for example, a lifting motion or a oscillating motion. The actuating drive can be configured as a pneumatic drive, an electric drive, or a hydraulic drive.

[0005] Components or auxiliary devices used for signal indication, adjustment, or control of regulating elements are, for example, so-called positioners. Furthermore, these components or auxiliary devices may also include solenoid valves, limit switches, position feedback devices, or flow amplifiers. Wiring (e.g., electrical wiring, pneumatic wiring, and / or hydraulic wiring) is also included.

[0006] For cost reasons, actuators in drive control often operate without a feedback channel, that is, they receive (e.g., via fieldbus) the set value of the manipulated or controlled variable and control or adjust the manipulated or controlled variable to that set value in the field.

[0007] Control valves are used in a variety of scenarios requiring control of media flow. In process industries, control valves are typically driven by pneumatic actuators. With the aid of an electro-pneumatic positioner, control pressure can be generated based on the detected valve position to move the valve to a predetermined rated position and maintain it there.

[0008] For example, the flow rate of the medium is controlled by the corresponding lift of the valve cone that interacts with the valve seat. This lift is generated by a pneumatic actuator and transmitted to the valve cone via a transmission element (e.g., valve stem). Such valves and / or such positioners are disclosed, for example, in DE 10 2019 211 213 A1 and DE10 2021 211 592 A1.

[0009] Pneumatic actuators can be configured as linear or rotary actuators. Single-acting and double-acting pneumatic actuators are also known. As alternatives to pneumatic actuators, other drive types, such as electric motor actuators, can also be used.

[0010] The valve position required for control and / or regulation can be determined in various ways. For example, it is known that the movement of a transmission element (e.g., a lever or coupling) is transmitted to the positioner via a mechanical actuation mechanism (lever or coupling) on ​​the transmission element. A sensor is provided within the positioner to measure the position of the transmission element. This sensor can be, for example, a potentiometer, a magnetic sensor, or an inductive sensor. Furthermore, it is also known that a magnet is arranged on the transmission element, and the position of this magnet is determined by a magnetic sensor within the positioner.

[0011] Actuators, and especially their positioners, typically require manual parameterization in the field or workshop. Positioners are usually capable of self-starting (initialization). This process begins in the field. Here, the actuator's basic parameters (e.g., end positions) are autonomously detected and stored accordingly. However, all parameters required to ensure low wear and proper operation of the actuator still need to be entered by the user. These parameters are frequently misset or incomplete, and erroneous input cannot be ruled out.

[0012] Similarly, in service scenarios, it is also necessary to perform and read key indicators or specific tests on-site. Positioners already provide various diagnostic functions, including self-diagnostics and diagnostics capable of judging valve status. For example, these diagnostics include full-stroke and partial-stroke tests, step response tests, valve performance tests, and valve signature tests. However, these diagnostics also have limitations.

[0013] DE 10 2016 207 058 A1 discloses a mobile diagnostic device for field equipment and a diagnostic method. The diagnostic device includes an interface, a storage device, and a camera. The device is configured to acquire diagnostic data from the field equipment via the interface and store it in the storage device; and to acquire time-varying optical information data of the environment surrounding the field equipment using the camera, such as the position of a stirrer, the liquid level in a container, or the color of the liquid. Furthermore, the device is configured to correlate the optical information data with the acquired diagnostic data in time and store it in the storage device. The device is portable. Diagnostic data can refer to sensor data, particularly data from level sensors, material level sensors, temperature sensors, pressure sensors, pH sensors, and / or conductivity sensors. Diagnostic data can also include actuator status data or status values, such as the valve position of a valve.

[0014] DE 10 2013 019 601 A1 relates to an apparatus having a valve, the valve including a valve control device and a (static) optical identifier. The apparatus also includes a mobile device having an optical acquisition unit for acquiring the optical identifier and configured to generate an identifier dataset from image data acquired by the optical acquisition unit. To simplify the process of attributing valve-related data to the valve, the valve dataset is transmitted from the valve control device to the mobile device via a wireless communication connection, and a dataset is generated in the mobile device, the dataset including the identifier dataset and the valve dataset. The valve may include a sensor for detecting the position of a position transmitter connected to the valve's actuation rod. Operating status data, such as characterizing the valve's open and / or closed positions and intermediate positions, is obtained from the sensor data and stored in the valve control device. The mobile device may be used, in a manner not further described, to read the operating status from the valve control device and transmit it to an external analysis unit.

[0015] DE 10 2016 117 813 A1 discloses a portable diagnostic device for actuators used in process fluid delivery, such as control valves in process equipment. This diagnostic device includes an identification unit for acquiring individual actuator identification and at least one acoustic sensing unit for non-contact acquisition of the actuator's acoustic emissions. Actuator-specific measurements output on an actuator display can be read or received from the actuator electronics unit of the positioner using a short-range communication unit (e.g., a camera). The information displayed on the display can be the current and / or historical operating status and / or environmental measurements of the actuator (e.g., a valve). The actuator's operating status can be, for example, pressure and / or temperature measurements related to the process fluid being delivered by the actuator. If the actuator is a control valve, the actuator-specific operating status can be, for example, its valve position, such as open, closed, or partially open. Summary of the Invention

[0016] Based on the mobile diagnostic device described in the preamble of claim 1 and the diagnostic method described in the preamble of claim 9, the object of the present invention is to further improve the diagnosis of actuators. This object can be achieved by the respective features of the diagnostic device of claim 1 and the diagnostic method of claim 9. Advantageous improvements are defined by the respective dependent claims.

[0017] A motion diagnostic device for an actuator according to the present invention, particularly for a valve, the motion diagnostic device comprising: - An interface for establishing, preferably wireless, data connection between the diagnostic device and the actuator; -At least one sensor, The diagnostic device is configured to: - Obtain diagnostic data from the executor via the interface. - Acquire additional, time-varying information data using at least one sensor.

[0018] Here, diagnostic data includes data or values ​​of the actuator's manipulated or controlled variables, and information data includes data or values ​​of quantities acquired by sensors at the actuator. Preferably, the variable acquired at the actuator is a physical quantity generated by the actuator itself, such as acceleration, vibration, noise, or a similar quantity.

[0019] Therefore, according to the present invention, the information data is obtained from the actuator itself, rather than acquiring only information data related to the environment surrounding the actuator as in the prior art (wherein, such environmental information data can still be acquired separately within the framework of the present invention). Furthermore, what is acquired here is data or values ​​that change over time, rather than only time-invariant static quantities, such as optical identifiers. Further, according to the present invention, the diagnostic data acquired from the actuator via the interface includes data or values ​​of the actuator's manipulated or controlled variables; in the case of a valve positioner, for example, it includes relevant data or measurements of the position or displacement of the valve actuator. That is, what is acquired here is not only the operating state (e.g., valve open, valve closed), but also precise (numerical) data or values ​​of the manipulated or controlled variables.

[0020] Studies have shown that a variety of time-varying variables can be measured on actuators. Combining these variables with data or values ​​of the actuator's manipulator or controlled variables can create new diagnostic possibilities, particularly for parameterizing actuators, their control and / or regulation devices, or improving test reliability, without requiring additional sensors to be installed on the actuator itself. Due to the use of mobile, preferably portable, diagnostic devices, the aforementioned variables can also be measured on actuators already installed in devices / systems. Examples of variables that can be measured on actuators include vibration / acceleration, acoustic noise, and optical properties.

[0021] In addition to manipulated or controlled variables, other variables can be transmitted along with diagnostic data via the interface, such as pressure in the actuator or pressure supply line, or switching signals.

[0022] The sensor can acquire the variable, for example, from the regulating element of the actuator, the drive mechanism, the positioner, other additional components, or on the line.

[0023] For example, in the case of a ball valve process valve with a magnetic pilot valve, if the acceleration sensor of the diagnostic device is brought into physical contact with the valve body, the minute acceleration of the valve body can be measured, thereby detecting the opening and closing action of the pilot valve and taking it into account during valve diagnosis.

[0024] Using acoustic sensors (such as microphones) in diagnostic devices, it is possible to measure the airborne noise caused by vibrations generated by the actuator during the opening and closing processes. Acoustic sensors can also be used to detect leak locations in pneumatically driven actuators, and even detect internal leaks within the actuator's control and / or regulating devices (such as positioners), or leaks in supply lines.

[0025] Furthermore, acoustic sensors can be used to determine valve stem friction and starting torque, which can then be taken into account in actuator diagnostics. These sensors can also determine the minimum necessary force to achieve a valve's sealed closure and are used for leak detection within the valve body. Through acoustic analysis and directional control of the actuator, spring breakage in pneumatic actuators can also be detected.

[0026] Similarly, accelerometers can be used to determine valve stem friction and starting torque, which can then be taken into account in actuator diagnostics. Accelerometers can also determine the minimum force required to achieve a valve's sealed closure and detect spring breakage. Vibration measurements can also identify cavitation in valves.

[0027] With the help of optical sensors (such as cameras), it is possible to detect the position of the pressure gauge pointer mounted on the actuator and determine its movement along an arc.

[0028] A particular advantage is that the diagnostic device includes multiple different types of sensors.

[0029] The preferred interface is a wireless communication interface, especially one based on the Bluetooth standard. However, other interface technologies can also be used, such as interfaces based on cellular mobile communication, Wi-Fi, infrared, Ethernet, and / or fieldbus.

[0030] Diagnostic devices can be advantageously, at least partially, located in smartphones, mobile communication devices, laptops, or tablets, especially integrated therein. The functionality of the diagnostic device can also be implemented as a software-based module, allowing for advantageous retrofitting (upgrades / additions). Integration into smartphones is particularly advantageous here, as smartphones often already include various sensors that can be used with diagnostic devices; furthermore, the relatively small size and maneuverability of smartphones allow their sensors to easily make physical contact with actuators.

[0031] Diagnostic devices are particularly designed / configured to receive diagnostic data from and / or read diagnostic data from the corresponding actuator (especially the actuator's control and / or regulation equipment) via an interface.

[0032] According to a particularly advantageous embodiment, the diagnostic device is configured to control an actuator, preferably via an interface, to acquire diagnostic data and information data. For example, it can control a control device to perform a defined motion process (e.g., rapid movement followed by slow movement) or to adopt a defined set position (e.g., a position endpoint). Thus, the actuator motion or position required for the desired diagnostic operation can be set, and corresponding diagnostic data and information data can be acquired in the process. Preferably, the control of the actuator and the acquisition of diagnostic data and information data are performed simultaneously. For this purpose, the diagnostic device can, for example, be configured to generate set values ​​for manipulated or controlled variables and send these set values ​​to the actuator via an interface. These set values ​​can, for example, be associated with a defined motion process or a defined position point.

[0033] According to an advantageous embodiment of the invention, the diagnostic device is configured to acquire information data simultaneously by means of at least one sensor during the acquisition of diagnostic data.

[0034] The diagnostic device may include a storage device and be configured to store acquired diagnostic data and information data in that storage device. Optionally, the diagnostic device may also be configured to send the acquired diagnostic data and information data to an external storage device via the aforementioned interface or another interface, and also to receive the data again via a corresponding interface. The external storage device may, for example, be a cloud-based storage device. In both cases, data can be analyzed directly within the diagnostic device.

[0035] The diagnostic device can include an analysis unit configured to temporally correlate information data acquired by at least one sensor with diagnostic data acquired via an interface, particularly to synchronize them. For example, time information (e.g., a timestamp) can be assigned to the data when the actuator generates data or when the diagnostic device acquires data to achieve this temporal correspondence. Furthermore, time synchronization can be performed between timers in the actuator and timers in the diagnostic device via the interface.

[0036] The diagnostic device can also be configured to send acquired diagnostic data and information data to an external analysis unit via the interface or another interface, and to receive diagnostic data and information data that have a time correspondence, especially a time synchronization relationship, with each other via a corresponding interface.

[0037] According to another advantageous embodiment, the diagnostic device includes a user interface and is configured to output diagnostic data and information data that are time-correlated, especially time-synchronized, on the user interface.

[0038] According to a particularly advantageous embodiment, the user interface is configured to acquire control commands from the user for controlling the actuator. This allows targeted diagnostic operations for predetermined movements or positioning to be triggered directly on-site by the user of the diagnostic device (e.g., a service technician). Furthermore, multiple different defined diagnostic operations can be provided to the user through a user-interactive dialogue on the user interface, with the user selecting one to generate the corresponding control command. Here, the defined diagnostic operations or corresponding control commands can be pre-stored in the diagnostic device's storage or obtained dynamically, for example, by receiving them from the actuator via an interface in the first step after establishing a communication connection with the actuator.

[0039] According to another highly advantageous embodiment, the diagnostic device is configured to output operational instructions to a user via a user interface for acquiring information data using at least one sensor. These instructions may include specific instructions on placing the diagnostic device and / or sensor on the actuator to acquire information data. The instructions may be stored in advance as an electronic document in the storage device of the diagnostic device, or obtained dynamically, for example, by receiving them from the actuator via an interface in the first step after establishing a communication connection with the actuator.

[0040] According to another advantageous embodiment, at least one sensor is an accelerometer, a microphone, an optical sensor (camera), a humidity sensor, a brightness sensor, an impact sensor, and / or a lidar (LiDAR) sensor.

[0041] According to another advantageous embodiment, the diagnostic device is configured to parameterize the actuator via an interface (preferably automatically) using the acquired diagnostic data and information data.

[0042] A diagnostic method for actuators according to the present invention, particularly for valves, the diagnostic method comprising the following steps: - Establish a data connection, preferably wireless, between the mobile diagnostic device and the actuator; - Acquire diagnostic data of the actuator via a data connection using a mobile diagnostic device; - Acquire additional information data that changes over time using at least one sensor in a mobile diagnostic device.

[0043] Here, diagnostic data includes data or values ​​of the actuator's manipulated or controlled variables, and information data includes data or values ​​of variables acquired by sensors on the actuator.

[0044] According to an advantageous implementation, the variable acquired on the actuator is a physical quantity generated by the actuator itself.

[0045] According to another advantageous embodiment, in order to acquire diagnostic data and information data, the diagnostic device preferably controls the actuator via a data connection, causing the actuator to perform a defined motion process or to adopt a defined set position. Preferably, the control of the actuator and the acquisition of diagnostic data and information data are performed simultaneously. For this purpose, the diagnostic device can, for example, generate set values ​​for the manipulated variable or the controlled variable and send these set values ​​to the actuator via an interface. These set values ​​can, for example, correspond to a defined motion process or a defined position point.

[0046] The actuator may include a control and / or regulation unit for controlling and / or regulating the position of the actuator by means of a manipulated variable or a controlled variable (e.g., by giving setpoints to the manipulated variable and / or the controlled variable). The control and / or regulation unit may also include an interface through which a data connection is established with a corresponding interface of a mobile diagnostic device.

[0047] According to another advantageous embodiment, in the mobile diagnostic device, acquiring diagnostic data and acquiring information data by means of at least one sensor are performed simultaneously.

[0048] The acquired diagnostic data and information can be stored in the storage device of the mobile diagnostic device. This storage device can be included within the diagnostic device itself or located outside the diagnostic device, such as a cloud-based storage device.

[0049] According to an advantageous embodiment, information data acquired by means of at least one sensor and diagnostic data acquired via an interface are time-correlated and, in particular, time-synchronized. This time correspondence / synchronization can be implemented directly in the mobile diagnostic device or outside the mobile diagnostic device, for example, in a cloud-based manner.

[0050] According to another advantageous embodiment, diagnostic data and information data that are correlated in time, and especially synchronized in time, will be output on the user interface of the mobile diagnostic device.

[0051] It can also obtain control commands from the user through the user interface to control the actuator, and the diagnostic device then controls the actuator according to the control commands.

[0052] Preferably, the diagnostic device outputs operation instructions to the user via a user interface for acquiring information data using at least one sensor.

[0053] At least one sensor is preferably an accelerometer, microphone, optical sensor (camera), impact sensor, and / or lidar (LiDAR) sensor.

[0054] According to another advantageous embodiment, the diagnostic device parameterizes the actuator using the acquired diagnostic data and information data, preferably in an automated manner.

[0055] The effects and advantages described in the method of the present invention and its advantageous embodiments also apply to the positioner of the present invention and its advantageous embodiments. Attached Figure Description

[0056] The invention and further advantageous embodiments formed according to the features of the dependent claims will be further described below with reference to the accompanying drawings. Identical or corresponding parts are denoted by the same reference numerals. The drawings show: Figure 1 A regulating valve having an actuating drive, a positioner, and a diagnostic device according to the invention is shown; Figure 2 A flowchart of the method according to the present invention is shown; Figure 3 The first measurement results obtained on the process valve are shown; Figure 4 It shows Figure 3 A magnified view of the measurement results; Figure 5 The second measurement result obtained on the process valve is shown; Figure 6 The measurement process for diagnosis using a camera is shown; Figure 7 It shows Figure 6 The measurement results of the measurement process. Detailed Implementation

[0057] Figure 1 A simplified schematic diagram shows an actuator in the form of a control valve 1, which includes a control element 2, an electro-pneumatic actuation drive 5, and a valve positioner 8.

[0058] The regulating element 2 includes a valve body 4, a valve seat 3, and a closing element in the form of a valve cone 3′ that works in conjunction with the valve seat 3.

[0059] The regulating valve 1 controls the flow rate of the medium M by the corresponding lift of the valve cone 3′. This lift is generated by the electro-pneumatic actuator 5 and transmitted to the valve cone 3′ via the transmission element 6 (here, the valve stem).

[0060] The actuator 5 is connected to the valve body 4 via a bracket 7. An electro-pneumatic positioner 8 is mounted on the bracket 7. This positioner includes an electronic adjustment unit 14, which acquires the valve position s value via a displacement sensor 9 acting on the transmission component 6, and compares this value with a set value S. The pneumatic actuator 5 is controlled by a pneumatic control unit 16 (which has a compressed air outlet connected to a compressed air line 10) to eliminate adjustment deviations.

[0061] The pneumatic actuator 5 shown here is a single-acting diaphragm actuator with a spring return and a drive chamber 11. The positioner 8 selectively inflates or deflates the drive chamber 11 via the conduit 10, thereby generating a control pressure p within the drive chamber. This control pressure acts on the diaphragm 13, which is connected to the transmission member 6, in a direction opposite to the force of the spring 12. Alternatively, a double-acting actuator can be used in conjunction with a double-acting positioner, so that the double-acting positioner generates two control pressures in opposite directions on both sides of the diaphragm 13. Furthermore, if a rotary actuator is required for the regulating valve 1 instead of a non-linear lift motion, a rotary actuator can be provided to replace the diaphragm actuator.

[0062] The mobile diagnostic device 20 for regulating valve 1 according to the present invention includes a first data interface 21, a second data interface 22, an analysis unit 23, a storage device 24, a user interface 25, and multiple sensors of different types 26, 27 and 28.

[0063] The first data interface 21 is used to establish a data connection 30 between the diagnostic device 20 and the data interface 15 of the positioner 8.

[0064] The diagnostic device 1 is configured to acquire diagnostic data of the control valve 1 via the first interface 21, and to acquire additional time-varying information data by means of sensors 26 to 28. The diagnostic data includes data or values ​​of the manipulated or controlled variables of the actuator 1, in this case, the valve position s; the information data includes data or values ​​of time-varying quantities measurable on the control valve 1, particularly data or values ​​of physical quantities generated by the control valve 1 itself.

[0065] Diagnostic data can also include other data or values, such as the control pressure p within the drive chamber 11.

[0066] As has been demonstrated, various time-varying quantities, particularly physical quantities generated by the control valve 1 itself, can be measured at the control valve 1. These quantities, combined with data or values ​​of the manipulated or controlled variable s (and, if necessary, with other variables of the control valve 1, such as pressure within the actuator 5), offer new diagnostic possibilities, especially for parameterizing the control valve 1 and / or the positioner 8, or for improving test reliability, without requiring additional sensors to be installed on the control valve 1 itself. Examples of physical quantities measurable at the control valve 1 and generated by the control valve 1 itself include vibration or acceleration, acoustic noise, optical properties, etc.

[0067] Because of the use of a mobile, preferably portable, diagnostic device 20, the above-mentioned variables can still be measured even if the regulating valve 1 is already installed in the facility.

[0068] As an example, sensor 26 is an accelerometer, sensor 27 is an acoustic sensor (microphone), and sensor 28 is an optical sensor (camera).

[0069] Sensors 26 to 28 are able to acquire the amount of time-varying quantity at actuator 1, such as at the actuator's regulating element 2, actuation drive 5, positioner 8, conduit 10 or other components or lines not specifically shown.

[0070] Interfaces 15 and 21 are preferably interfaces for wireless communication, particularly interfaces based on the Bluetooth standard. However, other interface technologies can also be used, such as interfaces based on cellular mobile communication, interfaces based on Wi-Fi, interfaces based on infrared, interfaces based on Ethernet, and / or interfaces based on fieldbus.

[0071] The diagnostic device 20 can be advantageously arranged, at least partially, in, and especially integrated into a smartphone, mobile communication device, laptop, or tablet computer. The functionality of the diagnostic device 20 can also be implemented as a software-based module, thereby allowing for advantageous subsequent installation of the diagnostic device.

[0072] The diagnostic device 20 is configured to acquire information data simultaneously with the aid of sensors 26 to 28 during the acquisition of diagnostic data.

[0073] The diagnostic device 20 is also configured to store diagnostic data and information data acquired via interface 21 into storage device 24.

[0074] The analysis unit 23 is configured to temporally associate, and particularly temporally synchronize, information data acquired by sensors 26 to 28 with diagnostic data acquired via interface 21. This can be achieved, for example, by assigning time information (e.g., timestamps) to the data during data generation in positioner 8 or data acquisition in diagnostic device 20. The timer in control valve 1 or positioner 8 can also be time-synchronized with the timer in diagnostic device 20 via first interface 21 and interface 15.

[0075] Optionally or additionally, the diagnostic device 20 can also be configured to send the acquired diagnostic data and information data to an external service device 40 via the second interface 22, particularly to a cloud-based external service device 40.

[0076] External service device 40 may therefore include interface 41, analysis unit 42 and storage device 43.

[0077] Interfaces 22 and 41 are preferably interfaces for wireless communication, especially interfaces based on cellular mobile communication or wireless local area networks.

[0078] The external service device 40 can be used only to store diagnostic data and information data in the storage device 43. That is, the diagnostic device 20 stores this data in the storage device 43 and retrieves this data from the storage device 43 for subsequent analysis by the analysis unit 23.

[0079] The external service device 40 can also be used to coordinate diagnostic data and information data in time, especially to synchronize them in time, in the analysis unit 42, and then send the coordinated and synchronized diagnostic data and information data to the diagnostic device 20.

[0080] The diagnostic device 20 is also configured to receive diagnostic data and information data that are time-dependent and, in particular, time-synchronized, via the second interface 22.

[0081] The user interface 25 is preferably configured as a graphical user interface, and the diagnostic device is configured to output diagnostic data and information data that are time-dependent, and especially time-synchronized, on the user interface 25.

[0082] The control and analysis unit 23 is also configured to control the regulating valve 1 via interface 21 to acquire diagnostic and information data. For this purpose, the control and analysis unit can generate a setpoint S for the manipulated or controlled variable. The set value is sent to the positioner 8 via interface 21. This enables simultaneous (synchronous) control of the control valve 1 and acquisition of diagnostic and information data. For example, it allows for targeted initiation and execution of a predetermined movement or predetermined positioning of the control valve 1 or its valve cone 3′ for diagnostic operations.

[0083] To this end, the user interface 25 is configured to acquire control commands from the user for controlling the regulating valve 1. Thus, a diagnostic operation, including targeted predetermined movement or positioning of the control valve, can be initiated directly on-site by the user of the diagnostic device 20 (e.g., a service technician). The user can also be provided with multiple different defined diagnostic operations to choose from through a user interaction dialog on the user interface 25, and the user generates the corresponding control command by selecting one of the diagnostic operations.

[0084] The defined diagnostic operations or corresponding control commands can be pre-stored in the storage device 24 or obtained dynamically, for example, by receiving them from the control valve 1 via the interface 21 in the first step after establishing a communication connection with the control valve 1.

[0085] The diagnostic device 20 is also configured to output operational instructions to the user via the user interface 25 for acquiring information data using sensors 26 to 28. These instructions may include specific instructions on placing the diagnostic device 20 and / or the corresponding sensors 26 to 28 on the control valve 1 to acquire the information data. These instructions may be stored in advance as an electronic document in the storage device 24, or obtained dynamically, for example, by receiving them from the control valve 1 via the first interface 21 in the first step after establishing a communication connection with the control valve 1.

[0086] Figure 2 against Figure 1 An exemplary embodiment illustrates a flowchart 50 of the method of the present invention.

[0087] In the first step 51, the user's instruction for establishing a data connection 30 between interfaces 15 and 21 is obtained via the user interface 25 and the instruction is passed to the control and analysis unit 23.

[0088] Furthermore, in the second step 52, the control and analysis unit 23 establishes a data connection 30 between the diagnostic device 20 and the positioner 8, more specifically, establishes a data connection 30 between their respective interfaces 15 and 21.

[0089] In the third step 53, the user is provided with multiple testing and parameterization options on the user interface 25. These options can be pre-stored in the storage device 24 or retrieved from the locator 8 via the data connection 30.

[0090] In step 54, the user selects one of the options via user interface 25. The control and analysis unit 23 obtains this selection via user interface 25.

[0091] Based on this selection, in step 55, operational instructions for using sensors 26 to 28 are output to the user, for example, instructions on the arrangement of sensors 26 to 28 on the control valve 1. These instructions could, for example, be to place the sensors in direct physical contact with the valve body 4 of the control valve 1.

[0092] In step 56, the control and analysis unit 23 prompts the user via the user interface 25 to input start or control commands for the selected test or parameterization option. Based on the user's start or control commands obtained via the user interface 25, the control and analysis unit generates control commands for the actuator 1, for example, generating a setpoint S for the valve position. The control command is then sent to the locator 8 via data connection 30.

[0093] In step 57, the positioner 8 determines the value of the valve position s obtained by the displacement sensor 9 and compares this value with the set value S input via the data interface 15. The pneumatic actuator 5 is controlled via the pneumatic control unit 16 and compressed air line 10 to eliminate adjustment deviations. Optionally, time information (e.g., a timestamp) is assigned to the valve position s value acquired by the displacement sensor 9, and the valve position s (along with the time information if necessary) is transmitted to the diagnostic device 20 via interfaces 15 and 21. Time information (e.g., a timestamp) can also be assigned when the valve position s is acquired at interface 15. At the same time, the diagnostic device acquires physical quantities measurable outside the regulating valve 1 via sensors 26 to 28, such as acceleration (vibration), noise, or optical characteristics (e.g., pressure gauge display), and also assigns time information (e.g., timestamps) to them.

[0094] The control and analysis unit 23 stores this data along with time information into the storage device 24. Optionally or additionally, this data or measurement value can also be stored in a cloud-based storage device 43.

[0095] In step 58, the data or measurements acquired by sensors 26 to 28 are matched in time with the data or values ​​of valve position s acquired via interface 21, and especially synchronized in time. This can be directly achieved by the control and analysis unit 23 in the mobile diagnostic device 20. Optionally or additionally, it can also be achieved by the cloud-based control and analysis unit 42; in this case, the matched, especially synchronized, data is then transmitted back to the diagnostic device 20.

[0096] In step 59, the control and analysis unit 23 outputs data that are mutually associated in time, especially synchronized in time, to the user interface 25. The user can use this data for parameterization during debugging and for extended diagnostics or testing. Preferably, the diagnostic device 20 automatically parameterizes the positioner 8 using the acquired diagnostic and information data.

[0097] Figure 3 Taking a ball valve process valve with a magnetic pilot valve as an example, this invention illustrates new diagnostic possibilities. The ball valve process valve includes a magnetic pilot valve, a double-acting electro-pneumatic actuator, and a valve positioner. The diagnostic device is integrated into a smartphone.

[0098] At time T (in seconds), the time synchronization measurement results for the following variables were output: a) Diagnostic data: P1, P2: Chamber pressure values ​​of the double-acting electro-pneumatic drive device (unit: bar); S: The position S of the valve stem of the drive device (a controlled variable), normalized to a value based on the maximum value (%). Pz: The pressure value in the compressed air line from a valve of the positioner to the electric drive unit; Ue: The drive control signal at the solenoid valve, normalized to its maximum value.

[0099] b) Information and data: Ax, Ay, Az: Acceleration components along the x, y, and z directions at the valve body (unit: m / s²) 2 ).

[0100] The vibration of the valve can be measured based on accelerations Ax, Ay, and Az. The valve's accelerations Ax, Ay, and Az can be measured using an acceleration sensor of the diagnostic device according to the invention; this acceleration sensor is in direct surface-to-surface physical contact with the valve body, thereby substantially measuring the solid-state sound of the valve body.

[0101] from Figure 3 The acceleration data can be used to read the opening and closing process of the solenoid valve (marked as 60), the pressure change in the chamber (marked as 61), the starting torque of the drive device (marked as 62), and the closing process of the valve (marked as 63).

[0102] Vibration of the valve body can also produce airborne noise, which can be measured, for example, using a microphone on a diagnostic device. Figure 3 In the figure, the vibration that can produce airborne sound is illustrated by reference numeral 64.

[0103] Measurement results show that, compared to position and drive control data, the data or measurements of accelerations Ax, Ay, and Az contain additional information that can be used to perform automation parameterization or determine the state of control valves. It can even provide information related to the switching action of solenoid valves.

[0104] 1. Application examples using smartphone microphones

[0105] according to Figure 1 A smartphone with integrated diagnostic device 20 communicates with the positioner 8 via Bluetooth connection 30. The user can use a smartphone application on the graphical user interface 25 to select auxiliary parameterization or control valve diagnostics via menu. At this time, the control and analysis unit 23 graphically displays the correct way to hold the smartphone relative to the control valve 1 (orientation and distance relative to the control valve 1) to the user on the user interface 25. After pressing the corresponding button on the user interface 25, a control command is sent to the positioner 8 via data connection 30. Simultaneously, measurements for determining acoustic information data are initiated using the built-in microphone.

[0106] 1a) Leakage identification: Leakage locations can be detected by targeted actuation control of each chamber of the drive unit (depending on the drive unit type: single-acting or double-acting). Different distinguishable fault states include: - Leaks in the supply lines (e.g., leaks in line 10); - Leakage in the positioner 8 itself (e.g., diaphragm rupture); - Leakage in drive unit 5 (for a double-acting drive unit, the leakage in both chambers can be quantitatively determined).

[0107] In particular, it provides additional assistance to field services in determining the location of leaks. Therefore, it can also identify leaks inside the locator and leaks in the supply pipeline.

[0108] 1b) Determination of valve stem friction / starting torque: Some positioners typically offer two diagnostic modes for estimating friction within the control valve: a full-stroke test and a partial-stroke test. These tests utilize the number of pressure pulses and the time behavior of position changes for analysis. Additional information provided by acoustic diagnostics allows for further refinement of the testing process.

[0109] When full shutdown or full opening is not permitted during operation, facility operators conduct partial trip tests. In such cases, the risk can be minimized, for example, using acoustic diagnostics, and can even be completed with minimal or no noticeable change in location. Figure 4 for Figure 3 A magnified view of the "start (disengage)" time interval. It can be seen that, due to internal stress and the minute movement of the valve stem, the torque critical point can be identified through vibration data and / or acoustic data at the instant before start-up (see attached figure 65).

[0110] The following sections will further illustrate two other particularly advantageous applications for using microphones for acoustic analysis to determine starting torque: Every drive device with sliding bearings, in addition to having a relatively definite sliding friction, also experiences static friction. Starting torque refers to the torque required to overcome the holding force of static friction and initiate movement. After starting, the driving force only needs to contend with inertial forces, internal system forces, and sliding friction. For valves, especially safety valves, corrosion or adhesion effects often occur due to their long-term static position, significantly determining the magnitude of static friction. This value is particularly important for users, especially when performing trend analysis. However, once the valve has moved, this value cannot be determined using traditional methods. With this invention, the starting torque can still be determined even after the valve has moved.

[0111] Besides corrosion or adhesion effects caused by prolonged inactivity, sliding bearings also experience wear during continuous operation, affecting both sliding and static friction. By performing targeted drive control on the actuator multiple times under real-world conditions and measuring at various points within the operating range, these two types of friction values ​​can be determined separately. This allows for the assessment not only of the sliding bearing's condition but also of its condition distribution along the length of the valve stem's working stroke.

[0112] 1c) Determination of the minimum necessary force for sealing closure / Process valve leakage detection

[0113] The endpoint position of a control valve can typically be detected by the positioner itself. The endpoint position is defined as the position where no further pressure increase / decrease results in any change in position. If the facility operator must achieve a stable endpoint (typically closed) for the valve during process operation, this can be ensured through the "sealed shut-off" function in the parameterization. In this case, the positioner continues to increase or decrease the pressure in the actuator, thereby pressing the valve body to the endpoint or seal with excess force, making the valve more reliably closed, for example, more reliably sealing even in the event of pressure pulses. However, this method also leads to increased wear on the shut-off and seal components.

[0114] Vibration occurs during the process of the closing element entering the seal and pressing it against the seal, even when the positioner can no longer detect further positional changes. Utilizing this fact, and in conjunction with the smartphone microphone solution described in this paragraph, the degree of pressure can be quantified. Figure 5 Exemplary Figure 3 The measurement data was magnified and extracted for visualization.

[0115] Mark 66 indicates contact between the closing element and the seal. From the moment of contact, further increasing the pressure will only cause the position s of the control valve to change by 0.7% of the total stroke, a change that is no longer meaningfully discernible by the positioner. The curve below shows the vibration data acquired synchronously with the entire measurement range. Vibrations generated during the clamping process are still clearly discernible, providing additional information.

[0116] In addition to the vibrations generated by compression, the process valve also vibrates and causes sound propagation when the medium flows through it. This means that even moments when the medium flow rate is zero can be detected in a characteristic manner using a microphone.

[0117] This information enables facility operators to automate and parameterize "sealed shutdown" under conditions of minimal process valve wear. Furthermore, it allows for leak detection of process valves.

[0118] 1d) Spring breakage detection

[0119] Pneumatic actuators typically incorporate steel springs to ensure process valves remain in a defined position during pressure loss. These springs are susceptible to fatigue and even breakage, rendering the aforementioned function unreliable depending on the specific design. Currently, detecting such spring breakage is generally very costly (e.g., disassembly and visual inspection, or analysis of pressure pulse width trends).

[0120] Through acoustic analysis and targeted control, this type of fault can be detected based on highly characteristic acoustic features (acoustic signatures).

[0121] 1e) Cavitation Identification

[0122] Cavitation is one of the most critical failure conditions for process valves, and facility operators must avoid it. Even short-term operation under cavitation conditions can damage process valves. Cavitation generates strong vibrations, creating a characteristic acoustic signature that can be identified using the smartphone microphone method presented here.

[0123] Based on the facility operator's domain knowledge, process valves should be selected / designed and parameterized accordingly to ensure cavitation suppression under all process conditions. Targeted parameterization of positioners, combined with acoustic diagnostics, can provide support to the facility operator. The benefits to the facility operator include: - Avoid potential incorrect parameterization; - It can protect process valves even when process parameters fluctuate drastically; - Avoid over-selection of process valves (which would lead to excessive costs); - Increase throughput / Run the process near its optimal limits.

[0124] 2. Application examples using smartphone accelerometers

[0125] The cause of airborne sound radiation, and the basis of acoustic diagnostics, is the vibration of a control valve. This solid-borne sound also propagates throughout the control valve and can be detected by contact acceleration measurements on its surface. The main difference between airborne sound measurements and acceleration measurements lies in the different frequency ranges where they have the highest sensitivity. This difference depends on both the sensors built into the smartphone (accelerometer and microphone) and the propagation characteristics of solid-borne sound and its coupling / conversion characteristics to airborne sound.

[0126] Therefore, frequencies below 1 kHz are more suitable for detection using accelerometers, while frequencies between 1 and 40 kHz are more suitable for detection using microphones.

[0127] It is also possible to combine the two types of sensors.

[0128] Possible application examples that use only an accelerometer include: - Determination of valve stem friction / starting torque (static friction breaking torque); - Used for detection and parameterization of seal closure; - Spring breakage detection.

[0129] In this application example, the user initiates the measurement via a smartphone app as described above. The smartphone must then be pressed firmly against the defined position of the regulating valve with a precisely defined orientation.

[0130] 3. Examples of applications using smartphone cameras

[0131] The smartphone communicates with the positioner wirelessly. Users can select auxiliary parameterization or valve diagnostics via the application menu. The correct smartphone holding position (orientation and distance) relative to the valve is then graphically displayed to the user. Pressing the corresponding button on the smartphone sends control commands to the positioner. Simultaneously, the smartphone's built-in camera begins recording. By processing the image data, for example, the position of the attached pressure gauge pointer can be detected, and its movement along an arc can be determined. Figure 6 This is illustrated by an example. The regulating valve 1 includes a pressure gauge 70 and its pointer 71. The designation 80 indicates a smartphone integrated with the diagnostic device 20 according to the invention. An image 83 of the pressure gauge 70, captured by the smartphone camera, is displayed on the graphical user interface 81 of the smartphone 80, and the image is further magnified in a local area 74 of the image. Figure 7 The example shows the change in pressure Pz and the position Z of pointer 71 over time T.

[0132] The stiffness of the entire system to the defined pressure pulse generated by the supply pressure Pz can be estimated from the jump response marked 85. The stiffness of the pneumatic actuator is dominant. Therefore, the pointer position signal contains information about the diaphragm and spring states of the actuator. Especially when performing trend analysis on multiple measurements, information about potential system degradation can be obtained. Furthermore, vibrations and deformations of the control valve can be identified using image processing methods.

[0133] The above application scenarios can also be combined, meaning that multiple sensors of a smartphone can be used simultaneously or sequentially. One example is using microphone data and vibration data simultaneously to eliminate the spectral insensitivity of a single sensor.

Claims

1. A motion diagnostic device (20) for an actuator (1), particularly for a valve, the motion diagnostic device comprising: - Interface (21), the interface is used to establish a preferably wireless data connection (30) between the diagnostic device (20) and the actuator (1). -At least one sensor (26); The diagnostic device (20) is configured to, - Obtain diagnostic data of the actuator (1) via the interface (21); - Additional time-varying information data is acquired by means of the at least one sensor (26), wherein the information data includes data or values ​​of variables acquired by the sensor (26) at the actuator (1); Its features are, - The diagnostic data includes data or values ​​of the manipulator or controlled variable(s) of the actuator (1).

2. The mobile diagnostic device (20) according to claim 1, wherein, The variable obtained at the actuator (1) is a physical quantity generated by the actuator (1) itself.

3. The mobile diagnostic device (20) according to claim 1 or 2, wherein, The mobile diagnostic device is configured to, in order to acquire the diagnostic data and the information data, preferably control the actuator (1) via the interface (21) to cause the actuator to perform a defined motion process or to cause the actuator to adopt a defined set position.

4. The mobile diagnostic device (20) according to any one of the preceding claims, wherein, The mobile diagnostic device is configured to acquire the information data simultaneously with the aid of the at least one sensor (26) during the acquisition of the diagnostic data.

5. The mobile diagnostic device (20) according to any one of the preceding claims includes an analysis unit (23) configured to temporally associate the information data acquired by means of the at least one sensor (26) with the diagnostic data acquired via the interface (21), and in particular to temporally synchronize them.

6. The mobile diagnostic device (20) according to any one of the preceding claims, wherein, The mobile diagnostic device includes a user interface (25) and is configured to output diagnostic data and information data on the user interface (25) that are mutually associated in time and, in particular, mutually synchronized in time.

7. The mobile diagnostic device (20) according to any one of the preceding claims, wherein, The at least one sensor (26) is an accelerometer, a microphone, an optical sensor (camera), a humidity sensor, a brightness sensor, an impact sensor, and / or a lidar sensor.

8. The mobile diagnostic device (20) according to any one of the preceding claims, wherein, The mobile diagnostic device is configured to parameterize the actuator (1) via a first interface (21) using the acquired diagnostic data and information data.

9. A diagnostic method for an actuator (1), the diagnostic method being particularly applicable to valves, the diagnostic method comprising the following steps: - Establish a preferably wireless data connection (30) between the mobile diagnostic device (20) and the actuator (1); - The mobile diagnostic device (20) acquires diagnostic data of the actuator (1) via the data connection; - Additional time-varying information data is acquired by means of at least one sensor (26) of the mobile diagnostic device, wherein the information data includes data or values ​​of variables acquired by the sensor (26) at the actuator (1); Its features are, - The diagnostic data includes data or values ​​of the manipulator or controlled variable(s) of the actuator (1).

10. The diagnostic method according to claim 9, wherein, The variable obtained at the actuator (1) is a physical quantity generated by the actuator (1) itself.

11. The diagnostic method according to claim 9 or 10, wherein, In order to obtain the diagnostic data and the information data, the diagnostic device (20) preferably controls the actuator (1) via the data connection (30) to make the actuator perform a defined motion process or to make the actuator adopt a defined set position.

12. The diagnostic method according to any one of claims 9 to 11, wherein, The acquisition of diagnostic data in the mobile diagnostic device (20) and the acquisition of information data by means of at least one sensor (26) are performed simultaneously.

13. The diagnostic method according to any one of claims 9 to 12, wherein, The information data acquired by means of the at least one sensor (26) and the diagnostic data acquired via the interface (21) are matched in time, and in particular synchronized in time.

14. The diagnostic method according to any one of claims 9 to 13, wherein, The diagnostic data and information data will be output on the user interface (25) of the mobile diagnostic device (20) and will be correlated in time and, in particular, synchronized in time.

15. The diagnostic method according to any one of claims 9 to 14, wherein, The at least one sensor is an accelerometer, a microphone, an optical sensor (camera), a humidity sensor, a brightness sensor, an impact sensor, and / or a lidar sensor.

16. The diagnostic method according to any one of claims 9 to 15, wherein, The diagnostic device (20) parameterizes the actuator (1) using the acquired diagnostic data and information data.

Images