Valve life detection apparatus and detection method

Abstract

The application relates to a valve life detection device and a detection method thereof, and belongs to the technical field of valve testing. The device comprises a rack, a clamping mechanism, a fluid circulation system, a driving mechanism, a sensing and monitoring system and a data analysis controller. The clamping mechanism is used for fixing a valve to be detected. The fluid circulation system is connected with an inlet of the valve to be detected and is used for providing controllable test medium and pressure. The driving mechanism is connected with a valve rod of the valve to be detected and is used for simulating valve opening and closing actions. The sensing and monitoring system comprises a torque sensor used for collecting valve rod torque, a position sensor used for collecting valve core position and a flow sensor used for collecting valve rear leakage. In the application, valve mechanical performance degradation data and sealing performance degradation data are associated, the valve residual life can be more comprehensively and accurately predicted, and the problems of single function and inaccurate life evaluation of the existing test equipment are solved.

Description

Technical Field

[0001] This invention relates to the field of valve testing technology, and in particular to a valve life testing device and its testing method. Background Technology

[0002] Valves are key control components in industrial pipeline systems and are widely used in continuous industrial fields such as petroleum, chemical, power, and metallurgy. The reliability and service life of valves are directly related to the safety and stability of the entire system. Valve failure often leads to media leakage, production interruption, environmental pollution, or even catastrophic accidents. Therefore, valve life testing and evaluation have important engineering significance and economic value.

[0003] Currently, there are relevant technical solutions for valve life testing both domestically and internationally. For example, patent CN201710233116.3 published by Lanzhou University of Technology discloses a valve static pressure life test system, including a high-pressure clean water system, a low-pressure solid-liquid two-phase flow system, and a valve test system, realizing static pressure life testing under two media: clean water and solid-liquid two-phase flow. Patent CN202010202144.0 published by Wuzhong Instrument Co., Ltd. discloses an automatic valve static pressure life test device based on gasification pressurization, including a control system, a gas source pressurization system, a loading system, and a drive system, which monitors the pressure life through pressure sensors and limit switches. Regarding valve opening and closing status and sealing performance, Zhengzhou Butterfly Valve Factory's patent CN03243865.6 discloses a valve life testing device, which consists of a pressure tank, pipeline, opening and closing valve, and pressure sensor, and judges valve leakage based on pressure loss. Konica Minolta Corporation's patent CN202010856920.9 discloses a valve deterioration determination method, which determines the valve deterioration degree based on the pressure of the storage section. Kaiji Corporation's patent CN201980037679.2 discloses a valve status monitoring system, which uses a gyroscope sensor to measure the valve shaft angular velocity to monitor the status and predict the life of the rotating valve.

[0004] However, the aforementioned existing technologies all have the following shortcomings: First, the detection dimensions are limited. Most technologies rely solely on pressure loss or a single sensor to determine the valve status, failing to comprehensively collect multi-dimensional performance degradation data of the valve throughout its lifespan, such as changes in valve stem friction, valve core closure position offset, and microscopic wear of the sealing surface. Second, mechanical performance testing and sealing performance testing are isolated from each other, failing to correlate and analyze the data from both, resulting in low accuracy in lifespan assessment. Third, there is a lack of early failure warning capabilities. Most technologies can only detect faults after leakage occurs, which is a post-event detection and cannot achieve preventative maintenance. Fourth, the remaining life prediction methods are simple, mostly using threshold judgment or single parameter trend analysis, without establishing a nonlinear prediction model that integrates multiple degradation characteristics, resulting in limited prediction accuracy. Fifth, the degree of automation varies, with some early-stage devices still requiring manual operation and observation, leading to low testing efficiency and consistency.

[0005] Therefore, there is an urgent need for a testing device and method that can comprehensively monitor multi-dimensional degradation indicators, achieve integrated analysis of mechanical and sealing performance, provide early warning capabilities, and accurately predict the remaining life of valves. Summary of the Invention

[0006] This invention provides a valve life testing device and method, which solves the problems mentioned in the background technology. By integrating a multi-dimensional sensing and monitoring system, it fuses and analyzes data on mechanical performance degradation and sealing performance degradation to achieve accurate prediction of the remaining life of the valve.

[0007] The present invention provides the following solution to the above-mentioned technical problems: On one hand, a valve life testing device includes a frame, a clamping mechanism, a fluid circulation system, a drive mechanism, and a sensing and monitoring system. The clamping mechanism is disposed on the frame and clamps and positions a valve to be tested. The fluid circulation system is connected to the inlet of the valve to be tested to provide a test medium with a set pressure and flow rate to the valve to be tested. The drive mechanism is disposed on the frame, and its output end is used to connect to the valve stem of the valve to be tested to drive the valve stem to perform opening and closing actions. The sensing and monitoring system includes a torque sensor, a position sensor, a flow sensor, and a data analysis controller. The torque sensor is located at the output end of the drive mechanism and collects the torque signal when the valve stem moves in real time. The position sensor is used to collect the displacement signal of the valve core in real time. The flow sensor is located on the outlet pipeline of the valve under test and is used to collect the leakage signal when the valve is closed. The data analysis controller is electrically connected to the fluid circulation system, the drive mechanism, and the sensing and monitoring system. The data analysis controller receives the torque signal, displacement signal, and leakage signal, and evaluates the remaining life of the valve based on a preset algorithm model.

[0008] Based on the above technical solution, the present invention can be further improved as follows.

[0009] Furthermore, the fluid circulation system includes a medium storage tank, a booster pump, and a pressure regulating valve connected sequentially via pipelines. The outlet of the medium storage tank is connected to the inlet of the valve under test. The fluid circulation system also includes a pressure sensor installed on the pipeline near the inlet of the valve under test to detect the inlet pressure. Through the cooperation of the booster pump and the pressure regulating valve, a stable and precisely adjustable test medium pressure and flow rate can be provided to the valve under test to simulate the actual operating conditions of the valve under different working conditions. The pressure sensor monitors the inlet pressure in real time and feeds it back to the data analysis controller to form a closed-loop control, ensuring constant pressure during the test, thereby guaranteeing the accuracy and repeatability of the test results.

[0010] Furthermore, the drive mechanism includes a servo motor and a reducer. The output shaft of the servo motor is connected to the input end of the torque sensor via the reducer. The output end of the torque sensor is equipped with a coupling, which is connected to the valve stem of the valve under test. The servo motor can precisely control the speed and angle to accurately simulate the valve opening and closing action. The reducer is used to reduce the speed and increase the output torque to meet the driving force requirements of different types of valves. The coupling facilitates quick connection of valve stems of different specifications and can compensate for installation deviations, ensuring smooth torque transmission and thus improving the accuracy of the torque sensor's signal acquisition.

[0011] Furthermore, the sensing and monitoring system also includes an acoustic emission sensor, which is installed on the valve body of the valve under test. The acoustic emission sensor is used to collect acoustic emission signals generated by internal leakage of the valve. The acoustic emission sensor can capture high-frequency sound wave signals generated when there is microscopic leakage on the sealing surface. Its sensitivity is much higher than that of traditional flow sensors. It can issue an early warning in the early stage of leakage (even before a measurable macroscopic flow has been formed), realize the monitoring of early degradation of valve sealing performance, and provide more time for preventive maintenance.

[0012] Furthermore, the data analysis controller has a built-in life prediction model. The model takes the cumulative number of actions, the peak torque of the current cycle, the torque fluctuation, the valve core displacement error, and the leakage as input parameters, and the remaining effective life as the output parameter. This model integrates and analyzes multi-dimensional characteristic parameters that reflect mechanical performance (torque, displacement) and sealing performance (leakage) to comprehensively evaluate the overall health status of the valve, avoiding the one-sidedness of single parameter evaluation. By inputting multiple degradation indicators, the model can more accurately capture nonlinear degradation trends, thereby outputting high-precision remaining life prediction results.

[0013] On the other hand, a testing method for a valve life testing device includes the following steps: S1. Installing the valve to be tested on a clamping mechanism and connecting the output end of the drive mechanism to the valve stem; S2. Set test parameters through the data analysis controller, including test pressure, action frequency, and maximum number of actions; S3. Start the fluid circulation system to provide a test medium at a set pressure to the inlet of the valve under test; S4. The data analysis controller controls the drive mechanism to drive the valve to perform continuous opening and closing cycles according to the set operating frequency; S5. During the opening and closing cycle, the sensing and monitoring system collects torque and displacement signals in real time during each action, and collects leakage signals after each closing action; S6. The data analysis controller processes the acquired signals in real time and plots curves showing the changes in torque, displacement, and leakage with the number of actions; S7. When the leakage exceeds the preset failure threshold, or the driving torque exceeds the preset safety threshold, the data analysis controller determines that the valve has reached the end of its lifespan and records the current total number of actions; S8. The data analysis controller combines historical trends to output a prediction report of the valve's remaining life.

[0014] Furthermore, in step S6, the variation curves include the peak torque-number of cycles curve, the torque fluctuation-number of cycles curve, the valve stem full stroke time-number of cycles curve, and the leakage rate-number of cycles curve. These curves visually demonstrate the degradation process of valve performance with the number of cycles from different perspectives: the peak torque reflects the change in driving force, the torque fluctuation reflects the stability of the friction pair, the full stroke time reflects the transmission efficiency, and the leakage rate reflects the sealing performance. Through comprehensive analysis of these curves, major failure modes (such as seal wear, valve stem jamming, etc.) can be quickly identified, and rich visual data support can be provided for life prediction.

[0015] Furthermore, in step S5, the acoustic emission sensor monitors the internal leakage of the valve in the closed state in real time. The data analysis controller compares the acoustic emission signal intensity with the data from the flow sensor 503 to correct the leakage calculation result. The acoustic emission signal is highly sensitive to early micro-leakage, while the flow sensor can quantitatively measure macroscopic leakage. Combining the two can achieve complementary advantages. By comparing the two signals, the data analysis controller can correct measurement errors caused by environmental interference or sensor drift. At the same time, by utilizing the early warning characteristic of the acoustic emission signal, the correction algorithm can be activated before the leakage reaches the detection limit of the flow sensor, thereby obtaining more accurate and timely leakage assessment results.

[0016] Furthermore, in step S8, the remaining life prediction report is generated based on a trend extrapolation algorithm. This algorithm predicts the theoretical number of actions required to reach the failure threshold based on the inflection point and slope of the leakage rate-number curve. The trend extrapolation algorithm utilizes historical data patterns for prediction. By identifying the inflection point (representing the start of accelerated degradation) and subsequent slope on the leakage rate curve, it can dynamically calculate the remaining number of actions required to reach the preset failure threshold. This method is more forward-looking than simple fixed threshold judgment, providing a quantitative estimate of remaining life and offering a scientific basis for developing maintenance or replacement plans.

[0017] Furthermore, the process includes step S9: the data analysis controller generates and stores test logs from the entire testing process to establish a lifespan database for a specific valve model. By accumulating a large amount of test data from valves of the same model or type, a statistically significant lifespan database can be gradually established. This database can be used to verify and optimize lifespan prediction models, provide feedback for valve design improvements, and provide a reference benchmark for subsequent lifespan assessments of valves of the same model, thereby continuously improving the intelligence and accuracy of the testing.

[0018] The beneficial effects of this invention are as follows: This invention provides a valve life testing device and its testing method, which have the following advantages: 1. This invention solves the technical problem of single detection dimensions and realizes multi-dimensional comprehensive monitoring of valve performance. By integrating torque sensors, position sensors, flow sensors, and optional acoustic emission sensors, it can comprehensively collect mechanical performance degradation data (such as changes in valve stem friction and driving torque fluctuations) and sealing performance degradation data (such as changes in leakage and acoustic emission signal characteristics) of valves during their life cycle. This breaks through the limitations of existing technologies that rely solely on pressure loss or a single sensor to determine valve status, and provides a rich data foundation for the comprehensive assessment of valve health status and accurate prediction of remaining life.

[0019] 2. This invention solves the technical problem of the separation between mechanical performance testing and sealing performance testing, and realizes the fusion analysis of multi-source data. The data analysis controller of this invention has a built-in life prediction model, which takes multi-dimensional characteristic parameters such as cumulative number of actions, peak torque, torque fluctuation, valve core displacement error and leakage as input. By fusion analysis of the correlation and degradation law between mechanical performance and sealing performance, it comprehensively evaluates the overall health status of the valve, avoids the one-sidedness of single parameter evaluation, and significantly improves the accuracy of life assessment.

[0020] 3. This invention solves the technical problem of lacking early failure warning capabilities and enables the monitoring of early degradation of valve sealing performance. By adding an acoustic emission sensor, this invention can capture high-frequency acoustic signals generated when there is microscopic leakage on the sealing surface. Its sensitivity is much higher than that of traditional flow sensors. It can issue an early warning in the early stage of leakage (even before a measurable macroscopic flow has been formed), transforming the post-event detection of existing technologies into pre-event warning, providing more time for preventive maintenance and effectively reducing the risk of sudden failures.

[0021] 4. This invention addresses the technical issues of limited accuracy and simplicity in remaining lifetime prediction methods, achieving high-precision remaining lifetime prediction. On one hand, the data analysis controller visually displays the multi-dimensional performance degradation process by plotting torque peak-time-time curves, torque fluctuation-time-time curves, valve stem full stroke time-time-time-time curves, and leakage rate-time-time curves, facilitating the identification of major failure modes. On the other hand, based on a trend extrapolation algorithm, it dynamically calculates the theoretical number of actions required to reach the failure threshold by identifying the inflection point and slope of the leakage rate curve, providing a quantitative remaining lifetime estimate. The prediction results are more forward-looking and scientific than simple fixed threshold judgments.

[0022] 5. This invention solves the technical problems of inconsistent levels of automation and low testing efficiency and consistency, achieving automation and standardization of the testing process. The data analysis controller of this invention is electrically connected to the fluid circulation system, drive mechanism, and sensing and monitoring system, and can automatically complete the entire process of parameter setting, action cycle control, data acquisition and processing, threshold judgment, and report generation, reducing manual intervention and improving testing efficiency and result consistency. At the same time, by generating and storing test data into logs, a life database for specific valve models is gradually established, providing valuable data support for subsequent valve design improvement, selection optimization, and maintenance strategy formulation, continuously improving the intelligence level and accuracy of testing.

[0023] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it according to the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Specific embodiments of the present invention are given in detail below with reference to the accompanying drawings. Attached Figure Description

[0024] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings: Figure 1 This is a schematic diagram of a valve life testing device and its testing method according to an embodiment of the present invention; Figure 2A front view of a valve life testing device and testing method according to an embodiment of the present invention; Figure 3 This is a side view of a valve life testing device and testing method according to an embodiment of the present invention. Figure 4 This is a flowchart illustrating a valve life testing device and testing method according to an embodiment of the present invention.

[0025] The following is a list of components represented by each label in the attached diagram: 1. Frame; 2. Clamping mechanism; 3. Fluid circulation system; 301. Medium storage tank; 302. Booster pump; 303. Pressure regulating valve; 304. Pressure sensor; 4. Drive mechanism; 401. Servo motor; 402. Reducer; 403. Coupling; 5. Sensing and monitoring system; 501. Torque sensor; 502. Position sensor; 503. Flow sensor; 504. Data analysis and controller; 505. Acoustic emission sensor; 6. Valve under test. Detailed Implementation

[0026] The following is in conjunction with the appendix Figure 1-4 The principles and features of the present invention are described below. The examples given are for illustrative purposes only and are not intended to limit the scope of the invention. The invention is described more specifically in the following paragraphs by way of example with reference to the accompanying drawings. The advantages and features of the invention will become clearer from the following description. It should be noted that the drawings are in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the invention.

[0027] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The terminology used herein includes, and / or encompasses, any and all combinations of one or more of the associated listed items.

[0028] like Figure 1-3 As shown, the present invention provides a valve life testing device, including a frame 1, a clamping mechanism 2, a fluid circulation system 3, a drive mechanism 4, and a sensing and monitoring system 5; The frame 1 serves as the installation base for the entire equipment, providing stable support for other components. The clamping mechanism 2 is mounted on the frame 1 and is used to clamp and position the valve 6 to be tested. The clamping mechanism 2 can be a manual, pneumatic, or hydraulically driven clamp, which can adapt to valves of different specifications and models, ensuring that the valve remains fixed during the test and preventing displacement due to vibration or torque, which would affect the test accuracy. The fluid circulation system 3 is used to supply the valve under test 6 with a test medium (such as water, oil, or gas) with a set pressure and flow rate to simulate the working environment of the valve under actual operating conditions. Specifically, the fluid circulation system 3 includes a medium storage tank 301, a booster pump 302, and a pressure regulating valve 303 connected in sequence via pipelines. The medium storage tank 301 is used to store the test medium; the booster pump 302 is used to pressurize the medium and deliver it to the inlet of the valve 6 under test; and the pressure regulating valve 303 is used to precisely adjust and stabilize the pressure of the test medium. Furthermore, the system also includes a pressure sensor 304 installed on the pipeline near the inlet of the valve 6 under test. The pressure sensor 304 is used to detect and feed back the inlet pressure to the data analysis controller 504 in real time, forming a closed-loop control to ensure that the pressure is constant during the test, thereby ensuring the accuracy and repeatability of the test results. The drive mechanism 4 is mounted on the frame 1, and its output end is used to connect to the valve stem of the valve 6 to be tested, so as to simulate the repeated opening and closing actions of the valve stem driven by a person or an actuator. In a preferred embodiment, the drive mechanism 4 includes a servo motor 401 and a reducer 402. The output shaft of the servo motor 401 is connected to the input end of the torque sensor 501 through the reducer 402. The output end of the torque sensor 501 is provided with a coupling 403, which is connected to the valve stem of the valve 6 under test. The servo motor 401 can precisely control the speed, angle, and frequency of operation to achieve accurate simulation of the valve opening and closing process. The reducer 402 is used to reduce the speed and increase the output torque to meet the driving force requirements of different types of valves (especially large-diameter, high-torque valves). The coupling 403 facilitates the quick connection of valve stems of different specifications and can compensate for the coaxiality deviation generated during installation, ensuring the smoothness of torque transmission. The sensing and monitoring system 5 is the core of this invention for realizing multi-dimensional data acquisition and lifespan prediction, and it includes: Torque sensor 501: Located at the output end of drive mechanism 4 (specifically between reducer 402 and coupling 403), it is used to collect torque signals of valve stem during opening and closing in real time. This signal can reflect the changes in friction between valve stem and stuffing box, the clamping force of sealing surface, and whether there is mechanical performance degradation such as jamming. Position sensor 502: Used to acquire the displacement signal of valve core (or valve stem) in real time. This sensor can be a linear displacement sensor or an angular displacement sensor, depending on the valve type (such as a gate valve or a ball valve). Through the displacement signal, the valve opening height, closing position and full stroke time can be accurately determined, thereby monitoring the valve core position offset caused by wear or deformation. Flow sensor 503: installed on the outlet pipeline of the valve under test 6, used to collect the flow signal of the medium leaking through the sealing surface when the valve is closed. This signal is a key indicator for evaluating whether the valve sealing performance meets the standard and whether it has failed. Data analysis controller 504: As the control and calculation core of the entire equipment, it is electrically connected to the fluid circulation system 3 (such as booster pump 302, pressure regulating valve 303, pressure sensor 304), drive mechanism 4 (such as servo motor 401), and sensing and monitoring system 5 (various sensors). The data analysis controller 504 is responsible for receiving and processing signals such as torque, displacement, and leakage, and automatically controlling the coordinated work of each component according to the preset test process. More importantly, it has an advanced algorithm model built in, which can comprehensively evaluate and predict the remaining life of the valve based on the collected multi-dimensional data. The sensing and monitoring system 5 may also include an acoustic emission sensor 505, which is usually attached to the outside of the valve body of the valve 6 under test. It is used to collect high-frequency acoustic emission signals generated inside the valve due to the impact of medium leakage on the sealing surface. Acoustic emission technology is extremely sensitive to early micro-leakage, and its detection sensitivity is much higher than that of traditional flow sensors. It can detect signs of sealing performance degradation before a measurable macro-flow is formed, thereby providing earlier failure warnings.

[0029] Please see Figure 4 The specific working principle and usage method of this invention are as follows: A testing method using the aforementioned valve life testing equipment is provided. This method is automatically executed by a data analysis controller 504 and mainly includes the following steps: S1. Install the valve to be tested. The operator installs the valve to be tested 6 on the clamping mechanism 2 and secures it reliably through the clamping mechanism 2. Then, adjust the position of the drive mechanism 4 so that its output end (coupling 403) is accurately connected to the valve stem of the valve to be tested 6. At the same time, connect the inlet pipe of the fluid circulation system 3 and install the outlet pipe, acoustic emission sensor 505, etc. as needed. S2. Set test parameters. The operator sets the operating conditions parameters for this life test through the human-machine interface of the data analysis controller 504. These parameters mainly include: test pressure (simulating actual operating pressure), action frequency (simulating the speed of valve opening and closing), maximum number of actions (or test duration), and various failure thresholds (such as maximum allowable leakage and maximum allowable torque). S3. Start the fluid circulation system. The data analysis controller 504 starts the fluid circulation system 3, and the booster pump 302 starts working. It draws the medium from the medium storage tank 301 and pressurizes it. After the pressure is precisely adjusted to the set pressure by the pressure regulating valve 303, the test medium is continuously and stably supplied to the inlet of the valve under test 6. The pressure sensor 304 monitors the inlet pressure in real time and feeds it back to the controller to ensure that the pressure is constant. S4. Execute the opening and closing cycle. The data analysis controller 504 sends instructions to the servo motor 401 of the drive mechanism 4 according to the set action frequency. The servo motor 401 drives the valve stem of the valve under test 6 to perform continuous opening-closing cycle actions through the reducer 402 and coupling 403, simulating the long-term use process of the valve under actual working conditions. S5. Real-time acquisition of multi-dimensional data: During each opening and closing action, the sensing and monitoring system 5 collects data in real time. When the valve stem moves, the torque sensor 501 collects and records the torque change data (including opening torque, closing torque, peak torque, etc.) in real time throughout the entire stroke. When the valve stem moves, the position sensor 502 collects and records the displacement trajectory of the valve core in real time, and records the full stroke time of the valve and the precise position when it is closed. After the valve closes completely and stabilizes, the flow sensor 503 starts to work and measures the amount of leakage through the sealing surface. Throughout the process, especially during the valve closing phase, the acoustic emission sensor 505 continuously monitors the acoustic emission signal generated by microscopic leakage inside the valve body. The data analysis controller 504 compares and fuses the intensity of the acoustic emission signal with the data from the flow sensor 503. The high-sensitivity acoustic emission signal can be used to perform early correction and calibration of the flow sensor's measurement results, thereby improving the accuracy of leakage calculation. S6. Data Processing and Curve Plotting: The data analysis controller 504 processes the massive amounts of collected data in real time and plots various change curves that can intuitively reflect the valve performance degradation process, including but not limited to: Peak torque-time curve: reflects the changing trend of the maximum driving force required for each action, and can be used to determine the evolution of valve stem friction and sealing surface clamping force; Torque fluctuation quantity-time curve: reflects the stability of torque and can be used to determine whether there is abnormal wear or jamming; Valve stem full stroke time-time curve: reflects the change in transmission efficiency and can be used to determine whether the transmission components are fatigued or deformed; Leakage rate-time curve: reflects the degradation process of sealing performance and is the most crucial basis for determining whether a valve has failed; S7. Determine the end of the service life. After each cycle, the data analysis controller 504 compares the collected key data with the preset failure threshold: If the leakage in the current cycle (or the leakage corrected by the acoustic emission signal) exceeds the preset failure threshold, the valve is determined to have reached the end of its service life due to sealing failure. If the driving torque exceeds the preset safety threshold during a certain opening and closing process (indicating that there may be serious jamming or damage), the valve is determined to have reached the end of its service life due to mechanical failure. Once the end of the valve's lifespan is determined, the data analysis controller 504 will immediately stop the test and record the total number of actions. This number represents the actual service life of the valve under this operating condition. S8. Output a remaining life prediction report. If the valve has not failed before reaching the preset maximum number of operations, or if the user needs to understand the valve's health status in real time, the data analysis controller 504 will combine the changing trends of historical data to output a remaining life prediction report. This report is generated based on a built-in algorithm model. As a preferred approach, this model uses a trend extrapolation algorithm. For example, based on the inflection point of the leakage rate-number curve (representing the start of accelerated degradation) and the subsequent slope of the curve, the theoretical remaining number of operations required for the leakage rate to reach the preset failure threshold is extrapolated. This report not only provides a quantitative remaining life prediction estimate, but also lists the current status and historical trend charts of key indicators such as torque and displacement, providing a comprehensive basis for operation and maintenance decisions. S9. Data Storage and Database Establishment. Finally, the data analysis controller 504 generates a structured test log from the complete test process data (including all raw signals, processed characteristic parameters, change curves, and final report) and stores it. As the number of valves tested increases, these logs will gradually build a life database for specific models or types of valves. This database can not only be used to verify and continuously optimize the built-in life prediction model, but also provide a valuable reference benchmark for subsequent valve selection, design improvement, and the formulation of preventive maintenance strategies.

[0030] In summary, this invention, through a highly integrated multi-dimensional sensing and monitoring system and an intelligent data analysis controller, deeply integrates the mechanical performance testing and sealing performance testing of valves. It achieves a leap from single-index testing to multi-source data fusion analysis, from post-fault detection to early failure warning, and from simple threshold judgment to accurate life prediction, greatly improving the automation, intelligence, and accuracy of valve life testing.

[0031] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Content not described in detail in this specification is prior art known to those skilled in the art.

[0032] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Those skilled in the art can readily implement the present invention based on the accompanying drawings and the above description. However, any modifications, alterations, or variations made by those skilled in the art without departing from the scope of the present invention, utilizing the disclosed technical content, are equivalent embodiments of the present invention. Furthermore, any equivalent changes, alterations, or variations made to the above embodiments based on the essential technology of the present invention are still within the protection scope of the present invention.

Claims

1. A valve life detection device and its detection method, comprising a rack (1), a clamping mechanism (2), a fluid circulation system (3), a driving mechanism (4), a sensing monitoring system (5), characterized in that: The clamping mechanism (2) is mounted on the frame (1). The clamping mechanism (2) clamps and positions the valve to be tested (6). The fluid circulation system (3) is connected to the inlet of the valve to be tested (6) to provide the valve to be tested (6) with a set pressure and flow rate. The driving mechanism (4) is mounted on the frame (1). Its output end is used to connect to the valve stem of the valve to be tested (6) to drive the valve stem to perform opening and closing actions. The sensing and monitoring system (5) includes a torque sensor (501), a position sensor (502), a flow sensor (503), and a data analysis controller (504). The torque sensor (501) is located at the output end of the drive mechanism (4) and collects the torque signal when the valve stem moves in real time. The position sensor (502) is used to collect the displacement signal of the valve core in real time. The flow sensor (503) is located on the outlet pipe of the valve under test (6) and is used to collect the leakage signal when the valve is closed. The data analysis controller (504) is electrically connected to the fluid circulation system (3), the drive mechanism (4), and the sensing and monitoring system (5). The data analysis controller (504) receives the torque signal, displacement signal, and leakage signal, and evaluates the remaining life of the valve based on a preset algorithm model.

2. The valve life testing equipment and method according to claim 1, characterized in that, The fluid circulation system (3) includes a medium storage tank (301), a booster pump (302), and a pressure regulating valve (303) connected in sequence by pipelines. The outlet of the medium storage tank (301) is connected to the inlet of the valve to be tested (6). The fluid circulation system (3) also includes a pressure sensor (304) installed on the pipeline near the inlet of the valve to be tested (6) for detecting the inlet pressure.

3. The valve life testing equipment and testing method according to claim 1, characterized in that, The drive mechanism (4) includes a servo motor (401) and a reducer (402). The output shaft of the servo motor (401) is connected to the input end of the torque sensor (501) through the reducer (402). The output end of the torque sensor (501) is provided with a coupling (403) and is connected to the valve stem of the valve to be tested (6) through the coupling (403).

4. The valve life testing equipment and testing method according to claim 1, characterized in that, The sensing and monitoring system (5) also includes an acoustic emission sensor (505), which is installed on the valve body of the valve to be tested (6) and is used to collect acoustic emission signals generated by internal leakage of the valve.

5. The valve life testing equipment and testing method according to claim 1, characterized in that, The data analysis controller (504) has a built-in life prediction model. The model takes the cumulative number of actions, the peak torque of the current cycle, the torque fluctuation, the valve core displacement error, and the leakage as input parameters, and the remaining effective life as output parameters.

6. A testing method using the valve life testing equipment as described in any one of claims 1 to 5, characterized in that, Includes the following steps: S1. Install the valve to be tested (6) on the clamping mechanism (2) and connect the output end of the drive mechanism (4) to the valve stem; S2. Set test parameters, including test pressure, action frequency, and maximum number of actions, through the data analysis controller (504); S3. Start the fluid circulation system (3) and provide the test medium at the set pressure to the inlet of the valve to be tested (6); S4. The data analysis controller (504) controls the drive mechanism (4) to drive the valve to perform continuous opening and closing cycle actions according to the set action frequency; S5. During the opening and closing cycle, the sensing and monitoring system (5) collects the torque signal and displacement signal in real time during each action, and collects the leakage signal after each closing action; S6. The data analysis controller (504) processes the collected signals in real time and plots the curves of torque, displacement, and leakage as a function of the number of actions; S7. When the leakage exceeds the preset failure threshold or the driving torque exceeds the preset safety threshold, the data analysis controller (504) determines that the valve has reached the end of its life and records the current total number of actions; S8. The data analysis controller (504) combines historical change trends to output a prediction report of the valve's remaining life.

7. The testing method for a valve life testing device according to claim 1, characterized in that, In step S6, the variation curves include the peak torque-number curve, the torque fluctuation-number curve, the valve stem full stroke time-number curve, and the leakage rate-number curve.

8. The testing method of the valve life testing equipment according to claim 1, characterized in that, In step S5, the internal leakage of the valve in the closed state is monitored in real time by the acoustic emission sensor (505), and the data analysis controller (504) compares the acoustic emission signal intensity with the data of the flow sensor (503) to correct the leakage calculation result.

9. The testing method for a valve life testing device according to claim 1, characterized in that, In step S8, the remaining life prediction report is generated based on a trend extrapolation algorithm, that is, based on the inflection point and slope of the leakage rate-number curve, the theoretical number of actions required to reach the failure threshold is predicted.

10. The testing method of the valve life testing equipment according to claim 1, characterized in that, It also includes step S9: the data analysis controller (504) generates and stores the data from the entire testing process to establish a life database for a specific type of valve.

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