A ship valve fault simulation and redundancy switching test system and method

Abstract

The application discloses a kind of ship valve fault simulation and redundancy switching test system and method, it is related to ship valve simulation technical field, and its technical scheme main point is: water source circulation module, for providing medium with rated pressure and flow rate, to meet the simulation of fault condition;And test execution module, for the medium that the water source circulation module flows out is simulated different fault condition, after simulation is completed, medium flows into the water source circulation module;Wherein, the test execution module includes two parallelly arranged test branches, respectively first test branch and second test branch;Wherein, the first test branch is used as test object to simulate fault condition and provide state monitoring data;When control system diagnosis determines that the test butterfly valve of the first test branch occurs serious failure, automatically enable the second test branch to carry out redundancy takeover, to provide the verification to ship valve health management system and redundancy switching control algorithm.

Description

Technical Field

[0001] This invention relates to the field of ship valve simulation technology, and more specifically, to a ship valve fault simulation and redundancy switching test system and method. Background Technology

[0002] Ship piping systems (such as seawater cooling systems and ballast water systems) are crucial components ensuring a ship's survivability and mission completion capabilities. Valves, as core actuators in piping systems that control the flow and pressure of media, directly impact the safety of the entire ship. However, the harsh operating environment of ships, with piping systems constantly subjected to high humidity, high salt spray, vibration, and variable load conditions, makes electro-hydraulic butterfly valves prone to malfunctions such as internal leakage, actuator jamming, and seal failure.

[0003] Currently, most existing valve test benches focus on the factory performance testing of individual valves or the calibration of single physical quantities, lacking a comprehensive fault simulation platform capable of highly replicating the real fluid network (high pressure, high flow rate) of a ship in a land-based laboratory environment. More importantly, existing testing technologies are often limited to "fault diagnosis," i.e., alarming and shutting down after a fault is detected. However, in real ship combat or navigation missions, the failure of a single node cannot lead to system shutdown; the system must possess "fault tolerance" and "redundant reconfiguration" capabilities. That is, when a major valve experiences a serious failure, the system should be able to automatically identify and seamlessly switch to backup piping to maintain the continuity of system function.

[0004] While existing technical solutions provide an electric valve fault simulation and data acquisition and analysis test bench that enables the simulation and data acquisition of various fault modes, they are not specifically designed for ship-specific electro-hydraulic driven butterfly valves and lack hardware support and experimental verification methods for dual valve (main / standby) redundant switching control logic. Summary of the Invention

[0005] The purpose of this invention is to provide a ship valve fault simulation and redundancy switching test system and method, which solves the problems of the prior art not simulating the jamming fault and internal leakage fault of ship-specific electro-hydraulic driven butterfly valves, and lacking the test of the dual valve (main / standby) redundancy switching control logic.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution:

[0007] In a first aspect, the present invention provides a ship valve failure simulation and redundancy switching test system, the system comprising:

[0008] A water circulation module is used to provide a medium with rated pressure and flow rate to meet the simulation of fault conditions; and

[0009] The test execution module is used to simulate different fault conditions of the medium flowing out of the water circulation module. After the simulation is completed, the medium flows into the water circulation module.

[0010] The test execution module includes two parallel test branches: a first test branch equipped with a test butterfly valve and a second test branch equipped with a spare test butterfly valve. The two test branches converge and return to the water circulation module. The first test branch serves as the test object to simulate fault conditions and provide status monitoring data. When the control system diagnoses and determines that the test butterfly valve in the first test branch has a serious fault, it automatically activates the second test branch for redundant control to verify the ship's valve health management system and redundancy switching control algorithm.

[0011] In one implementation, the water source circulation module includes a medium circulation branch, which includes a water tank, a Y-type filter, and a motor pump set, which are connected in sequence.

[0012] A first manual ball valve is installed between the water tank and the Y-type filter, a first check valve is installed at the outlet of the motor pump unit, and a safety valve and a pressure regulating valve are connected in parallel on the medium circulation branch.

[0013] In one implementation, the water circulation module further includes a cooling circulation branch for simulating different temperature conditions or maintaining thermal balance. The cooling circulation branch includes a cooling pump, an air filter, and a cooler, which are connected in sequence.

[0014] A second manual ball valve is installed between the water tank and the cooling pump.

[0015] In one implementation, the water tank is equipped with a level gauge and a level switch for real-time monitoring of the medium's level; the bottom of the water tank is equipped with an oil drain ball valve for use as a drain valve.

[0016] In one implementation, the outlet of the motor pump unit is further provided with a pressure testing module, which includes a pressure testing connector, a pressure testing hose and a pressure gauge connected in sequence, as well as a pressure sensor.

[0017] In one implementation, the output of the medium circulation branch is connected in series with a flow regulating valve and a first electromagnetic flow meter to regulate the flow rate into the test execution module.

[0018] In one implementation, a third manual ball valve is installed at the end where the medium flows into the test butterfly valve, a fourth manual ball valve is installed at the end where the medium flows out of the test butterfly valve, a fifth manual ball valve is installed at the end where the medium flows into the standby test butterfly valve, and a sixth manual ball valve is installed at the end where the medium flows out of the standby test butterfly valve.

[0019] An air vent valve and a back pressure valve are installed between the first test branch and the second test branch and the water tank.

[0020] When the first test branch is operating normally, the fifth and sixth manual ball valves are closed.

[0021] In one implementation, a leakage test bypass is provided between the test butterfly valve and the fourth manual ball valve, and a backup leakage test bypass is provided between the backup test butterfly valve and the sixth manual ball valve. A seventh manual ball valve is installed on the leakage test bypass, and an eighth manual ball valve is installed on the backup leakage test bypass.

[0022] The outputs of the leakage test bypass and the backup leakage test bypass are equipped with a second electromagnetic flow meter. The output of the second electromagnetic flow meter is connected in parallel with a ninth manual ball valve and an isolation ball valve. The output of the isolation ball valve is connected to an electronic scale.

[0023] In one implementation, the test butterfly valve and its electro-hydraulic actuator are further equipped with an acoustic emission sensor, an acceleration sensor, a torque sensor, and an angular displacement sensor. The acoustic emission sensor is installed on the outer wall of the pipe within a range from the valve jet position to 8 times the jet orifice diameter. The acceleration sensor is installed on the valve flange and the actuator housing. The torque sensor is installed at the connection between the actuator and the valve shaft.

[0024] A second aspect of the present invention provides a method for simulating ship valve failures and conducting redundancy switching tests, the method comprising:

[0025] A ship valve fault simulation and redundancy switching test system as provided in the first aspect of this invention is constructed. The system includes a water circulation module for providing a medium with rated pressure and flow rate to simulate fault conditions; and a test execution module for simulating different fault conditions on the medium flowing out of the water circulation module. After simulation, the medium flows back into the water circulation module. The test execution module includes two parallel test branches: a first test branch equipped with a test butterfly valve and a second test branch equipped with a spare test butterfly valve. The two test branches merge and flow back to the water circulation module. The first test branch serves as the test object to simulate fault conditions and provide status monitoring data. When the control system diagnoses and determines that the test butterfly valve in the first test branch has a serious fault, the second test branch is automatically activated for redundant control, providing verification of the ship valve health management system and redundancy switching control algorithm.

[0026] Open the valve of the first test branch, close the valve of the second test branch, and adjust the rated operating conditions and flow rate;

[0027] The electro-hydraulic actuator of the test butterfly valve is used to control the valve plate to generate an angular deviation to simulate an internal leakage fault, or the hydraulic circuit damping of the electro-hydraulic actuator is adjusted to simulate a jamming fault.

[0028] Real-time data from fault simulation is collected, and the operating status of the test butterfly valve is diagnosed based on the real-time data. Redundant control logic is executed based on the diagnosis results. The redundant control logic is as follows: when the test butterfly valve is diagnosed as being in a normal state, the test butterfly valve is kept open and the standby test butterfly valve is closed, maintaining the rated pressure unchanged; when the test butterfly valve is diagnosed as having slight internal leakage, the test butterfly valve is kept open and the rated pressure is reduced; when the test butterfly valve is diagnosed as having severe internal leakage or being stuck, the test butterfly valve is determined to be faulty, the standby test butterfly valve of the second test branch is opened, and the test butterfly valve of the first test branch is closed simultaneously.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] In the ship valve failure simulation and redundancy switching test system provided by this invention, by constructing a hydraulic circulation system consistent with the parameters of the actual ship, and combining multi-source heterogeneous sensors such as acoustic emission, vibration, and torque, it can not only simulate typical faults such as internal leakage and jamming of electro-hydraulic driven butterfly valves, but also verify the control strategy of automatically switching to the backup valve when the main valve fails through the parallel redundancy design of the hardware, thereby ensuring the continuous operation capability of the ship's seawater system under fault conditions. Attached Figure Description

[0031] The accompanying drawings, which are included to provide a further understanding of embodiments of the invention and form part of this application, do not constitute a limitation thereof. In the drawings:

[0032] Figure 1 A structural diagram of a ship valve fault simulation and redundancy switching test system provided in an embodiment of the present invention;

[0033] Figure 2 This is a schematic diagram of the sensor installation for a test butterfly valve provided in an embodiment of the present invention.

[0034] Figure labels and figure descriptions:

[0035] 1. Water tank; 2. Cooler; 3. Second manual ball valve; 4. Cooling pump; 5. Air filter; 6. Level gauge; 7. Safety valve; 8. Level switch; 9. First manual ball valve; 10. Y-type filter; 11. Oil drain ball valve; 12. Pressure regulating valve; 13. Motor pump set; 14. First check valve; 15. Pressure test connector; 16. Pressure test hose; 17. Pressure gauge; 18. Pressure sensor; 19. Flow regulating valve; 20. High-precision pressure sensor; 21. First electromagnetic flow meter; 22. Fifth manual ball valve; 23. Third manual ball valve; 24. Sixth manual ball valve; 25. Fourth manual ball valve; 26. Eighth manual ball valve; 27. Seventh manual ball valve; 28. Second electromagnetic flow meter; 29. ​​Isolation ball valve; 30. Electronic scale; 31. Second check valve; 32. Back pressure valve; 33. Exhaust valve; 34. Ninth manual ball valve. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the embodiments and accompanying drawings. The illustrative embodiments and descriptions of the present invention are only used to explain the present invention and are not intended to limit the present invention.

[0037] It should be noted that the terms "comprising" or "may include" used in the various embodiments of this application indicate the presence of the claimed function, operation, or element, and do not limit the addition of one or more functions, operations, or elements. Furthermore, as used in the various embodiments of this application, the terms "comprising," "having," and their cognates are intended only to indicate a specific feature, number, step, operation, element, component, or combination of the foregoing, and should not be construed as primarily excluding the presence of one or more other features, numbers, steps, operations, elements, components, or combinations of the foregoing, or adding one or more combinations of the foregoing.

[0038] It should be understood that terms such as "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0039] Please refer to Figure 1 This invention provides a ship valve failure simulation and redundancy switching test system, the system comprising:

[0040] A water circulation module is used to provide a medium with rated pressure and flow rate to meet the simulation of fault conditions; and

[0041] The test execution module is used to simulate different fault conditions of the medium flowing out of the water circulation module. After the simulation is completed, the medium flows into the water circulation module.

[0042] The test execution module includes two parallel test branches: a first test branch equipped with a test butterfly valve and a second test branch equipped with a spare test butterfly valve. The two test branches converge and return to the water circulation module. The first test branch serves as the test object to simulate fault conditions and provide status monitoring data. When the control system diagnoses and determines that the test butterfly valve in the first test branch has a serious fault, it automatically activates the second test branch for redundant control to verify the ship's valve health management system and redundancy switching control algorithm.

[0043] Specifically, the water circulation module includes a media circulation branch, which includes a water tank 1, a Y-type filter 10, and a motor pump set 13, which are connected in sequence. A first manual ball valve 9 is provided between the water tank 1 and the Y-type filter 10. A first check valve 14 is installed on the outlet of the motor pump set 13. A safety valve 7 and a pressure regulating valve 12 are connected in parallel on the media circulation branch.

[0044] The media circulation branch starts at water tank 1, which stores the circulating media. Water tank 1 is equipped with a level gauge 6 and a level switch 8 for real-time monitoring and feedback of the liquid level, preventing the pump unit from running dry. Power is provided by a motor-pump unit 13, whose rated parameters meet the actual operating conditions of the ship's valves (rated pressure approximately 2.5 MPa, flow rate up to 600 L / min). A safety valve 7 and a filter are installed in the pump outlet pipeline to ensure system pressure safety and media cleanliness.

[0045] The water circulation module also includes a cooling circulation branch for simulating different temperature conditions or maintaining thermal balance. This cooling circulation branch includes a cooling pump 4, an air filter 5, and a cooler 2, which are connected sequentially. A second manual ball valve 3 is installed between the water tank 1 and the cooling pump 4. The medium is drawn out by the cooling pump 4, flows through the air filter 5 and the second check valve 31, exchanges heat with the cooler 2, and then returns to the water tank 1. This branch is controlled by the second manual ball valve 3.

[0046] In the test cycle of the first test branch, the medium flows out of the water tank 1 and enters the Y-type filter 10 via the first manual ball valve 9 to filter out mechanical impurities in the medium to protect precision valve components. The filtered medium enters the core power source - the motor pump unit 13, which provides high-pressure medium (rated pressure 2.5MPa) to meet the ship's operating conditions. A first check valve 14 is connected in series on the outlet pipeline of the motor pump unit 13 to prevent backflow of the medium during shutdown. To ensure the safety of the test system, a safety valve 7 is installed in parallel on the main outlet pipeline of the motor pump unit 13, which automatically opens to release pressure when the pressure exceeds a preset safety threshold.

[0047] The pressure and flow regulation of the motor pump unit 13 is accomplished by the pressure testing module. The main pipeline is equipped with a pressure gauge 17, a pressure testing connector 15 (15), and a pressure testing hose 16, which, together with a high-precision pressure sensor 18, enable real-time monitoring of the pressure at the outlet of the motor pump unit 13. Among them, the pressure gauge 17 is a purely mechanical instrument, which is used by the operator to conduct on-site inspections and quickly confirm the system status next to the test bench. The pressure testing connector 15 (15) is a miniature quick-connect connector with a one-way valve. The pressure testing hose 16 is a flexible capillary hose that connects the main pipeline to the pressure gauge 17, which can reduce vibration and prevent high-frequency vibration of the pipeline system from affecting the reading of the pressure gauge 17.

[0048] A pressure regulating valve 12 is connected in parallel to the medium circulation branch to control the overall pressure of the pipeline network, and a flow regulating valve 19 is connected in series to regulate the flow rate entering the test section. A first electromagnetic flowmeter 21 measures the flow rate. After regulation, the medium enters the measurement and control section. At the inlet of the measurement and control section, there is a high-precision pressure sensor 20 that measures the actual working pressure before entering the test butterfly valve after regulation.

[0049] Subsequently, the media circulation branch is divided into two parallel branches, forming the core redundant test structure. These are the first test branch equipped with a test butterfly valve and the second test branch equipped with a spare test butterfly valve. The two test branches merge and flow back to the water circulation module.

[0050] In some embodiments, a third manual ball valve 23 is installed at one end of the test butterfly valve into which the medium flows, a fourth manual ball valve 25 is installed at one end of the test butterfly valve into which the medium flows, a fifth manual ball valve 22 is installed at one end of the pipeline into the standby test butterfly valve into which the medium flows, and a sixth manual ball valve 24 is installed at one end of the pipeline into the standby test butterfly valve into which the medium flows; an air vent valve 33 and a back pressure valve 32 are installed between the first test branch and the second test branch and the water tank 1; when the first test branch is operating normally, the fifth manual ball valve 22 and the sixth manual ball valve 24 are closed.

[0051] Specifically, in the first test branch (main test branch): the medium flows through the first electromagnetic flowmeter 21 for flow measurement, and then flows through the test butterfly valve. In this embodiment, the test butterfly valve serves as the main test object (i.e., the main valve) to simulate fault conditions such as internal leakage and jamming, and simultaneously collects multi-dimensional health status data such as acoustic emission, acceleration, torque, and motor current. A third manual ball valve 23 and a fourth manual ball valve 25 are installed at both ends of the valve to isolate the pipeline when replacing the valve under test.

[0052] The second test branch (backup test branch): The medium flows through the first electromagnetic flowmeter 21 for flow measurement, and then flows through the backup test butterfly valve. During the test, this branch serves as a backup redundant pipeline, automatically switching to this branch when the test butterfly valve fails. A fifth manual ball valve 22 and a sixth manual ball valve 24 are installed at both ends of this branch to isolate the pipeline when replacing the valve under test.

[0053] In some embodiments, a leakage test bypass is provided between the test butterfly valve and the fourth manual ball valve 25, and a backup leakage test bypass is provided between the backup test butterfly valve and the sixth manual ball valve 24. A seventh manual ball valve 27 is installed on the leakage test bypass, and an eighth manual ball valve 26 is installed on the backup leakage test bypass. A second electromagnetic flowmeter 28 is installed at the output of the leakage test bypass and the backup leakage test bypass. The output of the second electromagnetic flowmeter 28 is connected in parallel to a ninth manual ball valve 34 and an isolation ball valve 29. The output of the isolation ball valve 29 is connected to an electronic scale 30.

[0054] Specifically, for internal leakage fault simulation, a leakage test bypass is specially designed at the back end of the two test branches: For example, when conducting an internal leakage fault simulation test on the test butterfly valve, the fourth manual ball valve 25 and the eighth manual ball valve 26, the fifth manual ball valve 22 and the sixth manual ball valve 24 are closed, while the seventh manual ball valve 27 and the ninth manual ball valve 34 are ensured to be open, and the isolation ball valve 29 is closed. The leaking medium passes through the seventh manual ball valve 27, the second electromagnetic flowmeter 28 measures the leakage flow rate, and then returns through the ninth manual ball valve 34. If the internal leakage is less than the effective range of the second electromagnetic flowmeter 28, the ninth manual ball valve 34 is closed, and the electronic scale 30 and the isolation ball valve 29 above it are opened. The minute leakage is accurately measured using a weighing collection method.

[0055] An air vent valve 33 is installed at the end of the test branch to remove air accumulated at high points in the closed-loop water circulation system, which can easily cause pressure fluctuations and gas noise that can mask the acoustic emission signal. Afterwards, all media flowing through the test branch converge and return to the water tank 1 via the return water pipe, passing through a back pressure valve 32. The back pressure valve 32 provides necessary damping and pressure holding, and also prevents cavitation and protects the acoustic emission signal. Additionally, an oil drain ball valve 11 is installed at the bottom of the water tank 1, which can be used as a drain or vent valve.

[0056] In some embodiments, the test butterfly valve and its electro-hydraulic actuator are further equipped with an acoustic emission sensor, an acceleration sensor, a torque sensor and an angular displacement sensor. The acoustic emission sensor is installed on the outer wall of the pipe within a range from the valve jet position to 8 times the jet orifice diameter. The acceleration sensor is installed on the valve flange and the actuator housing. The torque sensor is installed at the connection between the actuator and the valve shaft.

[0057] Specifically, the test butterfly valve provided in this embodiment is a DN65 electro-hydraulic driven butterfly valve, equipped with a customized electro-hydraulic actuator, with a maximum output torque of 200 N·m, and has local and remote control functions. Figure 2 As shown, Figure 2 The diagram illustrates the sensor installation locations for simulating internal leakage and jamming faults. Detailed sensor selection and arrangement were implemented based on the fault characteristics of electro-hydraulic driven butterfly valves: Acoustic emission sensors: Two units, mounted on the pipe wall in the downstream jet region (0~8D range) of the valve, used to capture high-frequency noise (50kHz-400kHz) generated by internal leakage. Accelerometers: Three units, orthogonally mounted on the valve flange and actuator housing, respectively, to monitor mechanical vibration. Torque sensors: Installed at the coupling connecting the output shaft of the electro-hydraulic actuator and the valve stem, directly measuring the valve stem rotation torque. Current sensors: Measuring the input current of the electro-hydraulic actuator.

[0058] This invention also provides a method for simulating ship valve failures and conducting redundancy switching tests, the method comprising:

[0059] A ship valve fault simulation and redundancy switching test system as described in the above embodiment is constructed. The system includes a water circulation module for providing a medium with rated pressure and flow rate to simulate fault conditions; and a test execution module for simulating different fault conditions on the medium flowing out of the water circulation module. After simulation, the medium flows back into the water circulation module. The test execution module includes two parallel test branches: a first test branch equipped with a test butterfly valve and a second test branch equipped with a spare test butterfly valve. The two test branches merge and flow back to the water circulation module. The first test branch serves as the test object to simulate fault conditions and provide status monitoring data. When the control system diagnoses a serious fault in the test butterfly valve of the first test branch, it automatically activates the second test branch for redundant control, providing verification of the ship valve health management system and redundancy switching control algorithm.

[0060] Open the valve of the first test branch, close the valve of the second test branch, and adjust the rated operating conditions and flow rate;

[0061] The electro-hydraulic actuator of the test butterfly valve is used to control the valve plate to generate an angular deviation to simulate an internal leakage fault, or the hydraulic circuit damping of the electro-hydraulic actuator is adjusted to simulate a jamming fault.

[0062] Real-time data from fault simulation is collected, and the operating status of the test butterfly valve is diagnosed based on the real-time data. Redundant control logic is executed based on the diagnosis results. The redundant control logic is as follows: when the test butterfly valve is diagnosed as being in a normal state, the test butterfly valve is kept open and the standby test butterfly valve is closed, maintaining the rated pressure unchanged; when the test butterfly valve is diagnosed as having slight internal leakage, the test butterfly valve is kept open and the rated pressure is reduced; when the test butterfly valve is diagnosed as having severe internal leakage or being stuck, the test butterfly valve is determined to be faulty, the standby test butterfly valve of the second test branch is opened, and the test butterfly valve of the first test branch is closed simultaneously.

[0063] This test bench can simulate various working conditions. The specific operation is as follows: Adjust the pressure reducing valve and flow regulating valve 19 to bring the test platform pipeline to the preset rated working pressure (e.g., 2.5 MPa) and flow state. Then, relying on the control system to fine-tune the angular displacement of the electro-hydraulic actuator, the test butterfly valve is deviated from the fully closed position by a small opening (e.g., 0.5°, 1.0°, 1.5°) to perform quantitative structural internal leakage simulation; or, different depths of scratches are pre-placed on the sealing surface to reproduce wear-induced internal leakage. At this time, high-pressure fluid is injected through the tiny gap, simultaneously inducing high-frequency stress waves and broadband fluid structure vibration. The acoustic emission sensor (AE) will receive a continuous high-frequency signal. The amplitude (dB), energy, and ringdown count of the AE signal are extracted. As the leakage gap (opening) increases, the root mean square (RMS) value of the AE signal increases non-linearly; this characteristic can be used as the primary quantitative indicator of the severity of internal leakage.

[0064] During valve opening and closing, an adjustable mechanical friction brake is installed on the connecting shaft between the electro-hydraulic actuator output shaft and the butterfly valve stem, outside the pipeline. By tightening the preload adjusting bolt on the outside of the brake, the two friction pads apply a continuously adjustable radial positive pressure to the valve stem. During valve opening and closing rotation, this device can apply a constant or nonlinear reverse Coulomb friction load torque to the valve stem, thereby safely and accurately simulating abnormal resistance increases caused by excessively tight valve stem packing, salt spray scaling, or foreign object embedding. At this time, under the influence of abnormal friction load, the mechanical, fluid, and electrical system data all show significant changes. The torque sensor reading will show a step increase, and at the same time, due to the friction-induced "stick-slip" effect, the low-frequency vibration signal collected by the accelerometer will show rich harmonic components. By extracting the skewness and kurtosis of the vibration signal, the phase of jamming can be effectively identified. Simultaneously, when the valve's operating resistance increases sharply, the load torque of the electro-hydraulic actuator fluctuates, and this change in physical quantity directly modulates and is reflected in the motor current signal. In the time domain, this manifests as a prolonged transient process during motor startup, and a significant increase in the root mean square value of the current and the amplitude of the current envelope during the steady-state operating range. In the frequency domain, the nonlinear mechanical jamming load modulates the amplitude of the fundamental current, resulting in specific fault characteristic sidebands on both sides of the fundamental frequency in the current spectrum. By performing spectral analysis of the current, non-invasive quantitative diagnosis of jamming faults can be achieved. The motor current sensor indicates an increase in current.

[0065] This invention is based on redundant control of the test butterfly valve's state monitoring, and the specific logic is shown in Table 1:

[0066] Table 1 Valve Redundancy Switching Control Logic Table

[0067]

[0068] The specific switching process is described as follows: When the control system determines that the main valve has "severe internal leakage" based on the acoustic emission signal amplitude exceeding the set threshold (e.g., exceeding the reference value by 20dB), the PLC controller immediately executes the following sequence: it sends an "open" command to the standby test butterfly valve; after detecting the standby valve's open position signal (feedback from the angular displacement sensor), it sends a "close" command to the test butterfly valve; during the transition moment of the redundancy switch (approximately 2-5 seconds of overlap), the parallel conduction of the two branches will cause a sudden drop in local liquid resistance in the test section, which will in turn cause a transient drop in system pressure; at this time, the PID algorithm module in the PLC control unit adjusts the opening of the pressure regulating valve 12 on the main line and the back pressure valve 32 at the test end according to the real-time differential pressure signal fed back by the pressure sensor 18, in order to compensate for the pipeline pressure fluctuation caused by changes in system volume and flow resistance, effectively suppress the water hammer effect, and ensure that the water supply pressure of the downstream pipeline (such as cooler 2) transitions smoothly without sudden changes.

[0069] Through the above-described embodiments, this invention not only achieves in-depth quantitative simulation of typical fault mechanisms such as internal leakage and jamming in electro-hydraulic driven butterfly valves, and constructs a test bench for valve faults and multi-dimensional signals (such as current, acoustic emission, and vibration) that closely approximates the high-pressure, high-flow-rate operating conditions of real ships, but also verifies the automatic redundancy reconfiguration technology of shipboard pipeline networks under sudden fault conditions. This invention effectively enhances the fault-tolerant reconfiguration capability of shipboard fluid pipeline networks in response to single-point failures, fills the gap in dynamic fault-tolerant verification of shipboard high-pressure pipeline network faults in a land-based laboratory environment, and provides a crucial experimental foundation for the development of highly reliable shipboard equipment.

[0070] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A ship valve fault simulation and redundancy switching test system, characterized in that, The system includes: The water circulation module is used to provide a medium with rated pressure and flow rate to meet the simulation of fault conditions; as well as The test execution module is used to simulate different fault conditions of the medium flowing out of the water circulation module. After the simulation is completed, the medium flows into the water circulation module. The test execution module includes two parallel test branches: a first test branch equipped with a test butterfly valve and a second test branch equipped with a spare test butterfly valve. The two test branches converge and return to the water circulation module. The first test branch serves as the test object to simulate fault conditions and provide status monitoring data. When the control system diagnoses and determines that the test butterfly valve in the first test branch has a serious fault, it automatically activates the second test branch for redundant control to verify the ship's valve health management system and redundancy switching control algorithm.

2. The ship valve fault simulation and redundancy switching test system according to claim 1, characterized in that, The water source circulation module includes a medium circulation branch, which includes a water tank, a Y-type filter, and a motor pump set, which are connected in sequence. A first manual ball valve is installed between the water tank and the Y-type filter, a first check valve is installed at the outlet of the motor pump unit, and a safety valve and a pressure regulating valve are connected in parallel on the medium circulation branch.

3. The ship valve fault simulation and redundancy switching test system according to claim 2, characterized in that, The water circulation module also includes a cooling circulation branch for simulating different temperature conditions or maintaining thermal balance. The cooling circulation branch includes a cooling pump, an air filter, and a cooler, which are connected in sequence. A second manual ball valve is installed between the water tank and the cooling pump.

4. The ship valve fault simulation and redundancy switching test system according to claim 2, characterized in that, The water tank is equipped with a level gauge and a level switch for real-time monitoring of the liquid level of the medium. The bottom of the water tank is equipped with an oil drain valve, which is used for sewage discharge or venting.

5. The ship valve fault simulation and redundancy switching test system according to claim 2, characterized in that, The outlet of the motor pump unit is also equipped with a pressure testing module, which includes a pressure testing connector, a pressure testing hose and a pressure gauge connected in sequence, as well as a pressure sensor.

6. The ship valve fault simulation and redundancy switching test system according to claim 2, characterized in that, The output of the medium circulation branch is connected in series with a flow regulating valve and a first electromagnetic flow meter to regulate the flow rate into the test execution module.

7. The ship valve fault simulation and redundancy switching test system according to claim 2, characterized in that, A third manual ball valve is installed at the end where the medium flows into the test butterfly valve, a fourth manual ball valve is installed at the end where the medium flows out of the test butterfly valve, a fifth manual ball valve is installed at the end where the medium flows into the standby test butterfly valve, and a sixth manual ball valve is installed at the end where the medium flows out of the standby test butterfly valve. An air vent valve and a back pressure valve are installed between the first test branch and the second test branch and the water tank. When the first test branch is operating normally, the fifth and sixth manual ball valves are closed.

8. The ship valve fault simulation and redundancy switching test system according to claim 7, characterized in that, A leakage test bypass is provided between the test butterfly valve and the fourth manual ball valve. A backup leakage test bypass is provided between the backup test butterfly valve and the sixth manual ball valve. A seventh manual ball valve is installed on the leakage test bypass. An eighth manual ball valve is installed on the backup leakage test bypass. The outputs of the leakage test bypass and the backup leakage test bypass are equipped with a second electromagnetic flow meter. The output of the second electromagnetic flow meter is connected in parallel with a ninth manual ball valve and an isolation ball valve. The output of the isolation ball valve is connected to an electronic scale.

9. The ship valve fault simulation and redundancy switching test system according to claim 1, characterized in that, The test butterfly valve and its electro-hydraulic actuator are also equipped with an acoustic emission sensor, an acceleration sensor, a torque sensor and an angular displacement sensor. The acoustic emission sensor is installed on the outer wall of the pipe within a range of 8 times the diameter of the jet outlet from the valve jet position; the acceleration sensor is installed on the valve flange and the actuator housing; and the torque sensor is installed at the connection between the actuator and the valve shaft.

10. A method for simulating ship valve failures and conducting redundancy switching tests, characterized in that, The methods include: A ship valve fault simulation and redundancy switching test system as described in any one of claims 1 to 9 is constructed. The system includes a water circulation module for providing a medium with rated pressure and flow rate to simulate fault conditions; and a test execution module for simulating different fault conditions on the medium flowing out of the water circulation module. After simulation, the medium flows back into the water circulation module. The test execution module includes two parallel test branches: a first test branch equipped with a test butterfly valve and a second test branch equipped with a spare test butterfly valve. The two test branches merge and flow back to the water circulation module. The first test branch serves as the test object to simulate fault conditions and provide status monitoring data. When the control system diagnoses and determines that the test butterfly valve in the first test branch has a serious fault, the second test branch is automatically activated for redundant control, providing verification of the ship valve health management system and redundancy switching control algorithm. Open the valve of the first test branch, close the valve of the second test branch, and adjust the rated operating conditions and flow rate; The electro-hydraulic actuator of the test butterfly valve is used to control the valve plate to generate an angular deviation to simulate an internal leakage fault, or the hydraulic circuit damping of the electro-hydraulic actuator is adjusted to simulate a jamming fault. Real-time data from fault simulation is collected, and the operating status of the test butterfly valve is diagnosed based on the real-time data. Redundant control logic is executed based on the diagnosis results. The redundant control logic is as follows: when the test butterfly valve is diagnosed as being in a normal state, the test butterfly valve is kept open and the standby test butterfly valve is closed, maintaining the rated pressure unchanged; when the test butterfly valve is diagnosed as having slight internal leakage, the test butterfly valve is kept open and the rated pressure is reduced; when the test butterfly valve is diagnosed as having severe internal leakage or being stuck, the test butterfly valve is determined to be faulty, the standby test butterfly valve of the second test branch is opened, and the test butterfly valve of the first test branch is closed simultaneously.

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