Control valve fault diagnosis method and device, electronic equipment and medium

Abstract

This application relates to the field of valve diagnostic technology, providing a method, apparatus, electronic device, and medium for diagnosing control valve faults. The method includes: acquiring the operating parameters of the control valve during a target fault test; determining stroke fault characteristic points matching the target fault test in the stroke variation curve; and determining pressure fault characteristic points matching the target fault test in the pressure variation curve; determining the performance parameters of the control valve during its operation based on the stroke fault characteristic points and the pressure fault characteristic points; comparing and analyzing the performance parameters with preset standard data to determine the fault type of the control valve and outputting the diagnostic result of the control valve. This application can diagnose multiple fault types of control valves, comprehensively assess the health status of valves, and meet practical needs.

Description

Technical Field

[0001] This application belongs to the field of valve diagnostic technology, and in particular relates to a method, device, electronic equipment and medium for diagnosing control valve faults. Background Technology

[0002] Valves are control components in pipeline fluid transport systems, used to control the on / off state, flow direction, flow rate, pressure, and temperature of fluids in the pipeline. They have functions such as guiding, shutting off, throttling, diverting, or overflowing. Valves are widely used in petroleum, chemical, power, pharmaceutical, and nuclear energy industries. Because valves often operate in high-temperature, high-pressure, and highly corrosive environments, they may experience performance degradation or malfunction due to mechanical wear, media corrosion, and seal aging over time. Failure to detect and address these malfunctions in a timely manner can lead to valve malfunction, decreased control accuracy, and even equipment shutdown or safety accidents. Currently, valve fault detection diagnostics are relatively limited, relying solely on changes in valve position to determine if a valve is stuck, making it difficult to comprehensively assess the valve's health status and failing to meet practical needs. Summary of the Invention

[0003] In view of the shortcomings of the prior art, this application provides a control valve fault diagnosis method, device, electronic device and medium to solve the problem that the valve fault detection diagnosis types in the related art are relatively simple, making it difficult to comprehensively assess the health status of the valve and failing to meet actual needs.

[0004] In a first aspect, this application provides a method for diagnosing control valve faults, including:

[0005] The system acquires the operating parameters of the control valve during a target fault test, which includes at least one of a full-stroke test, a basic error hysteresis test, a step performance test, and a partial-stroke test. The operating parameters include a stroke variation curve over time and a cylinder pressure variation curve over time. The system identifies stroke fault characteristic points matching the target fault test in the stroke variation curve and a pressure fault characteristic point matching the target fault test in the pressure variation curve. Based on the stroke and pressure fault characteristic points, the system determines the performance parameters of the control valve during operation. The system compares and analyzes the performance parameters with preset standard data to determine the fault type of the control valve and outputs the diagnostic results.

[0006] In one embodiment of this application, obtaining the action parameters of the control valve during a target fault test includes: determining the control signal of the valve positioner during the target fault test; inputting the control signal into the valve positioner; and collecting the action parameters during the operation of the control valve.

[0007] In one embodiment of this application, initial control parameters and target control parameters are obtained, and the control signal of the valve positioner in the full stroke test is determined based on the initial control parameters and target control parameters; the forward step change amount, the reverse step change amount, and the number of steps are determined, and the control signal of the valve positioner in the basic error hysteresis test is determined based on the initial step parameters, target step parameters, forward step change amount, reverse step change amount, and the number of steps, and each step is held for a first preset time; the required number of steps is determined, and the control signal of the valve positioner in the step performance test is determined based on the required number of steps, the initial step parameters, and the target step parameters, and each step is held for a second preset time; a preset stroke threshold is obtained, and the control signal of the valve positioner in the partial stroke test is determined based on the initial control parameters and the preset stroke threshold.

[0008] In one embodiment of this application, during the full-stroke test, the stroke fault characteristic points include the start point of the action, the end point of the opening action, the start point of the closing action, and the closing point; the pressure fault characteristic points include the start point of venting, the start point of the opening friction force, the end point of the opening friction force, the start point of the closing friction force, and the end point of the closing friction force. Based on the stroke fault characteristic points and the pressure fault characteristic points, the performance parameters of the control valve during the operation process are determined, including: determining the actual stroke, opening time, and closing time of the control valve based on the start point of the action, the end point of the opening action, the start point of the closing action, and the closing point; determining the friction parameters of the control valve based on the start point of venting, the start point of the opening friction force, the end point of the opening friction force, the start point of the closing friction force, and the end point of the closing friction force; wherein, if the control valve is a straight-through valve, the friction parameters include average friction force, maximum friction force, and maximum static friction force; if the control valve is a rotary valve, the friction parameters include maximum friction force, minimum friction force, forward maximum static friction force, and reverse maximum static friction force.

[0009] In one embodiment of this application, in the basic error hysteresis test, the stroke fault characteristic points include the characteristic points at which each step in the stroke change curve stabilizes; after determining the stroke fault characteristic points in the stroke change curve that match the target fault test, the method further includes: determining the basic error at each positive step based on the actual and theoretical stroke of the characteristic points at which the positive step stabilizes, and the rated stroke of the control valve; determining the basic error at each reverse step based on the actual and theoretical stroke of the characteristic points at which the reverse step stabilizes, and the rated stroke of the control valve; and determining the hysteresis at each step based on the basic error at each positive step, the basic error at the corresponding reverse step, and the rated stroke of the control valve.

[0010] In one embodiment of this application, in the step performance test, the stroke fault characteristic points include the characteristic points at which each step in the stroke change curve is stable, the overshoot and undershoot points in the opening section, and the overshoot and undershoot points in the closing section. The pressure fault characteristic points include the starting point, ending point, starting point, and ending point of the opening friction force at each step. Based on the stroke fault characteristic points and the pressure fault characteristic points, the performance parameters of the control valve during the operation process are determined, including: determining the basic error and hysteresis at each step based on the characteristic points at which each step in the stroke change curve is stable; determining the overshoot and undershoot values ​​based on the overshoot and undershoot points in the opening and closing sections; and determining the maximum friction force at each step based on the starting point, ending point, starting point, and ending point of the opening friction force.

[0011] In one embodiment of this application, in a partial stroke test, the stroke fault feature point includes the stroke curve abrupt change point, and the pressure fault feature point includes the pressure curve feature point corresponding to the stroke curve abrupt change point; based on the stroke fault feature point and the pressure fault feature point, the performance parameters of the control valve during the operation process are determined, including: based on the pressure curve feature point corresponding to the stroke curve abrupt change point, determining the average friction force, the maximum friction force, and the maximum static friction force.

[0012] Secondly, this application also provides a control valve fault diagnosis device, comprising: The parameter acquisition module is configured to acquire the operating parameters of the control valve during a target fault test, wherein the target fault test includes at least one of a full stroke test, a basic error hysteresis test, a step performance test, and a partial stroke test, and the operating parameters include a stroke change curve over time and a cylinder pressure change curve over time; the point matching module is configured to determine the stroke fault feature point matching the target fault test in the stroke change curve, and to determine the pressure fault feature point matching the target fault test in the pressure change curve; the parameter determination module determines the performance parameters of the control valve during the operating process based on the stroke fault feature point and the pressure fault feature point; the result output module compares and analyzes the performance parameters with preset standard data, determines the fault type of the control valve, and outputs the diagnostic results of the control valve.

[0013] Thirdly, this application also provides an electronic device, which includes: one or more processors; and a storage device for storing one or more programs, which, when executed by one or more processors, cause the electronic device to perform the steps of the above-described control valve fault diagnosis method.

[0014] Fourthly, the present invention also provides a computer-readable storage medium comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, when the processor executes the computer program, the computer-readable storage medium implements the steps of the above-described control valve fault diagnosis method.

[0015] The beneficial effects of this technical solution are as follows: By setting four test types—full stroke test, basic error hysteresis test, step performance test, and partial stroke test—the operating parameters of the control valve under different operating conditions are obtained. Feature points matching each test type are selected on the stroke change curve and pressure change curve to calculate the performance parameters of the control valve's operation under different operating conditions. This allows for the determination of the control valve's fault type and the output of diagnostic results. The solution can diagnose various fault types, including but not limited to packing damage, valve stem connection failure, valve jamming or sticking, actuator leakage, positioner failure, limit device failure, sealing surface damage, air path blockage, excessive basic error, excessive hysteresis, overshoot / undershoot abnormalities, valve stem damage, and creeping. This overcomes the limitation of related technologies that can only diagnose a single fault type, enabling a comprehensive assessment of the valve's health status and meeting practical needs.

[0016] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort. In the drawings: Figure 1 This is a schematic flowchart illustrating a control valve fault diagnosis method according to an exemplary embodiment of this application; Figure 2 This is a schematic flowchart illustrating another control valve fault diagnosis method in an exemplary embodiment of this application; Figure 3 This is a schematic diagram of the structure of a control valve fault diagnosis device shown in an exemplary embodiment of this application; Figure 4 A schematic diagram of the structure of a computer system suitable for implementing the electronic device of the present application is shown. Detailed Implementation

[0018] The embodiments of this application will be described below with reference to the accompanying drawings and preferred embodiments. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. This application can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be understood that the preferred embodiments are only for illustrating this application and are not intended to limit the scope of protection of this application.

[0019] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this application. Therefore, the drawings only show the components related to this application and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the shape, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0020] In the following description, numerous details are explored to provide a more thorough explanation of embodiments of the present application. However, it will be apparent to those skilled in the art that embodiments of the present application may be practiced without these specific details. In other embodiments, well-known structures and devices are shown in block diagram form rather than in detail to avoid obscuring embodiments of the present application.

[0021] Please see Figure 1 , Figure 1 This is a flowchart illustrating a control valve fault diagnosis method according to an exemplary embodiment of this application. The control valve fault diagnosis method can be executed by a system controller. Figure 1 As shown, in an exemplary embodiment, the control valve fault diagnosis method includes steps S101 to S104, and each step is described in detail below.

[0022] S101, Obtain the operating parameters of the control valve during the target fault test; The target failure test includes at least one of the following: full stroke test, basic error hysteresis test, step performance test and partial stroke test. The action parameters include the stroke change curve over time and the cylinder pressure change curve over time. It should be noted that before obtaining the action parameters of the control valve in the target fault test, a valve parameter acquisition hardware system and a fault diagnosis software platform can be designed to perform data acquisition, data analysis and fault diagnosis of the control valve.

[0023] The valve parameter acquisition hardware system can utilize mature products from National Instruments, including: the NI cDAQ-9185 chassis, NI-9202 ±10V voltage acquisition module, NI-9203 ±20mA current acquisition module, NI-9227 5Arms current acquisition module, NI-9265 0-20mA current output module, and NI-9375 digital I / O module. The NI cDAQ-9185 chassis controls the timing, synchronization, and data transmission between the C-series I / O modules and the external host. The NI-9202 module is used to acquire ±10V voltage signals; the NI-9203 module is used to acquire pull-wire displacement sensors, pressure sensors, and ±20mA current signals; the NI-9227 module acquires 5Arms current signals to monitor the solenoid valve's switching action; the NI-9265 module outputs a 0-20mA current signal to the positioner to control the valve's action; and the NI-9375 module is used to acquire and output digital signals. The specific specifications are shown in Table 1.

[0024] Table 1

[0025] Additionally, a 220V to 24V transformer, aviation plugs and sockets, computer connectors and network ports, power plugs, signal cables, network cables, a power adapter, and a data acquisition box are assembled and integrated into a valve parameter acquisition hardware system. This hardware system, combined with a pull-wire displacement sensor, pressure sensor, strain gauge, and host computer software platform, enables valve parameter acquisition, analysis, and fault diagnosis.

[0026] The data acquisition box housing can be composed of an aluminum alloy outer shell panel. The front panel wiring ports have eight categories: stroke, pressure, deformation, 5A, ±20mA AI, ±20mA AO, DI, and DO. During testing, the corresponding wiring terminals are selected for connection. The stroke channel acquires signals from a pull-wire displacement sensor, the pressure channel acquires signals from a pressure sensor, and the deformation channel acquires torque / tension / compression. The ±20mA, 5A, and ±10V channels acquire ±20mA current signals, 5A high-current signals, and ±10V voltage signals, respectively. The 0-20mA output control current signal controls the positioner's action. DI and DO are used for acquiring and outputting digital signals.

[0027] A 220V to 24V transformer powers the NI-9265, NI-9375, wire-type displacement sensor, and pressure sensor. An aviation plug / socket connects the hardware system and signal cables. A computer connector / network port connects the host computer to the chassis. A power plug connects to an external 220V power supply to power the transformer and chassis power adapter. Signal cables transmit various signal data. The data acquisition box integrates all hardware components to form a complete data acquisition device. This compact and portable device can be taken to the field for valve data acquisition and fault diagnosis.

[0028] Secondly, the fault diagnosis software platform can be developed based on the .NET platform and programmed in C#, which has the advantages of concise syntax, powerful performance, complete ecosystem, cross-platform development, powerful memory management, support for multiple application scenarios and high code security.

[0029] See Figure 2 The fault diagnosis software platform comprises four parts: valve information maintenance, data acquisition, data analysis, and fault diagnosis. The diagnostic system performs tests according to different test types, is simple to operate, and highly targeted. Different test types can diagnose different types of faults, and users can select the test type according to their actual needs. There are four test types: full-stroke test, basic error hysteresis test, step performance test, and partial-stroke test. In addition, it can also perform only valve data acquisition, data acquisition and storage, or data acquisition and analysis.

[0030] The valve information maintenance parameters include three aspects: general information, valve information, and actuator information, as shown in Table 2. After maintaining the valve information, select the test type to enter the data acquisition interface.

[0031] Table 2 Valve Information Maintenance Parameters

[0032] In some embodiments, obtaining the operating parameters of the control valve during a target fault test includes: Determine the control signal for the valve positioner during the target fault test; input the control signal into the valve positioner, and collect the action parameters during the valve's operation.

[0033] It is understandable that different fault tests correspond to different control signals. Specifically, full-stroke tests, basic error hysteresis tests, step performance tests, and partial-stroke tests each have their own control signals. The control signals input to the valve positioner differ depending on the selected test type. Therefore, the control signals can be determined based on the target fault test. For example, if the target fault test includes a full-stroke test and a basic error hysteresis test, then the control signals corresponding to the full-stroke test and the basic error hysteresis test are input. If the target fault test includes a full-stroke test, a basic error hysteresis test, a step performance test, and a partial-stroke test, then the control signals corresponding to all four tests are input. It should be noted that the input of the control signals has a sequential relationship; that is, after completing one test, the control signal for another test is input to the valve positioner. Then, during the valve's operation, action parameters are collected, including the stroke variation curve over time and the cylinder pressure variation curve over time.

[0034] In some embodiments, determining the control signal for the control valve positioner during a target fault test includes: Obtain initial control parameters and target control parameters, and determine the control signal of the valve positioner during the full stroke test based on the initial control parameters and target control parameters; Specifically, the initial control parameters and target control parameters can characterize the valve position from 0% to 100%, and the control signal for the full-stroke test is 0% to 100% to 0%.

[0035] Determine the forward step change, the reverse step change, and the number of steps. Based on the initial step parameters, the target step parameters, the forward step change, the reverse step change, and the number of steps, determine the control signal of the valve positioner in the basic error hysteresis test, and maintain the first preset time for each step. Specifically, the forward step change amount, the reverse step change amount, and the number of steps can be set according to actual needs. This embodiment does not impose specific limitations on this, but the forward step change amount and the reverse step change amount must maintain the same step amount at each step.

[0036] The initial step parameter and the target step parameter can characterize the valve position from 0% to 100%.

[0037] In some examples, the control signal for the basic error hysteresis test can be 0%-10%-25%-50%-75%-100%-75%-50%-25%-10%-0%, and each step is maintained for a first preset time (e.g., 30s).

[0038] Determine the required number of step jumps, and based on the required number of step jumps, the initial step parameters, and the target step parameters, determine the control signal for the valve positioner in the step performance test, and maintain the second preset time for each step jump; Specifically, the number of required step jumps can be set according to actual needs, and this embodiment does not impose a specific limitation on this. For example, 5 steps, 10 steps, and 20 steps. If the required number of step jumps is 5, then the control signal for the step performance test is 0%—10%—25%—50%—75%—100%—75%—50%—25%—10%—0%, and each step jump is maintained for a first preset time (e.g., 30 seconds). Obtain the preset stroke threshold, and determine the control signal for the valve positioner during the partial stroke test based on the initial control parameters and the preset stroke threshold.

[0039] Specifically, the preset travel threshold can be set according to actual needs, and this embodiment does not impose specific limitations on it. For example, the preset travel threshold can be 20%, then the control signal for the partial travel test is 0%-20%-0%.

[0040] S102, determine the stroke failure characteristic point that matches the target failure test in the stroke change curve, and determine the pressure failure characteristic point that matches the target failure test in the pressure change curve. S103, determine the performance parameters of the control valve during the operation process based on the stroke fault characteristic points and pressure fault characteristic points; It is understandable that after determining the characteristic points of stroke failure and pressure failure, since each point already contains stroke and pressure parameters, the performance parameters of the control valve during the operation process can be calculated through each point.

[0041] In some embodiments, during the full-stroke test, the stroke failure characteristic points include the start point of action, the end point of opening action, the start point of closing action, and the closing point; the pressure failure characteristic points include the start point of venting, the start point of opening friction force, the end point of opening friction force, the start point of closing friction force, and the end point of closing friction force. Based on the characteristic points of stroke failure and pressure failure, determine the performance parameters of the control valve during its operation, including: Based on the start point of the action, the end point of the opening action, the start point of the closing action, and the closing point, determine the actual stroke, opening time, and closing time of the control valve; based on the start point of venting, the start point of the opening friction force, the end point of the opening friction force, the start point of the closing friction force, and the end point of the closing friction force, determine the friction force parameters of the control valve. If the control valve is a straight-through valve, the friction parameters include average friction force, maximum friction force, and maximum static friction force. If the control valve is a rotary valve, the friction parameters include maximum friction force, minimum friction force, maximum static friction force in the forward direction, and maximum static friction force in the reverse direction.

[0042] In addition, if a pilot valve is present, the stroke failure characteristic point can also include the end point of the pilot stroke, and then the valve pilot stroke can be calculated.

[0043] In some embodiments, in the basic error hysteresis test, the stroke fault characteristic points include the characteristic points at which stability is achieved at each step in the stroke variation curve; after determining the stroke fault characteristic points in the stroke variation curve that match the target fault test, the test further includes: Based on the actual and theoretical strokes of the characteristic points when the positive step is stable, and the rated stroke of the control valve, determine the basic error at each positive step; based on the actual and theoretical strokes of the characteristic points when the reverse step is stable, and the rated stroke of the control valve, determine the basic error at each reverse step; based on the basic errors at each positive step and the corresponding basic errors at the reverse step, and the rated stroke of the control valve, determine the hysteresis at each step.

[0044] Continuing the previous example, if the control signal for the basic error hysteresis test is 0%-10%-25%-50%-75%-100%-75%-50%-25%-10%-0%, then characteristic points can be selected on the stroke change curve at the valve's stable points at the forward 25%, 50%, 75%, 100% steps and the reverse 100%, 75%, 50%, 25%, 0% steps. The actual and theoretical strokes at these characteristic points at each stable step are then determined, along with the rated stroke of the control valve. Using the actual and theoretical strokes at these characteristic points, and the rated stroke of the control valve, the basic error at each step is determined. Then, based on the basic errors at each forward step and the corresponding basic errors at the reverse step, and the rated stroke of the control valve, the hysteresis at each step is determined.

[0045] In some embodiments, in the step performance test, the stroke failure characteristic points include the characteristic points at the stable point of each step in the stroke change curve, the overshoot point and undershoot point of the opening segment, and the overshoot point and undershoot point of the closing segment. The pressure failure characteristic points include the starting point of the opening friction force, the ending point of the opening friction force, the starting point of the closing friction force, and the ending point of the closing friction force at each step. Based on the characteristic points of stroke failure and pressure failure, determine the performance parameters of the control valve during its operation, including: The basic error and hysteresis at each step are determined based on the characteristic points at the stable point of each step in the stroke change curve; the overshoot and undershoot values ​​are determined based on the overshoot and undershoot points of the opening and closing sections; and the maximum friction force at each step is determined based on the starting point, ending point, starting point, and ending point of the opening friction force.

[0046] Continuing from the previous example, if the control signal for the step performance test is 0%-10%-25%-50%-75%-100%-75%-50%-25%-10%-0%, then characteristic points can be selected on the stroke change curve at the valve's forward step of 25%, 50%, 75%, 100% and the reverse step of 100%, 75%, 50%, 25%, 0% when it stabilizes, and the basic error and hysteresis at each step can be calculated.

[0047] In some embodiments, during a partial stroke test, stroke failure feature points include stroke curve abrupt change points, and pressure failure feature points include pressure curve feature points corresponding to the stroke curve abrupt change points. Based on the characteristic points of stroke failure and pressure failure, determine the performance parameters of the control valve during the operation process, including: determining the average friction force, maximum friction force, and maximum static friction force based on the characteristic points of the pressure curve corresponding to the abrupt change points of the stroke curve.

[0048] Specifically, the abrupt change point of the stroke curve is the point in the defined stroke change curve where abrupt change occurs, and the characteristic point of the pressure curve is the point in the vertical direction corresponding to the abrupt change point in the stroke change curve. At this time, the average friction force, maximum friction force, and maximum static friction force can be determined based on the characteristic point of the pressure curve corresponding to the abrupt change point of the stroke curve.

[0049] S104 compares and analyzes the performance parameters with preset standard data to determine the fault type of the control valve and outputs the diagnostic results of the control valve.

[0050] Specifically, the preset standard data can be set by the test personnel according to the actual situation, or the analysis result of a certain test data can be used as the preset standard data, and the analysis result of the preset standard data can be used as a reference for subsequent fault diagnosis.

[0051] Then, by comparing and analyzing the performance parameters with preset standard data, the fault type of the control valve can be determined and the diagnostic results can be output. This fault type can be displayed using a fault severity indicator light, and the risk type, its level, and the corresponding handling plan can be output simultaneously.

[0052] It is understandable that, since this application has built a fault diagnosis software platform, after determining the performance parameters of the control valve during the operation process, relevant personnel can directly and intuitively judge whether the valve has a fault in the characteristic curve or the control valve's movement state on the fault diagnosis software platform. If so, they can check the corresponding box on the fault diagnosis software platform to facilitate subsequent fault diagnosis and improve the convenience of fault detection.

[0053] This ensures a comprehensive evaluation of the control valve. Full-stroke testing can diagnose faults such as packing damage, stem connection failure, valve jamming or sticking in the open position, actuator leakage, positioner malfunction, limit device failure, sealing surface damage, sealing surface or limit device damage, jamming at a specific position, prediction of the probability of subsequent jamming, stem damage, sticking / creeping, air circuit blockage, positioner malfunction, air circuit rupture, and loose connection between the stem and actuator. Basic error hysteresis testing and step performance testing can diagnose faults such as stem damage at a specific position (stem defect, potential leakage risk), excessive basic error (overly tight packing, incorrect positioner settings), excessive hysteresis at a specific position (overly tight packing, incorrect positioner settings), limit device failure, sealing surface damage (causing over-closing), sealing surface or limit device damage, jamming at a specific position, prediction of the probability of subsequent jamming, and stem damage. Partial-stroke testing can diagnose faults such as sticking, jamming, and abrupt stoppage.

[0054] According to the technical solution provided in the embodiments of this application, by setting four test types—full stroke test, basic error hysteresis test, step performance test, and partial stroke test—the operating parameters of the control valve under different operating conditions are obtained respectively. Feature points matching each test type are selected on the stroke change curve and pressure change curve to calculate the performance parameters of the control valve's operating process under different operating conditions. This determines the fault type of the control valve and outputs the diagnostic results of the control valve. It can diagnose multiple fault types, overcoming the deficiency of related technologies that can only diagnose a single fault type, so as to comprehensively evaluate the health status of the valve and meet actual needs.

[0055] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the process of the embodiments of this application.

[0056] All of the above-mentioned optional technical solutions can be combined in any way to form the optional embodiments of this application, and will not be described in detail here.

[0057] The following are embodiments of the apparatus described in this application, which can be used to execute the embodiments of the method described in this application. For details not disclosed in the apparatus embodiments of this application, please refer to the embodiments of the method described in this application.

[0058] Figure 3 This is a schematic diagram illustrating the structure of a control valve fault diagnosis device according to an exemplary embodiment of this application. Figure 3 As shown, the exemplary control valve fault diagnosis device includes: The parameter acquisition module 301 is configured to acquire the action parameters of the control valve in the target fault test, wherein the target fault test includes at least one of the following: full stroke test, basic error hysteresis test, step performance test and partial stroke test, and the action parameters include the stroke change curve over time and the cylinder pressure change curve over time. The point matching module 302 is configured to determine the stroke fault feature point that matches the target fault test in the stroke change curve, and to determine the pressure fault feature point that matches the target fault test in the pressure change curve. The parameter determination module 303 determines the performance parameters of the control valve during the operation process based on the stroke fault characteristic points and pressure fault characteristic points. The result output module 303 compares and analyzes the performance parameters with preset standard data to determine the fault type of the control valve and outputs the diagnostic results of the control valve.

[0059] Embodiments of this application also provide an electronic device, including: one or more processors; and a storage device for storing one or more programs, which, when executed by one or more processors, cause the electronic device to implement the methods provided in the above embodiments.

[0060] Figure 4 A schematic diagram of a computer system suitable for implementing the embodiments of this application is shown. It should be noted that... Figure 4 The computer system 400 of the electronic device shown is merely an example and should not impose any limitation on the functionality and scope of use of the embodiments of this application.

[0061] like Figure 4 As shown, the computer system 400 includes a Central Processing Unit (CPU) 401, which can perform various appropriate actions and processes, such as executing the methods described in the above embodiments, based on programs stored in Read-Only Memory (ROM) 402 or programs loaded from storage portion 408 into Random Access Memory (RAM) 403. The RAM 403 also stores various programs and data required for system operation. The CPU 401, ROM 402, and RAM 403 are interconnected via a bus 404. An Input / Output (I / O) interface 405 is also connected to the bus 404.

[0062] The following components are connected to I / O interface 405: an input section 406 including a keyboard, mouse, etc.; an output section 407 including a cathode ray tube (CRT), liquid crystal display (LCD), etc., and speakers, etc.; a storage section 408 including a hard disk, etc.; and a communication section 409 including a network interface card such as a LAN (Local Area Network) card, modem, etc. The communication section 409 performs communication processing via a network such as the Internet. A drive 410 is also connected to I / O interface 405 as needed. Removable media 411, such as a disk, optical disk, magneto-optical disk, semiconductor memory, etc., are installed on drive 410 as needed so that computer programs read from them can be installed into storage section 408 as needed.

[0063] Specifically, according to embodiments of this application, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments of this application include a computer program product comprising a computer program carried on a computer-readable medium, the computer program including a computer program for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via communication section 409, and / or installed from removable medium 411. When the computer program is executed by central processing unit (CPU) 401, it performs various functions defined in the system of this application. It should be noted that the computer-readable medium shown in embodiments of this application can be a computer-readable signal medium or a computer-readable storage medium or any combination thereof. The computer-readable storage medium can be, for example, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination thereof. More specific examples of computer-readable storage media may include, but are not limited to: electrical connections having one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), flash memory, optical fiber, portable compact disc read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof. In this application, a computer-readable signal medium may include a data signal propagated in baseband or as part of a carrier wave, carrying a computer-readable computer program. Such propagated data signals may take various forms, including but not limited to electromagnetic signals, optical signals, or any suitable combination thereof. A computer-readable signal medium may also be any computer-readable medium other than a computer-readable storage medium, which can send, propagate, or transmit a program for use by or in connection with an instruction execution system, apparatus, or device. A computer program contained on a computer-readable medium may be transmitted using any suitable medium, including but not limited to: wireless, wired, etc., or any suitable combination thereof.

[0064] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation that may be implemented in systems, methods, and computer program products according to various embodiments of this application. Each block in a flowchart or block diagram may represent a module, segment, or portion of code, which contains one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutively indicated blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in a block diagram or flowchart, and combinations of blocks in a block diagram or flowchart, may be implemented using a dedicated hardware-based system that performs the specified function or operation, or using a combination of dedicated hardware and computer instructions.

[0065] The units described in the embodiments of this application can be implemented in software or hardware, and the described units can also be located in a processor. The names of these units do not necessarily limit the specific unit itself.

[0066] Another aspect of this application provides a computer-readable storage medium storing a computer program thereon, which, when executed by a computer's processor, causes the computer to perform the method as described above. This computer-readable storage medium may be included in the electronic device described in the above embodiments, or it may exist independently and not assembled into the electronic device.

[0067] Another aspect of this application provides a computer program product or computer program including computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform the methods described in the various embodiments above.

[0068] The above embodiments are merely illustrative of the principles and effects of this application and are not intended to limit this application. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this application should still be covered by the steps of this application.

Claims

1. A method for diagnosing control valve faults, characterized in that, include: Obtain the operating parameters of the control valve in the target fault test, wherein the target fault test includes at least one of the following: full stroke test, basic error hysteresis test, step performance test and partial stroke test, and the operating parameters include the stroke change curve over time and the cylinder pressure change curve over time. Determine the stroke failure characteristic point that matches the target failure test in the stroke variation curve, and determine the pressure failure characteristic point that matches the target failure test in the pressure variation curve; Based on the stroke fault characteristic points and the pressure fault characteristic points, determine the performance parameters of the control valve during the operation process; The performance parameters are compared and analyzed with preset standard data to determine the fault type of the control valve and output the diagnostic results of the control valve.

2. The method according to claim 1, characterized in that, The acquisition of the control valve's operating parameters during the target fault test includes: Determine the control signal of the valve positioner of the control valve during the target fault test; The control signal is input to the valve positioner, and the action parameters are collected during the operation of the control valve.

3. The method according to claim 2, characterized in that, The determination of the control signal for the valve positioner during the target fault test includes: Acquire initial control parameters and target control parameters, and determine the control signal of the valve positioner during the full stroke test based on the initial control parameters and target control parameters; Determine the positive step change amount, the negative step change amount, and the number of steps. Based on the initial step parameters, the target step parameters, the positive step change amount, the negative step change amount, and the number of steps, determine the control signal of the valve positioner in the basic error hysteresis test, and maintain the first preset time for each step. The number of demand step jumps is determined, and the control signal of the valve positioner in the step performance test is determined based on the number of demand step jumps, the initial step parameters, and the target step parameters, and the second preset time is maintained for each step jump. Obtain a preset stroke threshold, and determine the control signal for the valve positioner during the partial stroke test based on the initial control parameters and the preset stroke threshold.

4. The method according to claim 1, characterized in that, In the full-stroke test, the stroke fault characteristic points include the start point of action, the end point of opening action, the start point of closing action, and the closing point; the pressure fault characteristic points include the start point of venting, the start point of opening friction force, the end point of opening friction force, the start point of closing friction force, and the end point of closing friction force. The step of determining the performance parameters of the control valve during its operation based on the stroke fault characteristic points and the pressure fault characteristic points includes: The actual stroke, opening time, and closing time of the control valve are determined based on the start point of the action, the end point of the opening action, the start point of the closing action, and the closing point. The friction parameters of the control valve are determined based on the starting point of venting, the starting point of the opening friction force, the ending point of the opening friction force, the starting point of the closing friction force, and the ending point of the closing friction force. If the control valve is a straight-through valve, the friction parameters include average friction force, maximum friction force, and maximum static friction force. If the control valve is a rotary valve, the friction parameters include maximum friction force, minimum friction force, maximum static friction force in the forward direction, and maximum static friction force in the reverse direction.

5. The method according to claim 1, characterized in that, In the basic error hysteresis test, the stroke fault characteristic points include the characteristic points at each step point of the stroke change curve when the stroke is stable. After determining the stroke fault characteristic point that matches the target fault test in the stroke variation curve, the method further includes: Based on the actual and theoretical travel of the characteristic point at the stable point of the positive step, and the rated travel of the control valve, the basic error at each positive step is determined. Based on the actual and theoretical travel of the characteristic point at the stable point of the reverse step, and the rated travel of the control valve, the basic error at each reverse step is determined. The hysteresis at each step is determined based on the basic error at each positive step and the basic error at the corresponding negative step, as well as the rated stroke of the control valve.

6. The method according to claim 1, characterized in that, In the step performance test, the stroke fault characteristic points include the characteristic points at the stable point of each step in the stroke change curve, the overshoot and undershoot points in the opening segment, and the overshoot and undershoot points in the closing segment. The pressure fault characteristic points include the starting point, ending point, starting point, and ending point of the opening friction force at each step. The step of determining the performance parameters of the control valve during its operation based on the stroke fault characteristic points and the pressure fault characteristic points includes: Determine the basic error and hysteresis at each step based on the characteristic points at which the stroke change curve stabilizes. The overshoot and undershoot values ​​are determined based on the overshoot and undershoot points of the opening and closing segments. The maximum friction force at each step is determined based on the starting point, ending point, starting point, and ending point of the open-direction friction force.

7. The method according to claim 1, characterized in that, In the partial stroke test, the stroke failure feature point includes the stroke curve abrupt change point, and the pressure failure feature point includes the pressure curve feature point corresponding to the stroke curve abrupt change point; The step of determining the performance parameters of the control valve during its operation based on the stroke fault characteristic points and the pressure fault characteristic points includes: Based on the pressure curve characteristic points corresponding to the abrupt change points of the stroke curve, the average friction force, maximum friction force, and maximum static friction force are determined.

8. A control valve fault diagnosis device, characterized in that, include: The parameter acquisition module is configured to acquire the action parameters of the control valve in a target fault test, wherein the target fault test includes at least one of a full stroke test, a basic error hysteresis test, a step performance test, and a partial stroke test, and the action parameters include a stroke change curve over time and a cylinder pressure change curve over time. The point matching module is configured to determine, in the stroke variation curve, a stroke fault feature point that matches the target fault test, and in the pressure variation curve, a pressure fault feature point that matches the target fault test. The parameter determination module determines the performance parameters of the control valve during the operation process based on the stroke fault characteristic points and the pressure fault characteristic points. The results output module compares and analyzes the performance parameters with preset standard data to determine the fault type of the control valve and outputs the diagnostic results of the control valve.

9. An electronic device, characterized in that, include: One or more processors and a memory, the memory storing a computer program that, when executed by the one or more processors, causes the device to perform the steps of the control valve fault diagnosis method as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, It stores a computer program that, when executed by one or more processors, causes the device to perform the control valve fault diagnosis method as described in any one of claims 1 to 7.

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