A smart manual ball valve with electronic locking function

Abstract

This invention relates to the field of industrial valve technology. It discloses an intelligent manual ball valve with electronic locking function, comprising a valve body, a valve ball, a valve stem, and a handle, and further including an electronic locking unit located above or to the side of the valve stem. The electronic locking unit includes a housing, a locking mechanism located within the housing, an electric actuator, and a control module. The locking mechanism restricts the rotation of the handle relative to the valve body in the locked state. The electric actuator drives the locking mechanism to switch between locked and unlocked states. The control module is electrically connected to the electric actuator and an external signal interface. The control module is configured to output a drive signal to the electric actuator based on control information from at least one local authorized operation, remote control command, and process interlock signal, thereby controlling the locking mechanism to switch between locked and unlocked states, thus achieving electronic locking and unlocking of the handle. The valve opening and closing actions are completed by the operator through manual rotation of the handle.

Description

Technical Field

[0001] This invention relates to the field of industrial valve technology, and more specifically, to an intelligent manual ball valve with electronic locking function. Background Technology

[0002] Ball valves, as a commonly used shut-off valve, are widely used in petroleum, chemical, power, metallurgy, and municipal water supply and drainage fields due to their simple structure, rapid opening and closing, and low flow resistance. Currently, manual ball valves are widely used in engineering projects. These valves typically consist of a valve body, ball, seat, stem, and a handle mounted on the stem. The operator manually rotates the handle to drive the ball's rotation, thus controlling the flow of media. While these manual ball valves are low-cost and easy to maintain, they have significant shortcomings in safety management and status monitoring.

[0003] In many applications with high process safety requirements, such as pipelines handling high pressure, high temperature, toxic or hazardous media, and critical switching valve positions, accidental opening or closing of valves can lead to media misflow, equipment overpressure, or other process accidents. Therefore, it is often necessary to implement "lock-in management" for some critical manual ball valves to prevent unauthorized operation. Common practices in existing technologies include: 1. Mechanical Padlock Method: A padlock hole is provided on the handle or stem of the manual ball valve, and the handle rotation is restricted by attaching a mechanical padlock, latch, or wire seal. This method is simple in structure and low in cost, but it relies entirely on on-site personnel to manually lock and unlock according to procedures. It cannot automatically control the locking state based on remote control commands or process interlock signals, making it difficult to meet the needs of modern process control systems for centralized valve management, remote authorization, and operation recording.

[0004] 2. Manual ball valves with limit switches or proximity switches: Some manual ball valves have limit switches or proximity switches added to the valve stem or handle to detect the open / closed state of the valve and feed back to the host computer. However, this type of structure is still only a status detection and does not provide electronic locking capability for the handle itself, so it cannot prevent human error or illegal operation from the source.

[0005] 3. Electric ball valve or electric actuator + ball valve combination: The valve stem is driven by a motor to rotate, and remote opening and closing and status feedback are achieved with the help of a controller. It can be linked with DCS / PLC systems. However, this type of solution usually no longer relies on a manual handle, and the operation mode is completely different from that of traditional manual valves. It is not suitable for working conditions where the on-site manual operation habit is still desired and only the locking control and intelligent monitoring functions of the existing manual ball valve need to be added. In addition, electric actuators are more expensive and have a larger structural volume, making it difficult to promote in some space-constrained or retrofit projects. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention discloses an intelligent manual ball valve with electronic locking function, comprising a valve body, a valve ball, a valve stem, and a handle, and further comprising an electronic locking unit disposed above or on the side of the valve stem; the electronic locking unit comprises a housing, a locking mechanism located within the housing, an electric actuator, and a control module, wherein the locking mechanism is used to restrict the rotation of the handle relative to the valve body in the locked state, the electric actuator is used to drive the locking mechanism to switch between the locked and unlocked states, and the control module is electrically connected to the electric actuator and an external signal interface respectively; the control module is configured to output a drive signal to the electric actuator based on control information from at least one local authorized operation, remote control command, and process interlock signal, to control the locking mechanism to switch between the locked and unlocked states, thereby realizing electronic locking and unlocking of the handle, and the opening and closing of the valve is completed by the operator through manual rotation of the handle.

[0007] Furthermore, the valve body has a valve cavity, the valve ball is located in the valve cavity, the valve stem is connected to the valve ball, and the valve stem extends to the top of the valve body and is connected to the handle, thus forming a conventional manual ball valve structure.

[0008] Furthermore, the locking mechanisms include: Locking disc, the locking disc is mounted on the valve stem, and the locking disc has multiple locking grooves distributed circumferentially; A wedge-shaped locking block, at least one set of wedge-shaped locking blocks is installed on the actuator end of the electric actuator, and the head of the wedge-shaped locking block has a wedge-shaped tooth surface that mates with the locking groove.

[0009] Furthermore, the two sets of wedge-shaped locking blocks engage with the opposite sides of the locking disc, and the tail of the wedge-shaped locking block is fixedly connected to the actuator end of the electric actuator through a connecting rod. Under the drive of the electric actuator, it reciprocates along the axial direction of the valve stem. The wedge-shaped head of the wedge-shaped locking block is used to insert into the locking groove. A floating sleeve is sleeved on the outer periphery of the middle section of the wedge-shaped locking block. An elastic element is provided between the outer periphery of the floating sleeve and the inner wall of the housing. The elastic element is configured to allow the wedge-shaped locking block to move relative to the housing in a direction perpendicular to the valve stem axis while the wedge-shaped locking block moves along the axial direction of the valve stem, so as to achieve self-centering when the wedge-shaped head engages with the locking groove.

[0010] Furthermore, the electric actuator is a bistable magnetic holding electromagnet. The electric actuator is configured to keep the locking mechanism in a preset locked or unlocked state when the power supply is interrupted. The housing is provided with an emergency operation hole corresponding to the wedge-shaped locking block. By inserting a special tool, the wedge-shaped locking block can be manually moved to achieve emergency locking or emergency unlocking in the event of system failure and / or power failure.

[0011] Furthermore, the electronic locking unit also includes a position detection module, which consists of a magnetic element and a magnetic angle sensor. The magnetic element is mounted on the valve stem to rotate synchronously with the valve stem. The magnetic angle sensor is arranged opposite to the magnetic element. The control module is electrically connected to the magnetic angle sensor and is configured to acquire the angle signal output by the magnetic angle sensor, calibrate the angle value when the valve ball is in the fully closed position as zero opening, calibrate the angle value when the valve ball is in the fully open position as maximum opening, and convert the intermediate angle into the corresponding valve opening information and / or opening percentage based on the calibration result.

[0012] Furthermore, the electronic locking unit also includes a torque detection module, which includes: The torque-sensitive section is set on the valve stem and undergoes elastic torsional deformation under torque. At least one set of strain gauges is arranged on the torque-sensitive section to measure the strain of the torque-sensitive section and output an electrical signal related to the torque. The signal conditioning circuit is electrically connected between the strain gauge and the control module and is used to amplify and filter the electrical signal output by the strain gauge. The control module is configured to acquire torque signals during valve opening and / or locking and unlocking to form torque-angle relationship data, and compare the torque-angle relationship data with preset reference torque data. When the torque exceeds a preset threshold and / or the torque change trend is abnormal, the module outputs a torque abnormality and / or jamming warning signal, and / or restricts the electric actuator from driving the locking mechanism to switch from the unlocked state to the locked state or from the locked state to the unlocked state.

[0013] Furthermore, the control module is configured as follows: The operation feature data corresponding to at least one authorized operator is pre-stored. The operation feature data is obtained by learning the torque signal and angle signal during the operation of the handle by the authorized operator. While the locking mechanism is in the unlocked state and the operator manually rotates the handle, the current torque and angle signals are collected in real time to generate real-time operation data. The real-time operation data is compared with the pre-stored operation feature data corresponding to the identity of the operator performing the local authorized operation; When the deviation of the comparison result exceeds the first preset threshold, the operation consistency is determined to be abnormal, and a risk warning signal for the substitute operation is output and / or the locking mechanism is controlled to switch back to the locking state.

[0014] Furthermore, the control module is configured as follows: The angle signal output by the position detection module is monitored in real time, and the angular velocity of the valve stem is calculated. Receive external process interlock signals; When the process interlock signal indicates that the process parameter exceeds the limit, the reason for the process parameter exceeding the limit is determined based on the current angular velocity. If the angular velocity is greater than the preset velocity threshold, it is determined that the process parameter exceedance is caused by transient fluctuations due to valve action, and the interlocking action is temporarily suspended within a dynamic tolerance time window; if the process parameter exceedance is not eliminated after the dynamic tolerance time window, the locking mechanism is controlled to switch to the locked state. If the angular velocity is not greater than the preset velocity threshold, it is determined that the process parameter exceeding the standard is a real process abnormality, and the locking mechanism is immediately controlled to switch to the locked state.

[0015] Furthermore, the control module is configured to execute a locking performance self-test program after the locking mechanism switches to the locked state, the self-test program including: Monitor the applied torque signal applied to the handle in the locked state, and the small angular displacement signal of the valve stem caused by the applied torque; The locking stiffness of the locking mechanism is calculated based on the relationship between the applied torque signal and the minute angular displacement signal. The locking stiffness is compared with preset reference stiffness data to assess the wear level of the locking mechanism; When the locking stiffness is lower than the preset stiffness threshold, a warning signal for decreased locking performance is output.

[0016] Compared with the prior art, the present invention has the following advantages: 1. The present invention provides an intelligent manual ball valve with electronic locking function. While retaining the traditional manual ball valve operation habit of manually rotating the handle, it integrates an electronic locking unit on the valve stem to realize electronic authorized control of the handle rotation. It can automatically switch the locking / unlocking state according to local authorized operation, remote control command and process interlock signal, thereby realizing centralized management of key valve positions and protection against misoperation. It has a compact structure, is easy to modify and has a relatively low cost, and is suitable for upgrading existing manual ball valves.

[0017] 2. The present invention provides an intelligent manual ball valve with electronic locking function. The locking mechanism is formed by the cooperation of a locking disc and a wedge-shaped locking block. A floating sleeve and elastic element are set on the wedge-shaped locking block to realize automatic centering and pre-tightening during the locking engagement process. With the cooperation of a bistable magnetic holding electromagnet, a position detection module and a torque detection module, it can not only maintain the preset locking / unlocking state in the event of power failure, but also monitor the valve opening degree and torque-angle relationship online. When jamming or abnormal torque is detected, an early warning is issued and the locking / unlocking action is restricted, thereby significantly improving the safety and reliability of valve operation.

[0018] 3. This invention provides an intelligent manual ball valve with electronic locking function, which achieves full monitoring of the operation process by introducing behavioral biometric recognition technology based on operating torque characteristics. The control module can learn and store the authorized operator's operating fingerprint (torque-angle-time characteristic curve) and perform real-time comparison during manual operation. This solution effectively prevents the risk of proxy operation ("authorized by A, operated by B"), realizes human-machine consistency verification and operation compliance monitoring from the moment of authorization to the entire operation process, fills the regulatory blind spot of traditional access control, and significantly improves the level of safety management, operation traceability, and accuracy of responsibility definition in high-risk scenarios.

[0019] 4. This invention provides an intelligent manual ball valve with electronic locking function, proposing an intelligent interlocking strategy that integrates real-time valve angular velocity information and process interlocking signals. By monitoring the valve stem angular velocity in real time, the system can intelligently distinguish between transient fluid fluctuations (such as water hammer effect) caused by rapid valve opening and closing and actual process anomalies. A dynamic tolerance time window is provided for transient fluctuations, effectively reducing false interlocking triggers and improving production efficiency; simultaneously, it maintains a zero-delay rapid response in the event of actual process anomalies, resolving the contradiction between response speed and anti-interference capability in traditional interlocking systems and ensuring process safety.

[0020] 5. This invention provides an intelligent manual ball valve with electronic locking function, featuring online self-testing of the locking mechanism's performance. By utilizing built-in high-precision torque and angle sensors, the relationship between minute applied torque and minute angular displacement of the valve stem is analyzed in the locked state, enabling online quantitative evaluation of the locking mechanism's stiffness. This solution can monitor the mechanical wear and performance degradation of the locking mechanism in real time, promptly detecting hidden faults that are difficult to detect using traditional methods. It provides data support for condition-based predictive maintenance, effectively preventing the risk of internal leakage or locking failure due to insufficient locking stiffness, and improving the long-term reliability of the valve. Attached Figure Description

[0021] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of an intelligent manual ball valve with electronic locking function disclosed in this invention; Figure 2This is a schematic diagram of the locking mechanism structure in an intelligent manual ball valve with electronic locking function disclosed in this invention; Figure 3 for Figure 2 Enlarged view of number A; Figure 4 This is a schematic diagram of the control principle of an intelligent manual ball valve with electronic locking function disclosed in this invention.

[0023] In the diagram: 10. Valve body; 11. Valve ball; 12. Valve stem; 13. Valve chamber; 14. Handle; 15. Electronic locking unit; 16. Housing; 17. Locking mechanism; 18. Electric actuator; 19. Control module; 20. Locking disc; 21. Locking groove; 22. Wedge-shaped locking block; 23. Floating sleeve; 24. Position detection module; 25. Torque detection module. Detailed Implementation

[0024] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] Example 1: As Figure 1 As shown, this embodiment provides an intelligent manual ball valve with electronic locking function, including a valve body 10, a valve ball 11, a valve stem 12, and a handle 14. The valve body 10 has a valve cavity 13, in which the valve ball 11 is rotatably arranged. One end of the valve stem 12 is connected to the valve ball 11, and the other end extends through the top of the valve body 10 and is fixedly connected to the handle 14. The operator rotates the handle 14 to drive the valve stem 12 to rotate, thereby driving the valve ball 11 to switch between the open and closed positions, thus realizing the opening and closing control of the valve.

[0026] An electronic locking unit 15 located above or to the side of the valve stem 12 includes a housing 16, a locking mechanism 17 located within the housing 16, an electric actuator 18, and a control module 19. The housing 16 is fixed to the valve body 10, and an installation space is formed within the housing 16 to accommodate the aforementioned components.

[0027] The locking mechanism 17 restricts the rotation of the handle 14 relative to the valve body 10 in the locked state, thereby locking the valve's current position. In the unlocked state, the locking mechanism 17 releases the constraint on the valve stem 12, allowing the handle 14 to rotate freely. The electro-actuator 18 drives the locking mechanism 17 to switch between the locked and unlocked states. The control module 19 is housed within the housing 16 and is electrically connected to the electro-actuator 18 and external signal interfaces (such as local button / key modules, remote control cables, process interlock signal input terminals, etc.). Specifically, the local authorization operation can be implemented through an identity recognition module integrated on the electronic locking unit 15. This identity recognition module can be a contactless radio frequency identification (RFID) reader, a near field communication (NFC) interface, a biometric identification device (such as a fingerprint scanner), or a secure keypad. The operator submits an authorization request to the control module 19 on-site by swiping a card, biometric verification, or entering an authorization code. The control module 19 compares the received identity information with a pre-stored authorization list; only after successful verification is the unlocking operation allowed.

[0028] The control module 19 may include a microprocessor, power management circuit, input / output interface circuit, etc., for receiving control information from at least one local authorized operation, remote control command, and process interlock signal. After logical judgment, it outputs a corresponding drive signal to the electric actuator 18, causing the electric actuator 18 to drive the locking mechanism 17 to switch between locked and unlocked states. Throughout the process, the valve opening and closing actions are always manually performed by the operator through the handle 14; this invention only electronically controls whether the handle is allowed to rotate.

[0029] Example 2: Figure 2 Based on Embodiment 1, the locking mechanism 17 includes a locking disc 20 and a wedge-shaped locking block 22. The locking disc 20 is mounted on the valve stem 12, coaxial with the valve stem 12, and rotates with the valve stem 12. Multiple locking grooves 21 are distributed along the circumferential direction on the outer circumference of the locking disc 20. Each locking groove 21 corresponds to a valve angle that allows locking, such as a fully closed position, a fully open position, and one or more intermediate opening positions.

[0030] Wedge-shaped locking blocks 22 are arranged on the side of the locking disc 20, and at least one set of wedge-shaped locking blocks 22 is installed on the actuating end side of the electric actuator 18. The front end of the wedge-shaped locking block 22 is a wedge-shaped head, and its front end face and / or side face have wedge-shaped toothed surfaces that mate with the locking groove 21. When the wedge-shaped locking block 22 is in the locked position, the wedge-shaped head is inserted into the corresponding locking groove 21, and the wedge-shaped toothed surfaces are tightly engaged with the side wall of the locking groove 21, so that the valve stem 12 and the handle 14 cannot rotate; when the wedge-shaped locking block 22 is in the unlocked position, the wedge-shaped head is disengaged from the locking groove 21, and the valve stem 12 and the handle 14 can rotate freely.

[0031] Preferably, two sets of opposing wedge-shaped locking blocks 22 are arranged on opposite sides of the locking disc 20. The two sets of wedge-shaped locking blocks 22 can simultaneously move closer to or further away from the locking disc 20 under the drive of the electric actuator 18. When the two sets of wedge-shaped locking blocks 22 are inserted into the locking grooves 21 on opposite sides of the locking disc 20, the locking disc 20 can be clamped from both sides, increasing the torsional load-bearing capacity of the locking mechanism. This is most suitable for applications requiring large manual operating torque.

[0032] As shown in the figure, the tail of each wedge-shaped locking block 22 is fixedly connected to the actuating end of the electric actuator 18 via a connecting rod. The connecting rod can be a threaded connection, a pin connection, or an integrally machined structure. When the electric actuator 18 is working, its actuating end moves axially along the valve stem 12, driving the wedge-shaped locking block 22 to reciprocate linearly along the valve stem 12 via the connecting rod, causing the wedge head to switch between the locking groove 21 of the locking disc 20 and the retracted position.

[0033] To accommodate manufacturing and assembly errors of the valve stem 12 and locking disc 20, and to improve the reliability of locking engagement, a floating sleeve 23 is fitted around the outer periphery of the middle section of the wedge-shaped locking block 22 in this embodiment. The floating sleeve 23 is rigidly connected to or interference-fitted with the wedge-shaped locking block 22. An elastic element is provided between the outer periphery of the floating sleeve 23 and the inner wall of the housing 16. The elastic element can be an annular elastic element (such as a wave spring coil or an elastic rubber ring) and / or multiple helical compression springs evenly distributed along the circumferential direction. When the wedge-shaped locking block 22 moves axially under the drive of the electric actuator 18, the elastic element allows the floating sleeve 23 and the wedge-shaped locking block 22 to generate a slight displacement relative to the housing 16 in a direction perpendicular to the axis of the valve stem 12. Thus, when the wedge head contacts the entrance of the locking groove 21, it can automatically adjust its position under the guidance of the inclined surface of the locking groove 21 to achieve self-centering engagement. After engagement, the elastic element provides appropriate preload to ensure a stable and reliable locking state.

[0034] Example 3: Based on the above examples, the electric actuator 18 is preferably a bistable magnetic latching electromagnet. The bistable magnetic latching electromagnet can maintain its state in both the locked and unlocked positions using a permanent magnet or magnetic latching structure, requiring only a short period of power supply during state switching, thereby significantly reducing power consumption. This makes it suitable for applications with limited power supply or those requiring improved energy efficiency.

[0035] In specific applications, the electric actuator 18 can be designed to remain locked or unlocked when power is interrupted, depending on process safety requirements. For example, in situations where the valve position needs to remain unchanged in the event of a fault, it can be set to remain locked when power is interrupted; in situations where manual emergency operation is required in the event of a fault, it can be set to remain unlocked when power is interrupted.

[0036] To further improve the system's safety and maintainability, the housing 16 is provided with an emergency operation hole corresponding to the wedge-shaped locking block 22. The emergency operation hole can be sealed with a screw plug or a protective cover. If necessary, the operator can remove the protective cover and directly move the wedge-shaped locking block 22 between the locked and unlocked positions by inserting a special tool (such as a rod tool or a hex wrench), thereby achieving emergency locking or unlocking in the event of system failure and / or power failure.

[0037] Example 4: Figure 4 As shown, based on the above embodiments, the electronic locking unit 15 may further include a position detection module 24. The position detection module 24 consists of a magnetic element and a magnetic angle sensor. The magnetic element can be a permanent magnet, which is fixedly mounted on the valve stem 12 to rotate synchronously with the valve stem 12; the magnetic angle sensor is fixedly mounted on the housing 16 and arranged opposite to the magnetic element to form a non-contact angle detection structure.

[0038] The control module 19 is electrically connected to the magnetic angle sensor and is configured to periodically acquire the angle signal output by the magnetic angle sensor. During installation and commissioning, when the valve ball 11 is in the fully closed position, the current angle value is recorded and calibrated as zero opening; when the valve ball 11 is in the fully open position, the current angle value is recorded and calibrated as maximum opening. Based on these two calibration points, the control module 19 maps the intermediate angle value to the corresponding valve opening information and / or opening percentage, and can output it to an external system through a local display or communication interface to achieve real-time monitoring of the manual ball valve opening.

[0039] Example 5: Figure 4 As shown, based on the above embodiments, the electronic locking unit 15 may further include a torque detection module 25. The torque detection module 25 includes a torque-sensitive section, at least one set of strain gauges, and a signal conditioning circuit.

[0040] The torque-sensitive section can be formed by locally thinning, slotting, or selecting a specific cross-sectional shape on the valve stem 12, which will produce measurable elastic torsional deformation under torque. Strain gauges are arranged on the surface of the torque-sensitive section to measure the strain at that location and output a torque-related electrical signal. A signal conditioning circuit is electrically connected to the strain gauges and the control module 19 to amplify, filter, and perform analog-to-digital conversion on the weak signal output by the strain gauges to obtain a stable and reliable torque signal.

[0041] The control module 19 is configured to acquire torque signals during valve opening and / or locking / unlocking processes, and combine this data with the valve stem angle information output by the position detection module 24 to form torque-angle relationship data. The control module 19 can compare the current torque-angle curve with preset benchmark torque data. When it detects that the torque exceeds a preset threshold and / or the torque change trend is abnormal (e.g., a sudden increase in torque within a certain angle range), it outputs a torque abnormality and / or jamming warning signal, prompting on-site or host computer maintenance. Simultaneously, the control module 19 can also limit the action of the electric actuator 18 driving the locking mechanism 17 based on the torque detection results. For example, it can prohibit locking / unlocking actions when the valve is detected to be jammed, preventing damage to the valve or pipeline caused by forced locking or unlocking under abnormal operating conditions.

[0042] Example 6: Building upon Example 5, this example provides an intelligent manual ball valve with operator identity verification and operational compliance monitoring functions. This example aims to address the safety hazards arising from the separation of authorization and operation, a common problem in existing technologies. In high-risk industrial settings such as petrochemicals, valve operation requires not only legal authorization but also standardized procedures and human-machine consistency. Traditional electronic locks or mechanical padlocks can only verify authorization at the moment of unlocking, but they cannot ensure that the person actually operating the handle 14 is the authorized person, nor can they monitor whether the operation meets process requirements, such as whether there are violations that could damage the valve or cause process fluctuations, such as excessive speed or force. If a situation of "authorization by A, operation by B" occurs, it is difficult to trace responsibility in the event of an accident, creating blind spots in safety management.

[0043] To address the aforementioned technical issues, this embodiment utilizes the data acquisition capabilities provided by the position detection module 24 described in Embodiment 4 and the torque detection module 25 described in Embodiment 5, combined with the intelligent analysis function of the control module 19, to introduce behavioral biometric technology based on operating torque characteristics. The core idea is that different operators, due to differences in physiological conditions, operating habits, and proficiency, exhibit individual differences and relative stability in the comprehensive characteristics formed by parameters such as the magnitude of the applied torque, the rate of torque change, the smoothness of operation, and the total time required to complete the operation when operating the same manual ball valve. By pre-learning and storing these characteristics of authorized operators, comparisons can be made in subsequent operations, thereby achieving auxiliary verification of operator identity and monitoring of operational compliance.

[0044] Specifically, the control module 19 is configured to execute a complete workflow that includes a learning phase and a monitoring phase.

[0045] During the learning phase, the primary objective is to acquire and store the operational characteristic data of authorized operators. First, a mapping relationship needs to be established between the authorized operator's identification (e.g., employee ID, RFID card number, or biometric information) and the operational characteristic data. When a newly authorized operator operates the valve for the first time, or when the system undergoes periodic calibration, the control module 19 enters learning mode. After being authorized and unlocking the valve, the operator performs one or more complete opening and / or closing actions according to standard operating procedures.

[0046] During operation, the control module 19 acquires torque signals from the torque detection module 25 and angle signals from the position detection module 24 in real time at high frequency. These raw signals contain a wealth of information. For example, in the initial stage of the ball valve moving from fully closed to open, it needs to overcome static friction and the sealing preload of the valve seat, typically resulting in a momentary peak in opening torque. In the middle stroke stage, the torque is mainly used to overcome packing friction and fluid dynamic pressure torque, and the torque is relatively stable. As it approaches the fully open position, the torque changes again until it reaches the limit. Simultaneously, combined with time information, derived parameters such as the angular velocity, angular acceleration, and rate of change of torque of the valve stem 12 can be calculated.

[0047] The control module 19 preprocesses these multi-dimensional time-series data, including filtering and noise reduction, data segmentation (distinguishing between opening and closing actions), and data standardization. Since the torque required for valve operation may vary under different operating conditions (such as different medium pressures or temperatures), standardization is crucial. For example, the angle signal can be normalized to an opening range of 0% to 100%, and the torque signal can be compensated and corrected according to the current process conditions to ensure that the characteristic data is not significantly affected by changes in operating conditions. The specific method for compensation and correction can be based on a physical model. The control module 19 acquires the current process medium pressure value through an external signal interface. Since the operating torque of the ball valve (especially the sealing friction torque) is approximately proportional to the pressure difference across the valve, the control module 19 pre-stores a torque-pressure coefficient calibrated based on the valve model. The control module 19 calculates the additional torque component caused by the pressure difference based on the real-time pressure signal and subtracts this component from the real-time acquired torque signal to obtain a pressure-independent standardized torque signal.

[0048] As an alternative implementation, a multi-condition learning strategy can be adopted. During the learning phase, operational characteristic data are collected under different typical process pressures (e.g., low pressure, medium pressure, and high pressure), and multiple templates are stored. During the monitoring phase, the control module 19 selects the closest template for comparison based on the current process conditions, or generates a dynamic reference template adapted to the current operating conditions through an interpolation algorithm.

[0049] After preprocessing, the control module 19 extracts key feature points from these data, such as peak opening torque, average operating torque, maximum angular velocity, total operating time, smoothness index of the torque curve (reflecting operating rhythm and stability), and buffer deceleration characteristics when approaching the limit. The smoothness index can be quantified by calculating the variance or root mean square value of the first derivative of the torque signal (i.e., the rate of change of torque); a smaller value indicates smoother operation. The buffer deceleration characteristics can be quantified by analyzing the ratio of the average angular velocity at the end of the operation (e.g., opening greater than 90%) to the average angular velocity in the middle stroke (e.g., opening between 20% and 80%); a smaller ratio indicates significant deceleration control by the operator when approaching the limit. The control module 19 fits these feature points into a complete multidimensional feature curve or integrates them into a multidimensional feature vector, which those skilled in the art can figuratively call an "operation fingerprint." This operation fingerprint is the aforementioned operation feature data. This operation feature data is stored in the non-volatile memory of the control module 19 and associated with the operator's identification. It should be noted that these feature data focus on the operator's behavior patterns, which is fundamentally different from the valve characteristic curves used to diagnose the valve's own health status. Their purpose is to identify people, not to identify equipment malfunctions.

[0050] To improve the robustness of the system and adapt to normal operational fluctuations caused by individual operators' fatigue or fine-tuning of long-term operating habits, this invention proposes an adaptive learning mechanism.

[0051] In the subsequent monitoring phase, if the control module 19 confirms that an operation was performed by the authorized person and is compliant, it can use the Exponentially Weighted Moving Average (EWMA) algorithm to fuse the data of this operation into the pre-stored operation feature data, thereby achieving dynamic updates and optimization of the operation fingerprint. During fusion, the new data is assigned a preset smoothing coefficient (e.g., 0.1 to 0.3) to control the update speed.

[0052] Furthermore, the setting of the first preset threshold can also be adaptively determined during the learning phase based on the internal differences between the data from multiple operations performed by the authorized operator. Specifically, the control module 19 first calculates the sequence of deviation values ​​between the multiple operation data performed by the authorized operator during the learning phase and the baseline operation feature data generated by the operator, and then calculates the standard deviation of the deviation sequence. The first preset threshold is preferably set to a specific multiple of this standard deviation, such as three times the standard deviation (i.e., following the three sigma principle in statistics), to cover the vast majority of normal operating situations, thereby achieving personalized threshold setting and effectively reducing the misjudgment rate.

[0053] During the monitoring phase, when an operator requests unlocking via a local authorization operation (such as swiping a card or entering a password), the control module 19 first verifies the operator's identity and permissions. Upon successful verification, the control module 19 outputs a drive signal to the electric actuator 18, causing the locking mechanism 17 to switch to the unlocked state, allowing the handle 14 to rotate. At this time, the control module 19 retrieves pre-stored operation feature data corresponding to the authorized identity from its memory and enters real-time monitoring mode.

[0054] The operator begins rotating handle 14 to open and close the valve. Control module 19 synchronously acquires the current torque and angle signals in real time, generating real-time operation data. The core algorithm of control module 19 continuously compares this real-time operation data with retrieved pre-stored operation feature data. This comparison is not a simple numerical comparison, but rather a comprehensive similarity assessment of the characteristic curve shape, key feature point positions, and values ​​throughout the entire operation process. Preferably, to accommodate potential nonlinear changes in the time scale during operation (i.e., variations in operation speed), a dynamic time warping approach can be adopted. This involves finding the optimal alignment path between the real-time operation curve and the pre-stored template curve to calculate the accumulated minimum distance, which directly reflects the degree of difference in operation modes. The specific steps for implementing this dynamic time warping algorithm in control module 19 are as follows: First, a two-dimensional distance matrix is ​​constructed from pre-stored operational feature data (template sequence) and real-time operational data (test sequence). Each element in the matrix represents the distance (e.g., Euclidean distance) between a point in the template sequence and a point in the test sequence. Then, starting from the beginning of the matrix, a dynamic programming algorithm is used to find a path to the end of the matrix that minimizes the cumulative distance of all elements along the path. When searching for the path, constraints of continuity and monotonicity must be followed (i.e., movement can only proceed to adjacent cells and must monotonically increase over time). The final minimum cumulative distance is the difference metric (DTW distance) between the two operations.

[0055] For example, an experienced operator typically operates smoothly and at a moderate speed; while an untrained substitute operator may be rough, move too fast or too slow, or use improper force during the opening phase. These differences will be directly reflected in the deviation between real-time operation data and pre-stored operation characteristic data.

[0056] The control module 19 calculates the cumulative or instantaneous value of this deviation in real time. When the deviation of the comparison result exceeds a preset first threshold, the control module 19 determines that there is an operational inconsistency anomaly in the current operation.

[0057] Once an operational inconsistency is detected, the control module 19 immediately takes intervention measures. On the one hand, it can output a risk warning signal for subrogation to the host computer via a local audible and visual alarm or communication interface, notifying management personnel to conduct on-site verification. On the other hand, in situations with extremely high safety requirements, the control module 19 can directly output a reverse drive signal to the electric actuator 18, controlling the locking mechanism 17 to switch back to the locked state, forcibly interrupting the current operation, thereby physically preventing potential misoperation or illegal operation.

[0058] Furthermore, this function can be used not only for identity verification but also for monitoring operational compliance. For example, standard operational characteristic templates can be set for specific process operations, requiring all operators to follow these templates (e.g., limiting maximum switching speed to prevent water hammer). If real-time operational data deviates significantly from the standard template, even if the operator is the same person, the system will determine it as non-compliant and intervene. All operational data, regardless of whether it is abnormal, will be recorded to form a complete operational log, providing data support for subsequent accident analysis and safety management optimization.

[0059] In summary, this embodiment, by introducing behavioral biometric technology based on operating torque characteristics, achieves continuous monitoring from the moment of authorization to the entire operation process, effectively solving the problems of proxy operation and non-compliant operation, and significantly improving the safety management level and operational reliability of manual ball valves.

[0060] Example 7: Building upon Example 4, this example provides an intelligent manual ball valve with intelligent interlocking and anti-false triggering function. This example primarily addresses the potential false triggering problem of process interlocking systems in manual valve operation scenarios during industrial processes. In modern industrial control, critical valve positions are typically interlocked with process parameters (such as pressure, temperature, and liquid level). When process parameters exceed limits, the interlocking system will forcibly close or lock the valve to ensure production safety. However, during manual valve operation, especially during rapid valve opening and closing, the fluid flow state changes drastically, easily causing transient fluid dynamic effects, such as water hammer or pressure fluctuations. These transient effects can cause the readings of process parameter sensors (such as pressure transmitters) to rise or fall sharply within a very short time, exceeding the interlocking threshold, thus erroneously triggering the interlocking lock, interrupting normal operation, and affecting production efficiency.

[0061] Existing technologies typically employ fixed delays or filtering to process interlocking signals. However, these methods have significant drawbacks: fixed delays reduce the safety response speed of the interlocking system, failing to promptly prevent genuine process anomalies; while excessive filtering may mask real, rapid changes. This trade-off between speed and accuracy has long been a technical challenge in this field.

[0062] To address the aforementioned technical problems, this embodiment proposes an intelligent interlocking strategy that integrates valve dynamic information and process parameters. The core idea is to determine the physical cause of process parameter deviations by real-time monitoring of the valve's own motion state (i.e., the angular velocity of the valve stem), distinguishing between transient fluctuations caused by valve action and genuine anomalies in the process system itself, thereby adopting different response strategies. The core of this solution lies in using the causal relationship between valve action and transient fluctuations for logical judgment.

[0063] Specifically, the electronic locking unit 15 in this embodiment integrates the position detection module 24 described in embodiment 4. The control module 19 is configured to monitor the angle signal output by the position detection module 24 in real time. By performing time differentiation processing on the angle signal, or by calculating the ratio of the angle difference within adjacent sampling periods to the time interval, the control module 19 can accurately calculate the real-time angular velocity of the valve stem 12. This angular velocity directly reflects the speed at which the operator operates the handle 14.

[0064] Meanwhile, the control module 19 receives process interlock signals from a higher-level system (such as a distributed control system or a programmable logic controller) via an external signal interface. These signals are typically based on a comparison between the measured values ​​of field process parameter sensors and preset safety thresholds.

[0065] When the control module 19 receives a process interlock signal indicating that the process parameters have exceeded the limit, it does not immediately execute the locking action, but instead enters the intelligent judgment process. The control module 19 first reads the current valve stem angular velocity and compares it with a preset speed threshold.

[0066] The preset velocity threshold is set based on the analysis of the fluid dynamics characteristics of a specific pipeline system. This threshold needs to be calibrated during the system commissioning phase. The calibration process can be performed as follows: Under safe system operation conditions, the operator performs valve opening and closing operations at different speeds (from slow to fast). Control module 19 records the maximum angular velocity and the corresponding transient fluctuation amplitude of process parameters (such as pipeline pressure) during each operation. By analyzing multiple sets of experimental data, a relationship curve between angular velocity and transient fluctuation amplitude is established. Based on the maximum allowable range of transient fluctuations in the process system (i.e., the safety margin between the interlock-set safety threshold and normal process parameters), the corresponding critical angular velocity is derived backward from this relationship curve and set as the preset speed threshold, or a slightly lower value is set using a safety factor (e.g., 0.8). For example, a critical speed can be determined by testing the pipeline pressure response characteristics at different operating speeds through field experiments; or by computational fluid dynamics simulation analysis. This threshold should be stored in control module 19 and can be adjusted or adaptively compensated according to changes in process conditions (such as medium viscosity and temperature changes).

[0067] If the current angular velocity exceeds the preset speed threshold, it indicates that the operator is rapidly manipulating the valve. In this case, the control module 19 determines that the current process parameter deviation is likely due to transient fluctuations caused by valve movement, rather than a genuine process anomaly. To avoid false triggering of interlocks, the control module 19 initiates a dynamic tolerance time window.

[0068] Within the dynamic tolerance time window, control module 19 temporarily suspends the interlocking action, allowing the operator to continue the current operation while continuously monitoring the process interlock signal. Transient fluctuations are typically characterized by rapid onset and rapid resolution, quickly attenuating after the valve movement stops or slows down. If the process interlock signal returns to normal (i.e., the parameter exceedance is eliminated) at the end of the dynamic tolerance time window, control module 19 cancels the current interlock request, and the system returns to normal monitoring status.

[0069] If the process interlock signal still indicates that the parameter exceeds the limit after the dynamic tolerance time window ends, it means that the exceeding phenomenon is not a transient fluctuation, or that a transient fluctuation is superimposed on a real process anomaly. At this time, the control module 19 immediately outputs a drive signal to the electric actuator 18 to control the locking mechanism 17 to switch to the locked state to ensure process safety.

[0070] Preferably, the dynamic tolerance time window described in this invention can be of a fixed duration or dynamically adjusted based on the real-time angular velocity. If a dynamic adjustment strategy is adopted, the control module 19 can adjust the length of the time window based on the real-time monitored angular velocity. For example, the control module 19 can use a piecewise function relationship or a lookup table (LUT) to describe the relationship between angular velocity and tolerance time. That is, a basic tolerance time (e.g., 2 seconds) is set, and when the real-time angular velocity exceeds a preset velocity threshold, the tolerance time is increased in segments according to the degree of excess. To ensure safety redundancy, the dynamic tolerance time also has an upper limit (e.g., a maximum of 10 seconds) to ensure that the interlocking response is not excessively delayed. The specific adjustment relationship needs to be determined based on the aforementioned experimental calibration results or fluid dynamics simulation analysis. For example, a higher angular velocity indicates a potentially stronger transient effect, and the time window can be appropriately extended to achieve a more optimized filtration effect. This dynamic adjustment capability further enhances the intelligence level of the system.

[0071] If the current angular velocity is not greater than a preset velocity threshold, it indicates that the valve is stationary or moving slowly. In this case, the fluid state is relatively stable, and significant transient fluctuations are unlikely. Therefore, the control module 19 determines that the current process parameter exceedance is a genuine process anomaly, such as a sudden increase in upstream pressure or a downstream equipment failure. At this time, safety is the primary consideration, and the control module 19 immediately skips the waiting period and directly outputs a drive signal to the electric actuator 18, controlling the locking mechanism 17 to switch to the locked state, achieving rapid response (zero-delay response) and ensuring system safety. This zero-delay response when a real anomaly occurs is a significant advantage of this invention over the fixed-delay method in the prior art.

[0072] To further improve the accuracy of the judgment, the control module 19 can also combine the rate of change of process parameters for comprehensive judgment. Transient fluctuations usually manifest as spike pulses with extremely high rates of change but short durations; while true process anomalies may manifest as a continuous upward or downward trend with relatively low rates of change but long durations. By simultaneously analyzing angular velocity and the rate of change of process parameters, different types of abnormal events can be more reliably distinguished. During comprehensive judgment, the control module 19 also calculates the rate of change of process parameters (e.g., the rate of change of pressure dP / dt) in real time. The control module 19 sets a rate of change threshold. When an angular velocity greater than a preset velocity threshold is detected, and the absolute value of the rate of change of process parameters exceeds this rate of change threshold, but its duration is less than a preset pulse width threshold (e.g., several hundred milliseconds), the control module 19 determines that the signal is a transient fluctuation in the form of spike pulses and initiates a dynamic tolerance time window. If the duration of the rate of change exceeding the threshold is long, even if the angular velocity is large, it should be considered a true process anomaly trend, and a lockout should be executed immediately.

[0073] Through the aforementioned intelligent interlocking strategy, this embodiment successfully distinguishes between transient fluctuations and actual process anomalies, resolving the inherent contradiction between response speed and anti-interference capability in traditional interlocking systems. Without sacrificing the safety response speed of the interlocking system, it effectively reduces false triggering of interlocks caused by manual operation, thereby improving production efficiency and operational safety.

[0074] Example 8: Based on Example 5, this example provides an intelligent manual ball valve with online self-testing function for the locking mechanism performance. This example aims to solve the problem of difficulty in online monitoring of the mechanical performance degradation of the locking mechanism in existing electronic locking valves. The locking mechanism 17 in the electronic locking unit 15, such as the locking disc 20 and wedge-shaped locking block 22 described in Example 2, is a key mechanical component for valve locking. During long-term use, especially under high-frequency operation or conditions subjected to large external impacts, the meshing surfaces of the locking mechanism (such as the wedge-shaped tooth surface and the sidewall of the locking groove) will inevitably experience wear, fatigue, or plastic deformation.

[0075] The degradation of these mechanical properties leads to a decrease in the locking stiffness of the locking mechanism. Locking stiffness refers to the ability of the locking mechanism to resist external torque and maintain the valve stem position in the locked state. When the locking stiffness decreases to a certain level, although the electronic signal of the control module 19 indicates that the valve is in the locked state, the handle 14 may still rotate slightly under the action of external force, causing the valve ball 11 to deviate from the preset position, which may cause internal leakage of the medium or even lead to locking failure, resulting in serious safety hazards. Existing electronic locking valves can usually only detect whether the locking mechanism is in place, but lack the ability to conduct online self-diagnosis of the mechanical health status of the locking mechanism itself. Maintenance work mainly relies on periodic offline inspections, resulting in problems of insufficient or excessive maintenance.

[0076] To address the aforementioned technical problems, this embodiment utilizes the high-precision measurement capabilities of the position detection module 24 described in Embodiment 4 and the torque detection module 25 described in Embodiment 5, combined with the data analysis function of the control module 19, to propose an online self-testing method for the stiffness of a locking mechanism based on micro-motion testing. The core idea is that, in the locked state, by analyzing the relationship between the minute external torque applied to the valve stem and the resulting minute angular displacement of the valve stem, the locking stiffness of the locking mechanism can be quantified, and its wear degree can be assessed accordingly.

[0077] Specifically, the control module 19 is configured to automatically or according to instructions execute a self-test procedure for locking performance after the locking mechanism 17 switches to the locked state. This self-test procedure is completed entirely online without disassembling the valve or adding additional testing equipment.

[0078] The first step of the self-test procedure is to acquire the excitation signal and the response signal. In this invention, the excitation signal refers to the external torque applied to the handle 14 or the valve stem 12 in the locked state, and the response signal refers to the small angular displacement of the valve stem 12 caused by the external torque.

[0079] The source of the applied torque can be diverse, and this invention supports both passive monitoring and active testing modes.

[0080] In passive monitoring mode, control module 19 utilizes naturally occurring minor disturbances in the environment as excitation sources. For example, after confirming valve locking, operators typically and habitually gently shake handle 14 to verify the locking reliability; additionally, fluid pressure fluctuations or equipment vibrations in the piping system are transmitted to the locking mechanism through the valve body and stem, creating minor disturbance torques. Control module 19 continuously monitors these applied torque signals via torque detection module 25. The strain gauges and signal conditioning circuitry in torque detection module 25 need to have sufficiently high sensitivity and signal-to-noise ratio to capture these minute torque changes.

[0081] In active testing mode, if environmental disturbances are too small to obtain an effective excitation signal, the control module 19 can actively apply test torque. One approach is for the control module 19 to guide the operator to apply a brief, controlled test torque (e.g., a light push on the handle) after locking via local prompts (e.g., flashing indicator lights) to ensure the self-test procedure is completed. Another approach is for the control module 19 to actively control the electric actuator 18 to generate test excitation. If the electric actuator 18 is a type with precise force control capabilities (e.g., a linear servo motor or voice coil motor), the control module 19 can directly control it to generate a small, controlled pulse or vibration force.

[0082] Even if the electric actuator 18 uses a bistable magnetic holding electromagnet as described in Embodiment 3, active testing can still be achieved. Although the bistable electromagnet is mainly used for state switching, it can generate excitation through a specific control strategy. For example, the control module 19 can execute a rapid "pseudo-unlock-relock" action sequence: applying a pulse current in the unlocking direction for a very short time, causing the wedge-shaped locking block 22 to generate a small axial displacement tendency or impact, and then immediately restoring the locked state. The transient impact force generated in this process can serve as an effective excitation signal. Alternatively, during the process of the locking mechanism 17 switching from the unlocked state to the locked state, the control module 19 can control the electric actuator 18 to apply an impact force slightly greater than that required for normal locking at the moment it is about to fully engage, using this impact process as an excitation signal.

[0083] While detecting the applied torque, the control module 19 monitors the angular displacement signal of the valve stem 12 via the position detection module 24. Since the valve is in a locked state, these angular displacements are typically very small, falling within the range of elastic deformation of the locking mechanism. The magnetic angle sensor in the position detection module 24 needs to have sufficiently high resolution and accuracy, for example, better than 0.1 degrees, to detect these minute angular changes.

[0084] The second step of the self-test procedure is to calculate the locking stiffness based on the acquired excitation and response signals. According to the principles of mechanics of materials, within the elastic deformation range, the stiffness of an object can be characterized by the ratio of the applied force to the generated displacement. In this invention, the locking stiffness can be defined as the ratio of the change in applied torque to the change in a small angular displacement.

[0085] The control module 19 performs fine signal conditioning on the acquired applied torque signal and minute angular displacement signal. For example, a bandpass filter is used to extract signals within a specific frequency range to eliminate the influence of DC bias and high-frequency noise. More importantly, cross-correlation analysis can be used to confirm the causal relationship and time delay between the detected angular displacement and the applied torque, thereby effectively distinguishing the effective angular displacement component caused by the applied torque, rather than displacement caused by random sensor drift or other irrelevant factors.

[0086] Then, the control module 19 can perform linear regression analysis or least squares fitting on the collected data points to obtain a straight line describing the "torque-displacement" relationship. The slope of this line represents the current locking stiffness. Specifically, the locking stiffness K is characterized as the ratio of the change in applied torque (ΔT) to the corresponding change in small angular displacement (Δθ). During the self-test process, the control module 19 collects a series of (ΔT, Δθ) data points and then uses the least squares method to fit the optimal K value, minimizing the sum of squares of the deviations of all data points from the fitted line (T=K*θ), where T is the applied torque and θ is the small angular displacement. The K value obtained in this way can most accurately reflect the overall stiffness characteristics of the current locking mechanism. For example, if a relatively large angular displacement of the valve stem is detected after applying a small applied torque, it indicates that the locking stiffness is low; conversely, if the angular displacement of the valve stem is small after applying the same applied torque, it indicates that the locking stiffness is high.

[0087] To improve the reliability of self-testing, the control module 19 can perform multiple measurements over a period of time and perform statistical analysis on the measurement results, such as calculating the average stiffness or minimum stiffness, to reduce the impact of random errors.

[0088] The third step of the self-test procedure is to assess the wear level of the locking mechanism and issue a warning. The control module 19 compares the calculated locking stiffness with preset reference stiffness data. The reference stiffness data can be the initial locking stiffness value of the valve when it left the factory, or the locking stiffness value measured after the most recent maintenance.

[0089] By comparing the current locking stiffness with the reference stiffness data, the control module 19 can assess the degree of wear on the locking mechanism. For example, different wear levels (such as slight wear, moderate wear, and severe wear) can be defined based on the percentage decrease in stiffness.

[0090] When the calculated locking stiffness falls below a preset stiffness threshold, it indicates that the performance of the locking mechanism has deteriorated to a level requiring attention. This preset stiffness threshold is determined based on safety management requirements and the design life of the locking mechanism. At this point, the control module 19 outputs a locking performance degradation warning signal to the host computer via a local display or communication interface, prompting maintenance personnel to promptly arrange for repair or replacement of the locking mechanism, thereby achieving condition-based predictive maintenance. The system can also record historical stiffness data to generate a performance degradation trend curve, which can be used to predict the remaining service life.

[0091] In summary, this embodiment, through innovative online self-testing technology for the stiffness of the locking mechanism, achieves real-time monitoring and quantitative evaluation of the health status of key mechanical components of electronic locking valves, effectively solving the problem of difficult detection of hidden faults in traditional electronic locking valves, and significantly improving the safety and reliability of valve operation.

[0092] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A smart manual ball valve with electronic locking function, comprising a valve body (10), a valve ball (11), a valve stem (12) and a handle (14), characterized in that, Also includes: An electronic locking unit (15) is provided above or on the side of the valve stem (12). The electronic locking unit (15) includes a housing (16), a locking mechanism (17) located in the housing (16), an electric actuator (18), and a control module (19). The locking mechanism (17) is used to restrict the rotation of the handle (14) relative to the valve body (10) in the locked state. The electric actuator (18) is used to drive the locking mechanism (17) to switch between the locked state and the unlocked state. The control module (19) is electrically connected to the electric actuator (18) and an external signal interface respectively. The control module (19) is configured to output a drive signal to the electric actuator (18) based on control information from at least one local authorized operation, remote control command and process interlock signal, so as to control the locking mechanism (17) to switch between the locked state and the unlocked state, thereby realizing the electronic locking and unlocking of the handle (14), and the opening and closing action of the valve is completed by the operator through the manual rotation of the handle (14).

2. The intelligent manual ball valve with electronic locking function according to claim 1, characterized in that, The valve body (10) has a valve cavity (13) inside, the valve ball (11) is located inside the valve cavity (13), the valve stem (12) is connected to the valve ball (11), and extends to the top of the valve body (10) and is connected to the handle (14).

3. The intelligent manual ball valve with electronic locking function according to claim 1, characterized in that, The locking mechanism (17) includes: Locking disc (20), the locking disc (20) is mounted on the valve stem (12), and the locking disc (20) has a plurality of locking grooves (21) distributed circumferentially. A wedge-shaped locking block (22), at least one set of the wedge-shaped locking blocks (22) is installed on the actuating end of the electric actuator (18), the head of the wedge-shaped locking block (22) having a wedge-shaped tooth surface that cooperates with the locking groove (21).

4. The intelligent manual ball valve with electronic locking function according to claim 3, characterized in that, Two sets of wedge-shaped locking blocks (22) respectively engage with the opposite sides of the locking disc (20). The tail of the wedge-shaped locking block (22) is fixedly connected to the actuator (18) via a connecting rod. Under the drive of the actuator (18), it reciprocates along the axial direction of the valve stem (12). The wedge-shaped head of the wedge-shaped locking block (22) is used to be inserted into the locking groove (21). A floating sleeve (23) is sleeved on the outer periphery of the middle section of the wedge-shaped locking block (22). An elastic element is provided between the outer periphery of the floating sleeve (23) and the inner wall of the housing (16). The elastic element is configured to allow the wedge-shaped locking block (22) to move relative to the housing (16) in a direction perpendicular to the axis of the valve stem (12) while the wedge-shaped locking block (22) moves along the axial direction of the valve stem (12), so as to achieve self-centering when the wedge-shaped head engages with the locking groove (21).

5. The intelligent manual ball valve with electronic locking function according to claim 3, characterized in that, The electric actuator (18) is a bistable magnetic holding electromagnet. The electric actuator (18) is configured to keep the locking mechanism (17) in a preset locked state or unlocked state when the power supply is interrupted. The housing (16) is provided with an emergency operation hole corresponding to the wedge-shaped locking block (22). By inserting a special tool, the wedge-shaped locking block (22) can be manually moved to achieve emergency locking or emergency unlocking in the event of system failure and / or power failure.

6. The intelligent manual ball valve with electronic locking function according to claim 1, characterized in that, The electronic locking unit (15) further includes a position detection module (24), which consists of a magnetic element and a magnetic angle sensor. The magnetic element is mounted on the valve stem (12) to rotate synchronously with the valve stem (12). The magnetic angle sensor is arranged opposite to the magnetic element. The control module (19) is electrically connected to the magnetic angle sensor and is configured to collect the angle signal output by the magnetic angle sensor, calibrate the angle value when the valve ball (11) is in the fully closed position as zero opening, calibrate the angle value when the valve ball (11) is in the fully open position as maximum opening, and convert the intermediate angle into the corresponding valve opening information and / or opening percentage based on the calibration result.

7. The intelligent manual ball valve with electronic locking function according to claim 1, characterized in that, The electronic locking unit (15) further includes a torque detection module (25), which includes: A torque-sensitive section is provided on the valve stem (12) and undergoes elastic torsional deformation under torque. At least one set of strain gauges is arranged on the torque-sensitive section to measure the strain of the torque-sensitive section and output an electrical signal related to the torque. A signal conditioning circuit, electrically connected between the strain gauge and the control module, is used to amplify and filter the electrical signal output by the strain gauge. The control module (19) is configured to acquire torque signals during valve switching and / or locking / unlocking to form torque-angle relationship data, and compare the torque-angle relationship data with preset reference torque data. When the torque exceeds a preset threshold and / or the torque change trend is abnormal, the module outputs a torque abnormality and / or jamming warning signal, and / or restricts the electric actuator (18) from driving the locking mechanism (17) to switch from the unlocked state to the locked state or from the locked state to the unlocked state.

8. The intelligent manual ball valve with electronic locking function according to claim 7, characterized in that, The control module (19) is configured as follows: The operation feature data corresponding to at least one authorized operator is pre-stored. The operation feature data is obtained by learning the torque signal and angle signal during the operation of the handle (14) by the authorized operator. While the locking mechanism (17) is in the unlocked state and the operator manually rotates the handle (14), the current torque signal and angle signal are collected in real time to generate real-time operation data; The real-time operation data is compared with the pre-stored operation feature data corresponding to the identity of the operator performing the local authorized operation; When the deviation of the comparison result exceeds the first preset threshold, the operation consistency is determined to be abnormal, and a risk warning signal for the alternative operation is output and / or the locking mechanism (17) is controlled to switch back to the locking state.

9. A smart manual ball valve with electronic locking function according to claim 6, characterized in that, The control module (19) is configured as follows: The angle signal output by the position detection module (24) is monitored in real time, and the angular velocity of the valve stem (12) is calculated. Receive external process interlock signals; When the process interlock signal indicates that the process parameter exceeds the limit, the reason for the process parameter exceeding the limit is determined based on the current angular velocity. If the angular velocity is greater than the preset velocity threshold, it is determined that the process parameter exceeding the standard is a transient fluctuation caused by valve action, and the interlocking action is temporarily suspended within a dynamic tolerance time window; If the process parameters exceed the limit and are not eliminated after the dynamic tolerance time window, the locking mechanism (17) is controlled to switch to the locked state; If the angular velocity is not greater than the preset velocity threshold, it is determined that the process parameter exceeding the standard is a real process abnormality, and the locking mechanism (17) is immediately controlled to switch to the locking state.

10. A smart manual ball valve with electronic locking function according to claim 7, characterized in that, The control module (19) is configured to execute a locking performance self-test program after the locking mechanism (17) switches to the locked state, the self-test program including: Monitor the applied torque signal applied to the handle (14) in the locked state, and the small angular displacement signal of the valve stem (12) caused by the applied torque; Based on the relationship between the applied torque signal and the small angular displacement signal, the locking stiffness of the locking mechanism (17) is calculated; The locking stiffness is compared with preset reference stiffness data to evaluate the wear degree of the locking mechanism (17); When the locking stiffness is lower than the preset stiffness threshold, a warning signal for decreased locking performance is output.

Images