A pneumatic butterfly valve

Abstract

This application relates to the field of butterfly valve technology, and particularly to a pneumatic butterfly valve, comprising a pneumatic actuator, a valve stem, a valve body assembly, a first detection element, a second detection element, and a third detection element, wherein: the pneumatic actuator provides power; one end of the valve stem is connected to the power output end of the pneumatic actuator; the valve stem transmits power; the valve body assembly is connected to the other end of the valve stem; the valve body assembly and the pneumatic actuator are fixedly connected; the first detection element is installed at the connection between the pneumatic actuator and the valve stem; the second detection element is installed at the connection between the pneumatic actuator and the valve stem; the third detection element is installed on the pneumatic actuator or the valve body assembly; wherein the valve stem is used to rotate under the drive of the pneumatic actuator to drive the valve body assembly to realize the opening or closing action of the valve. The pneumatic butterfly valve provided by this application can solve the situation where leakage risk cannot be predicted due to the lack of active monitoring and risk prediction methods for the health status of the sealing surface.

Description

Technical Field

[0001] This application belongs to the field of butterfly valve technology, and particularly relates to a pneumatic butterfly valve. Background Technology

[0002] A pneumatic butterfly valve is a control device widely used in industrial pipelines. It uses compressed air as a power source and a pneumatic actuator to drive the valve disc to rotate, thereby realizing the opening and closing of the medium in the pipeline or the regulation of the flow rate.

[0003] In related technologies, the sealing performance of pneumatic butterfly valves depends on the tight contact between the butterfly plate and the resilient valve seat sealing ring. During long-term operation, the medium (especially those containing particles, high speeds, or corrosive media) can cause erosion and wear on the sealing ring. Influenced by the flow channel structure, installation posture, or medium characteristics, wear tends to concentrate in specific areas of the sealing ring, causing the sealing pressure in that area to drop first, thus leading to leakage risk. However, current technologies lack real-time monitoring and early prediction methods for the health status of the sealing surface of pneumatic butterfly valves. They cannot predict the degree of wear and leakage risk of the sealing surface through characteristic data during valve operation. Maintenance or replacement can only be performed passively after a leak occurs, which not only leads to safety hazards caused by sudden leaks but may also result in premature replacement of the pneumatic butterfly valve and increased operating costs. Summary of the Invention

[0004] This application provides a pneumatic butterfly valve that can solve the problems of unpredictable leakage risks, passive maintenance, and high costs caused by the lack of active monitoring and risk prediction methods for the health status of the sealing surface.

[0005] In a first aspect, embodiments of this application provide a pneumatic butterfly valve, the method comprising: Pneumatic actuators are used to provide power; A valve stem, one end of which is connected to the power output end of the pneumatic actuator; the valve stem is used to transmit power. A valve body assembly is connected to the other end of the valve stem; the valve body assembly and the pneumatic actuator are fixedly connected. The first detection element is installed at the connection between the pneumatic actuator and the valve stem; the first detection element is used to measure the rotation information of the valve stem. A second detection element is installed at the connection between the pneumatic actuator and the valve stem; the second detection element is used to measure the torque required to drive the valve stem to rotate; the second detection element and the first detection element are circumferentially spaced apart; and The third detection element is installed on the pneumatic actuator or the valve body assembly and is used to collect vibration information when the valve is actuated. The valve stem is used to rotate under the drive of the pneumatic actuator to drive the valve body assembly to open or close the valve.

[0006] The pneumatic butterfly valve provided in this application, by setting a first, second, and third detection element, can collect real-time information on valve stem rotation, the torque required to drive the valve stem rotation, and vibration information during valve operation. This information provides a data foundation for subsequent monitoring and prediction of the health status of the pneumatic butterfly valve's sealing surface. During actual operation, the pneumatic actuator provides power to drive the valve stem rotation, which in turn drives the valve body assembly to open or close the valve. The first detection element accurately measures the valve stem's rotation angle, speed, and other rotational information, allowing the operator to understand the valve stem's movement status. The second detection element measures the torque required to drive the valve stem rotation; the magnitude and changes in torque reflect the resistance encountered by the valve during opening or closing. The third detection element collects vibration information during valve operation; the vibration signal contains information about the valve's internal structure's operating status, enabling timely detection of potential abnormalities during operation. This allows for real-time monitoring and early prediction of the sealing surface's health status, effectively solving the problem of insufficient proactive monitoring and risk prediction methods for the sealing surface health status of pneumatic butterfly valves in existing technologies, avoiding safety hazards caused by sudden leaks, and reducing operating costs.

[0007] Secondly, embodiments of this application provide a method for predicting the health status of the sealing surface of a pneumatic butterfly valve, used to predict the health status of the sealing surface of the pneumatic butterfly valve described in the first aspect above, the method comprising: Establish an impact load baseline map; wherein, the impact load baseline map is used to characterize the health status benchmark of the pneumatic butterfly valve under opening and closing operations; During the simulation control of the pneumatic actuator driving the valve stem to rotate the butterfly plate from the fully open position to the test angle range, real-time operating condition data is obtained; wherein, the real-time operating condition data is the data obtained by the first detection element, the second detection element, and the third detection element during the rotation of the butterfly plate; A real-time torque-angle curve is obtained based on the real-time operating data; wherein, the torque-angle curve is used to indicate the change of torque with angle during the rotation of the disc plate; The real-time vibration spectrum characteristics are obtained based on the real-time operating data; wherein, the vibration spectrum characteristics are used to indicate the distribution of vibration frequency during the rotation of the butterfly plate; Risk prediction parameter data is obtained by analyzing the real-time torque angle curve and vibration spectrum characteristics in conjunction with the impact load baseline spectrum; wherein, the risk prediction parameter data is used to indicate the risk level of the sealing surface health status of the pneumatic butterfly valve; The health data of the sealing surface of the pneumatic butterfly valve is determined based on the risk prediction parameter data; wherein the health data is used to indicate the current health status of the sealing surface of the pneumatic butterfly valve.

[0008] The method for predicting the health status of the sealing surface of a pneumatic butterfly valve provided in this application establishes an impact load baseline map, which can provide a reliable benchmark reference for assessing the health status of the sealing surface of the pneumatic butterfly valve. Real-time operating data is obtained by simulating the process of the pneumatic actuator driving the valve stem to rotate the butterfly plate from the fully open position to the test angle range, comprehensively capturing various state information of the valve during dynamic operation. Based on the real-time operating data, a real-time torque angle curve is obtained; real-time vibration spectrum characteristics are also obtained based on the real-time operating data. Risk prediction parameter data is obtained by combining the real-time torque angle curve and vibration spectrum characteristics with the impact load baseline map. Based on the risk prediction parameter data, the health data of the sealing surface of the pneumatic butterfly valve is determined. This allows users to monitor the current health status of the sealing surface in real time, enabling real-time monitoring and early prediction of the health status of the sealing surface of the pneumatic butterfly valve, predicting the degree of wear and leakage risk, and preventing safety hazards caused by sudden leakage. Attached Figure Description

[0009] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0010] Figure 1 This is a schematic diagram of the structure of a pneumatic butterfly valve provided in one embodiment of this application; Figure 2 This is a schematic diagram of the structure of a pneumatic butterfly valve provided in one embodiment of this application from another perspective; Figure 3 This is a flowchart illustrating a method for predicting the health status of the sealing surface of a pneumatic butterfly valve according to an embodiment of this application. Figure 4 This is a schematic diagram of the implementation process of step S200 in the method for predicting the health status of the sealing surface of a pneumatic butterfly valve provided in an embodiment of this application. Figure 5 This is a schematic diagram of the implementation process of step S500 in the method for predicting the health status of the sealing surface of a pneumatic butterfly valve provided in an embodiment of this application. Figure 6 This is a schematic diagram of the implementation process of step S400 in the method for predicting the health status of the sealing surface of a pneumatic butterfly valve provided in an embodiment of this application. Figure 7 This is a schematic diagram of the structure of the pneumatic butterfly valve sealing surface health status prediction system provided in the embodiments of this application; Figure 8 This is a schematic diagram of the structure of the control component provided in the embodiments of this application.

[0011] The following are the labeling elements in the figure: 100. Pneumatic butterfly valve; 10. Pneumatic actuator; 20. Valve stem; 30. Valve body assembly; 31. Valve body component; 32. Butterfly plate; 33. Connecting bracket; 40. First detection component; 50. Second detection component; 60. Third detection component; 70. Control component. Detailed Implementation

[0012] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0013] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0014] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0015] As used in this application specification and the appended claims, the term "if" may be interpreted, depending on the context, as "when," "once," "in response to determination," or "in response to detection." Similarly, the phrase "if determined" or "if detected [the described condition or event]" may be interpreted, depending on the context, as meaning "once determined," "in response to determination," "once detected [the described condition or event]," or "in response to detection [the described condition or event]."

[0016] Furthermore, in the description of this application and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0017] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0018] A pneumatic butterfly valve is a control device widely used in industrial pipelines. It uses compressed air as a power source and a pneumatic actuator to drive the valve disc to rotate, thereby realizing the opening and closing of the medium in the pipeline or the regulation of the flow rate.

[0019] In related technologies, the sealing performance of pneumatic butterfly valves depends on the tight contact between the butterfly plate and the resilient valve seat sealing ring. During long-term operation, the medium (especially those containing particles, high speeds, or corrosive media) can cause erosion and wear on the sealing ring. Influenced by the flow channel structure, installation posture, or medium characteristics, wear tends to concentrate in specific areas of the sealing ring, causing the sealing pressure in that area to drop first, thus leading to leakage risk. However, current technologies lack real-time monitoring and early prediction methods for the health status of the sealing surface of pneumatic butterfly valves. They cannot predict the degree of wear and leakage risk of the sealing surface through characteristic data during valve operation. Maintenance or replacement can only be performed passively after a leak occurs, which not only leads to safety hazards caused by sudden leaks but may also result in premature replacement of the pneumatic butterfly valve and increased operating costs.

[0020] Based on this, in order to improve the technical problems in related technologies, such as the lack of active monitoring and risk prediction methods for the health status of sealing surfaces, which leads to the inability to predict leakage risks, passive maintenance and high costs, the embodiments of this application provide the following solutions.

[0021] Please refer to the following: Figure 1 and Figure 2 This application provides a pneumatic butterfly valve 100, including a pneumatic actuator 10, a valve stem 20, a valve body assembly 30, a first detection element 40, a second detection element 50, and a third detection element 60, wherein: The pneumatic actuator 10 is used to provide power.

[0022] One end of the valve stem 20 is connected to the power output end of the pneumatic actuator 10; the valve stem 20 is used to transmit power.

[0023] The valve body assembly 30 is connected to the other end of the valve stem 20; the valve body assembly 30 and the pneumatic actuator 10 are fixedly connected.

[0024] The first detection element 40 is installed at the connection between the pneumatic actuator 10 and the valve stem 20; the first detection element 40 is used to measure the rotation information of the valve stem 20.

[0025] The second detection element 50 is installed at the connection between the pneumatic actuator 10 and the valve stem 20; the second detection element 50 is used to measure the torque information required to drive the valve stem 20 to rotate; the second detection element 50 and the first detection element 40 are circumferentially spaced.

[0026] The third detection element 60 is installed on the pneumatic actuator 10 or the valve body assembly 30 and is used to collect vibration information when the valve is actuated.

[0027] The valve stem 20 is used to rotate under the drive of the pneumatic actuator 10, so as to drive the valve body assembly 30 to realize the opening or closing action of the valve.

[0028] It is understood that the pneumatic actuator 10 is a structure capable of providing power, such as including a pneumatic motor and a transmission component connected to the pneumatic motor. The power output end of the transmission component is connected to the valve stem 20. Primarily, compressed air drives the pneumatic motor, thereby transmitting power to the valve stem 20. The transmission component can be a drive shaft or a drive rod. The valve stem 20 is a component used to rotate under the action of the power output end; its material is typically selected as high-strength, corrosion-resistant material to ensure it can withstand various forces during long-term operation without damage. The valve body assembly 30 is a structure that cooperates with the valve stem 20 to realize the opening or closing of the valve.

[0029] The first detection element 40, the second detection element 50, and the third detection element 60 are structures used for detection. The first detection element 40 accurately measures the rotation angle and speed of the valve stem 20, for example, it can be a rotary encoder, which can capture the rotational state changes of the valve stem 20 with high precision. The second detection element 50 measures the torque information required to drive the valve stem 20 to rotate. The magnitude and change of torque can reflect the resistance encountered by the valve during opening or closing. For example, it can be a torque sensor, which senses the torque encountered by the valve stem 20 during rotation and converts it into an electrical signal for transmission and analysis. The third detection element 60 collects vibration information during valve operation. For example, it can be an accelerometer, which can monitor the vibration of the valve during operation in real time. The accelerometer obtains vibration information by means of a sensing element, such as a piezoelectric crystal or a microelectromechanical system (MEMS) structure, which is usually built into the accelerometer. When the valve vibrates during operation, the sensing element deforms due to the vibration, thereby generating an electrical signal proportional to the vibration acceleration, which is then converted into a digital signal.

[0030] As can be seen from the above, by setting the first detection element 40, the second detection element 50 and the third detection element 60, it is possible to collect the rotation information of the valve stem 20, the torque information required to drive the valve stem 20 to rotate, and the vibration information when the valve is in motion in real time. This information provides a data basis for subsequent monitoring and prediction of the health status of the sealing surface of the pneumatic butterfly valve 100. In actual operation, the pneumatic actuator 10 provides power to drive the valve stem 20 to rotate. The valve stem 20 drives the valve body assembly 30 to open or close the valve. The first detection element 40 accurately measures the rotation angle, speed, and other rotational information of the valve stem 20, allowing the operator to understand the movement state of the valve stem 20. The second detection element 50 measures the torque required to drive the valve stem 20 to rotate. The magnitude and changes in torque can reflect the resistance encountered by the valve during opening or closing. The third detection element 60 collects vibration information during valve operation. The vibration signal contains the operating status information of the valve's internal structure, which can promptly detect any abnormalities that may occur during the operation of the pneumatic butterfly valve 100. This enables real-time monitoring and early prediction of the health status of the sealing surface, effectively solving the problem of the lack of active monitoring and risk prediction methods for the health status of the sealing surface of the pneumatic butterfly valve 100 in the existing technology, avoiding safety hazards caused by sudden leakage, and reducing operating costs.

[0031] In some embodiments, please refer to the following: Figure 1 and Figure 2 The valve body assembly 30 includes a valve body component 31, a butterfly plate 32, and a connecting bracket 33, wherein: The valve body 31 has a fluid passage for fluid to pass through; the third detection element 60 is mounted on the pneumatic actuator 10 or the valve body 31.

[0032] The butterfly plate 32 is rotatably disposed in the fluid passage and is connected to the other end of the valve stem 20; the butterfly plate 32 is used to rotate under the drive of the valve stem 20 to control the degree of opening or closing of the fluid passage.

[0033] The connecting bracket 33 is fixedly connected to the valve body 31 and the pneumatic actuator 10.

[0034] It is understood that valve body component 31 is the main structure used to construct the fluid passage, and its material is a corrosion-resistant, high-strength alloy material to adapt to the needs of different media and harsh working conditions. The shape and size of the fluid passage are designed according to the actual application scenario.

[0035] The butterfly plate 32 is a key component for controlling the flow of fluid. Its surface is precision machined to ensure a tight seal with the inner wall of the valve body 31. Driven by the valve stem 20, the butterfly plate 32 can rotate within the fluid channel. By changing its relative position to the fluid channel, precise control of the flow or flow rate of the fluid can be achieved.

[0036] The connecting bracket 33 serves to fix and support the valve body 31 and the pneumatic actuator 10, firmly connecting them into a whole, thus ensuring the stability and reliability of the entire pneumatic butterfly valve 100 during operation.

[0037] With this configuration, the valve body assembly 30, through the coordinated work of the valve body component 31, the butterfly plate 32, and the connecting bracket 33, not only establishes the basic channel for fluid transmission but also achieves precise control over fluid flow and on / off states. The corrosion resistance and high strength of the valve body component 31 ensure stable operation under harsh conditions, while the customized design of the fluid channel meets the needs of different application scenarios. The butterfly plate 32, as the core control element, has a precision-machined surface that fits tightly against the inner wall of the valve body component 31, forming a reliable sealing structure that effectively prevents media leakage. Driven by the valve stem 20, the butterfly plate 32 rotates flexibly, precisely adjusting the opening degree of the fluid channel, thereby achieving meticulous control over the fluid flow rate. The connecting bracket 33 further enhances the overall structural strength of the pneumatic butterfly valve 100, tightly connecting the valve body component 31 to the pneumatic actuator 10, ensuring the stability of the valve under high-speed operation or high pressure.

[0038] This application also provides a method for predicting the health status of the sealing surface of a pneumatic butterfly valve, used to predict the health status of the sealing surface of the pneumatic butterfly valve in any of the above embodiments, the method comprising: Establish an impact load baseline map; the impact load baseline map is used to characterize the health status benchmark of the pneumatic butterfly valve under opening and closing operations. During the process of simulating the pneumatic actuator driving the valve stem to rotate the butterfly plate from the fully open position to the test angle range, real-time operating data is obtained; the real-time operating data is the data acquired by the first, second, and third detection devices during the rotation of the butterfly plate; The real-time torque-angle curve is obtained based on real-time operating data; the torque-angle curve is used to indicate how the torque changes with the angle during the rotation of the disc. The real-time vibration spectrum characteristics are obtained based on real-time operating data; among which, the vibration spectrum characteristics are used to indicate the distribution of vibration frequency during the rotation of the disc. Risk prediction parameter data is obtained by analyzing the real-time torque angle curve and vibration spectrum characteristics in conjunction with the impact load baseline map; among them, the risk prediction parameter data is used to indicate the degree of risk of the sealing surface health status of the pneumatic butterfly valve. The health data of the sealing surface of the pneumatic butterfly valve is determined based on the risk prediction parameter data; wherein, the health data is used to indicate the current health status of the sealing surface of the pneumatic butterfly valve.

[0039] The technical solutions described in this application embodiment have at least the following technical effects: The method for predicting the health status of the sealing surface of a pneumatic butterfly valve provided in this application establishes an impact load baseline map, which can provide a reliable benchmark reference for assessing the health status of the sealing surface of the pneumatic butterfly valve. Real-time operating data is obtained by simulating the process of the pneumatic actuator driving the valve stem to rotate the butterfly plate from the fully open position to the test angle range, comprehensively capturing various state information of the valve during dynamic operation. Based on the real-time operating data, a real-time torque angle curve is obtained; real-time vibration spectrum characteristics are also obtained based on the real-time operating data. Risk prediction parameter data is obtained by combining the real-time torque angle curve and vibration spectrum characteristics with the impact load baseline map. Based on the risk prediction parameter data, the health data of the sealing surface of the pneumatic butterfly valve is determined. This allows users to monitor the current health status of the sealing surface in real time, enabling real-time monitoring and early prediction of the health status of the sealing surface of the pneumatic butterfly valve, predicting the degree of wear and leakage risk, and preventing safety hazards caused by sudden leakage.

[0040] The method for predicting the health status of the sealing surface of a pneumatic butterfly valve provided in this application embodiment can be applied to a pneumatic butterfly valve. In this case, the pneumatic butterfly valve is the subject of execution of the method for predicting the health status of the sealing surface of a pneumatic butterfly valve provided in this application embodiment. This application embodiment does not impose any restrictions on the specific type of pneumatic butterfly valve.

[0041] For example, a pneumatic butterfly valve can be an intelligent control pneumatic butterfly valve with its own built-in control components. Of course, it can also be a control component that is set independently and interacts with the pneumatic butterfly valve through wired or wireless means. The control component is communicatively connected to the pneumatic actuator, the first detection component, the second detection component, and the third detection component. The control component can be a microprocessor or a controller. The specific model of the microprocessor or controller can be, for example, an STM32 series microprocessor, but it is not limited to this.

[0042] To better understand the method for predicting the health status of the sealing surface of a pneumatic butterfly valve provided in this application embodiment, the specific implementation process of the method for predicting the health status of the sealing surface of a pneumatic butterfly valve provided in this application embodiment will be described by way of example below.

[0043] Figure 3 A schematic flowchart of a method for predicting the health status of the sealing surface of a pneumatic butterfly valve according to an embodiment of this application is shown. The method for predicting the health status of the sealing surface of a pneumatic butterfly valve includes: S100, Establish the impact load baseline map; wherein, the impact load baseline map is used to characterize the health status benchmark of the pneumatic butterfly valve under opening and closing action.

[0044] It is understandable that the impact load baseline spectrum refers to the benchmark data spectrum formed by collecting key parameters through multiple standard opening and closing actions when the pneumatic butterfly valve is in an initial state with no faults and meeting performance standards, which is used for subsequent comparison and judgment; the health status benchmark is the parameter reference standard when the valve is working normally.

[0045] For example, when the pneumatic butterfly valve is in its initial state, the pneumatic actuator is controlled to perform multiple complete opening and closing actions at a standard speed to obtain multiple opening and closing data. Then, the impact load baseline spectrum is determined based on the opening and closing data. Alternatively, during the design phase of the pneumatic butterfly valve, computer simulation technology can be used to simulate the opening and closing actions of the pneumatic butterfly valve under different operating conditions to obtain a large amount of simulated opening and closing data. Then, the impact load baseline spectrum can be constructed based on these simulated data.

[0046] In one possible implementation, S100, an impact load baseline map is established, including: S110, with the pneumatic butterfly valve in its initial state, control the pneumatic actuator to perform multiple complete opening and closing actions at a standard speed to obtain multiple opening and closing data; among them, the opening and closing data are used to indicate the overshoot angle of the critical position of the butterfly plate obtained by the first detection element, the peak torque impact and phase at the moment of opening and closing obtained by the second detection element, and the radial vibration frequency of the valve stem obtained by the third detection element when the pneumatic butterfly valve is in its initial state.

[0047] It is understood that the initial state of a pneumatic butterfly valve refers to a valve that is unused, professionally calibrated, free from wear / jamming / leakage faults, and in which all components are in their rated operating condition. The standard speed is a pre-set rotational rate based on valve design specifications and actual application requirements, characterized by smooth and reproducible opening and closing actions. This could be a specific value such as 30 revolutions per minute or 60 revolutions per minute, but is not limited to this. Multiple complete opening and closing actions refer to repeatedly performing the full cycle operation from fully closed to fully open and back to fully closed under the same environmental conditions to eliminate interference from accidental factors. The overshoot angle of the butterfly plate at the critical position in the opening and closing data reflects the brief overtravel caused by inertia when the valve approaches its closing or opening limit. The peak value and phase of the torque impact at the moment of opening and closing are captured by a second detection element, showing the extreme value of the instantaneous torque experienced by the valve stem during opening and closing switching and its direction of action. The radial vibration frequency of the valve stem is obtained by a third detection element, characterizing the periodic vibration caused by fluid pressure fluctuations or mechanical resonance during valve operation.

[0048] For example, with the pneumatic butterfly valve in its initial state, the pneumatic actuator is controlled to perform five complete opening and closing actions at a standard speed of 30 revolutions per minute, with a two-minute interval between each action to allow the equipment to stabilize sufficiently. During each opening and closing process, the first detection device continuously records the overshoot angle data of the butterfly plate 5 degrees before the fully closed position and 5 degrees after the fully open position. The second detection device simultaneously captures the peak torque impact and its phase information at the moment of opening and closing. The third detection device collects the radial vibration frequency of the valve stem in three orthogonal directions. The overshoot angle, peak torque impact and phase, and radial vibration frequency obtained from the five opening and closing actions are arithmetically averaged to obtain the reference overshoot angle range, reference torque impact peak range, and reference vibration frequency distribution in the initial state. Based on the above reference data, the torque impact peak curve, overshoot angle change curve, and vibration frequency distribution curve are plotted with the butterfly plate rotation angle as the horizontal axis, thus forming an impact load baseline map.

[0049] S120 determines the baseline pattern of impact load based on multiple opening and closing data.

[0050] For example, firstly, outlier data (e.g., data where the torque peak deviates from other groups by more than 30% due to a sudden change in air pressure in a certain cycle) is removed from multiple sets of opening and closing data, retaining valid data sets (e.g., retaining 3 valid data sets out of 4 sets); secondly, statistical calculations are performed on the same parameters of each valid data set, i.e., the overshoot angle is averaged (e.g., the overshoot angles of the 3 sets of data are 0.2°, 0.3°, and 0.25°, with an average of 0.25°), and the torque impact peak value is averaged (e.g., 10 N·m, 9.8 N·m). The torque value is 10.2 N·m, with an average value of 10 N·m. The vibration frequency is taken as the average range (e.g., 19-21 Hz). Then, the parameters are integrated according to the angle sequence of the opening and closing action (from 0° to 90°, with each 1° as a node). Each angle node corresponds to the statistically obtained torque value and vibration frequency range. At the same time, the overshoot angle of the critical position is marked. Finally, the integrated parameters are plotted as curves according to angle and time series to form the impact load baseline spectrum (e.g., a biaxial curve with the horizontal axis being the rotation angle and the vertical axis being the torque value and vibration frequency).

[0051] This setup, with the graph format organized by angle or time series, facilitates point-by-point comparison between real-time operating data and the baseline, intuitively reflecting parameter deviations and providing a clear reference for fault diagnosis.

[0052] S200 simulates the process of controlling the pneumatic actuator to drive the valve stem to rotate the butterfly plate from the fully open position to the test angle range, and obtains real-time operating data; wherein, the real-time operating data is the data obtained by the first detection element, the second detection element and the third detection element during the rotation of the butterfly plate.

[0053] It can be understood that the fully open position can refer to the position where the butterfly plate is parallel to the center line of the fluid channel and the fluid can pass through without obstruction; the test angle range can refer to the specific angle range of the butterfly plate starting from the fully open position; real-time operating data can refer to multi-dimensional data (angle, torque, vibration) that are collected in real time during the rotation process and reflect the current working status of the valve.

[0054] For example, when the pneumatic butterfly valve is in the fully open position, the control system sends a command to the pneumatic actuator to drive the valve stem to rotate the butterfly plate at a preset rotation speed. During the rotation of the butterfly plate, the first detection element continuously monitors and records the overshoot angle data of the butterfly plate at each rotation angle position. The second detection element simultaneously captures the torque change data experienced by the valve stem during rotation, especially the torque impact peak and its phase information. The third detection element collects the radial vibration frequency data of the valve stem during rotation. The data obtained by the first, second and third detection elements together constitute the real-time operating condition data, which can reflect the various status information of the valve during dynamic operation in real time.

[0055] In one possible implementation, please refer to Figure 4 S200, during the process of simulating the pneumatic actuator driving the valve stem to rotate the butterfly plate from the fully open position to the test angle range, real-time operating data is obtained, including: S210, during the process of simulating the control of the pneumatic actuator to drive the valve stem and the butterfly plate to rotate from the fully open position to the test angle range, the rotation angle sequence of the valve stem is collected in real time by the first detection element.

[0056] For example, the rotation angle sequence can refer to a set of rotation angle data of the valve stem recorded continuously in chronological order at each moment (e.g., 0.1° in the 1st second, 0.3° in the 2nd second, etc.), which can reflect the dynamic process of the butterfly plate rotation.

[0057] Specifically, the angle encoder can be coaxially fixed to the end of the valve stem via a coupling, allowing the encoder and valve stem to rotate synchronously. Then, the sampling parameters are set, such as setting the encoder's sampling frequency to 100Hz (collecting 100 data points per second) via the controller. The data format is angle values ​​with timestamps (accurate to 0.01 seconds). Simulation control is then started. When the controller sends a rotation command, the encoder immediately begins real-time acquisition, recording the current rotation angle of the valve stem every 0.01 seconds. When the butterfly plate rotates to the end of the test angle range, the controller sends a stop acquisition command, and the encoder stops working. Finally, all the acquired angle data are arranged in order of timestamps to form a rotation angle sequence.

[0058] S220, the drive torque sequence corresponding to the rotation angle sequence is collected in real time by the second detection element.

[0059] For example, the drive torque sequence can refer to a set of torque data that is continuously recorded in chronological order at each moment, which can reflect the dynamic changes of torque during the rotation of the disc.

[0060] Specifically, a torque sensor can be installed at the connection between the valve stem and the pneumatic actuator, so that the torque sensor and the valve stem are subjected to force synchronously. Then, the sampling parameters of the torque sensor are set, for example, the sampling frequency of the torque sensor is set to 100Hz by the controller, the data format is torque value, and a timestamp is attached. Simulation control is started. When the controller sends a rotation command, the torque sensor immediately starts to collect data in real time, recording the torque currently borne by the valve stem every 0.01 seconds. When the butterfly plate rotates to the end of the test angle range, the controller sends a stop collection command, and the torque sensor stops working. Finally, all the collected torque data are arranged in the order of timestamps and matched with the previously collected rotation angle sequence, thereby forming a drive torque sequence corresponding to the rotation angle sequence.

[0061] S230 is a sequence of vibration signals collected in real time during the operation of a pneumatic butterfly valve through a third detection element.

[0062] For example, a piezoelectric vibration sensor can be selected as the third sensing element and fixed to the valve body shell of the pneumatic butterfly valve near the drive mechanism using a magnetic base. The sensor's signal output is connected to a data acquisition unit via a differential cable. The preset vibration acquisition frequency is 500Hz, and the vibration signal range is set. When the pneumatic butterfly valve starts, the sensor senses the vibration changes of the valve body in real time, converting the vibration physical quantity into a voltage signal. The data acquisition unit samples the voltage signal at a preset frequency and records the sampling timestamp to form a continuous vibration signal sequence.

[0063] S240 obtains real-time operating data based on rotation angle sequence, drive torque sequence, and vibration signal sequence.

[0064] For example, the three datasets—rotation angle sequence, drive torque sequence, and vibration signal sequence—can be first time-stamp aligned so that the rotation angle, torque value, and vibration signal at each moment correspond to the state at the same instant. Specifically, using the timestamp of the rotation angle sequence as a reference, interpolation or truncation operations are performed on the drive torque sequence and vibration signal sequence to ensure that the three have the same set of time points. Then, the rotation angle, torque value, and vibration signal at the same time point are combined into a single data point. All data points are arranged in chronological order to form the real-time operating condition dataset.

[0065] This setup, through the synchronous acquisition and integration of rotation angle, driving torque, and vibration signals, can comprehensively reflect the actual state of the pneumatic butterfly valve during dynamic operation, including the rotation position of the butterfly plate, the torque changes borne by the valve stem, and the vibration of the valve body. By comparing and analyzing the real-time data with the previously established impact load baseline map, abnormal deviations that occur during valve operation can be detected in a timely manner, thereby accurately judging the health status of the sealing surface, providing early warning of potential faults, and ensuring the safe and stable operation of the pneumatic butterfly valve.

[0066] In one possible implementation, please refer to Figure 4 S200, the test angle range includes: S201, the test angle range is the range where the butterfly plate rotates less than the center line of the fluid channel by less than the X range; where the X range is 15° to 75°.

[0067] For example, when the test angle range is set to less than 15° to 75° relative to the centerline of the fluid channel, this angle range covers the critical operating stage of the pneumatic butterfly valve from near full opening to partial opening. At less than 15°, the valve is in a near-fully open state. At this point, inspection of the sealing surface can detect minor anomalies that may occur during the initial opening stage, such as the fit of the sealing surface during the first operation after a long period of inactivity, or initial signs of impurities obstructing the seal. When the rotation angle exceeds 15° and enters a larger angle range up to 75°, the valve opening gradually increases, and the impact and force of the fluid on the sealing surface also change continuously. Within this range, inspection can capture the different pressures and friction experienced by the sealing surface as the valve opening changes, thereby comprehensively assessing the health status of the sealing surface under different operating conditions.

[0068] This setup allows for the capture of various changes in the sealing surface during valve opening. Whether it's minor anomalies in the initial stage or changes in pressure and friction as the opening degree increases, these changes can be effectively monitored and analyzed, helping to identify potential sealing problems in a timely manner.

[0069] The S300 generates a real-time torque-angle curve based on real-time operating data; the torque-angle curve is used to indicate how the torque changes with the angle during the rotation of the disc.

[0070] For example, the rotation angle sequence in the real-time operating data can be used as the x-axis and the driving torque sequence as the y-axis to plot the data points in a two-dimensional coordinate system. Specifically, for each time point, the corresponding rotation angle and driving torque value are located in the coordinate system and marked as data points. After all data points have been plotted, a suitable curve fitting method (such as spline interpolation, polynomial fitting, etc.) is used to connect these discrete data points into a smooth curve, which is the real-time torque-angle curve.

[0071] In one possible implementation, S300 obtains a real-time torque angle curve based on real-time operating condition data, including: S310 matches the drive torque value collected at each moment with the corresponding valve stem rotation angle value based on the time synchronization relationship between the rotation angle sequence and the drive torque sequence.

[0072] For example, this matching process can be implemented using processing software or programming tools (such as the Pandas library in Python). The rotation angle sequence and the drive torque sequence are imported into the data processing environment. Since both sequences have timestamps, the timestamp of the rotation angle sequence is used as a reference. By searching for matching timestamps, the drive torque value at each time point is accurately matched to the corresponding valve stem rotation angle value. For instance, if the timestamp at a certain moment is t1, the angle value corresponding to that moment in the rotation angle sequence is α1, and the torque value corresponding to that moment in the drive torque sequence is τ1, then τ1 is matched and associated with α1.

[0073] S320 uses the matched drive torque value and rotation angle value as data points, and performs curve fitting with the rotation angle of the valve stem as the abscissa and the drive torque as the ordinate to obtain the torque-angle curve.

[0074] For example, the imported matching drive torque and rotation angle data are used. A suitable curve fitting function is selected, with the valve stem rotation angle as the abscissa and the drive torque as the ordinate. Each set of matched data points is marked in the coordinate system. The selected curve fitting function is then used to fit these data points, and the function parameters are adjusted to make the fitted curve as close as possible to all data points. After calculation and optimization, a torque-angle curve that accurately reflects the torque variation with angle is finally obtained. This curve can intuitively show the magnitude of the torque borne by the valve stem at different rotation angles, providing an important basis for subsequent analysis of the pneumatic butterfly valve's operating status.

[0075] S400 obtains real-time vibration spectrum characteristics based on real-time operating data; among which, the vibration spectrum characteristics are used to indicate the distribution of vibration frequency during the rotation of the disc.

[0076] For example, a Fast Fourier Transform (FFT) is performed on the effective segment of the vibration signal to convert it from a time-domain signal to a frequency-domain signal, obtaining an initial spectral distribution. Using a spectral analysis algorithm (e.g., a peak detection algorithm), all spectral peaks with energy exceeding a preset threshold are identified in the initial spectral distribution. Among these peaks, the peak with the highest energy is selected, and its corresponding frequency is determined as the dominant vibration frequency. The height of this peak is determined as the energy amplitude. Then, a preset bandwidth (e.g., ±5Hz) is set around the dominant vibration frequency, and the total vibration energy within this bandwidth is calculated. Simultaneously, the total energy of the entire spectrum is calculated. The ratio of the vibration energy within the preset bandwidth to the total energy of the overall spectrum is determined as the energy ratio. Finally, The three parameters of dominant vibration frequency, energy amplitude, and energy ratio are jointly determined as the real-time vibration spectrum characteristics. Alternatively, the effective segments of vibration signals corresponding to the movement of the butterfly plate within the test angle range can be extracted from the vibration signal sequence, and the vibration spectrum diagram can be obtained by performing spectral analysis on the effective segments of the vibration signal. From the vibration spectrum diagram, all spectral peaks with energy exceeding a preset threshold are identified, and the frequency corresponding to the highest energy peak is determined as the dominant vibration frequency and energy amplitude. The vibration energy within a preset bandwidth centered on the dominant vibration frequency is calculated, and the energy ratio of the vibration energy within the preset bandwidth to the total energy of the overall spectrum is determined. Then, the dominant vibration frequency, energy amplitude, and energy ratio are determined as the real-time vibration spectrum characteristics.

[0077] In one possible implementation, please refer to Figure 6 S400, based on real-time operating data, obtains real-time vibration spectrum characteristics, including: S410 extracts the effective segment of the vibration signal from the vibration signal sequence, which corresponds to the movement of the butterfly plate within the test angle range, and performs spectral analysis on the effective segment of the vibration signal to obtain the vibration spectrum diagram.

[0078] For example, spectrum analysis is a processing method that converts a time-domain signal (which varies with time) into a frequency-domain signal (which varies with frequency). Based on a pre-defined test angle range, the corresponding time period is located within the vibration signal sequence. For instance, if the test angle range is from the fully open position to 30°, by establishing a correspondence between the rotation angle sequence and timestamps, the time point when the rotation angle reaches 30° is found. Using this as the endpoint, the time is traced back to the starting point of the rotation, thereby extracting a valid segment of the vibration signal within this time period. This extracted valid segment of the vibration signal is then processed, and the time-domain signal is converted into a frequency-domain signal, thus generating a vibration spectrum.

[0079] S420 identifies all spectral peaks in the vibration spectrum whose energy exceeds a preset threshold, and determines the dominant vibration frequency and energy amplitude by the frequency corresponding to the highest energy peak.

[0080] For example, the preset threshold can be set based on actual detection needs and experience. The preset threshold can be an energy limit value used to filter out spectral peaks with significant characteristics. In the vibration spectrum diagram, by traversing the energy values ​​corresponding to all frequency points, spectral peaks with energy exceeding the preset threshold are filtered out. Among these filtered peaks, the peak with the highest energy is identified; the frequency corresponding to this peak is the dominant vibration frequency, and its energy value is the energy amplitude. The energy amplitude can be understood as the magnitude of vibration energy represented by the spectral peak in the frequency domain, and its value directly reflects the intensity of vibration at the corresponding frequency.

[0081] S430, calculate the vibration energy within a preset bandwidth centered on the dominant vibration frequency, and determine the energy ratio of the vibration energy within the preset bandwidth to the total energy of the overall spectrum.

[0082] For example, a preset bandwidth is a frequency range set to focus on analyzing the distribution of vibration energy within a certain range near the dominant vibration frequency. For instance, it might be set to ±5Hz, meaning a frequency interval extending 5Hz towards both high and low frequencies from the dominant vibration frequency. After determining the preset bandwidth, the vibration energy within the preset bandwidth is obtained by summing the energy values ​​corresponding to all frequency points within that bandwidth in the vibration spectrum. Simultaneously, the total energy of the entire spectrum is obtained by summing the energy values ​​corresponding to all frequency points in the entire vibration spectrum. The energy ratio is then obtained by dividing the vibration energy within the preset bandwidth by the total energy of the entire spectrum. This energy ratio reflects the proportion of vibration energy near the dominant vibration frequency in the overall spectrum energy, which helps in further analyzing the vibration characteristics of the pneumatic butterfly valve during operation.

[0083] S440 determines the dominant vibration frequency, energy amplitude, and energy ratio as real-time vibration spectrum characteristics.

[0084] For example, the determined real-time vibration spectrum characteristics can be used to construct a data structure containing these three parameters, such as a triplet or a specific data object. The dominant vibration frequency is used as the first element, the energy amplitude as the second element, and the energy ratio as the third element. This forms a set of information that can completely describe the vibration spectrum characteristics of the pneumatic butterfly valve at a specific moment. This set is the real-time vibration spectrum characteristic. The vibration spectrum characteristics can be used for further evaluation of the pneumatic butterfly valve's operating status, such as comparing it with the vibration spectrum characteristics under normal conditions to determine whether there are abnormal vibrations, thus providing important information for the maintenance and fault diagnosis of the pneumatic butterfly valve.

[0085] S500 analyzes the real-time torque angle curve and vibration spectrum characteristics in conjunction with the impact load baseline map to obtain risk prediction parameter data; among them, the risk prediction parameter data is used to indicate the risk level of the sealing surface health status of the pneumatic butterfly valve.

[0086] For example, by combining the real-time torque angle curve and vibration spectrum characteristics with the impact load baseline map, the torque data and rotation angle data can be synchronously integrated according to the timestamp to generate a real-time torque angle curve. Then, real-time vibration signals are obtained from the vibration acceleration sensor deployed on the valve body. The time-domain vibration signal is converted into a frequency-domain signal through Fast Fourier Transform (FFT), and the vibration amplitude at different frequencies is extracted to form real-time vibration spectrum characteristics. Subsequently, the impact load baseline map pre-stored in the local database is retrieved, and the horizontal axis (rotation angle) and vertical axis (torque) of the real-time torque angle curve are dimensionally aligned with the torque angle reference curve under the same working condition in the baseline map. Simultaneously, the frequency axis and amplitude axis of the real-time vibration spectrum characteristics are calibrated with the vibration spectrum reference characteristics in the baseline spectrum. Then, by screening out the segments of the torque angle curve that deviate from the baseline, the vibration spectrum characteristics corresponding to the segment are matched to see if they exceed the baseline threshold. Finally, the risk prediction parameter data is obtained by combining the magnitude of the impact load corresponding to the deviating segment in the baseline spectrum and performing weighted calculation. Alternatively, abnormal feature points can be determined by comparing the real-time torque angle curve with the impact load baseline spectrum. Abnormal frequency components in the real-time vibration spectrum characteristics can be determined based on the real-time vibration spectrum characteristics and the impact load baseline spectrum. Finally, risk prediction parameter data is obtained based on the abnormal feature points and abnormal frequency components.

[0087] In one possible implementation, please refer to Figure 5 S500, based on the real-time torque angle curve and vibration spectrum characteristics combined with the impact load baseline spectrum, risk prediction parameter data is obtained, including: S510 compares the real-time torque angle curve with the impact load baseline map to identify abnormal feature points in the real-time torque angle curve.

[0088] For example, identifying anomalous feature points in the real-time torque angle curve can be achieved by comparing each data point on the real-time torque angle curve with the torque value at the corresponding angular position in the impact load baseline graph. For instance, at a certain rotation angle α, the torque value on the real-time torque angle curve is τ_real-time, while the torque reference value for that angle in the impact load baseline graph is τ_reference. If the difference between the two exceeds a preset allowable deviation range (e.g., ±10%), then the data point is determined to be an anomalous feature point. By traversing all data points on the entire real-time torque angle curve, all data points that meet the anomalous determination criteria are found, thus obtaining the anomalous feature points in the real-time torque angle curve.

[0089] S520 compares the real-time vibration spectrum characteristics with the impact load baseline spectrum to determine the abnormal frequency components in the real-time vibration spectrum characteristics.

[0090] For example, comparing the real-time vibration spectrum characteristics with the impact load baseline spectrum to determine the abnormal frequency components in the real-time vibration spectrum characteristics can be achieved by comparing the three parameters of the real-time vibration spectrum characteristics—dominant vibration frequency, energy amplitude, and energy ratio—with the corresponding vibration spectrum reference parameters in the impact load baseline spectrum. For instance, for the dominant vibration frequency, if the deviation between the real-time measured dominant vibration frequency and the dominant vibration frequency in the baseline spectrum under the same working condition exceeds a certain range, then that frequency is determined to be an abnormal frequency component. For the energy amplitude, if the ratio of the real-time energy amplitude to the baseline energy amplitude exceeds a preset normal fluctuation range, then an abnormal frequency component can also be considered to exist. For the energy ratio, similarly, by comparing it with the energy ratio in the baseline spectrum, if it exceeds a reasonable range, it is determined to be abnormal.

[0091] S530 obtains risk prediction parameter data based on abnormal feature points and abnormal frequency components.

[0092] For example, risk prediction parameter data can be obtained by establishing the correlation between abnormal feature points and abnormal frequency components. For instance, by analyzing the abnormal frequency components in the real-time vibration spectrum characteristics corresponding to the rotation angle range where the abnormal feature points appear, and then determining the number of abnormal feature points, the degree of abnormality, the energy magnitude of the abnormal frequency components, the degree of deviation from the baseline, and other factors. Each abnormal feature point and abnormal frequency component is assigned a corresponding risk weight value, and then the risk weight values ​​corresponding to all abnormal feature points and abnormal frequency components are weighted and summed to obtain the risk prediction parameter data.

[0093] This setup compares the real-time torque angle curve with the impact load baseline spectrum to identify abnormal feature points, capturing abnormal fluctuations in torque as the angle changes. It also compares the real-time vibration spectrum characteristics with the baseline spectrum to identify abnormal frequency components, revealing abnormal frequency patterns in the vibration signal. Finally, by combining the abnormal feature points and abnormal frequency components, risk prediction parameters are obtained, providing a more comprehensive reflection of the risk level of the pneumatic butterfly valve's sealing surface health.

[0094] In one possible implementation, please refer to Figure 5 S530, based on abnormal feature points and abnormal frequency components, obtains risk prediction parameter data, including: S531, based on the position of the abnormal feature point in the torque angle curve and the distribution of the abnormal frequency component in the vibration spectrum characteristics, determine the degree of abnormal impact on the sealing surface of the pneumatic butterfly valve during the opening and closing process; wherein, the degree of abnormal impact is used to indicate the intensity of the abnormal impact borne by the sealing surface of the pneumatic butterfly valve during the opening and closing process.

[0095] For example, determining the degree of abnormal impact on the sealing surface of a pneumatic butterfly valve during opening and closing can be achieved by analyzing the specific locations of abnormal feature points on the torque-angle curve, thus identifying the rotational angle range within which the sealing surface is subjected to abnormal torque. For instance, if the abnormal feature points are concentrated within a relatively small angle range, it indicates that the torque borne by the sealing surface within that angle range has significantly deviated from the normal value. Simultaneously, by combining the distribution of abnormal frequency components in the vibration spectrum characteristics, the vibration characteristics generated by this abnormal torque can be further assessed. For example, if the abnormal frequency components are concentrated in a specific frequency band and have a high energy amplitude, it indicates that within that angle range, the sealing surface has not only experienced abnormal torque but has also triggered strong vibrations at a specific frequency.

[0096] S532, Determine risk prediction parameter data based on the degree of abnormal impact.

[0097] For example, determining risk prediction parameters based on the degree of abnormal impact can be achieved through a pre-defined mapping table between the degree of abnormal impact and the risk level. This mapping table can be developed based on actual engineering experience and experimental data, but is not limited to this. For instance, the degree of abnormal impact can be divided into three levels: slight, moderate, and severe, each corresponding to a different risk weight coefficient. After determining the degree of abnormal impact experienced by the sealing surface of the pneumatic butterfly valve during opening and closing, the corresponding risk weight coefficient can be found according to this mapping table. Then, combined with factors such as the number of abnormal feature points and the energy magnitude of abnormal frequency components, the risk prediction parameters can be calculated using a specific calculation model (such as a weighted average model).

[0098] S600 determines the health data of the sealing surface of the pneumatic butterfly valve based on risk prediction parameter data; wherein, the health data is used to indicate the current health status of the sealing surface of the pneumatic butterfly valve.

[0099] For example, determining the health data of the sealing surface of a pneumatic butterfly valve can be achieved by pre-setting a correspondence between risk prediction parameters and health status levels. For instance, the risk prediction parameters can be divided into multiple intervals, each corresponding to a health status level, such as healthy, sub-healthy, minor malfunction, moderate malfunction, and severe malfunction. Once the risk prediction parameters are obtained, their values ​​are determined based on whether they fall into the corresponding interval, thus determining the current health status level of the sealing surface of the pneumatic butterfly valve; this health status level is the health data. Alternatively, historical health data and current risk prediction parameters can be combined for comprehensive analysis. For example, trend analysis can be used to observe the changing trend of the risk prediction parameters over time. If an upward trend is observed and the rate of increase is rapid, the health status of the sealing surface may further deteriorate in a short period. In this case, the health status level can be appropriately adjusted to more accurately reflect the actual health condition of the sealing surface.

[0100] In summary, this technology can promptly detect any abnormalities that may occur during the operation of pneumatic butterfly valves, thereby enabling real-time monitoring and early prediction of the health status of the sealing surface. This effectively solves the problem of the lack of proactive monitoring and risk prediction methods for the health status of the sealing surface of pneumatic butterfly valves in existing technologies, avoids safety hazards caused by sudden leaks, and reduces operating costs.

[0101] 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 implementation process of the embodiments of this application.

[0102] Corresponding to the method for predicting the health status of the sealing surface of a pneumatic butterfly valve described in the above embodiments, this application also provides a system for predicting the health status of the sealing surface of a pneumatic butterfly valve. Each unit of this system can implement each step of the method for predicting the health status of the sealing surface of a pneumatic butterfly valve. Figure 7 The diagram shows a structural block diagram of a pneumatic butterfly valve sealing surface health status prediction system provided in an embodiment of this application. For ease of explanation, only the parts related to the embodiments of this application are shown.

[0103] Reference Figure 7 The sealing surface health status prediction system for this pneumatic butterfly valve includes: A base unit is established to establish an impact load baseline map; wherein, the impact load baseline map is used to characterize the health status benchmark of the pneumatic butterfly valve under opening and closing operations. The simulation unit simulates the process of controlling the pneumatic actuator to drive the valve stem and rotate the butterfly plate from the fully open position to the test angle range, and obtains real-time operating condition data; wherein, the real-time operating condition data is the data obtained by the first detection element, the second detection element and the third detection element during the rotation of the butterfly plate; The first processing unit is used to obtain a real-time torque-angle curve based on the real-time operating data; wherein the torque-angle curve is used to indicate the change of torque with angle during the rotation of the disc. The second processing unit is used to obtain real-time vibration spectrum characteristics based on the real-time operating data; wherein the vibration spectrum characteristics are used to indicate the distribution of vibration frequency during the rotation of the butterfly plate. The analysis unit is used to analyze the real-time torque angle curve and the vibration spectrum characteristics in combination with the impact load baseline spectrum to obtain risk prediction parameter data; wherein, the risk prediction parameter data is used to indicate the risk level of the sealing surface health status of the pneumatic butterfly valve; The result unit is used to determine the health data of the sealing surface of the pneumatic butterfly valve based on the risk prediction parameter data; wherein the health data is used to indicate the current health status of the sealing surface of the pneumatic butterfly valve.

[0104] It should be noted that the information interaction and execution process between the above systems / units are based on the same concept as the method embodiments of this application. For details on their specific functions and technical effects, please refer to the method embodiments section, and they will not be repeated here.

[0105] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is merely an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the system can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units and modules are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units and modules in the above system can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0106] This application also provides a pneumatic butterfly valve. Figure 8 This is a schematic diagram of the structure of the control component 70 of a pneumatic butterfly valve provided in one embodiment of this application. Figure 8 As shown, the control unit 70 in this embodiment includes: at least one processor 703 ( Figure 8 Only one is shown in the image), at least one memory 701 ( Figure 8(Only one is shown in the image) and a computer program 702 stored in the at least one memory 701 and executable on the at least one processor 703, wherein when the processor 703 executes the computer program 702, it causes the control element 70 to perform the steps in any of the above embodiments of the method for predicting the sealing surface health status of pneumatic butterfly valves, or causes the control element 70 to perform the functions of each module / unit in the above embodiments of the systems.

[0107] For example, the computer program 702 may be divided into one or more modules / units, which are stored in the memory 701 and executed by the processor 703 to complete this application. The one or more modules / units may be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program 702 in the control unit 70.

[0108] The control component 70 may employ a common industrial control chip structure, such as an ARM-based processor chip like the STM32 series. These chips offer high performance and stability, meeting the data processing and control requirements during the prediction of the health status of the pneumatic butterfly valve's sealing surface. Internally, they may integrate peripheral interfaces for easy data interaction with various detection devices, enabling accurate acquisition of real-time operating data. The control component 70 may include, but is not limited to, a processor 703 and a memory 702. Those skilled in the art will understand that… Figure 8 The example of control component 70 is merely an illustration and does not constitute a limitation on control component 70. It may include more or fewer components than shown, or combine certain components, or different components, such as input / output devices, network access devices, buses, etc.

[0109] The processor 703 can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.

[0110] In some embodiments, the memory 701 may be an internal storage unit of the control component 70, such as a hard disk or memory of the control component 70. In other embodiments, the memory 701 may be an external storage device of the control component 70, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the control component 70. Furthermore, the memory 701 may include both internal storage units and external storage devices of the control component 70. The memory 701 is used to store operating systems, applications, bootloaders, data, and other programs, such as the program code of computer programs. The memory 701 can also be used to temporarily store data that has been output or will be output.

[0111] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps in any of the above method embodiments.

[0112] This application provides a computer program product that, when run on a pneumatic butterfly valve, causes the pneumatic butterfly valve to perform the steps described in any of the above method embodiments.

[0113] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the methods of the above embodiments of this application can be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include at least: any entity or device capable of carrying the computer program code to the pneumatic butterfly valve, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium. Examples include USB flash drives, portable hard drives, magnetic disks, or optical disks.

[0114] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0115] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0116] In the embodiments provided in this application, it should be understood that the disclosed pneumatic butterfly valve sealing surface health status prediction system, pneumatic butterfly valve, and method can be implemented in other ways. For example, the pneumatic butterfly valve sealing surface health status prediction system and pneumatic butterfly valve embodiments described above are merely illustrative. For instance, the division of modules or units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be an indirect coupling or communication connection through some interfaces, devices, or units, and may be electrical, mechanical, or other forms.

[0117] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0118] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A pneumatic butterfly valve, characterized in that, include: Pneumatic actuators are used to provide power; A valve stem, one end of which is connected to the power output end of the pneumatic actuator; the valve stem is used to transmit power. A valve body assembly is connected to the other end of the valve stem; the valve body assembly and the pneumatic actuator are fixedly connected. The first detection element is installed at the connection between the pneumatic actuator and the valve stem; The first detection element is used to measure the rotation information of the valve stem; The second detection element is installed at the connection between the pneumatic actuator and the valve stem; The second detection element is used to measure the torque required to drive the valve stem to rotate; the second detection element and the first detection element are circumferentially spaced apart; as well as The third detection element is installed on the pneumatic actuator or the valve body assembly and is used to collect vibration information when the valve is actuated. The valve stem is used to rotate under the drive of the pneumatic actuator to drive the valve body assembly to open or close the valve.

2. The pneumatic butterfly valve as described in claim 1, characterized in that, The valve body assembly includes: A valve body having a fluid passage for fluid passage; the third detection element is mounted on the pneumatic actuator or the valve body. A butterfly plate, rotatably disposed within the fluid passage and connected to the other end of the valve stem; the butterfly plate is used to rotate under the drive of the valve stem to control the opening or closing degree of the fluid passage; and A connecting bracket is fixedly connected to the valve body and the pneumatic actuator.

3. A method for predicting the health status of the sealing surface of a pneumatic butterfly valve, characterized in that, The method for predicting the sealing surface health status of a pneumatic butterfly valve as described in any one of claims 1 to 2 includes: Establish an impact load baseline map; wherein, the impact load baseline map is used to characterize the health status benchmark of the pneumatic butterfly valve under opening and closing operations; During the simulation control of the pneumatic actuator driving the valve stem to rotate the butterfly plate from the fully open position to the test angle range, real-time operating condition data is obtained; wherein, the real-time operating condition data is the data obtained by the first detection element, the second detection element, and the third detection element during the rotation of the butterfly plate; A real-time torque-angle curve is obtained based on the real-time operating data; wherein, the torque-angle curve is used to indicate the change of torque with angle during the rotation of the disc plate; The real-time vibration spectrum characteristics are obtained based on the real-time operating data; wherein, the vibration spectrum characteristics are used to indicate the distribution of vibration frequency during the rotation of the butterfly plate; Risk prediction parameter data is obtained by analyzing the real-time torque angle curve and vibration spectrum characteristics in conjunction with the impact load baseline spectrum; wherein, the risk prediction parameter data is used to indicate the risk level of the sealing surface health status of the pneumatic butterfly valve; The health data of the sealing surface of the pneumatic butterfly valve is determined based on the risk prediction parameter data; wherein the health data is used to indicate the current health status of the sealing surface of the pneumatic butterfly valve.

4. The method for predicting the health status of the sealing surface of a pneumatic butterfly valve as described in claim 3, characterized in that, The establishment of the impact load baseline map includes: With the pneumatic butterfly valve in its initial state, the pneumatic actuator is controlled to perform multiple complete opening and closing actions at a standard speed to obtain multiple opening and closing data. The opening and closing data are used to indicate the overshoot angle of the critical position of the butterfly plate obtained by the first detection element, the peak torque impact and phase at the moment of opening and closing obtained by the second detection element, and the radial vibration frequency of the valve stem obtained by the third detection element when the pneumatic butterfly valve is in the initial state. The impact load baseline pattern is determined based on multiple opening and closing data.

5. The method for predicting the health status of the sealing surface of a pneumatic butterfly valve as described in claim 3, characterized in that, During the simulation control process where the pneumatic actuator drives the valve stem to rotate the butterfly plate from the fully open position to the test angle range, real-time operating data is obtained, including: During the simulation control process, the pneumatic actuator drives the valve stem to rotate the butterfly plate from the fully open position to the test angle range, and the rotation angle sequence of the valve stem is collected in real time by the first detection element. The driving torque sequence corresponding to the rotation angle sequence is collected in real time by the second detection element; The vibration signal sequence during the operation of the pneumatic butterfly valve is collected in real time by the third detection element; Real-time operating data is obtained based on the rotation angle sequence, the driving torque sequence, and the vibration signal sequence.

6. The method for predicting the health status of the sealing surface of a pneumatic butterfly valve as described in any one of claims 3 to 5, characterized in that, The test angle range includes: The test angle range is the range where the butterfly plate rotates less than X relative to the center line of the fluid channel; wherein, the X range is 15° to 75°.

7. The method for predicting the health status of the sealing surface of a pneumatic butterfly valve as described in claim 4, characterized in that, The risk prediction parameter data obtained by analyzing the real-time torque angle curve and vibration spectrum characteristics in conjunction with the impact load baseline spectrum includes: The real-time torque angle curve is compared with the impact load baseline map to identify abnormal feature points in the real-time torque angle curve. The real-time vibration spectrum characteristics are compared with the impact load baseline spectrum to determine the abnormal frequency components in the real-time vibration spectrum characteristics. Risk prediction parameter data is obtained based on the abnormal feature points and the abnormal frequency components.

8. The method for predicting the health status of the sealing surface of a pneumatic butterfly valve as described in claim 7, characterized in that, The process of obtaining risk prediction parameter data based on the abnormal feature points and the abnormal frequency components includes: Based on the position of the abnormal feature points in the torque angle curve and the distribution of the abnormal frequency components in the vibration spectrum characteristics, the degree of abnormal impact on the sealing surface of the pneumatic butterfly valve during the opening and closing process is determined; wherein, the degree of abnormal impact is used to indicate the intensity of the abnormal impact that the sealing surface of the pneumatic butterfly valve is subjected to during the opening and closing process. The risk prediction parameter data is determined based on the degree of the abnormal impact.

9. The method for predicting the health status of the sealing surface of a pneumatic butterfly valve as described in claim 5, characterized in that, The process of obtaining the real-time torque angle curve based on the real-time operating data includes: Based on the time synchronization relationship between the rotation angle sequence and the driving torque sequence, the driving torque value collected at each moment is matched with the corresponding rotation angle value of the valve stem; Using the matched drive torque value and the rotation angle value as data points, a curve fitting is performed with the rotation angle of the valve stem as the horizontal axis and the drive torque as the vertical axis to obtain the torque-angle curve.

10. The method for predicting the health status of the sealing surface of a pneumatic butterfly valve as described in claim 5, characterized in that, The step of obtaining real-time vibration spectrum characteristics based on the real-time operating condition data includes: Effective segments of vibration signals corresponding to the movement of the butterfly plate within the test angle range are extracted from the vibration signal sequence, and spectral analysis is performed on the effective segments of vibration signals to obtain a vibration spectrum diagram. In the vibration spectrum diagram, all spectral peaks with energy exceeding a preset threshold are identified, and the frequency corresponding to the highest energy peak is determined as the dominant vibration frequency and energy amplitude. Calculate the vibration energy within a preset bandwidth centered on the dominant vibration frequency, and determine the energy ratio of the vibration energy within the preset bandwidth to the total energy of the overall spectrum. The dominant vibration frequency, the energy amplitude, and the energy ratio are determined as the real-time vibration spectrum characteristics.

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