A safety valve convenient for real-time monitoring

Abstract

The application discloses a safety valve convenient for real-time monitoring, relates to the field of safety valves, and realizes real-time monitoring of the stroke of a safety valve core and pressure, and obtains stroke data and pressure data. The SOC chip is used for controlling the collection speed, and the stroke data and the pressure data are transmitted in real time through Bluetooth. According to the stroke data and the pressure data, the fault of a hydraulic system can be judged in real time. The motion detection function of the three-axis accelerometer is used for realizing power consumption control. Because the safety valve core is not moved most of the time, the device for detecting the state of the safety valve can be in a low-power consumption mode most of the time, and the purpose of increasing the battery endurance is achieved.

Description

Technical Field

[0001] This invention relates to the field of safety valves, and more specifically, to a safety valve that is easy to monitor in real time. Background Technology

[0002] A safety valve is an automatic valve that discharges a certain amount of fluid without the aid of any external force, relying on the force of the medium itself to prevent the pressure in the system from exceeding a predetermined safety value.

[0003] Currently, there are ordinary safety valves used for automatic opening and closing, but they cannot monitor their own opening and closing status in real time in hydraulic systems, nor can they record opening and closing data, which is not conducive to troubleshooting hydraulic system faults.

[0004] Therefore, how to implement a self-monitoring safety valve to efficiently maintain the hydraulic system is a problem that needs to be solved. Summary of the Invention

[0005] The purpose of this invention is to provide a safety valve that is easy to monitor in real time, so as to solve the above-mentioned problems existing in the prior art.

[0006] This invention provides a safety valve that facilitates real-time monitoring, comprising a triaxial accelerometer, a SOC chip, a stroke sensor, and a safety valve core.

[0007] The triaxial accelerometer and SOC chip are integrated on the circuit board;

[0008] The circuit board is fixed to one end of the stroke sensor, and the other end of the stroke sensor is connected to the safety valve core; the triaxial accelerometer in the circuit board determines whether the safety valve core is moving by the motion state of the stroke sensor;

[0009] The circuit board is connected to one end of an external connector via a terminal block on the safety valve, and the other end of the external connector is connected to a pressure sensor via a terminal block on the pressure sensor; the pressure sensor and the safety valve are connected to the same hydraulic chamber.

[0010] The external connector is used to transmit the pressure data collected by the pressure sensor to the SOC chip on the circuit board.

[0011] Optionally, the circuit board may also include a Bluetooth communication module for communicating with a second processor;

[0012] The pressure and stroke data collected at multiple time points are transmitted in real time to the second processor via the Bluetooth communication module in the circuit board.

[0013] Optionally, the triaxial accelerometer is used for, S101: acquiring motion data; the motion data indicates whether the safety valve core is moving;

[0014] The SOC chip is used for, in S102: acquiring the acquisition speed of the pressure sensor and the stroke sensor based on the motion data;

[0015] S106: Based on the opening point, determine whether the safety valve is malfunctioning;

[0016] The stroke sensor is used in S103 to: acquire stroke data of the safety valve core based on the acquisition speed; the stroke data represents the vertical movement distance of the safety valve core;

[0017] The pressure sensor is used in S104 to acquire the pressure data of the safety valve based on the acquisition speed; the pressure data of the pressure sensor and the safety valve are the same at the same time point.

[0018] The second processor is used in S105 to receive stroke data and pressure data and obtain the opening point.

[0019] Optionally, obtaining the acquisition speed of the pressure sensor and stroke sensor based on the motion data includes:

[0020] The acquisition speed is obtained using the following formula:

[0021]

[0022] Where x represents motion data, x=1 indicates that the safety valve core is moving, and x=0 indicates that the safety valve core is not moving; y represents the acquisition speed, a represents the acquisition speed of 10 Hz, and b represents the acquisition speed of 1 Hz.

[0023] Optionally, determining whether the safety valve is malfunctioning based on the opening point includes:

[0024] The pressure data corresponding to the opening point is used as the opening pressure.

[0025] Use the stroke data corresponding to the opening pressure as the opening calibration stroke;

[0026] Obtain the opening tolerance and closing tolerance set by the second processor; the opening tolerance represents the tolerance of the opening calibration stroke when opening the safety valve; the closing tolerance represents the tolerance of the opening calibration stroke when closing the safety valve.

[0027] Based on the tolerance value and the opening calibration stroke, the opening stroke and closing stroke are obtained; the opening stroke represents the stroke data when the currently operating safety valve needs to be opened; the closing stroke represents the stroke data when the currently operating safety valve needs to be closed.

[0028] The start and stop parameters of the process are obtained using the following formula:

[0029]

[0030] in, This indicates that the calibration stroke has been initiated. This indicates the start of the trip. This indicates that tolerance is enabled. This indicates that the trip has been cancelled. Indicates that tolerance is turned off;

[0031] Based on the opening stroke, closing stroke, and opening pressure, determine whether the safety valve is faulty.

[0032] Optionally, determining whether the safety valve is faulty based on the opening stroke, closing stroke, and opening pressure includes:

[0033] Acquire the following data: valve core stroke data to be tested (open valve core stroke data to be tested), valve core pressure data to be tested; the valve core stroke data to be tested represents the stroke data of the safety valve core in the open state at the current time point; the valve core stroke data to be tested represents the stroke data of the safety valve core in the closed state at the current time point; the valve core pressure data to be tested represents the pressure data of the safety valve core at the current time point.

[0034] If the valve core stroke data to be tested is greater than the opening stroke, set it to safety valve open;

[0035] If the measured valve core stroke data is less than the closing stroke, set the safety valve to close.

[0036] Based on the pressure data and opening pressure of the valve core to be tested at the current time, determine whether there is a fault.

[0037] Optionally, the step of determining whether a fault exists based on the pressure data of the valve core to be detected and the opening pressure at the current time point includes:

[0038] If the safety valve is closed and the pressure data of the valve core to be tested at the second time point is greater than the opening pressure, it is set as the first fault;

[0039] If the safety valve is open, and the pressure data of the valve core to be tested at the second time point is less than the opening pressure, it is set as the second fault.

[0040] Optionally, receiving travel data and pressure data to obtain the start point includes:

[0041] A pressure image is obtained by plotting a line graph based on the pressure data; the length of the pressure image corresponds to the horizontal axis, representing a time point; the width of the pressure image corresponds to the horizontal axis, representing the pressure data.

[0042] In the pressure image, the point with the highest vertical coordinate is detected, and the opening point is obtained.

[0043] Optionally, the SOC chip controls the stroke sensor and pressure sensor to simultaneously acquire pressure data and stroke data;

[0044] One pressure data point corresponds to one travel data point;

[0045] The second processor is used to draw polylines and display pressure images;

[0046] The second processor sends the enable point to the SOC chip.

[0047] Optionally, the circuit board is connected to a first battery, which provides power to the circuit board.

[0048] The pressure sensor includes a terminal block, a housing, a second battery, and a pressure head; the second battery provides power to the pressure sensor.

[0049] Compared with the prior art, the embodiments of the present invention achieve the following beneficial effects:

[0050] This invention also provides a safety valve that facilitates real-time monitoring. It monitors the valve core stroke and system pressure in real time, obtaining stroke and pressure data. The monitored stroke and pressure data can be transmitted in real time via Bluetooth in the SOC chip. Based on the stroke and pressure data, faults in the hydraulic system can be identified in real time.

[0051] Furthermore, power consumption control can be achieved through the motion detection function of a triaxial accelerometer. Since the safety valve spool is mostly stationary, high-speed data acquisition is performed when the safety valve spool is moving, while the device detecting the safety valve's status remains in a low-power mode most of the time when the safety valve spool is stationary, thus increasing battery life. This achieves the technical effect of efficiently monitoring the safety valve's status and determining whether a malfunction has occurred. Attached Figure Description

[0052] Figure 1 This is a schematic diagram of the structure of a safety valve that is easy to monitor in real time, provided by an embodiment of the present invention.

[0053] Figure 2 This is a flowchart of a safety valve that facilitates real-time monitoring, provided by an embodiment of the present invention.

[0054] In the diagram, 1 is the circuit board, 11 is the first battery, 2 is the stroke sensor, 3 is the safety valve core, 4 is the pressure sensor, 41 is the housing, 42 is the second battery, 43 is the pressure head, and 5 is the terminal block. Detailed Implementation

[0055] The present invention will now be described in detail with reference to the accompanying drawings.

[0056] Example 1:

[0057] like Figure 1 As shown, this embodiment of the invention provides a safety valve that is easy to monitor in real time, including a triaxial accelerometer, a SOC chip, a stroke sensor 2, and a safety valve core 3.

[0058] In this embodiment, the safety valve is used to monitor the status of the hydraulic equipment. It can monitor the opening and closing status of the safety valve in real time, mark the opening pressure, closing stroke and opening stroke, and determine whether there is a malfunction.

[0059] The triaxial accelerometer and SOC chip are integrated on circuit board 1.

[0060] The circuit board 1 is fixed to one end of the travel sensor 2, and the other end of the travel sensor 2 is connected to the safety valve core. The triaxial accelerometer in the circuit board 1 determines whether the safety valve core 3 is moving by measuring the motion state of the travel sensor 2.

[0061] The stroke sensor 2 is a rod-shaped structure.

[0062] The circuit board 1 is connected to one end of an external connector via a terminal block 5 on the safety valve, and the other end of the external connector is connected to the pressure sensor 4 via a terminal block 5 on the pressure sensor 4; the pressure sensor 4 and the safety valve are connected to the same hydraulic chamber.

[0063] The external connector is used to transmit the pressure data collected by the pressure sensor 4 to the SOC chip on the circuit board 1.

[0064] In this embodiment, the second processor is the processor on a mobile phone. The SOC chip on circuit board 1 has Bluetooth communication capabilities, enabling communication with a mobile app via the second processor.

[0065] Optionally, the circuit board 1 further includes a Bluetooth communication module for communicating with the second processor;

[0066] The pressure and stroke data collected at multiple time points are transmitted in real time to the second processor via the Bluetooth communication module in circuit board 1.

[0067] Optionally, the triaxial accelerometer is used for, S101: acquiring motion data; the motion data indicates whether the safety valve core 3 is moving.

[0068] When the safety valve core moves, it triggers the motion detection mechanism of the triaxial accelerometer, causing the SOC chip to be interrupted, thus determining whether the safety valve core is moving.

[0069] The SOC chip is used for, in S102: obtaining the acquisition speed of the pressure sensor 4 and the stroke sensor 2 based on the motion data.

[0070] The acquisition speed refers to the speed at which the pressure sensor 4 acquires pressure data and the stroke sensor 2 acquires stroke data.

[0071] S106: Based on the opening point, determine whether the safety valve is faulty.

[0072] The stroke sensor 2 is used for, in S103: acquiring stroke data of the safety valve core 3 based on the acquisition speed; the stroke data represents the vertical movement distance of the safety valve core 3.

[0073] Specifically, according to the acquisition speed, the vertical movement distance of the safety valve core 3 is acquired and recorded by the stroke sensor 2 as stroke data.

[0074] The pressure sensor 4 is used in S104 to acquire the pressure data of the safety valve based on the acquisition speed. The pressure data of the pressure sensor 4 and the safety valve are the same at the same time point.

[0075] In this process, pressure sensor 4 is used to collect and record the pressure on the safety valve core 3 as pressure data, according to the acquisition speed.

[0076] The pressure sensor 4 is connected to the same hydraulic chamber as the safety valve.

[0077] The pressure sensor 4 and the safety valve are subjected to the same pressure at the same time point.

[0078] The second processor is used in S105 to receive stroke data and pressure data and obtain the opening point.

[0079] One pressure data point corresponds to one travel data point.

[0080] The pressure data and travel data are associated with time points. One time point corresponds to one pressure data point and one travel data point.

[0081] Optionally, controlling the acquisition speed of the pressure sensor 4 and the stroke sensor 2 based on the motion data includes:

[0082] The acquisition speed is obtained using the following formula:

[0083]

[0084] Where x represents motion data, x=1 indicates that the safety valve core 3 is moving, and x=0 indicates that the safety valve core 3 is not moving; y represents the acquisition speed, a represents the acquisition speed of 10 Hz, and b represents the acquisition speed of 1 Hz.

[0085] In this embodiment, 'a' represents the acquisition speed corresponding to high-speed acquisition, which is 10 times / second, meaning 10 acquisitions per second. 'b' represents the acquisition speed corresponding to low-speed acquisition, which is 1 time / second, meaning 1 acquisition per second.

[0086] Optionally, determining whether the safety valve is malfunctioning based on the opening point includes:

[0087] The pressure data corresponding to the opening point is used as the opening pressure.

[0088] The opening pressure refers to the threshold value at which the safety valve opens.

[0089] The stroke data corresponding to the opening pressure is used as the opening calibration stroke.

[0090] Specifically, a line graph is constructed using pressure data from multiple time points. During the pressure climb and subsequent decline of the safety valve as it opens, the highest pressure point is detected, and the pressure data at this point, along with the corresponding stroke data, are used as the calibrated opening pressure and calibrated opening stroke of the safety valve, respectively.

[0091] In this embodiment, the opening pressure and opening calibration stroke are calibrated on a hydraulic test bench during factory testing.

[0092] During factory testing, the valve was activated via a mobile app. Upon activation, the safety valve core 3 began to move. Circuit board 1 transmitted pressure and stroke data at high speed via Bluetooth communication, displaying a line graph in real-time on the app's screen, allowing manual judgment of the opening point. The opening point was then sent to the SOC chip on circuit board 1 as the safety valve's calibration stroke and opening pressure.

[0093] The opening calibration stroke refers to the stroke data detected by the stroke sensor 2 when the pressure data of the safety valve is at its maximum.

[0094] The opening tolerance and closing tolerance set by the second processor are obtained; the opening tolerance represents the tolerance of the opening calibration stroke when the safety valve is opened; the closing tolerance represents the tolerance of the opening calibration stroke when the safety valve is closed.

[0095] The opening tolerance refers to a safety margin deducted from the theoretical calibration value to ensure reliable operation of the safety valve. This is because mechanical actions are inherently uncertain in the physical world. In this embodiment, the safety valve will also experience wear over time, resulting in slight changes in the stroke data.

[0096] Based on the tolerance value and the opening calibration stroke, the opening stroke and closing stroke are obtained; the opening stroke represents the stroke data when the currently operating safety valve needs to be opened; the closing stroke represents the stroke data when the currently operating safety valve needs to be closed.

[0097] The start and stop parameters of the process are obtained using the following formula:

[0098]

[0099] in, This indicates that the calibration stroke has been initiated. This indicates the start of the trip. This indicates that tolerance is enabled. This indicates that the trip has been cancelled. This indicates that tolerance is turned off.

[0100] Based on the opening stroke, closing stroke, and opening pressure, determine whether the safety valve is faulty.

[0101] In this embodiment, after the safety valve is installed on the hydraulic equipment, the pressure data of the safety valve in both open and closed states is used to determine whether there is a fault when the hydraulic equipment generates pressure.

[0102] Optionally, determining whether the safety valve is faulty based on the opening stroke, closing stroke, and opening pressure includes:

[0103] Acquire the stroke data of the valve core to be tested when it is open, the stroke data of the valve core to be tested when it is closed, and the pressure data of the valve core to be tested; the stroke data of the valve core to be tested represents the stroke data of the safety valve core (3) in the open state at the current time point; the stroke data of the valve core to be tested when it is closed represents the stroke data of the safety valve core (3) in the closed state at the current time point; the pressure data of the valve core to be tested represents the pressure data of the safety valve core (3) at the current time point.

[0104] The "on" state indicates that the travel data increases over time. The "off" state indicates that the travel data decreases over time.

[0105] Among them, the valve core stroke data and valve core pressure data to be tested are used to monitor whether the safety valve has a fault in real time.

[0106] If the valve core stroke data to be tested is greater than the opening stroke, the safety valve is set to open.

[0107] If the measured valve core stroke is less than the actual closing stroke, the safety valve is set to closed.

[0108] Based on the pressure data and opening pressure of the valve core to be tested at the current time, determine whether there is a fault.

[0109] The SOC chip on circuit board 1 simultaneously collects pressure and stroke data, and determines the current opening / closing state of the safety valve by using the calibrated opening pressure and opening stroke. The opening / closing state includes an open state and a closed state. When an opening / closing event occurs, the event time and pressure data are recorded.

[0110] Optionally, the step of determining whether a fault exists based on the pressure data of the valve core to be detected and the opening pressure at the current time point includes:

[0111] If the safety valve is closed and the pressure data of the valve core to be tested at the second time point is greater than the opening pressure, it is set as the first fault.

[0112] If the safety valve is open, and the pressure data of the valve core to be tested at the second time point is less than the opening pressure, it is set as the second fault.

[0113] Optionally, receiving travel data and pressure data to obtain the start point includes:

[0114] A pressure image is obtained by plotting a line graph based on the pressure data; the length of the pressure image corresponds to the horizontal axis, representing a time point; the width of the pressure image corresponds to the horizontal axis, representing the pressure data.

[0115] In the pressure image, the point with the highest vertical coordinate is detected, and the opening point is obtained.

[0116] The opening point refers to the point of greatest pressure.

[0117] Optionally, the SOC chip controls the stroke sensor 2 and the pressure sensor 4 to collect pressure data and stroke data in real time and simultaneously.

[0118] One pressure data point corresponds to one travel data point;

[0119] The second processor is used to draw polylines and display pressure images;

[0120] The second processor sends the enable point to the SOC chip.

[0121] Optionally, the circuit board 1 is connected to a first battery 11, which provides power to the circuit board 1;

[0122] The pressure sensor 4 includes a terminal block 5, a housing 41, a second battery 42, and a pressure head 43; the second battery 42 is used to provide energy to the pressure sensor 4.

[0123] The pressure head 43 of the pressure sensor 4 is connected to the hydraulic chamber of the hydraulic equipment.

[0124] The algorithms and displays provided herein are not inherently related to any particular computer, virtual system, or other device. Various general-purpose systems can also be used in conjunction with the teachings herein. The required structure for constructing such systems is apparent from the above description. Furthermore, this invention is not directed to any particular programming language. It should be understood that the contents of the invention described herein can be implemented using various programming languages, and the above description of specific languages ​​is for the purpose of disclosing the best mode of implementation of the invention.

[0125] Numerous specific details are set forth in the specification provided herein. However, it will be understood that embodiments of the invention may be practiced without these specific details. In some instances, well-known methods, structures, and techniques have not been shown in detail so as not to obscure the understanding of this specification.

[0126] The various component embodiments of the present invention can be implemented in hardware, or as software modules running on one or more processors, or a combination thereof. Those skilled in the art will understand that microprocessors or digital signal processors (DSPs) can be used in practice to implement some or all of the functions of some or all of the components in the apparatus according to embodiments of the present invention. The present invention can also be implemented as a device or apparatus program (e.g., a computer program and computer program product) for performing part or all of the methods described herein. Such programs implementing the present invention can be stored on a computer-readable medium or can be in the form of one or more signals. Such signals can be downloaded from an Internet website, provided on a carrier signal, or provided in any other form.

Claims

1. A safety valve that facilitates real-time monitoring, characterized in that, It includes a triaxial accelerometer, a SOC chip, a stroke sensor (2), and a safety valve core (3). The triaxial accelerometer and SOC chip are integrated on the circuit board (1); The circuit board (1) is fixed to one end of the stroke sensor (2), and the other end of the stroke sensor (2) is connected to the safety valve core (3); the triaxial accelerometer in the circuit board (1) determines whether the safety valve core (3) is moving by the motion state of the stroke sensor (2); The circuit board (1) is connected to one end of an external connector via a terminal block (5) on the safety valve, and the other end of the external connector is connected to the pressure sensor (4) via a terminal block (5) on the pressure sensor (4); the pressure sensor (4) and the safety valve are connected to the same hydraulic chamber; The external connector is used to transmit the pressure data collected by the pressure sensor (4) to the SOC chip on the circuit board (1).

2. The safety valve for easy real-time monitoring according to claim 1, characterized in that, The circuit board (1) also includes a Bluetooth communication module for communicating with the second processor; The pressure data and stroke data collected at multiple time points are transmitted to the second processor in real time through the Bluetooth communication module in the circuit board (1).

3. A safety valve for easy real-time monitoring according to claim 2, characterized in that, The triaxial accelerometer is used for, S101: acquiring motion data; the motion data indicates whether the safety valve core (3) is moving; The SOC chip is used for, S102: based on the motion data, to obtain the acquisition speed of the pressure sensor (4) and the stroke sensor (2); S106: Based on the opening point, determine whether the safety valve is malfunctioning; The stroke sensor (2) is used for, S103: to acquire stroke data of the safety valve core (3) according to the acquisition speed; the stroke data represents the vertical movement distance of the safety valve core (3); The pressure sensor (4) is used for, S104: to acquire the pressure data of the safety valve according to the acquisition speed; the pressure data of the pressure sensor (4) and the safety valve at the same time point are the same; The second processor is used in S105 to receive stroke data and pressure data and obtain the opening point.

4. A safety valve for easy real-time monitoring according to claim 3, characterized in that, The acquisition of the acquisition speeds of the pressure sensor (4) and the stroke sensor (2) based on the motion data includes: The acquisition speed is obtained using the following formula: Where x represents motion data, x=1 indicates that the safety valve core (3) moves, and x=0 indicates that the safety valve core (3) does not move; y represents the acquisition speed, a represents the acquisition speed of 10 Hz, and b represents the acquisition speed of 1 Hz.

5. A safety valve for easy real-time monitoring according to claim 3, characterized in that, The step of determining whether the safety valve is malfunctioning based on the opening point includes: The pressure data corresponding to the opening point is used as the opening pressure. Use the stroke data corresponding to the opening pressure as the opening calibration stroke; Obtain the opening tolerance and closing tolerance set by the second processor; the opening tolerance represents the tolerance of the opening calibration stroke when opening the safety valve; the closing tolerance represents the tolerance of the opening calibration stroke when closing the safety valve. Based on the tolerance value and the opening calibration stroke, the opening stroke and closing stroke are obtained; the opening stroke represents the stroke data when the currently operating safety valve needs to be opened; the closing stroke represents the stroke data when the currently operating safety valve needs to be closed. The start and stop parameters of the process are obtained using the following formula: in, This indicates that the calibration stroke has been initiated. This indicates the start of the trip. This indicates that tolerance is enabled. This indicates that the trip has been cancelled. Indicates that tolerance is turned off; Based on the opening stroke, closing stroke, and opening pressure, determine whether the safety valve is faulty.

6. A safety valve for easy real-time monitoring according to claim 5, characterized in that, The determination of whether the safety valve is faulty based on the opening stroke, closing stroke, and opening pressure includes: Acquire the stroke data of the valve core to be tested when it is open, the stroke data of the valve core to be tested when it is closed, and the pressure data of the valve core to be tested; the stroke data of the valve core to be tested represents the stroke data of the safety valve core (3) in the open state at the current time point; the stroke data of the valve core to be tested when it is closed represents the stroke data of the safety valve core (3) in the closed state at the current time point; the pressure data of the valve core to be tested represents the pressure data of the safety valve core (3) at the current time point; If the valve core stroke data to be tested is greater than the opening stroke, set it to safety valve open; If the measured valve core stroke data is less than the closing stroke, set the safety valve to close. Based on the pressure data and opening pressure of the valve core to be tested at the current time, determine whether there is a fault.

7. A safety valve for easy real-time monitoring according to claim 6, characterized in that, The determination of whether a fault exists based on the pressure data and opening pressure of the valve core to be tested at the current time point includes: If the safety valve is closed and the pressure data of the valve core to be tested at the second time point is greater than the opening pressure, it is set as the first fault; If the safety valve is open, and the pressure data of the valve core to be tested at the second time point is less than the opening pressure, it is set as the second fault.

8. A safety valve for easy real-time monitoring according to claim 3, characterized in that, The process of receiving travel data and pressure data to obtain the start point includes: A pressure image is obtained by plotting a line graph based on the pressure data; the length of the pressure image corresponds to the horizontal axis, representing a time point; the width of the pressure image corresponds to the horizontal axis, representing the pressure data. In the pressure image, the point with the highest vertical coordinate is detected, and the opening point is obtained.

9. A safety valve for easy real-time monitoring according to claim 1, characterized in that, The SOC chip controls the stroke sensor (2) and pressure sensor (4) to simultaneously collect pressure data and stroke data; One pressure data point corresponds to one travel data point; The second processor is used to draw polylines and display pressure images; The second processor sends the enable point to the SOC chip.

10. A safety valve for easy real-time monitoring according to claim 1, characterized in that, The circuit board (1) is connected to a first battery (11), which provides energy to the circuit board (1). The pressure sensor (4) includes a terminal block (5), a housing (41), a second battery (42), and a pressure head (43); the second battery (42) is used to provide energy to the pressure sensor (4).

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