A multi-mode valve life test device and a fault isolation control method thereof

Abstract

The application discloses a kind of multimode valve life test device and its fault control isolation method, wherein a kind of multimode valve life test device involved, including host computer, for setting test parameters;Wherein test parameters include test mode parameters, valve feedback type parameters;Lower computer controller is connected with host computer, for determining current test mode according to test parameters and the in-place determination rule of each valve, and according to the data determined to valve drive module sends control instruction;Valve drive module is connected with lower computer controller, for driving multiple valves to be measured according to the control instruction sent by lower computer controller;Signal acquisition module is connected with lower computer controller, for collecting the status signal generated after each valve to be measured acts, and the status signal collected is output to lower computer controller, to make lower computer controller judge and count test times or record fault to received status signal.

Description

Technical Field

[0001] This invention relates to the field of valve testing technology, and in particular to a multi-mode valve life testing device and its fault isolation control method. Background Technology

[0002] Valves typically require numerous on / off cycle tests during production inspection, life testing, and aging testing to verify their reliability. Traditional testing methods often involve manually switching the power on and off, manually observing the position signal and recording the number of cycles, or using single-function control equipment for fixed-mode testing. These methods suffer from low efficiency, susceptibility to errors, and inability to process data in batches.

[0003] To address this, existing technologies have developed automated valve testing systems. For example, CN116336253A discloses a multifunctional valve testing system and method, including a host computer, a slave computer, sensors, an actuator, and a power supply. In the host computer, a drive control configuration module selects the drive type of the actuator and defines and configures the interface channel of the slave computer; a signal acquisition configuration module acquires and selects the signal types from the valve feedback device and sensors; and a PID self-tuning module automatically tunes the valve's PID controller parameters. In the slave computer, a signal conditioning module adjusts the sensor signals and transmits them to the core processing module for analog-to-digital conversion; a drive output conditioning module drives the actuator to control the valve; and the core processing module also executes logic algorithms. While these patents enable rapid configuration based on testing requirements and achieve partial automation of valve testing, the existing technologies represented by these patents still have the following shortcomings in actual batch valve life testing scenarios:

[0004] 1. When testing multiple valves, the number of valves, grouping methods, and arrival signal types may differ, and manual switching of the test method can easily lead to errors.

[0005] 2. The judgment conditions for valves with no position, only open position, only closed position, and double position valves are different. If the same counting method is used, it is easy to cause false counting or false alarms.

[0006] 3. During batch testing, if a single valve fails, the entire system will shut down, which will affect other normal valves from continuing to complete their life cycle.

[0007] Therefore, how to achieve efficient, accurate, and fault-isolated valve life testing under complex operating conditions involving multiple valves, multiple feedback types, and multiple testing modes has become a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0008] The purpose of this invention is to address the shortcomings of existing technologies by providing a multi-mode valve life testing device and its fault isolation control method, which solves problems such as inconvenient switching between multiple tests, inconsistent counting rules for valves with different position feedbacks, and the impact of faulty valves on the continued testing of normal valves in valve life testing.

[0009] To achieve the above objectives, the present invention adopts the following technical solution:

[0010] A multi-mode valve life testing device includes a host computer, a slave controller, a valve drive module, and a signal acquisition module;

[0011] The host computer is used to set test parameters, including test mode parameters and valve feedback type parameters.

[0012] The lower-level controller, connected to the upper-level controller, is used to determine the current test mode and the position determination rules of each valve based on the test parameters, and to send control commands to the valve drive module based on the determined data.

[0013] The valve drive module is connected to the lower-level controller and is used to drive multiple valves under test according to the control commands sent by the lower-level controller.

[0014] The signal acquisition module is connected to the lower-level controller and is used to acquire the status signals generated after each valve under test is activated. The acquired status signals are then output to the lower-level controller so that the lower-level controller can judge the received status signals and count the number of tests or record faults.

[0015] Furthermore, the current test mode determined in the lower-level controller includes: single-channel sequential mode, multi-channel group mode, and multi-channel simultaneous mode.

[0016] Furthermore, the valve feedback types in the host computer include no position feedback type, only open position feedback type, only closed position feedback type, and both open and closed position feedback type.

[0017] Furthermore, the rules for determining the position of each valve in the lower-level controller include:

[0018] For valve opening phases without feedback, the valve opening phase is completed when the first preset time is reached, and the number of valve openings is recorded. For valve closing phases, the valve closing phase is completed when the second preset time is reached, and the number of valve closings is recorded.

[0019] For the type of valve opening only feedback, the condition for recording the number of valve openings is that the valve opening state signal is received within the third preset time, and the condition for recording the number of valve closings is that the valve closing time is reached within the fourth preset time.

[0020] For the type of feedback only for valve closing, the condition for recording the number of valve openings is that the valve opening stage reaches the fifth preset time, and the condition for recording the number of valve closings is that the valve closing status signal is received within the sixth preset time.

[0021] For the dual-position feedback type of switch, the condition for recording the number of valve opening times is to receive the open position status signal within the seventh preset time period during the valve opening stage, and the condition for recording the number of valve closing times is to receive the closed position status signal within the eighth preset time period during the valve closing stage.

[0022] Furthermore, the control commands in the lower-level controller include:

[0023] For single-path sequential mode, a single valve is treated as a set of action objects. The current set of action objects is selected sequentially according to the valve number, and the test cycle of opening valve, waiting, closing valve, and waiting is executed on the selected set of action objects.

[0024] For the multi-group mode, multiple valves under test are divided into multiple action object sets according to the preset number of groups. The current action object set is selected in sequence according to the preset order, and the test cycle of valve opening, waiting, valve closing, and waiting is executed on the selected action object set.

[0025] For the multi-channel simultaneous mode, all valves are treated as a set of action objects, and a test cycle of opening valve, waiting, closing valve, and waiting is performed on this set of action objects.

[0026] Furthermore, the lower-level controller is also used for:

[0027] When the number of consecutive failures of the same valve under test in the same direction of action reaches a preset threshold, the valve under test is marked as a faulty valve and skipped in subsequent tests.

[0028] If all testable valves are marked as faulty valves in the current test mode, stop the test.

[0029] Furthermore, the lower-level controller's operation of skipping the faulty valve during subsequent testing specifically includes:

[0030] For single-path sequential mode, skip the number corresponding to the faulty valve and select the next measurable valve as the current action object;

[0031] In the multi-group mode, only the faulty valve is skipped, and the remaining valves in the action object set where the faulty valve is located continue to be tested.

[0032] In the multi-channel simultaneous mode, the faulty valve is removed from the set of valves that are simultaneously activated, while the remaining valves continue to perform tests synchronously.

[0033] Furthermore, the faults recorded in the lower-level controller are specifically as follows:

[0034] Record the faults according to the direction of action; the direction of action includes the valve opening direction and the valve closing direction.

[0035] Furthermore, it also includes:

[0036] The button module, connected to the lower-level controller, is used to perform operations such as starting the test, pausing the test, fault recovery, and clearing the cumulative count via buttons.

[0037] The display module, connected to the lower-level controller, is used to display test parameters, the cumulative number of tests for each valve, operating status, pause status, completion status, and fault prompts.

[0038] The non-volatile memory module connects to the lower-level controller and is used to store test parameters, the cumulative number of tests for each valve, and the fault status of each valve.

[0039] Furthermore, it also includes a fault isolation control method for a multi-mode valve life testing device, comprising:

[0040] S1. Set test parameters on the host computer; the test parameters include test mode parameters and valve feedback type parameters;

[0041] S2. The lower-level controller determines the current test mode and the position determination rules of each valve according to the test parameters, and sends control commands to the valve drive module according to the determined data;

[0042] S3. The valve drive module drives multiple valves under test according to the control commands sent by the lower-level controller;

[0043] S4. The signal acquisition module acquires the status signals generated after each valve under test is activated, and outputs the acquired status signals to the lower-level controller.

[0044] S5. The lower-level controller judges the received status signals and counts the number of tests or records the faults.

[0045] Compared with the prior art, the present invention has the following beneficial effects:

[0046] 1. The same device can complete 1 sequential test, 4 group tests and 8 simultaneous tests, reducing the operational complexity when switching between different test scenarios.

[0047] 2. Different effective counting rules are adopted for valves with different feedback types to avoid valves without feedback being misjudged as faulty, and to avoid valves with feedback being counted as effective lifespan even if they are not in position.

[0048] 3. The host computer centrally sets parameters, and the slave computer saves the parameters and displays the confirmation results, reducing the need for repeated on-site settings and verification.

[0049] 4. Record consecutive faults according to valve number and direction of action, and isolate faulty valves after reaching the threshold, so that normal valves can continue to be tested, thereby improving the data integrity of batch life test.

[0050] 5. Through the host computer interface, display module, and fault prompts, on-site personnel can intuitively see the test process, faulty objects, and end status.

[0051] 6. By recognizing single-click, double-click, and long-press with a single button, it can complete start-up, pause, fault recovery, and reset without adding a complicated operation panel. Attached Figure Description

[0052] Figure 1 This is a schematic diagram of a multi-mode valve life testing device provided in Embodiment 1;

[0053] Figure 2 This is a schematic diagram of the host computer parameter settings provided in Embodiment 1;

[0054] Figure 3 This is a diagram of the fault valve isolation treatment provided in Example 1. Detailed Implementation

[0055] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.

[0056] The purpose of this invention is to address the shortcomings of existing technologies by providing a multi-mode valve life testing device and its fault isolation control method.

[0057] Example 1

[0058] This embodiment provides a multi-mode valve life testing device, such as... Figure 1 As shown, it includes a host computer, a slave controller, a valve drive module, a signal acquisition module, a button module, a display module, a non-volatile memory module, and a power supply module.

[0059] The host computer and the slave controller are connected via a communication module to set and send test parameters, view test status, and export test data. The slave controller, as the control core of the entire device, is connected to the valve drive module, signal acquisition module, button module, display module, and non-volatile memory module. The power supply module provides operating voltage for the slave controller and all functional modules.

[0060] The host computer is used to set test parameters, such as... Figure 2 As shown.

[0061] Before the test begins, the operator sets the test parameters through the host computer. These parameters include test mode parameters, valve feedback type parameters, multiple preset times (e.g., 8 preset times), waiting time, and number of cycles.

[0062] This example illustrates the concept using a configuration of 8 valves.

[0063] The test mode parameters can be selected as single-channel sequential mode parameters (e.g., 1 channel), multi-channel group mode parameters (e.g., 4 channels), or multi-channel simultaneous mode parameters (e.g., 8 channels). The selection determines the test mode used in this test.

[0064] It should be noted that this embodiment is only described using an 8-way valve as an example, but the scope of protection is not limited to 8 channels and can be expanded to more channels according to actual needs.

[0065] Valve feedback type parameters include no position feedback type, open position feedback type, closed position feedback type, and both open and closed position feedback type. Operators need to set the corresponding feedback type parameters for each valve according to the actual type of valve being tested.

[0066] The 8 preset times include:

[0067] The first preset time is the valve opening time threshold for valves without position feedback.

[0068] The second preset time is the valve closing time threshold for valves without position feedback.

[0069] The third preset time is the valve opening time threshold for only the valve that is opened to the position feedback valve;

[0070] The fourth preset time is the valve closing time threshold for the valve that has been opened to the required position.

[0071] The fifth preset time is the threshold time for opening the valve only when it is closed to the required position.

[0072] The sixth preset time is the valve closing time threshold for the feedback valve that is closed to the desired position.

[0073] The seventh preset time is the valve opening time threshold for the dual-position feedback valve.

[0074] The eighth preset time is the valve closing time threshold for the double-position feedback valve.

[0075] The waiting time is the interval between the completion of the valve action and the start of the next action.

[0076] The number of cycles is the number of complete switching cycles that the test needs to complete. When the number of cycles is set to 0, the test will continue to run until the operator stops it manually or a fault occurs. When the number of cycles is set to an integer greater than 0, the test will automatically end after completing the specified number of cycles.

[0077] After the operator completes the parameter settings, the test parameters are sent to the lower-level controller via the send button on the host computer.

[0078] The lower-level controller is used to determine the current test mode and the positioning rules of each valve based on the test parameters, and to send control commands to the valve drive module based on the determined data.

[0079] After receiving the test parameters sent by the host computer, the lower-level controller first checks the range of the parameters to determine whether each parameter is within the preset valid range. If the parameter exceeds the valid range, the lower-level controller returns a parameter error message to the host computer and requests that it be reset; if the parameter is within the valid range, it is determined to be a valid parameter.

[0080] The lower-level controller saves the valid parameters to the non-volatile storage module, which uses EEPROM or Flash memory to ensure that the parameters are not lost after the device is powered off. After the parameters are saved, the lower-level controller displays the parameters as saved and the current parameter configuration status through the display module. The operator can confirm whether the parameters are correct through the display module.

[0081] If the device is powered off and then powered on again, the lower-level controller automatically reads the test parameters saved in the non-volatile storage module. If it detects that the parameters have been saved completely, the lower-level controller enters the parameter confirmation interface, where the operator can confirm to use the original parameters or reset them. If it does not detect the complete parameters, the lower-level controller enters the parameter setting interface and waits for the upper-level computer to send the complete parameters.

[0082] Next, the lower-level controller determines the current test mode based on the test mode parameters, specifically:

[0083] If the input test mode parameter is 1 channel, the lower-level controller determines that the current test mode is the 1-channel sequential mode. In this mode, only one valve is driven at a time, and the valves are driven in sequence from 1 to 8. That is, valve 1 is driven to complete the complete opening, waiting, closing and waiting cycle, then valve 2 is driven to complete a complete opening cycle, and so on, until valve 8 is completed and then valve 1 is returned to start again.

[0084] If the input test mode parameter is 4 channels, the lower-level controller determines that the current test mode is a 4-channel group mode. In this mode, the lower-level controller divides the multiple valves under test into multiple action object sets according to the preset number of groups. For example, valves 1 to 4 are taken as the first group and valves 5 to 8 are taken as the second group. At this time, the lower-level controller selects the current action object set in a preset order and performs a test cycle of opening valve, waiting, closing valve, and waiting for the selected action object set. Specifically, the first group (valve 1-4) is opened first and waits for the set waiting time. Then the first group is closed and waits for the set waiting time again. Next, the second group (valve 5-8) is opened and waits. The second group is closed and waits. Then the above process is repeated.

[0085] If the input test mode parameter is 8 channels, the lower-level controller determines that the current test mode is the 8-channel simultaneous mode. In this mode, the lower-level controller treats all valves (numbers 1 to 8) as a set of action objects and simultaneously executes the test cycle of opening valve, waiting, closing valve, and waiting on this set of action objects.

[0086] Meanwhile, the lower-level controller determines the positioning judgment rule for each valve based on the valve feedback type parameters set by the upper-level controller, specifically as follows:

[0087] For valves with no feedback type, the completion determination rule is as follows: the valve opening stage is determined by the arrival of the first preset time, and the valve closing stage is determined by the arrival of the second preset time. Since this type of valve does not generate any status signal, the lower-level controller does not detect the status signal, but only relies on timing to determine whether the action is completed, and records the number of valve openings and closings respectively.

[0088] For valves with only open-to-position feedback, the position determination rule is as follows: during the valve opening phase, receiving the open-to-position status signal within a third preset time is used as the condition for recording the number of valve openings; during the valve closing phase, reaching the fourth preset time is used as the condition for recording the number of valve closings. That is, after issuing the valve opening command, the lower-level controller starts a timer and waits to receive the open-to-position status signal within the third preset time. If the signal is received within the third preset time, the valve opening is determined to be successful, and one valve opening count is recorded. If the signal is not received after the third preset time, the valve opening is determined to be faulty. During the valve closing phase, no signal is detected; the valve closing is determined solely by timing.

[0089] For valves with a feedback type of "closed in position only", the position determination rule is as follows: during the valve opening phase, the condition for recording the number of valve openings is the arrival of the fifth preset time; during the valve closing phase, the condition for recording the number of valve closings is the receipt of the closed in position status signal within the sixth preset time. That is, during the valve opening phase, no signal is detected, and only timing is used; during the valve closing phase, the closed in position status signal needs to be received within the sixth preset time. If the signal is received within the sixth preset time, the valve is considered to have closed successfully, and one valve closing count is recorded; if the signal is not received after the sixth preset time, the valve closing is considered to have failed.

[0090] For valves with a dual-position feedback feedback type (on / off), the position determination rule is as follows: During the valve opening phase, receiving the open position signal within a seventh preset time is used as the condition for recording the number of valve openings; during the valve closing phase, receiving the close position signal within an eighth preset time is used as the condition for recording the number of valve closings. That is, after issuing the valve opening command, the lower-level controller starts a timer and waits to receive the open position signal within the seventh preset time. If the signal is received within the seventh preset time, the valve opening is considered successful, and one valve opening count is recorded. If the signal is not received after the seventh preset time, the valve opening is considered a failure. Similarly, during the valve closing phase, receiving the close position signal within the eighth preset time is required. If the signal is received within the eighth preset time, the valve closing is considered successful, and one valve closing count is recorded. If the signal is not received after the eighth preset time, the valve closing is considered a failure.

[0091] After the parameters are set and the operator starts the test, the lower-level controller begins to execute the test, specifically:

[0092] The lower-level controller determines the set of action objects according to the current test mode. In the 1-channel sequential mode, the initial set of action objects is valve No. 1; in the 4-channel group mode, the initial set of action objects is the first group of valves; and in the 8-channel simultaneous mode, the set of action objects is all valves.

[0093] The lower-level controller first sends a valve opening control command to the current set of action objects through the valve drive module. The valve drive module drives the corresponding valve to perform the opening action according to the received control command. The valve drive module adopts an optocoupler isolated relay circuit, with each relay corresponding to one valve. The lower-level controller outputs high and low levels through the I / O port to control the on and off of the relay coil, thereby controlling the power supply of the valve solenoid valve.

[0094] At the same time as issuing the valve opening command, the lower-level controller starts a timer and begins timing and signal detection according to the feedback type of each valve in the current action object set.

[0095] For valves that require detection of the open position status signal (i.e., open position feedback type and dual open / closed position feedback type), the lower-level controller waits for the open position status signal output by the signal acquisition module within the corresponding preset time.

[0096] The signal acquisition module uses an optocoupler-isolated input circuit. The valve's position signal is a dry contact signal, which is converted to a 3.3V level by the optocoupler and then input to the I / O port of the lower-level controller. It collects the status signals generated after each valve under test is activated in real time. For valves with feedback, when the valve is fully opened, the limit switch or proximity sensor inside the valve is triggered, generating an open position status signal. This signal is input to the lower-level controller through the signal acquisition module. For valves without feedback, the corresponding port of the signal acquisition module remains in a no-signal state.

[0097] The lower-level controller determines the received status signal according to the arrival determination rule, specifically as follows:

[0098] If an open-to-position signal is received within a preset time, the valve is considered to have opened successfully, and the valve opening count is incremented by 1.

[0099] If the pre-set time is not exceeded and the valve is not in the open position signal, and the current valve type requires the detection of this signal, the valve opening is determined to be faulty, and the valve is recorded as having one fault in the opening direction.

[0100] After the valve opening phase is completed, the lower-level controller enters the waiting phase, maintaining the current valve state and waiting for the set waiting time.

[0101] After the waiting time ends, the lower-level controller sends a valve closing command through the valve drive module, driving the valves in the current action object set to perform the closing action. The timing, signal detection and judgment logic of the valve closing stage is similar to that of the valve opening stage, but the preset time and status signal corresponding to the valve closing direction are used.

[0102] After the valve closing phase is completed, it enters the waiting phase again, waiting for the set waiting time.

[0103] After a complete test cycle (valve opening-wait-valve closing-wait) is completed, the lower-level controller switches to the next set of action objects according to the current test mode, specifically:

[0104] In the 1-way sequential mode, switch to the next valve number and repeat the above test cycle.

[0105] In 4-way group mode, switch to another group of valves and repeat the above test cycle.

[0106] In the 8-channel simultaneous mode, all valves will simultaneously execute the next test cycle again.

[0107] like Figure 3 As shown, the lower-level controller maintains a continuous fault counter for each valve according to the direction of action, including a continuous fault counter for the valve opening direction and a continuous fault counter for the valve closing direction. Initially, all counters have a value of 0.

[0108] During the above test, for the action direction that requires the detection of status signals, if the lower-level controller does not receive a status signal within the corresponding preset time, it is determined that the valve has experienced a fault in that action direction, and the lower-level controller increments the continuous fault counter for the corresponding direction of the valve by 1.

[0109] It should be noted that in this embodiment, the continuous fault counter is only activated when the current valve feedback type requires the detection of the status signal in the corresponding direction. For directions that do not require signal detection (such as the valve closing direction with only the valve in position feedback, the valve opening direction with only the valve in position feedback, and all directions without position feedback valves), the lower-level controller does not perform fault detection or update the continuous fault counter.

[0110] If the valve successfully completes its action in the same direction during subsequent tests (i.e., receives a status signal within a preset time), the lower-level controller will reset the continuous fault counter for that direction to zero.

[0111] When the lower-level controller detects that the number of consecutive failures of a certain valve in the same direction of action reaches a preset threshold (such as 3 times), the valve is marked as a faulty valve.

[0112] Once a valve is marked as faulty, the lower-level controller automatically skips that valve in subsequent tests, specifically:

[0113] In the 1-way sequential mode, the lower-level controller skips the number corresponding to the faulty valve and no longer issues any control commands to that valve. Instead, it directly selects the next testable valve as the current action target. For example, if valve number 2 is marked as a faulty valve, the test sequence becomes: valve 1, valve 3, valve 4, valve 5, valve 6, valve 7, valve 8, return to valve 1, and valve number 2 is not driven.

[0114] In the 4-way group mode, the lower-level controller skips only the faulty valve itself, and the other valves in the group containing the faulty valve continue to perform the test. If valve No. 2 in the first group is marked as the faulty valve, when it is the turn of the first group to act, the lower-level controller will only drive valves No. 1, No. 3, and No. 4 to act, and valve No. 2 will not be driven. The valves in the second group will not be affected and will perform the test normally.

[0115] In the 8-channel simultaneous mode, the lower-level controller removes the faulty valve from the set of simultaneous action objects. If valve 2 is marked as a faulty valve, the lower-level controller will only drive valves 1, 3, 4, 5, 6, 7, and 8 simultaneously in subsequent tests, and valve 2 will no longer be driven.

[0116] When the lower-level controller determines that all testable valves in the current test mode are marked as faulty valves, it stops the test and displays a message indicating that all valves are faulty and the test has stopped through the display module.

[0117] The display module in this embodiment is used to display various information during the testing process in real time, specifically including:

[0118] Displays the currently set test mode parameters, valve feedback type parameters, preset times, waiting times, and number of cycles; displays the cumulative number of valve openings and closings for each valve, and for tests that have completed multiple cycles, displays the number of completed cycles; displays whether the current test is running, paused, or stopped; when a fault occurs, displays the faulty valve number, fault direction (opening or closing), and the current number of consecutive faults; when the test reaches the set number of cycles, displays the test completion and final cumulative count.

[0119] The button module in this embodiment is used to perform multiple operations using a single button, specifically:

[0120] Start or pause the test by short pressing (less than 1 second); recover from the fault by double-clicking (press twice in quick succession within 0.5 seconds), clear the current fault prompt, and restore the normal display if the faulty valve has been skipped and no longer affects the test; clear the cumulative count by long pressing (more than 3 seconds), clear the cumulative test count of all valves, and save it to the non-volatile memory module.

[0121] The non-volatile storage module in this embodiment uses EEPROM or Flash memory to store data, including:

[0122] Complete test parameters (including test mode parameters, valve feedback type parameters, first preset time to eighth preset time, waiting time and number of cycles), cumulative number of valve openings and closings for each valve, and fault status of each valve (whether it is marked as a faulty valve and the continuous fault count value in each direction).

[0123] The above data is updated in real time during equipment operation and saved to a non-volatile storage module to ensure that the data will not be lost due to unexpected power outages.

[0124] In this embodiment, when the device is powered on again after a power outage, the lower-level controller automatically executes the following initialization process:

[0125] Initialize the system clock, timers, I / O ports, buttons, communication interface, non-volatile memory module, valve control module, and display module; then read the data stored in the non-volatile memory module; if the non-volatile memory module detects an abnormality (such as data corruption or inability to be read), the display module displays a storage error message, and the device stops operating.

[0126] If complete parameters are read, the lower-level controller displays a parameter confirmation interface through the display module. The operator can choose to confirm the use of the original parameters or reset the parameters. If the operator chooses to reset the parameters, the lower-level controller enters the parameter setting interface and waits for the upper-level controller to send new parameters.

[0127] If the complete parameters are not read (e.g., for first-time use or when the parameters have been cleared), the lower-level controller will directly enter the parameter setting interface and prompt the user to set the parameters via the display module, while waiting for the upper-level controller to send the complete parameters.

[0128] After parameter confirmation or setting, the lower-level controller enters the valve overview interface, displaying the cumulative number of tests and current status (normal or fault) of each valve. Operators can start the test via the button module or the start test button on the upper-level computer.

[0129] In this embodiment, the lower-level controller also stops the test under any of the following conditions:

[0130] 1. When the number of loops is set to an integer greater than 0, the lower-level controller will automatically stop the test after completing the specified number of complete loops and display the test completion status through the display module.

[0131] 2. When a pause command is received, the lower-level controller enters a pause state after the current test cycle (i.e., the valve opening or closing action currently being performed) is completed. In the pause state, all valves remain in their current state, and the lower-level controller stops issuing new control commands. When the operator presses the button again or clicks the continue button on the upper-level controller, the lower-level controller resumes execution from the pause position.

[0132] 3. When the lower-level controller determines that all testable valves in the current test mode have been marked as faulty valves, it will automatically stop the test and display a message on the display module indicating that all valves are faulty and the test has stopped.

[0133] After the test is stopped, the lower-level controller remains in a stopped state, waiting for the operator to perform a new round of parameter settings or fault recovery operations.

[0134] Compared with the prior art, this embodiment has the following beneficial effects:

[0135] 1. The lower-level controller selects the test mode according to the number of valves. The same device can support three test modes: 1-channel sequential mode, 4-channel group mode, and 8-channel simultaneous mode. It can adapt to different numbers of valve test requirements without changing equipment or rewiring, which significantly reduces the operation complexity and error probability when switching between multiple scenarios.

[0136] 2. The corresponding arrival judgment rule is determined according to the valve feedback type parameter (no arrival feedback, only open arrival feedback, only closed arrival feedback, and both open and closed arrival feedback). For valves without arrival feedback, the time reached is used as the condition for action completion. For valves with arrival feedback, the condition for valid counting is the receipt of a status signal within a preset time. This mechanism effectively avoids the problem of valves without feedback being misjudged as faulty, and valves with feedback being counted as valid lifespan counts even if they are not in place, thus improving the accuracy of test data.

[0137] 3. By recording the number of consecutive failures for each valve in both the opening and closing directions, when the number of consecutive failures of the same valve in the same direction reaches a preset threshold, the valve is marked as a faulty valve and skipped in subsequent tests. Simultaneously, depending on the current test mode, a corresponding skipping strategy is adopted (skip the number in sequential mode, skip only the faulty valve in group mode, and remove it from the action set in simultaneous mode). This mechanism ensures that the failure of a single valve will not affect the testing process of other normal valves, guaranteeing the continuity and integrity of normal sample data in batch life tests. When all testable valves are marked as faulty valves, the system automatically stops the test and provides a notification, avoiding invalid testing.

[0138] 4. Test parameters are centrally set via the host computer, and the lower-level controller receives and saves them to a non-volatile storage module. When the device is powered off and then powered on again, it can automatically read the saved parameters and enter the parameter confirmation interface or overview interface. This design reduces the workload of repeated on-site setting and verification, and facilitates the traceability and management of test data.

[0139] 5. The display module displays test parameters, cumulative counts for each valve, operating status, pause status, completion status, and fault prompts in real time, allowing on-site personnel to intuitively understand the test progress without connecting debugging tools. Meanwhile, the button module supports start, pause, fault recovery, and count reset operations by short press, double press, or long press of a single button, simplifying the operation panel while ensuring full functionality.

[0140] Correspondingly, a fault isolation control method for a multi-mode valve life testing device is also provided, including:

[0141] S1. Set test parameters on the host computer; the test parameters include test mode parameters and valve feedback type parameters;

[0142] S2. The lower-level controller determines the current test mode and the position determination rules of each valve according to the test parameters, and sends control commands to the valve drive module according to the determined data;

[0143] S3. The valve drive module drives multiple valves under test according to the control commands sent by the lower-level controller;

[0144] S4. The signal acquisition module acquires the status signals generated after each valve under test is activated, and outputs the acquired status signals to the lower-level controller.

[0145] S5. The lower-level controller judges the received status signals and counts the number of tests or records the faults.

[0146] Example 2

[0147] The difference between the multi-mode valve life testing device provided in this embodiment and Embodiment 1 is that:

[0148] This embodiment is illustrated with a specific example.

[0149] The lower-level controller uses an STM32 series microcontroller, while the upper-level computer runs a graphical control program. The upper-level computer and the lower-level computer are connected through a communication module to complete parameter setting and status viewing.

[0150] Suppose that 8 valves need to be tested, where valves 1-2 are of the type with no position feedback, valves 3-4 are of the type with only open position feedback, valves 5-6 are of the type with only closed position feedback, and valves 7-8 are of the type with both open and closed position feedback.

[0151] The operator selects the 4-way grouping mode, designating valves 1-4 as the first group and valves 5-8 as the second group; and sets the first preset time to 2 seconds, the second preset time to 2 seconds, the third preset time to 3 seconds, the fourth preset time to 2 seconds, the fifth preset time to 2 seconds, the sixth preset time to 3 seconds, the seventh preset time to 3 seconds, and the eighth preset time to 3 seconds; the waiting time is set to 1 second, and the number of cycles is set to 50.

[0152] After the test begins, the lower-level controller first drives the first group of valves (1-4) to open simultaneously. For valves 1-2 without feedback, the lower-level controller determines that the valve opening is complete after only 2 seconds and records the number of valve openings. For valves 3-4 that are only fully open, the lower-level controller waits for 3 seconds to see if it receives a fully open status signal. For valves 7-8 that are fully closed, the lower-level controller waits for 3 seconds to see if it receives a fully open status signal. Among them, valves 5-6 that are only fully closed do not require a detection signal during the valve opening stage; they are determined to be fully open after only 2 seconds.

[0153] Suppose that during the first valve opening process, valve 3 does not return the fully open status signal within 3 seconds, the lower-level controller records a fault in the opening direction of valve 3, but continues to execute subsequent tests.

[0154] After the valve is opened, wait 1 second, and then drive the first group of valves to close. For valves 1-2 without feedback, determine that the valve is closed after 2 seconds. For valves 3-4 that are only open to the limit, no detection signal is needed during the valve closing stage, and determine that the valve is closed after 2 seconds. For valves 5-6 that are only closed to the limit, wait 3 seconds to see if a closed status signal is received. For valves 7-8 that are both open to the limit, wait 3 seconds to see if a closed status signal is received.

[0155] After the valve is closed, wait for 1 second, and then drive the second group of valves (5-8) to perform the same valve open-wait-valve close-wait cycle.

[0156] This process continues until 50 cycles are completed or a malfunction occurs and the process stops.

[0157] If valve 3 fails three times consecutively in the opening direction, the lower-level controller will mark valve 3 as the faulty valve. In subsequent tests, when it is the turn of the first group of actions, the lower-level controller will only drive valves 1, 2, and 4 to act, automatically skipping valve 3. Other valves will not be affected and will continue to be tested normally.

[0158] Note that the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of the present invention, the scope of which is determined by the scope of the appended claims.

Claims

1. A multi-mode valve life testing device, characterized in that, Includes host computer, slave computer controller, valve drive module, and signal acquisition module; The host computer is used to set test parameters, including test mode parameters and valve feedback type parameters. The lower-level controller, connected to the upper-level controller, is used to determine the current test mode and the position determination rules of each valve based on the test parameters, and to send control commands to the valve drive module based on the determined data. The valve drive module is connected to the lower-level controller and is used to drive multiple valves under test according to the control commands sent by the lower-level controller. The signal acquisition module is connected to the lower-level controller and is used to acquire the status signals generated after each valve under test is activated. The acquired status signals are then output to the lower-level controller so that the lower-level controller can judge the received status signals and count the number of tests or record faults.

2. The multi-mode valve life testing device according to claim 1, characterized in that, The current test mode determined in the lower-level controller includes: single-channel sequential mode, multi-channel group mode, and multi-channel simultaneous mode.

3. The multi-mode valve life testing device according to claim 1, characterized in that, The valve feedback types in the host computer include no position feedback type, only open position feedback type, only closed position feedback type, and both open and closed position feedback type.

4. The multi-mode valve life testing device according to claim 3, characterized in that, The rules for determining the position of each valve in the lower-level controller include: For valve opening phases without feedback, the valve opening phase is completed when the first preset time is reached, and the number of valve openings is recorded. For valve closing phases, the valve closing phase is completed when the second preset time is reached, and the number of valve closings is recorded. For the type of valve opening only feedback, the condition for recording the number of valve openings is that the valve opening state signal is received within the third preset time, and the condition for recording the number of valve closings is that the valve closing time is reached within the fourth preset time. For the type of feedback only for valve closing, the condition for recording the number of valve openings is that the valve opening stage reaches the fifth preset time, and the condition for recording the number of valve closings is that the valve closing status signal is received within the sixth preset time. For the dual-position feedback type of switch, the condition for recording the number of valve opening times is to receive the open position status signal within the seventh preset time period during the valve opening stage, and the condition for recording the number of valve closing times is to receive the closed position status signal within the eighth preset time period during the valve closing stage.

5. The multi-mode valve life testing device according to claim 2, characterized in that, The control commands in the lower-level controller include: For single-path sequential mode, a single valve is treated as a set of action objects. The current set of action objects is selected sequentially according to the valve number, and the test cycle of opening valve, waiting, closing valve, and waiting is executed on the selected set of action objects. For the multi-group mode, multiple valves under test are divided into multiple action object sets according to the preset number of groups. The current action object set is selected in sequence according to the preset order, and the test cycle of valve opening, waiting, valve closing, and waiting is executed on the selected action object set. For the multi-channel simultaneous mode, all valves are treated as a set of action objects, and a test cycle of opening valve, waiting, closing valve, and waiting is performed on this set of action objects.

6. The multi-mode valve life testing device according to claim 2, characterized in that, The lower-level controller is also used for: When the number of consecutive failures of the same valve under test in the same direction of action reaches a preset threshold, the valve under test is marked as a faulty valve and skipped in subsequent tests. If all testable valves are marked as faulty valves in the current test mode, stop the test.

7. The multi-mode valve life testing device according to claim 6, characterized in that, The specific steps by which the lower-level controller skips the faulty valve during subsequent testing include: For single-path sequential mode, skip the number corresponding to the faulty valve and select the next measurable valve as the current action object; In the multi-group mode, only the faulty valve is skipped, and the remaining valves in the action object set where the faulty valve is located continue to be tested. In the multi-channel simultaneous mode, the faulty valve is removed from the set of valves that are simultaneously activated, while the remaining valves continue to perform tests synchronously.

8. The multi-mode valve life testing device according to claim 1, characterized in that, The specific faults recorded in the lower-level controller are as follows: Record the faults according to the direction of action; the direction of action includes the valve opening direction and the valve closing direction.

9. The multi-mode valve life testing device according to claim 1, characterized in that, Also includes: The button module, connected to the lower-level controller, is used to perform operations such as starting the test, pausing the test, fault recovery, and clearing the cumulative count via buttons. The display module, connected to the lower-level controller, is used to display test parameters, the cumulative number of tests for each valve, operating status, pause status, completion status, and fault prompts. The non-volatile memory module connects to the lower-level controller and is used to store test parameters, the cumulative number of tests for each valve, and the fault status of each valve.

10. A fault isolation control method for a multi-mode valve life testing device according to any one of claims 1-9, characterized in that, include: S1. Set test parameters on the host computer; The test parameters include test mode parameters and valve feedback type parameters; S2. The lower-level controller determines the current test mode and the position determination rules of each valve according to the test parameters, and sends control commands to the valve drive module according to the determined data; S3. The valve drive module drives multiple valves under test according to the control commands sent by the lower-level controller; S4. The signal acquisition module acquires the status signals generated after each valve under test is activated, and outputs the acquired status signals to the lower-level controller. S5. The lower-level controller judges the received status signals and counts the number of tests or records the faults.

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