Automatic testing device and testing method for mechanical cut-off valve controller

Abstract

The application relates to an automatic testing device of a mechanical cut-off valve controller, one end of an electromagnetic reversing valve is connected with a gas source, the other end is connected with a rotary air cylinder, the output end of the rotary air cylinder is coaxially connected with a reset joint; the reset joint has an annular internal space, the internal space is provided with right-angle limiting flanges which are separated by 180 DEG, a reset valve rod of the mechanical cut-off valve controller is located in the internal space, in the initial state: the clockwise rotating side is limited by one side of the right-angle limiting flanges; when an overpressure cut-off action is performed: the reset valve rod is rotated counterclockwise by 90 DEG in the internal space and is limited by the other side of the right-angle limiting flanges; when the reset valve rod performs a reset action: the reset valve rod is rotated clockwise by 90 DEG through the right-angle limiting flanges, and the reset valve rod is reset; when the reset joint performs a reset action: the electromagnetic reversing valve performs reversing, the rotary air cylinder drives the reset joint to rotate clockwise by 90 DEG to return to the initial state; and a control module serves as a control center.

Description

Technical Field

[0001] This invention relates to an automated testing device and method for a mechanical shut-off valve controller, belonging to the field of gas transmission and distribution technology. Background Technology

[0002] In gas transmission and distribution systems, indirect-acting shut-off valves can accurately sense changes in downstream pressure through a controller. When the downstream pressure exceeds the shut-off pressure setting, the controller activates the actuator to quickly close the shut-off valve, thereby protecting the gas circuit and ensuring gas safety.

[0003] Mechanical shut-off valve controllers, as a type of indirect-acting shut-off valve controller, do not rely on pneumatic control for their function, thus eliminating the need for venting to the atmosphere during operation and offering enhanced safety. Furthermore, they do not require pneumatic actuators, resulting in a compact structure and high expandability. However, due to the higher difficulty in manufacturing parts and the complexity of assembly processes, higher requirements are placed on performance testing (such as life testing) and quality control.

[0004] Traditional mechanical shut-off valve controller performance testing primarily relies on manual methods. This involves manually adjusting the pressure to shut off the valve, then manually rotating the valve stem to reset it. This process typically requires manual resetting every 15-30 seconds, and the entire performance test (e.g., lifespan testing) can require hundreds or even thousands of resetting operations (interrupted). Therefore, lifespan testing and high / low temperature performance testing demand significant manpower and time, resulting in low efficiency.

[0005] Furthermore, the performance testing of mechanical shut-off valve controllers has operating condition requirements. They generally need to be placed in a high and low temperature chamber with a temperature range of -20℃ to 60℃. The reset operation requires a person to enter the high and low temperature chamber, so it is generally necessary to wait for the ambient temperature to drop to a level that is tolerable for a person before the reset operation can be performed, which further leads to low efficiency.

[0006] It should be noted that manual testing also has its advantages. The advantages are strong controllability, the ability to promptly identify problems during the testing process and implement interruptions and adjustments, such as: excessive resistance or even jamming during reset: a manual twist can determine the amount of force required, and if it cannot be turned, the machine should be stopped immediately for inspection; failure to operate after a timeout: manual testing can detect abnormalities immediately; incorrect positioning, false reset, false cut-off: manual testing may be able to detect these with the naked eye and make immediate adjustments to avoid misoperation and test failure.

[0007] However, as mentioned above, manual testing requires a lot of manpower and time, is inefficient, and has high labor costs.

[0008] Therefore, in the actual production and debugging process of mechanical shut-off valve controllers, there is an urgent need to develop an automated testing device that can not only replace manual operation of shut-off / reset, but also identify possible excessive opening resistance and jamming during the testing process, protect the testing device in time, and provide alarm prompts. Summary of the Invention

[0009] The purpose of this invention is to provide an automated testing device and method for mechanical shut-off valve controllers, thereby solving the technical problems mentioned in the background section.

[0010] The present invention adopts the following technical solution:

[0011] An automated testing device for a mechanical shut-off valve controller includes an electro-proportional valve 1, a solenoid directional valve 6, a rotary cylinder 7, a reset connector 9, and a control module. One end of the electro-proportional valve 1 is connected to an air source, and the other end is connected to the balance chamber 3 of the mechanical shut-off valve controller 2. One end of the solenoid directional valve 6 is connected to an air source, and the other end is connected to the rotary cylinder 7. The output end of the rotary cylinder 7 is coaxially connected to the reset connector 9. The reset connector 9 has an annular internal space, within which right-angle limiting flanges spaced 180° apart are provided. The reset valve stem 5 of the mechanical shut-off valve controller is designed as a rectangular structure and is located within the internal space. In the initial state: the clockwise rotation side is stopped by one side of the right-angle limiting flange; when performing the overpressure cut-off action: the clockwise rotation is stopped by the other side of the right-angle limiting flange within the internal space; when the reset valve stem performs the reset action: the right-angle limiting flange drives the reset valve stem 5 to rotate 90° clockwise, thus resetting the reset valve stem 5; when the reset connector performs the reset action: the solenoid directional valve 6 performs the reversing action, and the rotary cylinder 7 drives the reset connector 9 to rotate 90° clockwise back to the initial state. During this process, the reset valve stem 5 does not move; the control module serves as the control center and is connected to the electro-proportional valve 1 and the solenoid directional valve 6 via signal.

[0012] Preferably, the system also includes a torsion sensor 8 and a position sensor 10, both of which are signal-connected to the control module. The torsion sensor 8 is located between the reset connector 9 and the rotary cylinder 7, and is used to monitor the real-time rotational resistance torque when the rotary cylinder drives the reset connector 9 to rotate the controller reset valve rod 5 to reset. This torque serves as a prerequisite for the control module to indicate the next operation. If an abnormality occurs, the control module will determine the abnormality and output a prompt. The position sensor 10 corresponds to the reset valve rod 5 and can monitor whether the reset valve rod 5 has rotated to the correct position. This position sensor serves as a prerequisite for the control module to indicate the next operation. If an abnormality occurs, the control module will determine the abnormality and output a prompt.

[0013] Preferably, the position sensor 10 is one of an inductive proximity switch, a photoelectric sensor, a Hall sensor, a magnetic sensor, a micro switch, or an angle sensor.

[0014] Furthermore, the electric proportional valve 1 is equipped with a pressure sensor, which adjusts the proportional opening by monitoring the pressure at the downstream end.

[0015] Furthermore, it also includes a time relay, which is used to determine if the reset valve stem 5 and / or reset connector 9 fail to operate within a timeout period, and the control module performs fault determination.

[0016] A test method for an automated test device for the above-mentioned mechanical shut-off valve controller.

[0017] The overpressure cutoff / reset test includes the following steps:

[0018] S1. Control the electric proportional valve 1 to slowly increase the air pressure entering the controller balance chamber 3 until it exceeds the set value, triggering the hook mechanism 4 to disengage. The controller reset valve rod 5 will rotate 90° counterclockwise under the action of internal torque to reach the overpressure cut-off state.

[0019] S2. Position sensor 10 detects reset valve rod 5 and, after completing the action, feeds back to the control module, controlling the electrical proportional valve to reduce the pressure to the normal operating pressure. When the pressure stabilizes at the normal operating value, it controls the solenoid reversing valve 6 to switch the air path, and the rotary cylinder rotates 90° clockwise. At this time, the limiting flange inside the reset connector 9 contacts the reset valve rod 5, causing it to rotate clockwise together. The hook mechanism 4 can overcome the internal torque and re-hook, completing the reset.

[0020] S3. When the position sensor 10 detects that the controller reset valve 5 has completed its operation, it feeds back to the control module, controls the solenoid reversing valve 6 to switch the air circuit back to the initial state, and the rotary cylinder 7 will drive the reset connector 9 to rotate 90° counterclockwise to return to the initial phase. During the entire process of steps S1-S3, if the torque sensor 8 or the position sensor 10 reports an abnormality, it can automatically stop and alarm to prompt manual intervention.

[0021] Preferably, the count is incremented by 1 when the overpressure cut-off / reset process completes one cycle. There are two ways to determine the completion of the test: First, the test is completed after the preset number of times is completed; Second, a fault occurs before the preset number of times is completed and the fault is confirmed to be caused by damage to the components inside the mechanical shut-off valve controller.

[0022] Preferably, the torque sensor 8, position sensor 10 and time relay are used to determine whether the mechanical controller under test is abnormal through logic, and provide fault identification, device protection and alarm prompts.

[0023] The beneficial effects of this invention are as follows:

[0024] 1) An electromagnetic reversing valve 6 was designed to provide the rotary cylinder 7 with the power to rotate in both directions and control the reset valve rod 5 to reset, which can reduce the labor intensity of the operator; the operator does not need to enter the high and low temperature chamber or wait for the ambient temperature to cool down, which greatly improves the efficiency of the test.

[0025] 2) By utilizing torque sensor 8, position sensor 10, and time relay, the mechanical controller can be individually determined to be faulty, or a composite logic can be used to determine whether the tested mechanical controller is faulty. This enables fault identification, device protection, and alarm notification.

[0026] 3) During performance testing, if an anomaly occurs, the fault scene can be preserved immediately, just like in manual operation, to better identify the specific problem. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of the automated testing device for the mechanical shut-off valve controller of the present invention.

[0028] Figure 2 This is a schematic diagram of the reset mechanism.

[0029] Figure 3 This is a logic block diagram of the test method for the automated test device of the mechanical shut-off valve controller of the present invention.

[0030] In the diagram, 1. Electrical proportional valve, 2. Mechanical shut-off valve controller (product under test), 3. Balance chamber, 4. Hook mechanism, 5. Controller reset valve stem, 6. Solenoid directional valve, 7. Rotary cylinder, 8. Torsion sensor, 9. Reset connector, 10. Position sensor.

[0031] Among them, the balance chamber 3, the hook mechanism 4, and the reset valve stem 5 are components of the mechanical cut-off controller. Detailed Implementation

[0032] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0033] First, let's introduce the background of performance testing (life testing) for mechanical shut-off valve controllers:

[0034] Mechanical shut-off valve controllers are typically designed for a lifespan of a few hundred resets (less than 1000). Therefore, during lifespan testing, failures usually occur after a few hundred to a thousand resets. This testing helps identify the location of the failure, pinpointing weaknesses in the mechanical shut-off valve controller design, and allowing for improvements. Thus, performance testing of mechanical shut-off valve controllers is a crucial step in the product design process.

[0035] The structure of the automated testing device for the mechanical shut-off valve controller of the present invention will be described below:

[0036] Electrical components are controlled by a control module. The proportional valve 1 controls the air pressure entering the controller's balance chamber 3 to simulate overpressure and normal operating conditions.

[0037] See Figure 1 In the figure, the mechanical shut-off valve controller 2 is the product to be tested, which includes a balance chamber 3, a hook mechanism 4, and a reset valve stem 5. Therefore, this part does not constitute the component of the automated testing device for the mechanical shut-off valve controller of the present invention, but the structure and function of the present invention are closely related to it.

[0038] One end of the reset connector 9 is connected to the torque sensor 8, which is mounted on the rotary cylinder 7, and the other end is fitted onto the controller reset valve stem 5. The rotary cylinder 7 is controlled to rotate forward and backward by the solenoid reversing valve 6, so as to achieve the effect of resetting the controller reset valve stem 5. The specific explanation is as follows:

[0039] See Figure 1 An automated testing device for a mechanical shut-off valve controller includes an electro-proportional valve 1, a solenoid directional valve 6, a rotary cylinder 7, a reset connector 9, and a control module.

[0040] One end of the electric proportional valve 1 is connected to an air source, and the other end is connected to the balance chamber 3 of the mechanical shut-off valve controller 2.

[0041] One end of the electromagnetic reversing valve 6 is connected to an air source, and the other end is connected to a rotary cylinder 7. The output end of the rotary cylinder 7 is coaxially connected to the reset connector 9 (not shown in the attached figure).

[0042] See Figure 2 The reset connector 9 has an annular internal space, within which right-angle limiting flanges spaced 180° apart are provided. The reset valve stem 5 of the mechanical shut-off valve controller is designed as a rectangular structure and is located within the internal space.

[0043] In the initial state: the clockwise rotating side is stopped by one side of the right-angle limiting flange; see Figure 1 The "initial state" on the left side of the middle;

[0044] When performing the overpressure cut-off action: it rotates 90° counterclockwise within the internal space and is stopped by the other side of the right-angle limiting flange; see Figure 1 The "overpressure cutoff state" in the text;

[0045] When the reset valve stem performs the reset action: it drives the reset valve stem 5 to rotate 90° clockwise via the right-angle limiting flange, thereby resetting the reset valve stem 5; see Figure 1 The "reset valve stem reset state" in the text;

[0046] When the reset connector performs the reset action: the solenoid directional valve 6 performs the reversing action, and the rotary cylinder 7 drives the reset connector 9 to rotate 90° clockwise to return to the initial state. During this process, the reset valve stem 5 does not move; see Figure 1 The "initial state" on the right side;

[0047] The control module serves as the control center and is connected to the electro-proportional valve 1 and the solenoid directional valve 6 via signal connections.

[0048] In this embodiment, see Figure 1 It also includes a torsion sensor 8 and a position sensor 10, both of which are also signal-connected to the control module.

[0049] The torsion sensor 8 is installed between the reset connector 9 and the rotary cylinder 7. It is used to monitor the real-time rotational resistance torque when the rotary cylinder drives the reset connector 9 to rotate and reset the controller reset valve rod 5. This serves as a prerequisite for the control module to indicate the next operation. When an abnormality occurs, the control module determines the abnormality and outputs a prompt.

[0050] The position sensor 10 corresponds to the reset valve stem 5 and can monitor whether the reset valve stem 5 has rotated into place. This serves as a prerequisite for the control module to indicate the next operation. When an abnormality occurs, the control module determines the abnormality and outputs a prompt.

[0051] In this embodiment, the position sensor 10 is one of an inductive proximity switch, a photoelectric sensor, a Hall sensor, a magnetic sensor, a micro switch, and an angle sensor.

[0052] In this embodiment, the electro-proportional valve 1 is equipped with a pressure sensor, which adjusts the proportional opening by monitoring the pressure at the downstream end.

[0053] In this embodiment, a time relay is also included, which is used to determine whether the reset valve stem 5 and / or the reset connector 9 fails to operate after a timeout, and the control module performs fault determination.

[0054] Combination Figure 1-3 The test method for the automated test device of the aforementioned mechanical shut-off valve controller.

[0055] The overpressure cutoff / reset test includes the following steps:

[0056] S1. The control electric proportional valve 1 slowly increases the air pressure entering the controller's balance chamber 3 until it exceeds the set value, triggering the hook mechanism 4 to disengage. The controller's reset valve stem 5 will then rotate 90° counterclockwise under internal torque, reaching the overpressure cut-off state. Figure 2 From the "initial state" on the left to the "overpressure cutoff state" in the middle;

[0057] S2, Position sensor 10 detects reset valve stem 5, and after the action is completed, it feeds back to the control module, controlling the electrical proportional valve 1 to reduce the pressure to the normal operating pressure; at this time, the air circuit connecting the electrical reversing valve 6 and the rotary cylinder 7 is... Figure 1 The same as shown, see Figure 1 The symbols P, A, and B in the text represent... Figure 2 "Overpressure switching status" in the text;

[0058] Once the pressure stabilizes at the normal operating value, control the solenoid directional valve 6 to switch the air path. Figure 1 P in the diagram detaches from A and connects to B (not shown in the attached diagram). The rotary cylinder rotates 90° clockwise. At this time, the limiting flange inside the reset connector 9 contacts the reset valve stem 5, causing it to rotate clockwise as well. The hook mechanism 4 overcomes the internal torque and re-engages, completing the reset. Figure 2 The "reset valve stem reset state" in the text;

[0059] S3. When the position sensor 10 detects that the controller reset valve 5 has completed its operation, it sends feedback to the control module, which then controls the solenoid reversing valve 6 to switch the air path back to its initial state. The rotary cylinder 7 will then drive the reset connector 9 to rotate 90° counterclockwise back to the initial phase. Figure 2 The "initial state" is on the right side of the middle.

[0060] Throughout steps S1-S3, if the torque sensor 8 or position sensor 10 reports an abnormality, the system will automatically stop and issue an alarm to prompt manual intervention. It should be noted that during performance testing, after an abnormality occurs, the fault scene can be preserved immediately, just as with manual operation, to better identify the specific problem.

[0061] The count increments by 1 when the overpressure cut-off / reset process completes one cycle. There are two ways to determine the completion of the test: First, the test is completed after the preset number of cycles; second, a fault occurs before the preset number of cycles is completed and the fault is confirmed to be caused by damage to a component inside the mechanical shut-off valve controller.

[0062] The torque sensor 8, position sensor 10, and time relay are used to determine whether the mechanical controller under test is abnormal through logic, and provide fault identification, device protection, and alarm prompts.

[0063] The above are preferred embodiments of the present invention. Those skilled in the art can make various modifications or improvements based on these embodiments. Without departing from the overall concept of the present invention, all such modifications or improvements should fall within the scope of protection claimed by the present invention.

Claims

1. An automated testing device for a mechanical shut-off valve controller, characterized in that: Includes an electric proportional valve (1), a solenoid directional valve (6), a rotary cylinder (7), a reset connector (9), and a control module; The electric proportional valve (1) is connected to a gas source at one end and to the balance chamber (3) of the mechanical shut-off valve controller (2) at the other end. The electromagnetic reversing valve (6) is connected to a gas source at one end and to a rotary cylinder (7) at the other end. The output end of the rotary cylinder (7) is coaxially connected to the reset connector (9). The reset connector (9) has an annular internal space, within which right-angle limiting flanges spaced 180° apart are provided. The reset valve stem (5) of the mechanical shut-off valve controller is designed as a rectangular structure and is located within the internal space. In the initial state: the clockwise rotating side is stopped by one side of the right-angle limiting flange; When performing the overpressure cut-off action: it rotates counterclockwise 90° within the internal space and is stopped by the other side of the right-angle limiting flange; When the reset valve stem performs the reset action: the right-angle limiting flange drives the reset valve stem (5) to rotate 90° clockwise, thereby resetting the reset valve stem (5); When the reset connector performs the reset action: the solenoid reversing valve (6) performs the reversing action, and the rotary cylinder (7) drives the reset connector (9) to rotate 90° clockwise to return to the initial state. During this process, the reset valve stem (5) does not move. The control module serves as the control center and is connected to the electric proportional valve (1) and the solenoid directional valve (6) via signals.

2. The automated testing device for the mechanical shut-off valve controller as described in claim 1, characterized in that: It also includes a torsion sensor (8) and a position sensor (10), both of which are also signal-connected to the control module; The torsion sensor (8) is set between the reset connector (9) and the rotary cylinder (7) to monitor the real-time rotational resistance torque when the rotary cylinder drives the reset connector (9) to rotate and reset the controller reset valve rod (5). This serves as a prerequisite for the control module to indicate the next operation. When an abnormality occurs, the control module determines the abnormality and outputs a prompt. The position sensor (10) corresponds to the reset valve stem (5) and can monitor whether the reset valve stem (5) has rotated into place. This serves as a prerequisite for the control module to indicate the next operation. When an abnormality occurs, the control module will determine the abnormality and output a prompt.

3. The automated testing device for the mechanical shut-off valve controller as described in claim 2, characterized in that: The position sensor (10) is one of the following: inductive proximity switch, photoelectric sensor, Hall sensor, magnetic sensor, micro switch, and angle sensor.

4. The automated testing device for the mechanical shut-off valve controller as described in claim 1 or 2, characterized in that: The electric proportional valve (1) is equipped with a pressure sensor and adjusts the proportional opening by monitoring the pressure at the back end.

5. The automated testing device for the mechanical shut-off valve controller as described in claim 1 or 2, characterized in that: It also includes a time relay, which is used to determine if the reset valve stem (5) and / or reset connector (9) fail to operate after a timeout, and the control module makes a fault determination.

6. A test method for an automated test apparatus for a mechanical shut-off valve controller as described in any one of claims 2-5, characterized in that, The overpressure cutoff / reset test includes the following steps: S1. Control the electric proportional valve (1) to slowly increase the air pressure entering the controller balance chamber (3) until it exceeds the set value, trigger the hook mechanism (4) to disengage, and the controller reset valve rod (5) will rotate 90° counterclockwise under the action of internal torque to reach the overpressure cut-off state. S2. The position sensor (10) detects the reset valve rod (5). After the action is completed, it feeds back to the control module and controls the electrical proportional valve to reduce the pressure to the normal operating pressure. When the pressure stabilizes at the normal operating value, the electromagnetic reversing valve (6) switches the air path and the rotary cylinder rotates 90° clockwise. At this time, the limiting flange inside the reset connector (9) contacts the reset valve rod (5) and drives it to rotate clockwise together. The hook mechanism (4) can overcome the internal torque and re-hook, completing the reset. S3. When the position sensor (10) detects again that the controller reset valve rod (5) has completed its action, it feeds back to the control module and controls the solenoid reversing valve (6) to switch the air circuit back to the initial state. The rotary cylinder (7) will drive the reset connector (9) to rotate 90° counterclockwise back to the initial phase. During the entire process of steps S1-S3, if the torque sensor (8) or position sensor (10) reports an abnormality, the system can automatically stop and issue an alarm to prompt manual intervention.

7. The test method for the automated test device of the mechanical shut-off valve controller as described in claim 6, characterized in that: The count increments by 1 when the overpressure cut-off / reset process completes one cycle. There are two ways to determine the completion of the test: First, the test is completed after the preset number of cycles; second, a fault occurs before the preset number of cycles is completed and the fault is confirmed to be caused by damage to a component inside the mechanical shut-off valve controller.

8. The test method for the automated test device of the mechanical shut-off valve controller as described in claim 6, characterized in that: Using a torque sensor (8), a position sensor (10), and a time relay, logic is used to determine whether the mechanical controller under test is abnormal, and to provide fault identification, device protection, and alarm prompts.

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