Passive and wireless manual valve opening degree sensor and opening degree monitoring system

Abstract

The utility model relates to the technical field of pipeline valve monitoring, and discloses a passive wireless manual valve opening degree sensor and an opening degree monitoring system, which comprise a shell, a main control chip, a communication transmission unit, a nine-axis sensor and a low-power-consumption power supply management unit, and are characterized in that the shell is internally provided with a power supply module; the processor is connected with the communication transmission unit, the nine-axis sensor unit, the low-power-consumption power management unit and the power supply module; the communication transmission unit comprises a wireless communication module, and the wireless communication module is electrically connected with the main control center. By installing a passive wireless valve opening degree sensor, opening degree monitoring of each stock manual valve is achieved. The intelligent transformation of the manual valve can be realized by adopting a convenient and fast installation mode. Meanwhile, operation authority authorization management of the manual valve is achieved, and the use safety of the manual valve is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of pipeline valve monitoring, in particular to a passive wireless manual valve opening sensor and a manual valve opening monitoring system. Background Art

[0002] Manual valves are control components in pipeline fluid delivery systems. They are used to change the cross-section of the passage and the flow direction of the medium. They have functions such as diversion, cut-off, regulation, throttling, check, diversion or overflow pressure relief.

[0003] In existing technologies, manual valves lack the precise control of valve opening and the ability to monitor rotation via remote signal transmission, unlike electric valves. Furthermore, electric valves are much more expensive than manual valves, and most require wiring and electrical connections for proper operation, resulting in high construction costs and difficult maintenance. Converting existing manual valves to electric valves is virtually impossible due to the need to shut down production. Furthermore, the cost of replacing manual valves with electric valves in bulk is also very high.

[0004] However, manual valves are currently typically operated manually, requiring manual counting to calculate the valve's overall opening. When dealing with large valves that rotate hundreds or even thousands of times, manual counting is prone to errors and can result in significant inaccuracies. Furthermore, manual valves lack monitoring to prevent illegal operation, allowing any outsider to operate them and making subsequent accountability difficult. After a production accident, manually opening and closing the valve requires searching manually recorded opening records and locating the precise valve position. This difficult and slow process can delay emergency response, resulting in significant losses for the company or factory. Utility Model Content

[0005] In order to overcome the above-mentioned technical problems existing in the prior art, the embodiment of the present invention provides a passive wireless valve opening sensor and an opening monitoring system. By installing a passive wireless valve opening sensor on a manual valve, the opening and closing angles of the manual valve can be accurately managed, the operation authority authorization management and the location information can be centrally managed.

[0006] In order to achieve the above-mentioned purpose, an embodiment of the utility model provides a passive wireless manual valve opening sensor, including a shell, a main control chip, a communication transmission unit, a nine-axis sensor and a low-power power management unit, and a power supply module is arranged in the shell: the main control chip includes a microcontroller, which is connected to the communication transmission unit, the nine-axis sensor, the low-power power management unit and the power supply module; the communication transmission unit includes a wireless communication module, and the wireless communication module is electrically connected to the main control center.

[0007] Preferably, the passive wireless manual valve opening sensor further includes a positioning unit connected to the main control chip.

[0008] Preferably, the positioning unit is a Beidou positioning module or a GPS module.

[0009] Preferably, the passive wireless manual valve opening sensor also includes a photovoltaic conversion unit, which is arranged on the top of the shell and faces the sky. The photovoltaic conversion unit is connected to the power supply module, and a current reverse cutoff diode is arranged between the photovoltaic conversion unit and the power supply module.

[0010] Preferably, the low-power power management unit includes: a low-power power management chip, a power supply timing circuit, a first switch connected to the power supply circuit of the communication transmission unit, and a second switch connected to the positioning unit; the main control chip is connected to the low-power power management chip, the low-power power management chip is connected to the power supply timing circuit, and the power supply timing circuit is respectively connected to the first switch and the second switch.

[0011] Preferably, the wireless communication module is a 4G cat1 module.

[0012] Preferably, the passive wireless manual valve opening sensor also includes an anti-theft cable, which has a fixed resistance. A first interface connected to the power supply module and a second interface connected to the main control chip are provided on the shell. One end of the anti-theft cable is detachably connected to the first interface, and the other end is detachably connected to the second interface.

[0013] Preferably, the anti-theft cable is tightly wound around the manual valve when connected to the housing.

[0014] Preferably, an identification code is provided on the outer surface of the shell, and the identification code includes a unique identity recognition code corresponding to the passive wireless manual valve opening sensor.

[0015] Furthermore, an embodiment of the present invention provides a manual valve opening monitoring system, including a manual valve, wherein the manual valve opening monitoring system includes the passive wireless manual valve opening sensor described in the embodiment of the present invention, and the passive wireless manual valve opening sensor is bolted to the manual valve.

[0016] Through the technical solution provided by the utility model, the utility model has at least the following technical effects:

[0017] By installing the passive wireless valve opening sensor in this utility model, electrical and grid connection installation is eliminated, eliminating the need for modification of existing manual valves. This convenient and fast installation method allows for intelligent transformation of manual valves. This allows for authorized management of manual valve operation permissions, precise management of manual valve opening and closing angles, and centralized management of manual valve position information, effectively and cost-effectively resolving some of the drawbacks of existing manual valves.

[0018] Other features and advantages of the embodiments of the present invention will be described in detail in the subsequent detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The accompanying drawings are used to provide a further understanding of the embodiments of the present invention and constitute a part of the specification. Together with the following detailed description, they are used to explain the embodiments of the present invention, but do not constitute a limitation of the embodiments of the present invention. In the accompanying drawings:

[0020] Figure 1 This is a schematic structural diagram of a passive wireless manual valve opening sensor provided by an embodiment of the present utility model;

[0021] Figure 2 This is a schematic diagram of the circuit structure of a low-power power management unit provided by an embodiment of the present utility model;

[0022] Figure 3 This is a schematic diagram of the circuit structure of the anti-theft unit provided by an embodiment of the utility model;

[0023] Figure 4 This is a schematic diagram of the structure of a low-power power management unit provided by an embodiment of the present utility model;

[0024] Figure 5 This is a schematic structural diagram of a passive wireless manual valve opening sensor provided in the second embodiment of the present utility model.

[0025] Description of reference numerals:

[0026] Shell 1, main control chip 11, microcontroller 111, first interface 112, second interface 113, communication transmission unit 12, wireless communication module 121, nine-axis sensor 13, low-power power management unit 14, low-power power management chip 141, power supply timing circuit 142, first switch 143, second switch 144, power supply module 15, positioning unit 2, photovoltaic conversion unit 3, current reverse cut-off diode 31, anti-theft cable 4. DETAILED DESCRIPTION

[0027] The following describes the specific implementation of the embodiment of the present invention in detail with reference to the accompanying drawings. It should be understood that the specific implementation described herein is only used to illustrate and explain the embodiment of the present invention and is not intended to limit the embodiment of the present invention.

[0028] The terms "system" and "network" in the embodiments of the present invention can be used interchangeably. "Multiple" refers to two or more. In view of this, "multiple" can also be understood as "at least two" in the embodiments of the present invention. "And / or" describes the association relationship of associated objects, indicating that three relationships can exist. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the character " / ", unless otherwise specified, generally indicates that the previous and next associated objects are in an "or" relationship. In addition, it should be understood that in the description of the embodiments of the present invention, words such as "first" and "second" are only used to distinguish the purpose of description, and cannot be understood as indicating or implying relative importance, nor can they be understood as indicating or implying order.

[0029] See Figure 1 An embodiment of the utility model provides a passive wireless manual valve opening sensor, comprising a shell 1, a main control chip 11, a communication transmission unit 12, a nine-axis sensor 13 and a low-power power management unit 14, and a power supply module 15 is provided in the shell 1: the main control chip 11 includes a microcontroller 111, which is connected to the communication transmission unit 12, the nine-axis sensor 13, the low-power power management unit 14 and the power supply module 15; the communication transmission unit 12 includes a wireless communication module 121, and the wireless communication module 121 is electrically connected to the main control center.

[0030] In one possible implementation, to enable manual valve opening monitoring without replacing the manual valve, a passive, wireless manual valve opening sensor (hereinafter referred to as the opening sensor) is installed on the existing manual valve. Specifically, the microcontroller 111 serves as the core processing unit of the opening sensor. A technician can pre-program a control program into it to process the opening sensor data and control other units. The wireless communication module 121 wirelessly transmits all data from the opening sensor to a remote control center. The nine-axis sensor 13 detects valve acceleration and other data and transmits it to the main control chip 11, which determines the opening of the manual valve using a pre-programmed existing calculation algorithm. The low-power power management unit 14 implements intelligent, low-power management of the opening sensor through hardware circuit design. The power supply module 15 of this utility model adopts a passive design, including but not limited to energy harvesting technologies (such as solar panels and vibration energy harvesters) and energy storage devices (such as supercapacitors or rechargeable batteries).

[0031] During use, the nine-axis sensor 13 includes a three-axis accelerometer, a three-axis gyroscope, and a three-axis magnetometer, which are used to read corresponding acceleration or magnetic data to monitor the angle of rotation of the manual valve. When the valve is manually operated, the nine-axis sensor 13 sends the detected data to the microcontroller 111. After obtaining the sensor data, the microcontroller 111 uses existing algorithms to calculate the sensor data and calculate the cumulative rotation angle of any plane. Therefore, it can be used to calculate the opening of the valve plane at various installation angles. In the present invention, the angle calculation range is not limited to 0-360°, but can be calculated for a nearly infinite number of turns according to actual conditions. The actual number of turns calculated may reach thousands of turns, and the rotation angle statistics can reach hundreds of millions of degrees, which can more accurately quantify the opening of valves with a large number of turns.

[0032] Furthermore, the microcontroller 111 transmits valve opening data to the main control center via the wireless communication module 121 to monitor the opening of the manual valve. When the nine-axis sensor 13 is stationary or within a set angle range, the main control chip 11 automatically enters sleep mode. In this mode, the low-power power management unit 14 automatically disconnects the power supply circuits of the positioning unit 2 and the communication transmission unit 12, thereby reducing power consumption and improving the system's energy efficiency and battery life.

[0033] See Figure 2 In an embodiment of the present utility model, the passive wireless manual valve opening sensor further includes a positioning unit 2 connected to the main control chip 11 .

[0034] Preferably, the positioning unit 2 is a Beidou positioning module or a GPS module.

[0035] Preferably, the wireless communication module 121 is a 4G cat1 module.

[0036] In one possible implementation, positioning unit 2 can utilize a Beidou positioning module or a GPS module, depending on the actual situation. Specifically, positioning unit 2 is a built-in positioning chip within the present invention, which enables the acquisition of the position coordinates of the travel sensor and their display on a map on the software platform. Specifically, after installing a travel sensor on a manual valve, the travel sensor can be linked to obtain precise position coordinates, providing support for valve operation management and accident emergency response.

[0037] The wireless communication module 121 is responsible for the interaction of sensor data, mainly referring to uploading all data of the opening sensor itself to the control center software platform, and the software platform issuing sensor control or configuration instructions. The 4G cat1 module provides lower power consumption and cost. The maximum data rate of the 4G cat1 module is 10 Mbps downlink and 10 Mbps uplink, which is sufficient to meet the needs of opening sensor data transmission and device control. Secondly, the 4G cat1 module has a wide network coverage and can maintain a stable connection at a farther distance. Compared with the 2G network, it provides higher transmission speeds and more reliable connections. Due to its long battery life and low power consumption, the device can operate for a long time without frequent battery replacement. The 4G cat1 module provides a good balance between cost-effectiveness and performance, and is suitable for application scenarios that do not have high bandwidth requirements but require long-term stable connections.

[0038] See Figure 3 In an embodiment of the utility model, the passive wireless manual valve opening sensor also includes a photovoltaic conversion unit 3, which is arranged on the top of the shell 1 and faces the sky. The photovoltaic conversion unit 3 is connected to the power supply module 15, and a current reverse cutoff diode 31 is arranged between the photovoltaic conversion unit 3 and the power supply module 15.

[0039] In one possible embodiment, a photovoltaic conversion unit 3, such as an ultra-small solar panel, is designed on the top of the housing 1. This unit faces the sky to maximize solar energy collection. The photovoltaic conversion unit 3 is connected to the power supply module 15 via wires, ensuring that the collected solar energy is effectively converted and stored into electrical energy. A reverse current blocking diode 31 is provided between the photovoltaic conversion unit 3 and the power supply module 15 to prevent reverse current flow and damage to the solar panel, thereby protecting the circuit safety.

[0040] The power supply module 15 is, for example, a built-in lithium battery with a capacity of 6000Ah. Combined with the battery life of the solar panel, it can significantly extend the operating time of the device. Thanks to the continuous power provided by the solar panel and the low power consumption design of the entire device, the overall operating time of the opening sensor can reach more than 2 years. This design not only improves the endurance of the device, but also significantly reduces maintenance requirements and reduces dependence on external power sources.

[0041] See Figure 4In an embodiment of the utility model, the low-power power management unit 14 includes: a low-power power management chip 141, a power supply timing circuit 142, a first switch 143 connected to the power supply circuit of the communication transmission unit 12, and a third switch 144 connected to the positioning unit 2; the main control chip 11 is connected to the low-power power management chip 141, the low-power power management chip 141 is connected to the power supply timing circuit 142, and the power supply timing circuit 142 is respectively connected to the first switch 143 and the second switch 144.

[0042] In one possible embodiment, the low-power power management chip 141 is responsible for monitoring and regulating the power supply of each module in the opening sensor to ensure the efficient use and distribution of energy. The power supply timing circuit 142 is used to control the power supply timing distribution of the power supply module 15 to ensure that power is gradually supplied to each module such as the communication transmission unit 12 and the positioning unit 2 at the appropriate time. The first switch 143 and the second switch 144 respectively control the power supply to the power supply circuit for the communication transmission unit 12 and the power supply circuit for the positioning unit 2. In actual application, when the opening sensor is in low-power mode due to being stationary for a certain period of time, the main control chip 11 enters sleep mode. At this time, the low-power power management chip 141 will turn off the power of non-critical modules, such as disconnecting the power of all modules except the nine-axis sensor 13, to reduce energy consumption.

[0043] During use, the nine-axis sensor 13 responds to manual valve operation. Upon detecting a manual valve operation (open or close), it outputs a corresponding level signal to the main control chip 11, waking it up. This activates the power connections for the other modules, enabling automatic start / stop technology for the communication transmission unit 12 and the Beidou positioning unit 2. When the nine-axis sensor 13 remains inactive for a certain period of time, the main control chip 11 automatically enters sleep mode again, and the low-power power management chip 141 automatically switches to low-power mode. The hardware disconnects the power to the aforementioned modules, significantly reducing overall system power consumption.

[0044] See Figure 5 In an embodiment of the utility model, the passive wireless manual valve opening sensor also includes an anti-theft cable 4, the anti-theft cable 4 has a fixed resistor, and a first interface 112 connected to the power supply module 15 and a second interface 113 connected to the main control chip 11 are provided on the shell 1. One end of the anti-theft cable 4 is detachably connected to the first interface 112, and the other end is detachably connected to the second interface 113.

[0045] Preferably, the anti-theft cable 4 is tightly wound around the manual valve when connected to the housing 1 .

[0046] In one possible implementation, the travel sensor is further configured with a thin, flexible cable with a fixed resistance value, serving as an anti-theft cable 4. To prevent the sensor from being removed, disassembled, or stolen, in addition to securing it with screws and nuts during installation, the anti-theft cable 4 is also wrapped around the valve handwheel or valve body, creating a physical locking mechanism to prevent unauthorized removal. During use, if the travel sensor is illegally moved or disassembled, the main control chip 11 will immediately detect the voltage change and generate a corresponding alarm, enhancing device security.

[0047] In the embodiment of the present utility model, an identification code (not shown) is provided on the outer surface of the housing 1 , and the identification code includes a unique identity recognition code corresponding to the passive wireless manual valve opening sensor.

[0048] The unique identification code of each valve opening sensor is used to authorize and manage the actions of each manual valve in the master control center. When manual valve operation is required in subsequent production management, the unique identification code must first be scanned through a mobile terminal and the master control center must be requested to unlock the manual valve. After the manual valve verifies the information on the mobile terminal and confirms that it is correct, the manual valve is unlocked and authorized for manual operation. At this time, the operator operates the valve. After the operation is completed, the valve opening sensor automatically uploads the data and automatically enters low-power mode. After the upload is completed, the manual valve is relocked after the mobile phone app or platform confirms the completion of the operation.

[0049] On the other hand, in an embodiment of the present invention, the manual valve opening monitoring system includes the passive wireless manual valve opening sensor according to the embodiment of the present invention, and the passive wireless manual valve opening sensor is bolted to the manual valve;

[0050] In one possible implementation, the passive wireless valve opening sensor provided in the embodiment of the present invention is installed on all manual valves. The opening sensor can be directly mounted to the valve turntable or handle using a screw hose clamp, or indirectly mounted using a simple, low-cost intermediate connector such as screws and a hose clamp. All passive wireless valve opening sensors are managed by a main control center to form an opening monitoring system that performs real-time online management of all manual valves, thereby greatly improving the operational safety and management accuracy of manual valves and meeting the actual needs of enterprises.

[0051] The above describes in detail the optional implementation methods of the embodiment of the present invention in conjunction with the accompanying drawings. However, the embodiment of the present invention is not limited to the specific details in the above implementation methods. Within the technical concept of the embodiment of the present invention, the technical solution of the embodiment of the present invention can be subjected to various simple modifications, and these simple modifications all fall within the protection scope of the embodiment of the present invention.

[0052] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any appropriate manner without contradiction. To avoid unnecessary repetition, the embodiments of the present utility model will not further describe various possible combinations.

[0053] In addition, the various implementations of the embodiments of the present invention may be arbitrarily combined, and as long as they do not violate the concept of the embodiments of the present invention, they should also be regarded as the contents disclosed in the embodiments of the present invention.

Claims

1. A passive wireless manual valve opening sensor, comprising a housing (1), characterized in that: It also includes a main control chip (11), a communication transmission unit (12), a nine-axis sensor (13) and a low-power power management unit (14), and a power supply module (15) is provided inside the housing (1): The main control chip (11) includes a microcontroller (111) connected to the communication transmission unit (12), the nine-axis sensor (13), the low-power power management unit (14) and the power supply module (15); The communication transmission unit (12) comprises a wireless communication module (121), and the wireless communication module (121) is electrically connected to a main control center.

2. A passive wireless manual valve opening sensor according to claim 1, characterized in that: The passive wireless manual valve opening sensor further includes a positioning unit (2) connected to the main control chip (11).

3. A passive wireless manual valve opening sensor according to claim 2, characterized in that: The positioning unit (2) is a Beidou positioning module or a GPS module.

4. A passive wireless manual valve opening sensor according to claim 1, characterized in that: The passive wireless manual valve opening sensor further comprises a photovoltaic conversion unit (3) disposed on the top of the housing (1) and facing the sky, the photovoltaic conversion unit (3) being connected to the power supply module (15), and a current reverse cutoff diode (31) being disposed between the photovoltaic conversion unit (3) and the power supply module (15).

5. The passive wireless manual valve opening sensor according to claim 2, characterized in that: The low-power power management unit (14) comprises: a low-power power management chip (141), a power supply timing circuit (142), a first switch (143) connected to the power supply circuit of the communication transmission unit (12), and a second switch (144) connected to the positioning unit (2); The main control chip (11) is connected to the low-power power management chip (141), the low-power power management chip (141) is connected to the power supply timing circuit (142), and the power supply timing circuit (142) is respectively connected to the first switch (143) and the second switch (144).

6. The passive wireless manual valve opening sensor according to claim 1, characterized in that: The wireless communication module (121) is a 4G cat1 module.

7. The passive wireless manual valve opening sensor according to claim 1, characterized in that: The passive wireless manual valve opening sensor further includes an anti-theft cable (4), the anti-theft cable (4) having a fixed resistor, a first interface (112) connected to the power supply module (15) and a second interface (113) connected to the main control chip (11) are provided on the housing (1), one end of the anti-theft cable (4) is detachably connected to the first interface (112), and the other end is detachably connected to the second interface (113).

8. The passive wireless manual valve opening sensor according to claim 7, characterized in that: The anti-theft cable (4) and the housing (1) are tightly wound around the manual valve when in a connected state.

9. The passive wireless manual valve opening sensor according to claim 1, characterized in that: An identification code is provided on the outer surface of the housing (1), and the identification code includes a unique identity recognition code corresponding to the passive wireless manual valve opening sensor.

10. A manual valve opening monitoring system, comprising a manual valve, characterized in that: The manual valve opening monitoring system comprises the passive wireless manual valve opening sensor according to any one of claims 1 to 9, and the passive wireless manual valve opening sensor is bolted to the manual valve.

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