Valve with inner leakage detection function

Abstract

The utility model belongs to the technical field of valves, and particularly relates to a valve with an inner leakage detection function, which comprises a valve body and a controller, a valve cavity is arranged in the valve body, a valve seat is arranged in the valve cavity, a valve core and a valve rod are arranged on the valve seat, and a medium inlet and a medium outlet which are communicated with the valve cavity are respectively arranged at two ends of the valve body. Mounting flanges are arranged at the medium inlet end and the medium outlet end of the valve body, an ultrasonic probe assembly is arranged on the valve body close to the medium outlet, a probe channel for a probe of the ultrasonic probe assembly to pass through is formed in the valve body, and an ultrasonic probe penetrates through the probe channel and then is located in the valve cavity. A pressure sensor is at least arranged on the valve body at the medium outlet, and the pressure sensor and the ultrasonic probe assembly are connected with a controller through signal lines. The internal leakage detection device can effectively detect the internal leakage problem of the valve.

Description

Technical Field

[0001] This utility model relates to the field of valve technology, and in particular to a valve with internal leakage detection function. Background Technology

[0002] In industrial production processes, valves play a crucial role in control and regulation. Whether transporting gases, liquids, or corrosive media, the sealing performance of valves directly impacts the entire system. Traditional valves only possess basic on / off and regulation functions, making it difficult to detect internal leaks accurately and promptly during operation. If internal leaks occur and are not detected in time, they can lead to serious safety accidents involving hazardous media and cause reduced efficiency and product contamination in the production process. Therefore, there is an urgent need for instrument valves capable of effectively detecting internal leaks. Utility Model Content

[0003] The purpose of this invention is to provide a valve with internal leakage detection function to solve the problem that existing valves cannot effectively detect internal leakage, especially when handling gaseous, liquid and corrosive gaseous liquid media, which poses safety hazards and performance deficiencies.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a valve with internal leakage detection function, comprising a valve body and a controller, characterized in that: the valve body has a valve cavity, a valve seat is installed in the valve cavity, a valve core and a valve stem are provided on the valve seat, and the valve body has a medium inlet and a medium outlet communicating with the valve cavity at both ends, respectively; both the medium inlet and the medium outlet of the valve body are provided with mounting flanges; an ultrasonic probe assembly is provided on the valve body near the medium outlet, and a probe channel is provided on the valve body for the probe of the ultrasonic probe assembly to pass through, the ultrasonic probe passing through the probe channel and being located inside the valve cavity. A pressure sensor is provided on the valve body at least at the medium outlet, and both the pressure sensor and the ultrasonic probe assembly are connected to the controller via signal lines.

[0005] As a further aspect of this invention: a flange interface is provided on the outer port of the ultrasonic probe channel, and a sealing flange that mates with the flange interface is provided on the ultrasonic probe located outside the valve body. The sealing performance of the ultrasonic probe channel can be ensured by using the flange's mating bolts.

[0006] As a further aspect of this invention: the inner wall of the ultrasonic probe channel is provided with an internal thread, and the upper end of the ultrasonic probe is provided with an external thread that mates with the internal thread. This threaded structure ensures the sealing of the ultrasonic probe channel.

[0007] As a further embodiment of this utility model: the ultrasonic probe is a piezoelectric ultrasonic probe, the piezoelectric crystal of which is made of lead zirconate titanate, barium titanate, or quartz piezoelectric ceramic material, the working frequency range of the ultrasonic probe is 20kHz–1MHz, and the surface of the ultrasonic probe is provided with a wear-resistant protective layer that has good acoustic coupling performance.

[0008] As a further aspect of this invention: two pressure sensors are provided, one at the medium inlet and the other at the medium outlet. By placing the pressure sensors near the medium inlet and outlet of the valve body, the pressure changes on both sides are monitored when the valve is closed. The sensors immediately capture the pressure difference information and begin operation, either via ultrasonic waves or remotely via wired or wireless communication commands, or by pressing buttons on the controller.

[0009] As a further embodiment of this invention: the controller comprises a signal conditioning circuit, a data acquisition card, and a microprocessor connected in sequence. A display screen and an alarm are connected to the microprocessor. The signal conditioning circuit amplifies and filters the weak electrical signal received by the ultrasonic probe. The amplification circuit amplifies the signal to a suitable amplitude so that the subsequent signal processing unit can effectively identify it. Filtering removes environmental noise and other interference signals, improving the signal-to-noise ratio. The signal conditioning circuit includes a preamplifier, a bandpass filter, and a main amplifier connected in sequence. The passband frequency range of the bandpass filter is set appropriately according to the operating frequency of the ultrasonic probe. The data acquisition card converts the conditioned analog signal into a digital signal. The microprocessor analyzes and processes the digital signal. The microprocessor is also connected to a communication module, which transmits the detection results to a remote monitoring terminal. The communication module supports wired and wireless communication methods. Wired communication methods include RS485 and Ethernet communication, while wireless communication methods include 4G, 5G, Wi-Fi, and Bluetooth communication. The display screen shows the detection results of valve leakage, and the alarm emits an alarm signal when leakage is detected. The signal conditioning circuit, data acquisition card, and microprocessor mentioned are all publicly available products.

[0010] As a further aspect of this utility model, the microprocessor is connected to the display screen and the alarm via both wired and wireless transmission methods.

[0011] As a further embodiment of this utility model: the sampling frequency of the data acquisition card is not less than 5-10 times the working frequency of the ultrasonic probe, the sampling accuracy is not less than 12 bits, and the data acquisition card also includes a data buffer with a storage capacity of not less than 1MB.

[0012] As a further aspect of this invention: the microprocessor incorporates a signal feature extraction module and an internal leakage detection module. The signal feature extraction module extracts the frequency, amplitude, and phase characteristics of the digital signal, while the internal leakage detection module compares and analyzes the extracted feature information based on a preset internal leakage feature database to determine whether the valve has internal leakage and the degree of such leakage.

[0013] Compared with the prior art, the beneficial effects of the present invention are:

[0014] 1. By using ultrasonic components in conjunction with the controller settings, the internal leakage of valves can be monitored in real time and accurately. Whether it is a minor leak or a more serious leak, it can be effectively detected, which greatly improves the safety and reliability of the pipeline system and reduces the risk of safety accidents caused by internal leakage and the economic losses caused by media leakage.

[0015] 2. The ultrasonic probe surface is equipped with a wear-resistant protective layer with good acoustic coupling performance, which not only makes it suitable for a variety of media, but also ensures that the monitoring device can still operate stably in harsh environments, thus extending the service life and application range of the valve.

[0016] 3. The internal leakage monitoring device has a reasonable structural design and is organically integrated with the valve body. It does not occupy too much extra space, and its installation and maintenance are relatively convenient. It does not require complicated external equipment and cumbersome testing procedures, which can effectively reduce labor and time costs. Attached Figure Description

[0017] Figure 1 This is a cross-sectional structural diagram of the present invention;

[0018] Figure 2 This is a schematic diagram of the main structure of the present utility model;

[0019] Figure 3 This is a schematic diagram of the ultrasonic probe assembly structure of this utility model;

[0020] In the diagram: 1. Valve body; 2. Valve seat; 3. Valve stem; 4. Valve core; 5. Medium inlet; 6. Medium outlet; 7. Probe channel; 8. Ultrasonic probe assembly; 9. Pressure sensor; 10. Mounting flange; 11. Flange interface; 12. Signal line; 13. Sealing flange. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0022] Please see Figure 1 - Figure 3 As shown, this utility model provides the following technical solution:

[0023] A valve with internal leakage detection function includes a valve body 1 and a controller. The valve body 1 has a valve cavity containing a valve seat 2. The valve seat 2 has a valve core 4 and a valve stem 3. The valve body 1 has a medium inlet 5 and a medium outlet 6 communicating with the valve cavity at both ends. Both the medium inlet 5 and the medium outlet 6 of the valve body 1 have mounting flanges 10. An ultrasonic probe assembly 8 is mounted on the valve body 1 near the medium outlet 6. The valve body 1 has a probe channel 7 for the probe of the ultrasonic probe assembly 8 to pass through, and the ultrasonic probe passes through the probe channel 7 and is located inside the valve cavity. A pressure sensor 9 is mounted on the valve body 1 at least at the medium outlet 6. Both the pressure sensor 9 and the ultrasonic probe assembly 8 are connected to the controller via signal lines 12.

[0024] The ultrasonic probe channel 7 has a flange interface 11 on its outer port, and the ultrasonic probe located outside the valve body 1 has a sealing flange 13 that mates with the flange interface 11. The use of flange bolts ensures the sealing of the ultrasonic probe channel 7.

[0025] The ultrasonic probe channel 7 has an internal thread on its inner wall, and the upper end of the ultrasonic probe has an external thread that mates with the internal thread. The threaded structure ensures the sealing of the ultrasonic probe channel 7.

[0026] The ultrasonic probe is a piezoelectric ultrasonic probe, and its piezoelectric crystal is made of lead zirconate titanate, barium titanate, or quartz piezoelectric ceramic material. The working frequency range of the ultrasonic probe is 20kHz–1MHz, and the surface of the ultrasonic probe is provided with a wear-resistant protective layer with good acoustic coupling performance.

[0027] Two pressure sensors 9 are provided, located at the medium inlet 5 and the medium outlet 6 respectively. By placing the pressure sensors 9 on the valve body 1 near the medium inlet 5 and the outlet respectively, the pressure change on both sides is monitored when the valve is closed. The sensors immediately capture the pressure difference information and start working. The ultrasonic waves can also work remotely via wired or wireless communication commands or by pressing buttons on the controller.

[0028] The controller consists of a signal conditioning circuit, a data acquisition card, and a microprocessor connected in sequence. A display screen and an alarm are connected to the microprocessor. The signal conditioning circuit amplifies and filters the weak electrical signal received by the ultrasonic probe. The amplification circuit amplifies the signal to a suitable amplitude so that the subsequent signal processing unit can effectively identify it. Filtering removes environmental noise and other interference signals, improving the signal-to-noise ratio. The signal conditioning circuit includes a preamplifier, a bandpass filter, and a main amplifier connected in sequence. The passband frequency range of the bandpass filter is set appropriately according to the operating frequency of the ultrasonic probe. The data acquisition card converts the conditioned analog signal into a digital signal. The microprocessor analyzes and processes the digital signal. The microprocessor is also connected to a communication module, which transmits the detection results to a remote monitoring terminal. The communication module supports wired and wireless communication methods. Wired communication methods include RS485 and Ethernet communication, while wireless communication methods include 4G, 5G, Wi-Fi, and Bluetooth communication. The display screen shows the detection results of internal leakage in the valve, and the alarm emits an alarm signal when internal leakage is detected. The signal conditioning circuit, data acquisition card, and microprocessor mentioned are all existing technology products.

[0029] The microprocessor is connected to the display screen and alarm via both wired and wireless transmission methods.

[0030] The sampling frequency of the data acquisition card is not less than 5-10 times the working frequency of the ultrasonic probe, and the sampling accuracy is not less than 12 bits. The data acquisition card also includes a data buffer, and the storage capacity of the data buffer is not less than 1MB.

[0031] The microprocessor has a built-in signal feature extraction module and an internal leakage detection module. The signal feature extraction module is used to extract the frequency, amplitude, and phase feature information of the digital signal. The internal leakage detection module compares and analyzes the extracted feature information based on a preset internal leakage feature database to determine whether the valve has internal leakage and the degree of internal leakage.

[0032] When using this device, the ultrasonic probe needs to be calibrated. A standard ultrasonic signal generator is used to send a standard ultrasonic signal of known frequency and amplitude to the ultrasonic probe. The parameters of the signal conditioning circuit and data acquisition card are adjusted so that the acquired digital signal matches the standard ultrasonic signal, thereby calibrating the accuracy of the detection device. The calibrated ultrasonic probe is installed in the probe channel 7, and the flange interface 11 and sealing flange 13 are fixed and sealed with nuts. The signal line of the pressure sensor is led out through the probe channel 7, or a pressure sensor channel is set up so that the pressure sensor 9 can be installed on the valve body 1 near the medium outlet 6, and properly sealed and protected to ensure that it can accurately measure the pressure change feedback signal. When the valve is operating normally, the equipment is not working. When the valve is closed, the pressure sensor 9 will send the detected closure signal to the processing unit to trigger the operation. When gas or liquid leaks from the valve leak point, turbulence will be generated, thereby emitting ultrasonic signals. When the detected ultrasonic anomaly meets the internal leakage judgment condition, the alarm device and on-site data display are immediately triggered to remind the on-site operator that there is an internal leakage in the valve, so that maintenance or replacement measures can be taken in time.

[0033] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A valve with internal leakage detection function, comprising a valve body (1) and a controller, characterized in that: The valve body (1) has a valve cavity, and a valve seat (2) is installed in the valve cavity. The valve seat (2) is provided with a valve core (4) and a valve stem (3). The two ends of the valve body (1) are respectively provided with a medium inlet (5) and a medium outlet (6) communicating with the valve cavity. The medium inlet (5) end and the medium outlet (6) end of the valve body (1) are both provided with mounting flanges (10). An ultrasonic probe assembly (8) is provided on the valve body (1) near the medium outlet (6). The valve body (1) is provided with a probe channel (7) for the probe of the ultrasonic probe assembly (8) to pass through. After the ultrasonic probe passes through the probe channel (7), it is inside the valve cavity. At least at the medium outlet (6) of the valve body (1) is provided with a pressure sensor (9). The pressure sensor (9) and the ultrasonic probe assembly (8) are both connected to the controller through a signal line (12).

2. A valve with internal leakage detection function according to claim 1, characterized in that: The ultrasonic probe channel (7) is provided with a flange interface (11) on its outer port, and the ultrasonic probe located outside the valve body (1) is provided with a sealing flange (13) that cooperates with the flange interface (11).

3. A valve with internal leakage detection function according to claim 1, characterized in that: The ultrasonic probe channel (7) has an internal thread on its inner wall and an external thread at the upper end of the ultrasonic probe that engages with the internal thread.

4. A valve with internal leakage detection function according to claim 2 or 3, characterized in that: The ultrasonic probe is a piezoelectric ultrasonic probe, and its piezoelectric crystal is made of lead zirconate titanate, barium titanate, or quartz piezoelectric ceramic material. The operating frequency range of the ultrasonic probe is 20kHz–1MHz, and the surface of the ultrasonic probe is provided with a protective layer.

5. A valve with internal leakage detection function according to claim 1, characterized in that: Two pressure sensors (9) are provided, located at the medium inlet (5) and the medium outlet (6) respectively.

6. A valve with internal leakage detection function according to claim 1, characterized in that: The controller consists of a signal conditioning circuit, a data acquisition card, and a microprocessor connected in sequence. The microprocessor is equipped with a display screen and an alarm.

7. A valve with internal leakage detection function according to claim 6, characterized in that: The microprocessor is connected to the display screen and alarm via both wired and wireless transmission methods.

8. A valve with internal leakage detection function according to claim 6, characterized in that: The sampling frequency of the data acquisition card is not less than 5-10 times the working frequency of the ultrasonic probe, and the sampling accuracy is not less than 12 bits. The data acquisition card also includes a data buffer, and the storage capacity of the data buffer is not less than 1MB.

9. A valve with internal leakage detection function according to claim 6, characterized in that: The microprocessor has a built-in signal feature extraction module and an internal leakage detection module.

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