An inductive electromagnetic valve condition monitoring device

Abstract

The utility model discloses a kind of inductive electromagnetic valve state monitoring devices, it is related to electromagnetic valve state monitoring field, comprising: voltage and current detection module in electromagnetic valve shell, real-time acquisition voltage and current signal when electromagnetic valve coil works;Data processing module is electrically connected with voltage and current detection module, receives voltage and current signal, and calculates the real-time position state of moving iron core based on preset electromagnetic position identification model;Control interface module is communicatively connected with data processing module, for moving iron core position state is fed back to host computer or external control system;By real-time sampling electrical parameter variation of electromagnetic valve coil, whether moving iron core is completely, half-suction or inaction is monitored in real time, and the action state of moving iron core is analyzed by inductance position identification model.The utility model takes hardware detection module as core, realizes the non-contact, refinement, multilevel, high reliable monitoring of electromagnetic valve state, and has excellent versatility and fast deployment capability.

Description

Technical Field

[0001] This utility model relates to the field of solenoid valve status monitoring, and specifically to an inductive solenoid valve status monitoring device. Background Technology

[0002] Solenoid valves are widely used in petroleum, chemical, and automation control fields as key actuators in fluid control systems. Traditional solenoid valves typically control the opening and closing of the valve by driving the moving iron core to engage and disengage via electromagnetic force. However, existing technologies for solenoid valve status monitoring have the following shortcomings and deficiencies:

[0003] Limitations of traditional indicator lights: Many solenoid valves are equipped with simple indicator lights that only show whether the coil is energized. However, these indicator lights cannot accurately reflect the actual engagement or reset state of the moving iron core, making it impossible to detect abnormal behavior of the solenoid valve in cases of incomplete engagement, jamming, or delayed response, thus leading to misjudgment.

[0004] The drawbacks of mechanical contact sensors: To address the shortcomings of moving iron core position monitoring, some solenoid valves have incorporated mechanical contact sensors. Existing technology CN204141010U discloses a solenoid valve with status monitoring functionality. This involves pressurized gas lifting a piston baffle mechanism, compressing a return spring II, closing a torsion spring switch, and creating a path for the torsion spring switch sensor. This activates a light-emitting diode, and the linkage between the two enables monitoring of the solenoid valve core or other components. However, this torsion spring switch sensor suffers from a complex structure and requires modification of existing solenoid valves, increasing design and manufacturing difficulty. Furthermore, contact sensors have low reliability and are prone to wear or failure after prolonged use, affecting monitoring accuracy and overall equipment reliability. Additionally, mechanical sensors typically lack versatility and cannot be adapted to different solenoid valve models, thus limiting their application range.

[0005] The shortcomings of existing current / voltage detection technologies: Some solenoid valve monitoring solutions use current / voltage detection to determine whether the coil is open-circuited or short-circuited. For example, existing patent CN2564825Y discloses a solenoid valve status detection device. Although current / voltage signals can reflect the working status of the solenoid valve to some extent, these methods are usually limited to detecting the electrical connection of the coil and cannot accurately analyze the position of the moving iron core and its engagement state. More importantly, these methods ignore the dynamic behavior of the solenoid valve's moving iron core and cannot solve the problem of solenoid valve status judgment in complex working environments.

[0006] In summary, existing solenoid valve condition monitoring technologies suffer from numerous problems, including complex structure, low reliability, and poor adaptability. Therefore, there is an urgent need for a new non-contact solenoid valve condition monitoring solution that can accurately monitor the operating state of the moving iron core without altering the original structure of the solenoid valve, thereby improving the system's fault diagnosis efficiency and control reliability. Utility Model Content

[0007] The problem this invention aims to solve is through non-contact inductance change detection, which addresses the issues of monitoring accuracy and compatibility in existing technologies. It provides a non-contact monitoring solution that avoids mechanical sensor wear, has a lifespan consistent with the solenoid valve body, identifies all states, accurately determines the three states of full engagement, partial engagement, and no operation, is plug-and-play, and integrates the module within the solenoid valve housing. It is compatible with and requires no modification to the existing solenoid valve structure, making it a highly reliable inductive solenoid valve status monitoring device.

[0008] To address the aforementioned problems, this utility model provides an inductive solenoid valve status monitoring device, comprising:

[0009] The voltage and current detection module installed inside the solenoid valve housing is used to collect the voltage and current signals of the solenoid valve coil in real time.

[0010] The data processing module is electrically connected to the voltage and current detection module and is used to receive voltage and current signals and calculate the real-time position status of the moving iron core based on a preset electromagnetic position recognition model.

[0011] The control interface module is communicatively connected to the data processing module and is used to feed back the position status of the moving iron core to the host computer or an external control system.

[0012] By sampling the changes in electrical parameters of the solenoid valve coil in real time, without the need for external contact sensors, the system can monitor in real time whether the moving iron core is fully engaged, partially engaged, or not engaged, and analyze the operating state of the moving iron core through an inductor position recognition model.

[0013] Preferably, a moving iron core is installed in the valve body, and a stationary iron core and a solenoid valve coil are integrated in the solenoid valve housing. The stationary iron core is fixed in the solenoid valve housing, and the solenoid valve coil is wound around or installed close to the stationary iron core. When energized, a magnetic field is generated. The magnetic field is conducted and amplified through the stationary iron core to form a closed magnetic circuit. The magnetic force acts on the adjacent moving iron core, causing it to overcome the spring force and attract to the stationary iron core. The voltage and current detection module and the data processing module are fixed in the internal cavity of the solenoid valve housing.

[0014] Preferably, the moving iron core is mechanically connected to the return spring, and is reset by spring force when the solenoid valve is de-energized; when energized, the moving iron core is driven to move towards the stationary iron core by electromagnetic force.

[0015] Preferably, the voltage and current detection module includes a current detection unit and a voltage detection unit connected in series in the solenoid valve coil circuit, for synchronously acquiring the real-time electrical parameters of the solenoid valve coil.

[0016] Preferably, the data processing module has built-in abnormal state judgment logic. When the deviation between the position of the moving iron core and the control command exceeds a preset threshold, an abnormal alarm signal is triggered. When the actual position of the moving iron core deviates from the control command beyond the limit, an alarm signal is automatically triggered and fed back to the PLC system. This reduces the false judgment rate and overcomes the defect of traditional indicator lights that still display "normal" when the moving iron core is abnormal.

[0017] Preferably, the control interface module supports industrial standard communication protocols, including at least one of I / O signals, RS485, HART or LoRa wireless communication, to adapt to control systems in different industrial scenarios.

[0018] Preferably, the electromagnetic position recognition model is established based on the dynamic inductance change law. By analyzing the mapping relationship between the inductance value of the solenoid valve coil and the displacement of the moving iron core, the engagement state of the moving iron core (fully engaged, partially engaged, or not engaged) is identified. Through online comparison of the moving iron core's movement trajectory with control commands, and with built-in multi-level alarm and fault classification logic, maintenance personnel can accurately locate various abnormal causes such as incomplete engagement, jamming, and coil damage in the early stages of a fault. This accurate diagnostic capability not only significantly shortens downtime for maintenance but also reduces the risk of unplanned production stoppages caused by misjudgments, significantly improving the overall reliability and production efficiency of the system.

[0019] Preferably, the voltage and current detection module acquires current signals at a high sampling frequency of 0.5-1ms, and analyzes the fitting degree between the current curve and the known curve based on the acquired data to determine the working state of the solenoid valve. This allows for the real-time capture and accurate judgment of subtle changes in the movement process of the moving iron core, including abnormalities such as pull-in lag, jamming, or stall.

[0020] Compared with the prior art, the present invention achieves the following beneficial technical effects:

[0021] This invention directly acquires the electrical parameters of the solenoid valve coil through a voltage / current detection module, and dynamically analyzes the position state of the moving iron core using an electromagnetic position recognition model, completely eliminating mechanical contact sensors. No additional mechanical contacts or guide rods are needed on the moving iron core or valve stem, completely eliminating the risk of sensor failure due to friction, wear, or adhesion. With no physical contact parts, its lifespan is consistent with the solenoid valve body.

[0022] This utility model device is integrated inside the solenoid valve housing. The detection and processing module only needs to be installed in the housing and connected in series in the valve coil circuit. The moving iron core is installed in the valve body, keeping the original valve shape and working mechanism unchanged. Installation and maintenance are extremely simple, eliminating the debugging and replacement costs of traditional mechanical sensors. There is no need to modify the valve body or add external sensors. It is compatible with all existing solenoid valve models.

[0023] This invention achieves accurate identification across all states and multiple levels. Based on an electromagnetic position identification model established according to the dynamic inductance change law, it can distinguish between three operating states: "not activated," "partially engaged," and "fully engaged." This overcomes the shortcomings of existing single power-on / power-off indicator lights or simple current threshold judgments, which cannot differentiate between these levels. The device can complete the full-process monitoring and model fitting judgment of the moving iron core's displacement trajectory before the valve coil is energized, with a response speed far exceeding that of mechanical or single-current detection solutions. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the inductive solenoid valve status monitoring device of this utility model.

[0025] Figure 2 for Figure 1 Overall cross-sectional view along the middle AA.

[0026] Figure 3 This is a schematic diagram of the module of the inductive solenoid valve status monitoring device of this utility model.

[0027] Figure 4 This is a schematic diagram illustrating the working principle of the inductive solenoid valve status monitoring device of this utility model.

[0028] In the diagram: 1-valve body, 2-moving iron core, 2-reset spring, 3-stationary iron core, 4-solenoid valve coil, 5-voltage and current detection module, 6-solenoid valve housing, 7-data processing module, 8-control interface module. Detailed Implementation

[0029] The present invention will be further explained below with reference to the accompanying drawings and embodiments.

[0030] Reference Figures 1-4 As shown, this utility model provides an inductive solenoid valve status monitoring device, comprising:

[0031] The voltage and current detection module 5, installed inside the solenoid valve housing 6, is used to collect the voltage and current signals of the solenoid valve coil in real time.

[0032] The data processing module 7 is electrically connected to the voltage and current detection module 5 and is used to receive voltage and current signals and calculate the real-time position status of the moving iron core based on a preset electromagnetic position recognition model.

[0033] The control interface module 8 is communicatively connected to the data processing module and is used to feed back the position status of the moving iron core to the host computer or an external control system.

[0034] By sampling the changes in electrical parameters of the solenoid valve coil in real time, without the need for external contact sensors, the system can monitor in real time whether the moving iron core is fully engaged, partially engaged, or not engaged, and analyze the operating state of the moving iron core through an inductor position recognition model.

[0035] The moving iron core 2 is mechanically connected to the return spring 2-1, and is reset by spring force when the solenoid valve is de-energized; when energized, the moving iron core is driven to move towards the stationary iron core 3 by electromagnetic force. The voltage and current detection module 5 includes a current detection unit and a voltage detection unit connected in series in the solenoid valve coil circuit, used to synchronously collect the real-time electrical parameters of the solenoid valve coil. The data processing module 7 has built-in abnormal state judgment logic. When the deviation between the position state of the moving iron core and the control command exceeds a preset threshold, an abnormal alarm signal is triggered. When the actual position of the moving iron core deviates from the control command beyond the limit, an alarm signal is automatically triggered and fed back to the PLC system; reducing the false judgment rate and overcoming the defect of traditional indicator lights still displaying "normal" when the moving iron core is abnormal. The control interface module supports industrial standard communication protocols, including at least one of I / O signals, RS485, HART or LoRa wireless communication, adapting to control systems in different industrial scenarios. The electromagnetic position recognition model is based on the dynamic inductance variation law. By analyzing the mapping relationship between the inductance value of the solenoid valve coil and the displacement of the moving iron core, it identifies the engagement state of the moving iron core (fully engaged, partially engaged, or not activated). Through online comparison of the moving iron core's movement trajectory with control commands, and with built-in multi-level alarm and fault classification logic, maintenance personnel can accurately locate various abnormal causes such as incomplete engagement, jamming, and coil damage in the early stages of a fault. This precise diagnostic capability not only significantly shortens downtime for maintenance but also reduces the risk of unplanned production stoppages caused by misjudgments, significantly improving the overall reliability and production efficiency of the system. The voltage and current detection module collects current signals at a high sampling frequency of 0.5-1ms and analyzes the fitting degree between the current curve and known curves based on the collected data to determine the working state of the solenoid valve. This allows for real-time and accurate capture and judgment of subtle changes in the moving iron core's movement process, including abnormalities such as engagement lag, jamming, or stalling.

[0036] Specifically, the moving iron core 2 is installed inside the valve body 1, while the stationary iron core 3, coil 4, voltage and current detection module 5, and data processing module 7 are installed inside the solenoid valve housing 6. The solenoid valve housing 6 has a cable interface through which signal lines and power lines are connected to the solenoid valve. When the solenoid valve is de-energized, coil 4 is de-energized, and the moving iron core assembly 2 is reset by the action of the internal spring 2-1. At this time, the voltage and current detection module 5 does not detect voltage and current information, and the data processing module does not receive voltage and current information. At this time, the data processing module 7 determines that the solenoid valve is in a normal state, and the feedback control system solenoid valve is normal.

[0037] Feedback signals can be configured according to requirements, and the optional standards are: I / O signals, RS485 protocol, HART protocol, LoRa wireless communication, etc. Different feedback signals can be fed back to control systems such as PLCs, and the control systems can perform alarm and interlock control.

[0038] When the solenoid valve is energized, the coil 4 is energized at the instant, and the moving iron core assembly 2 and the stationary iron core assembly 3 generate an electromagnetic force that attracts each other under the action of the electromagnetic field. The moving iron core assembly 2 begins to move upward until it is in contact with the upper part of the stationary iron core assembly 3. During this process, due to the movement of the moving iron core assembly 2, the magnetic reluctance changes, and the voltage and current also change accordingly. At this time, the information detected by the voltage and current detection module 5 is sent to the data processing module 7. The data processing module 7 calculates the position of the moving iron core based on the waveform of the voltage and current and the established inductance position model, and thus determines whether the moving iron core assembly 2 is normal.

[0039] According to Ohm's law: I=U / Z; Z=√(R²+XL²); the inductive reactance calculation formula: XL=2πfL; and the formula for a cylindrical inductor with an iron core: L=μN²S / Le;

[0040] It is known that when DC current is applied to the coil, a magnetic field and self-inductance are generated around the coil at the instant of application. When the electromagnetic force is large enough, the moving iron core moves. When the effective length Le of the iron core inside the coil changes, the impedance Z also changes, and the current changes accordingly. When the iron core moves to its position, the effective length Le no longer changes, and the inductive reactance XL remains unchanged. According to the current change law, if the moving iron core moves within the first 50ms of the coil being energized, the current will first rise rapidly, then fall rapidly, then rise rapidly again, and finally stabilize at a certain value. We detect the coil current and voltage by connecting a detection module in series with the coil, collect current data at high frequency (about 0.5-1ms), and plot the current curve. By analyzing the fit between the current curve and the known curve, we determine whether the solenoid valve is normal.

[0041] In summary, this utility model, with a hardware detection module as its core, achieves non-contact, precise, multi-level, and highly reliable monitoring of the status of solenoid valves. It also possesses excellent versatility and rapid deployment capabilities, overcoming the shortcomings of existing technologies such as complex structure, easy wear, poor adaptability, and low monitoring accuracy.

[0042] In the description of this utility model, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0043] It should be noted that in this invention, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0044] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features of the present invention.

Claims

1. A state monitoring device for an inductive solenoid valve, characterized in that, include: The voltage and current detection module (5) installed inside the solenoid valve housing (6) is used to collect the voltage and current signals of the solenoid valve coil in real time. The data processing module (7) is electrically connected to the voltage and current detection module (5) and is used to receive voltage and current signals and calculate the real-time position status of the moving iron core based on the preset electromagnetic position recognition model. The control interface module (8) is connected to the data processing module and is used to feed back the position status of the moving iron core to the host computer or external control system. By sampling the changes in the electrical parameters of the solenoid valve coil in real time, the system monitors whether the moving iron core is fully engaged, partially engaged, or not engaged, and analyzes the operating state of the moving iron core through an inductor position recognition model.

2. The inductive solenoid valve status monitoring device according to claim 1, characterized in that, The valve body (1) is equipped with a moving iron core (2), a stationary iron core (3), and a solenoid valve coil (4) integrated in the solenoid valve housing (6). The stationary iron core (3) is fixed in the solenoid valve housing (6). The solenoid valve coil (4) is wound around or installed close to the stationary iron core (3). When energized, it generates a magnetic field. The magnetic field is conducted and amplified through the stationary iron core (3) to form a closed magnetic circuit. The magnetic force acts on the adjacent moving iron core (2), causing it to overcome the spring force and attract to the stationary iron core (3). The voltage and current detection module (5) and the data processing module (7) are fixed in the internal cavity of the solenoid valve housing (6).

3. The inductive solenoid valve status monitoring device according to claim 2, characterized in that, The moving iron core (2) is mechanically connected to the reset spring (2-1), and is reset by spring force when the solenoid valve is de-energized; when energized, the moving iron core is driven to move towards the stationary iron core (3) by electromagnetic force.

4. The inductive solenoid valve status monitoring device according to claim 1, characterized in that, The voltage and current detection module (5) includes a current detection unit and a voltage detection unit connected in series in the solenoid valve coil circuit, which are used to synchronously collect the real-time electrical parameters of the solenoid valve coil.

5. The inductive solenoid valve status monitoring device according to claim 1, characterized in that, The The data processing module (7) has built-in abnormal state judgment logic. When the deviation between the position state of the moving iron core and the control command exceeds the preset threshold, an abnormal alarm signal is triggered.

6. The inductive solenoid valve status monitoring device according to claim 5, characterized in that, The The control interface module supports industry-standard communication protocols, including at least one of I / O signals, RS485, HART, or LoRa wireless communication.

7. The inductive solenoid valve status monitoring device according to claim 1, characterized in that, The electromagnetic position recognition model is established based on the dynamic inductance change law. By analyzing the mapping relationship between the inductance value of the solenoid valve coil and the displacement of the moving iron core, the engagement state of the moving iron core is identified.

8. The inductive solenoid valve status monitoring device according to claim 7, characterized in that, The voltage and current detection module acquires current signals at a high sampling frequency of 0.5-1ms, and analyzes the fitting degree between the current curve and the known curve based on the acquired data to determine the working state of the solenoid valve.

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