Intelligent pressure regulating valve system

Abstract

The utility model relates to an intelligent pressure regulating valve system, the pressure regulating valve system includes execution unit, control hub, collection component and communication interface, its characterized in that, control hub receives the signal of collection component, and issues instruction to execution unit and communication interface, and execution unit contains one or more pressure regulating valves of system control, the utility model relates to an intelligent pressure regulating valve system, in the system configuration air pressure collection module, flow collection module, central control system MCU and CAN communication interface, whole is by execution unit, control hub and communication interface three big core module constitutes, has adopted high accuracy flow guide assembly of step motor drive in execution unit, has improved pressure regulating precision, real -time monitoring air pressure change, collection flow and air pressure change adaptively regulated output and feedback compensation pressure fluctuation, and the system establishes the system of data saving intelligent analysis according to historical data.

Description

[Technical Field] This utility model relates to the field of pressure regulating valve technology, and more particularly to the field of intelligent pressure regulating valve system. [Background Technology] Pressure regulating valves are commonly used industrial devices, primarily used to control the pressure of fluid media and maintain it stable within a certain range. They are widely used in petroleum, chemical, power, metallurgical, and pharmaceutical industries, serving to regulate media flow and protect equipment and pipelines. Specifically, the functions of pressure regulating valves include the following: Pressure regulation: Pressure regulating valves can automatically adjust the pressure in the system as needed to ensure stable operation of the medium within the normal range; Flow control: Pressure regulating valves control the flow rate of the medium by adjusting the valve opening to meet process requirements and equipment operation needs; Safety protection: In equipment and pipelines, excessive pressure of the medium may lead to explosions or other accidents. The presence of pressure regulating valves can prevent such problems from occurring, ensuring the safety of equipment and personnel; Equipment protection: Pressure regulating valves can effectively reduce vibration and impact caused by pressure changes in the system, prevent equipment wear, leakage and other problems, and extend the service life of the equipment.

[0001] Currently, most pressure regulating valves are still manually operated, relying mainly on mechanical structures and manual adjustments to regulate and control pressure. Traditional pressure regulating valves have long faced three major technical bottlenecks in the field of industrial fluid control. First, the pressure regulation accuracy is insufficient, failing to meet the high precision requirements of current industries. Furthermore, they cannot monitor air pressure changes in real time, nor can they automatically adjust the output or compensate for pressure fluctuations according to changes in operating conditions.

[0002] Currently, the data acquisition system for pressure regulating valves used in industrial environments lacks a coherent architecture and system. For example, while pilot-operated pressure regulating valves can achieve passive regulation, they lack real-time monitoring capabilities. Some electric regulating valves use RS-485 communication, and when the number of control nodes exceeds 32, the command delay can reach as high as 480ms, far exceeding the 200ms safety threshold for industrial processes. More seriously, system parameters are lost in the event of a power outage, requiring re-adjustment after reset, resulting in production line downtime and losses.

[0003] Furthermore, the data of pressure regulating valves in specific application scenarios and the adjustments made for peak fluctuations are not saved or recorded. The adjustment schemes cannot be copied or can not be recorded and learned autonomously. There is an urgent need to adopt a large-scale integrated intelligent system adapted to pressure regulating valves, which has the functions of collecting data, implementing monitoring, retaining analysis traces, and uploading to the cloud or backend. [Summary of the Invention] This invention addresses the technical problems existing in current pressure regulating valves and the industry itself by designing an intelligent pressure regulating valve system. The system includes a pressure acquisition module, a flow acquisition module, a central control system MCU, and a CAN communication interface. The entire system comprises three core modules: an execution unit, a control center, and a communication interface. The execution unit utilizes a high-precision flow guiding component driven by a stepper motor, improving pressure regulation accuracy, enabling real-time monitoring of pressure changes, adaptive adjustment of output based on flow and pressure variations, and feedback compensation for pressure fluctuations. The system also establishes a data storage and intelligent analysis system based on historical data.

[0004] An intelligent pressure regulating valve system includes an execution unit, a control center, data acquisition components, and a communication interface, characterized in that the control center receives signals from the data acquisition components and issues instructions to the execution unit and the communication interface; The execution unit includes one or more pressure regulating valves controlled by the system; Each pressure regulating valve includes a housing, a compression spring, and a valve core. The compression spring inside the housing presses down to drive the valve core. The valve core is characterized by having a stepper motor inside the housing, which drives a transmission threaded rod to rotate. The transmission threaded rod meshes with a top ball threaded rod, and the rotation of the transmission threaded rod drives the top ball threaded rod. A top plate and a compression spring are located below the top ball threaded rod. The top plate presses against the compression spring, causing the valve core to move. A digital pressure gauge is located on the side of the valve core.

[0005] The control center includes an MCU processor and an MCU power supply, wherein the MCU power supply supplies power to the MCU processor. The data acquisition components include a pressure acquisition module and a flow acquisition module, both of which are connected to different pressure regulating valves in the execution unit. The communication interface integrates a CAN bus transceiver and execution unit to exchange data and issue commands to external systems.

[0006] The communication interface connects to the back-end control center or cloud storage center via protocol data.

[0007] The intelligent pressure regulating valve system also includes a JATG download interface, a control board clock, buttons, and a ferroelectric memory, which are connected to the MCU processor via a data connection line.

[0008] The ferroelectric memory stores historical data, real-time location data during power outages, and various settings parameters of the control unit.

[0009] The intelligent pressure regulating valve also includes an LCD display screen, which is connected to the control center and receives commands from the control center.

[0010] The pressure regulating valve is also equipped with a motor mounting seat, a valve core mounting seat, and a bearing. A valve core mounting seat is provided on the outside of the valve core, and a motor mounting seat is provided outside the valve core mounting seat. A bearing is provided between the motor mounting seat and the transmission threaded rod.

[0011] The intelligent pressure regulating valve system involved in this utility model is equipped with a pressure acquisition module, a flow acquisition module, a central control system MCU, and a CAN communication interface. The whole system consists of three core modules: an execution unit, a control center, and a communication interface. The execution unit adopts a high-precision flow guiding component driven by a stepper motor, which improves the pressure regulation accuracy, monitors air pressure changes in real time, collects flow and air pressure changes to adaptively adjust the output and provide feedback to compensate for pressure fluctuations. The system establishes a data storage and intelligent analysis system based on historical data. [Attached Image Description] Figure 1 This is a framework diagram of an intelligent pressure regulating valve system involved in this utility model; Figure 2 This is a schematic diagram of the structure of an intelligent pressure regulating valve involved in this utility model; 110. Execution Unit; 120. Control Center; 121. MCU Processor; 122. MCU Power Supply; 130. Data Acquisition Components; 131. Air Pressure Acquisition Module; 132. Flow Acquisition Module; 140. Communication Interface; 150. JATG Download Interface; 160. Control Board Clock; 170. Buttons; 180. Ferroelectric Memory; 190. LCD Display Screen; 10. Housing; 11. Motor mounting base; 12. Valve core mounting base; 13. Bearing; 20. Stepper motor; 30. Transmission threaded rod; 40. Top ball threaded rod; 50. Pressure-sensing diaphragm; 60. Compression spring; 70. Valve core; 80. Digital display pressure gauge.

Detailed Implementation Methods

[0012] In the description of this utility model, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship, 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.

[0013] This utility model relates to an intelligent pressure regulating valve system, which improves upon the technical bottlenecks of current pressure regulating valves by configuring a pressure acquisition module and a flow acquisition module to monitor the pressure and flow data in the pressure regulating valve in real time and transmit the acquired data to the control center. The control center then controls the execution unit to execute instructions and displays the corresponding program and data on the LCD screen.

[0014] Please refer to the attached document. Figure 1 The invention illustrates an intelligent pressure regulating valve system, comprising an execution unit 110, a control center 120, a data acquisition component 130, and a communication interface 140. The control center 120 receives signals from the data acquisition component 130 and issues instructions to the execution unit 110 and the communication interface 140. The execution unit 110 includes one or more pressure regulating valves 100 controlled by the system. Each pressure regulating valve 100 includes a housing 10, a compression spring 60, and a valve core 70. Inside the housing 10, the compression spring 60 presses down to drive the valve core 70. A stepper motor 20 is installed inside the housing 10, which drives the transmission threaded rod 30 to rotate. The transmission threaded rod 30 meshes with the top ball threaded rod 40, and the rotation of the transmission threaded rod 30 drives the top ball threaded rod 40. A pressure-sensitive diaphragm 50 and a compression spring 60 are installed below the top ball threaded rod 40. The pressure-sensitive diaphragm 50 presses against the compression spring 60 to drive the valve core 70 to move. A digital display pressure gauge 80 is installed on the side of the valve core 70.

[0015] The control center 120 includes an MCU processor 121 and an MCU power supply 122, wherein the MCU power supply 122 supplies power to the MCU processor 121. The data acquisition device 130 includes a pressure acquisition module 131 and a flow acquisition module 132. Both the pressure acquisition module 131 and the flow acquisition module 132 are connected to different pressure regulating valves in the execution unit 110 to collect the pressure and flow data of the pressure regulating valves in each working state in real time.

[0016] The communication interface 140 integrates a CAN bus transceiver and an execution unit 110 to exchange data and issue commands to external systems.

[0017] The communication interface 140 is connected to the back-end control center or cloud storage center via protocol data.

[0018] The intelligent pressure regulating valve system also includes a JATG download interface 150, a control board clock 160, buttons 170, and a ferroelectric memory 180, which are connected to the MCU processor 121 via a data connection cable. It is used to download JATG data, perform system timing, and control the system via buttons.

[0019] The most crucial component is the ferroelectric memory 180, which stores historical data, real-time position data during power outages, and various set parameters of the control unit. It can promptly restore the system's state after a power outage, ensuring the system quickly returns to its working state.

[0020] The intelligent pressure regulating valve also includes an LCD display screen, which is connected to the control center and receives commands from the control center.

[0021] The pressure regulating valve is also provided with a motor mounting seat 11, a valve core mounting seat 12 and a bearing 13. The valve core mounting seat 12 is provided on the outside of the valve core 70, the motor mounting seat 11 is provided outside the valve core mounting seat 12, and the bearing 13 is provided between the motor mounting seat 11 and the transmission threaded rod.

[0022] A control method for an intelligent pressure regulating valve system is characterized in that the control center collects real-time air pressure data and flow data of the target pressure regulating valve in the execution unit through the air pressure acquisition module and flow acquisition module in the acquisition components. The pressure closed loop adjusts the stepper motor rotation angle after the air pressure data collected by the air pressure sensor is processed by the PID algorithm. The flow closed loop feeds back the flow data collected by the flow sensor to the control center. The control center combines the set value with the valve opening to achieve the purpose of closed-loop control. This includes an energy-saving control mode for busy and idle conditions. Based on the historical data stored in the control center, the system autonomously compares the historical data and establishes a flow-pressure correspondence model. When an idle period is detected, which is defined as a real-time flow rate < 30% of the peak flow rate, the system is automatically switched to the economy mode and this idle period instruction is uploaded to the background control center via the CAN bus. The background then issues instructions to the air compressor system to reduce the piston stroke. The control center sends background commands to the background control center via the CAN bus according to the real-time work flow and task arrangement, and steplessly adjusts the output air pressure and airflow value, thereby executing the busy and idle working conditions on site.

[0023] A control method for an intelligent pressure regulating valve system further includes adaptive pressure regulation of the system. The adaptive pressure regulation process refers to the process where, when a sudden change in pressure / flow is detected, the change value is compared and fed back to the control center. The control center then calculates and adjusts the stepper motor in the execution unit. Using ±Z as the pressure / flow fluctuation difference, X as the air pressure / airflow value collected by the MCU processor, and Y as the system's setpoint, a comparison is made. When |XY|>Z, the MCU sends the motor's rotational speed and corresponding angle parameters based on the magnitude of the difference. Upon receiving the command, the motor adjusts the height of the adaptive valve core through the execution unit, thereby adjusting the size of the vent valve and thus regulating the air pressure. Real-time data is then collected and fed to the control unit for calculation, and corresponding commands are issued based on the calculation, until |XY|≤Z.

[0024] A control method for an intelligent pressure regulating valve system, characterized in that the parameter adjustment strategy of the PID algorithm is as follows: Firstly, for pressure step change, the detection index is: rate of change > 5 kPa / s, and the adjustment strategy is to increase the differential gain and reduce the integral action; Secondly: continuous low-frequency oscillation, the detection index is: fluctuation period <8s, the adjustment strategy is to enhance low-pass filtering and reduce the proportional band; Thirdly: Changes in fluid characteristics, the detection index is: flow rate fluctuation >3%, the adjustment strategy is to readjust the integral time constant; Fourth: Mechanical response hysteresis; the detection index is: execution unit delay > 400ms, and the adjustment strategy is to add Smith prediction compensation.

[0025] In adaptive pressure regulation, if the fluctuation difference, based on historical data analysis, shows an anomaly greater than 10% of the system setpoint, the proportional gain coefficient needs to be dynamically adjusted. Specifically, when the motor speed is |XY| ≥ Z, the value of |XY| is B; when B < 0.1Y, A = KB, where A is the motor speed and K is a constant; when B ≥ 0.1Y, A = KB. 2 By combining primary and secondary integral methods, the motor speed can be quickly adjusted, reducing the pressure recovery time to within 2 seconds.

[0026] The integrated CAN bus transceiver adopts a three-layer architecture: the device layer connects to field sensors via the CAN2.0B protocol; real-time data mapping: the gateway polls the 11-bit identifier of the CAN bus every 50ms to collect parameters such as valve opening, air pressure, and flow rate.

[0027] The integrated CAN bus transceiver adopts a three-layer architecture: the device layer connects to field sensors via the CAN2.0B protocol; real-time data mapping: the gateway polls the 11-bit identifier of the CAN bus every 50ms to collect parameters such as valve opening, air pressure, and flow rate. Tests show that the communication latency has been reduced from 480ms to 65ms, meeting the 200ms process requirement.

[0028] Remote setting: The background sends hexadecimal command frames (e.g., 0x01 set pressure value, 0x02 request status), which are parsed by the controller and written into the register. Users can adjust parameters in the central control room or via mobile APP, such as adjusting the pipeline pressure setpoint from 0.8MPa to 0.5MPa at night, a reduction of 37.5%.

[0029] Fault warning: When the motor temperature exceeds the limit (>85℃) or the torque is abnormal (fluctuation ≥15%), a 0xE alarm frame is immediately sent to trigger a cloud-based push maintenance work order.

[0030] A triple protection mechanism is designed to address sudden power outages: True multi-turn encoders can save position data in real time, without the need for batteries or supercapacitors, and will not cause data loss problems during long-term downtime.

[0031] Ferroelectric memory can quickly save various settings parameters of the control unit.

[0032] Mechanical self-locking device: In the instant of power interruption, the electromagnetic brake locks the push rod position to prevent valve position drift. After power is restored, the ferroelectric data is automatically read, and the operating conditions before the power failure are restored within 0.5 seconds.

[0033] Offline autonomous control; the system switches to autonomous computing mode when the network is interrupted. Local decision-making: Fits a trend line based on the most recent 10 minutes of data and adjusts according to preset logic. If a continuous decrease in pressure is detected (slope < -0.5 kPa / s), automatically compensates for the opening by 5%-8%.

[0034] Manual seamless switching: On-site personnel set parameters via keyboard, and the settings are automatically synchronized to the control platform after the network is restored.

[0035] Flexible start-stop: The motor is controlled by the SVM-DTC algorithm, and the torque is smooth during the start-stop phase (the rate of change is <5N·m / s) to avoid water hammer impact.

[0036] High-performance control module: During normal operation, the main control algorithm is executed by a 64-bit high-speed chip; it collects data such as air pressure, flow rate, and real-time location, and exchanges data with the execution unit and the background control platform, issuing commands and receiving instructions and feedback data.

[0037] CAN bus: Multiple background CAN bus systems operate with a communication rate of up to 1M / S, enabling rapid real-time adjustment of field conditions.

[0038] This patent has six significant advantages over existing technologies: 1. Precise control and improved stability: The adaptive PID algorithm suppresses pressure fluctuations within ±1.5% of the set value, far superior to the ±5% level of traditional valves. The maintenance cycle is extended from 3 months to 2 years.

[0039] 2. Outstanding energy-saving benefits: This utility model can adjust the output air pressure and flow rate in real time via CAN bus according to background instructions, which can save energy efficiently.

[0040] 3. Enhanced safety and reliability: The dual-core architecture achieves a failover time of <100ms, and FRAM data storage eliminates the need for battery backup. Electromagnetic-mechanical dual braking ensures valve position deviation of <0.5% during power failure, completely resolving the pain point of requiring manual calibration after reset in traditional systems.

[0041] 4. Significantly Enhanced Intelligence: The CAN bus supports networking of 256 devices, achieving network-wide pressure balancing in conjunction with a big data platform. In the refining and chemical plant upgrade project, the system availability reached 99.98% (720 hours of testing), and the coordinated response latency of over 32 valves was only 65ms.

[0042] 5. Easy installation and maintenance: Driven by a safe 24VDC voltage, no dedicated power distribution is required. The modular design allows for hot-swappable replacement of components such as gateways and motors, reducing downtime by 75%.

[0043] 6. Extend equipment life: Flexible start-stop technology reduces mechanical shock and increases bearing life by 3 times; backflushing function avoids scaling and corrosion, extending valve body service life from 5 years to 10 years.

[0044] I. Multimodal Adaptive Control Architecture The 64-bit high-performance MCU can process field data quickly and efficiently, while exchanging data with the execution unit, acquisition unit, and background control center.

[0045] Autonomous computing mode: The local computing engine (built-in trend fitting algorithm) ensures stable offline operation, and automatically synchronizes data to the cloud after the network is restored.

[0046] Dynamic energy-saving model: Based on historical big data, a flow-pressure relationship function is established to automatically switch between busy and idle conditions (such as reducing pressure to 75% of the set value at night).

[0047] II. High-Reliability Data Protection System Non-volatile storage solution: Ferroelectric memory saves parameters every 5 seconds (write speed 100ns / byte), true multi-turn encoder can save position data in real time, no external power supply or supercapacitor, no risk of failure after long period of non-use; three-stage recovery mechanism: power failure → mechanical locking → data saving → automatic loading after power restoration.

[0048] III. Industrial Internet of Things Integration CAN bus low-latency communication: high-speed communication mode, up to 1M / S; the CAN bus has a much stronger anti-interference capability than the RS485 bus, and the ICP / IP communication mode makes this patented product applicable to complex electromagnetic environments. IV. Power failure protection actuator: A dual locking device of electromagnetic brake and mechanical pawl to ensure valve position deviation <0.5%. Protection range: Combined application of true multi-turn encoder and ferroelectric memory (life ≥10^12 times).

[0049] V. Adaptive PID algorithm, dynamically adjusts parameters based on multi-sensor data, including: increasing derivative gain when pressure change rate > 5 kPa / s; readjusting integral time constant when flow rate change rate > 3%; adding Smith predictor when execution delay > 400 ms; and allowing user-defined adjustment of control accuracy.

[0050] VI. Busy / Idle Operating Condition Energy Saving Model: It can receive background instructions and steplessly change the idle ratio, making it easy to set the energy-saving ratio.

[0051] VII. CAN bus data mapping method: bind CAN identifier with IP address, implement 50ms polling cycle through dual protocol gateway, and generate 0xE class alarm frames (motor temperature > 85℃ or torque fluctuation ≥ 15%).

[0052] This invention addresses the shortcomings of pressure regulating valves, such as low accuracy, inability to monitor in real time, and inability to automatically adjust output based on changes in operating conditions. It incorporates a pressure acquisition module, a flow acquisition module, a central control system MCU, and a CAN communication interface. The overall design consists of three core modules: an execution unit, a control center, and a communication interface. The execution unit utilizes a high-precision flow guide component driven by a stepper motor. The control center employs a 64-bit high-speed MCU for communication and interrupt handling. Simultaneously, the I / O interface enables microcontroller execution of control algorithms. The communication interface integrates a CAN bus transceiver, improving pressure regulation accuracy, enabling real-time monitoring of pressure changes, adaptive output adjustment based on flow and pressure variations, and feedback compensation for pressure fluctuations.

[0053] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some changes or modifications to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes, and modifications made to the above embodiments based on the present utility model without departing from the scope of the present utility model shall fall within the scope of the present utility model.

Claims

1. An intelligent pressure regulating valve system, characterized in that, The pressure regulating valve system includes an execution unit, a control center, data acquisition components, and a communication interface. The control center receives signals from the data acquisition components and sends instructions to the execution unit and the communication interface. The execution unit includes one or more pressure regulating valves controlled by the system; Each pressure regulating valve includes a housing, a compression spring, and a valve core. Inside the housing, the compression spring presses down to drive the valve core. A stepper motor is installed inside the housing, which drives a transmission threaded rod to rotate. The transmission threaded rod meshes with a top ball threaded rod, and the rotation of the transmission threaded rod drives the top ball threaded rod. Below the top ball threaded rod, there is a top plate and a compression spring. The top plate presses against the compression spring, causing the valve core to move. A digital pressure gauge is installed on the side of the valve core. The control center includes an MCU processor and an MCU power supply, wherein the MCU power supply supplies power to the MCU processor. The data acquisition components include a pressure acquisition module and a flow acquisition module, both of which are connected to different pressure regulating valves in the execution unit. The communication interface integrates a CAN bus transceiver and execution unit to exchange data and issue commands to external systems.

2. The intelligent pressure regulating valve system according to claim 1, characterized in that, The communication interface connects to the back-end control center or cloud storage center via protocol data.

3. The intelligent pressure regulating valve system according to claim 1, characterized in that, The intelligent pressure regulating valve system also includes a JATG download interface, a control board clock, buttons, and a ferroelectric memory, which are connected to the MCU processor via a data connection line.

4. The intelligent pressure regulating valve system according to claim 3, characterized in that, The ferroelectric memory stores historical data, real-time location data during power outages, and various settings parameters of the control unit.

5. The intelligent pressure regulating valve system according to claim 4, characterized in that, The intelligent pressure regulating valve system also includes an LCD display screen, which is connected to the control center and receives commands from the control center.

6. The intelligent pressure regulating valve system according to claim 1, characterized in that, The pressure regulating valve is also equipped with a motor mounting seat, a valve core mounting seat, and a bearing. A valve core mounting seat is provided on the outside of the valve core, and a motor mounting seat is provided outside the valve core mounting seat. A bearing is provided between the motor mounting seat and the transmission threaded rod.

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