A valve capable of monitoring fluid conditions in real time

Abstract

The utility model discloses a valve can real -time monitoring fluid state relates to valve field, including mechanical valve, sensor, communication module, the sensor installs the outer wall of mechanical valve, and communication module is connected with sensor through signal connecting line, and the core position of hand wheel drive mechanism of mechanical valve has integrated sensor as the core valve position feedback unit of system, is used for real -time collection mechanical valve's state information and converts the accurate angular displacement of valve shaft, a valve can real -time monitoring fluid state of the utility model discloses, can upgrade as intelligent valve on the basis of original valve, and the cost is low, can real -time detection valve's position, pressure, temperature, flow, opening -close state, leakage situation etc, can adjust sensor position according to the installation situation of valve on the box, to reach the detection effect that wants, can remote monitoring valve condition, meets the abnormal situation and can send out alarm signal, reminds the operator in time processing, avoids the accident to expand.

Description

Technical Field

[0001] The utility model relates to the field of valves, in particular to a valve capable of monitoring fluid state in real time. Background Art

[0002] In the field of industrial fluid control, valves, as key actuating elements, are widely used in petroleum, chemical industry, storage and transportation and other industries to regulate, cut off or guide fluid flow. Traditional valves, such as emergency shut-off valves, ball valves, butterfly valves, gate valves, oil discharge valves and combinations thereof, are usually installed at the top or bottom of tanks and rely on pure mechanical structures to achieve basic functions. Although these valves have the advantages of simple structure and low cost, they lack intelligent monitoring capability and cannot feed back valve status information in real time, resulting in low operation efficiency and potential safety hazards.

[0003] In the prior art, valve monitoring mainly relies on manual inspection or simple mechanical indicators, for example, judging the opening / closing state of the valve and system pressure by observing the position of a handwheel or a pressure gauge. This method not only has large response delay, but also cannot realize continuous monitoring. Especially in harsh environments (such as high temperature, high pressure or explosive occasions), manual inspection has high risks. When leakage, jamming or abnormal wear occurs to the valve, it is often difficult for operators to find it in time, which may cause fluid leakage, equipment damage and even safety accidents. In addition, traditional valve systems are difficult to integrate remote communication functions, cannot support data uploading, multi-valve coordination or big data analysis, which limits the development of industrial automation. For example, during the loading and unloading process of storage tanks, changes in valve status cannot automatically trigger linkage control (such as opening of an oil and gas recovery valve), and rely on manual intervention, which increases labor costs and operation complexity. Therefore, there is an urgent need in the industry for a low-cost, upgradable intelligent valve solution to make up for the deficiencies of the prior art in real-time monitoring, remote control and data analysis.

[0004] Therefore, it is necessary to propose a valve capable of real-time monitoring of fluid state to solve the above problems. Utility Model Content

[0005] The main objective of the present utility model is to provide a valve capable of real-time monitoring of fluid state, which can effectively solve the problems in the background art.

[0006] To achieve the above objective, the technical scheme adopted by the utility model is as follows:

[0007] A valve capable of real-time monitoring of fluid state, comprising a mechanical valve, a sensor and a communication module, wherein the sensor is installed on the outer wall of the mechanical valve, and the communication module is connected with the sensor through a signal connection line;

[0008] The core of the handwheel transmission mechanism of the mechanical valve integrates a sensor as the core valve position feedback unit of the system, which is used to collect the status information of the mechanical valve in real time and convert the precise angular displacement of the valve shaft.

[0009] Preferably, the mechanical valve is a conventional valve, including an emergency shut-off valve, a ball valve, a butterfly valve, a gate valve, an oil unloading valve, a discharge valve, and combination valves of these valves, and the mechanical valve is used to be installed at the top or bottom of the tank.

[0010] Preferably, the sensor is a waterproof, explosion-proof, and anti-static sensor, which is used to detect the position, pressure, temperature, flow rate, opening and closing status, and leakage of the mechanical valve in real time.

[0011] Preferably, the communication module is used to upload the information collected by the sensor to an external terminal system. The communication module is used to remotely monitor the status of mechanical valves, alarm abnormal conditions, coordinate the cooperation of multiple valves through signals, and perform big data analysis.

[0012] Preferably, the digital position signal output by the core valve position feedback unit is preprocessed and encapsulated by the built-in microprocessor. The core valve position feedback unit follows the frame format and electrical characteristics specified by the RS-communication protocol to upload the data packet containing the absolute position information of the mechanical valve to the monitoring terminal in an asynchronous serial transmission mode. The monitoring terminal parses this data stream in real time to accurately calculate and display the instantaneous opening of the mechanical valve.

[0013] Preferably, the pressure monitoring of the sensor uses a diffused silicon piezoresistive transmitter, which accurately measures the system static pressure through a MEMS chip; the temperature monitoring of the sensor uses a three-wire PT platinum resistance thermometer, which eliminates measurement errors based on the four-wire principle; the flow detection of the sensor is based on Bernoulli's equation, and the flow value is obtained through differential pressure measurement and square root calculation; the leakage monitoring of the sensor uses a capacitive sensor array based on the edge electric field effect, with distributed detection nodes arranged at the packing and flange connections of the mechanical valve.

[0014] Preferably, the valve position status monitoring of the sensor adopts a binary sensing system composed of Hall effect proximity switches. By detecting the displacement trajectory of the cylinder piston rod, the limit position of the mechanical valve is determined. The sensor is hardwired to the communication module.

[0015] The communication network of the core valve position feedback unit adopts a master-slave topology. Each sensing node is equipped with a serial communication interface that conforms to the EIA-RS-C standard. The physical layer uses a DB connector, the data link layer uses a Modbus RTU protocol frame structure, and the communication system of the communication network uses a cyclic redundancy check mechanism to ensure data integrity.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] This valve, capable of real-time fluid status monitoring, can upgrade existing valves to intelligent valves at low cost. It can monitor valve position, pressure, temperature, flow rate, opening / closing status, and leakage in real time. Sensor positions can be adjusted based on the valve's installation on the housing to achieve the desired monitoring effect. It allows for remote monitoring of valve status, issuing alarm signals in case of abnormalities to alert operators and prevent escalation of accidents. It also enables statistical analysis using big data, a significant feature. For example, data analysis can predict valve maintenance cycles and potential faults, enabling predictive maintenance and greatly reducing repair time and costs. Furthermore, data analysis can statistically analyze the demand for various products in different regions, allowing for increased safety stock and shorter replenishment cycles in high-demand areas, while reducing inventory in low-demand areas to avoid overstocking. Multiple valves can work together via signals; for instance, when the foot valve opens, the sensor transmits a signal to the module system, which determines whether to open the oil and gas recovery valve (another type of valve). The oil and gas recovery valve's gas path is controlled via an electrical signal, significantly reducing labor costs. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0019] Figure 2 This is the circuit diagram of the sensor of this utility model.

[0020] In the diagram: 1. Mechanical valve; 2. Sensor; 3. Communication module. Detailed Implementation

[0021] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the present utility model will be further described below in conjunction with specific embodiments.

[0022] Example 1:

[0023] like Figure 1 , Figure 2As shown, a valve capable of real-time monitoring of fluid status includes a mechanical valve 1, a sensor 2, and a communication module 3. The sensor 2 is installed on the outer wall of the mechanical valve 1. The communication module 3 is connected to the sensor 2 via a signal connection line. The mechanical valve 1 is a traditional valve, including emergency shut-off valves, ball valves, butterfly valves, gate valves, unloading valves, discharge valves, and combination valves of these types. The mechanical valve 1 is used to install on the top or bottom of the tank. If the customer needs to replace it with an intelligent valve, there is no need to change the tank truck configuration; only an intelligent module needs to be added to the original valve. The sensor 2 is a waterproof, explosion-proof, and anti-static sensor. The sensor 2 is used to detect the position, pressure, temperature, flow rate, opening and closing status, leakage, etc. of the mechanical valve 1 in real time. The sensor position can be adjusted according to the actual valve installation. The communication module 3 is used to upload the information collected by the sensor 2 to an external terminal system. The communication module 3 is used for remote monitoring of the status of the mechanical valve 1, alarm for abnormal conditions, multi-valve signal coordination, and big data analysis.

[0024] Example 2:

[0025] like Figure 1 , Figure 2As shown, a valve capable of real-time monitoring of fluid status is described. A sensor 2, serving as the core valve position feedback unit of the system, is integrated into the core position of the handwheel drive mechanism of the mechanical valve 1. This sensor collects the status information of the mechanical valve 1 in real time and converts the precise angular displacement of the valve shaft. The digital position signal output by the core valve position feedback unit is preprocessed and encapsulated by a built-in microprocessor. Following the frame format and electrical characteristics specified by the RS-232 communication protocol, the core valve position feedback unit uploads a data packet containing the absolute position information of the mechanical valve 1 to the monitoring terminal via asynchronous serial transmission. The monitoring terminal analyzes this data stream in real time to accurately calculate and display the instantaneous opening of the mechanical valve 1. The pressure monitoring of sensor 2 uses a diffused silicon piezoresistive transmitter, precisely measuring the system static pressure through a MEMS chip. The temperature monitoring of sensor 2 uses a three-wire PT100 platinum resistance thermometer, eliminating measurement errors based on the four-wire principle. The flow detection of sensor 2 is based on Bernoulli's equation, obtaining the flow value through differential pressure measurement and square root calculation. The leakage monitoring of sensor 2 uses a capacitive sensing array based on the edge electric field effect, located at the packing and flange connection of the mechanical valve 1. Distributed detection nodes are arranged at key sealing points. When the dielectric constant undergoes a step change, the sensing circuit detects that the capacitance value exceeds the preset threshold, immediately triggering an alarm signal and activating the safety interlock protection system such as the electric shut-off valve. The valve position status monitoring of sensor 2 adopts a binary sensing system composed of Hall effect proximity switches. By detecting the displacement trajectory of the cylinder piston rod, it is used to determine the extreme position of mechanical valve 1. This sensor is hardwired to communication module 3. When abnormal conditions such as overpressure or overtemperature are detected, an emergency shut-off ESD program can be triggered within 50ms, driving the solenoid valve to quickly cut off the air source, while activating the spring reset mechanism of the pneumatic actuator. The communication network of the core valve position feedback unit adopts a master-slave topology. Each sensing node is equipped with a serial communication interface conforming to the EIA-RS-232C standard. The physical layer uses a DB9 connector, and the data link layer uses a Modbus RTU protocol frame structure. The communication system of the communication network uses a cyclic redundancy check mechanism to ensure data integrity and is equipped with signal conditioning circuits and opto-isolation devices to effectively suppress common-mode interference and fully meet the real-time and reliability requirements of the process control system.

[0026] Example 3:

[0027] Mechanical valve 1 is a traditional valve, including emergency shut-off valves, ball valves, butterfly valves, gate valves, unloading valves, and other unloading valves, as well as combination valves of these valves. These valves can be installed on the top or bottom of the tank. If intelligent valves are required, there is no need to change the tank truck configuration; only the communication module 3 needs to be added to the original valve. Sensor 2 has waterproof, explosion-proof, and anti-static functions and can be safely and efficiently installed on mechanical valve 1. Sensor 2 can detect the position, pressure, temperature, flow, opening and closing status, leakage, etc. of mechanical valve 1 in real time. The position of sensor 2 can be adjusted according to the actual installation of mechanical valve 1. Communication module 3 can upload the information collected by sensor 2 to the terminal system, enabling remote monitoring of the status of mechanical valve 1, alarm for abnormal conditions, multi-valve signal coordination, big data analysis, etc.

[0028] Working principle: Sensor 2 detects various parameters of mechanical valve 1 and transmits this information to the module system. The module system uploads these signals to the terminal, which can remotely monitor the valve status in the background. In addition, the module system can perform data analysis and recording and abnormal alarms.

[0029] This invention integrates multiple intelligent sensors for position, pressure, temperature, flow, leakage, and opening / closing, constructing an industrial valve status monitoring and intelligent control system based on a distributed acquisition architecture. The system adopts a modular design concept, realizing end-to-end digital management from data acquisition and signal processing to control execution.

[0030] At the core of the handwheel drive mechanism of mechanical valve 1, a high-precision sensor is integrated as the system's core valve position feedback unit, acquiring and converting the precise angular displacement of the valve shaft in real time. The output digital position signal is preprocessed and encapsulated by the built-in microprocessor, strictly adhering to the frame format and electrical characteristics specified by the RS-232 communication protocol, and uploaded to the monitoring terminal via asynchronous serial transmission of a data packet containing the valve's absolute position information. The terminal, by parsing this data stream in real time, can accurately calculate and display the valve's instantaneous opening.

[0031] Pressure monitoring employs a diffused silicon piezoresistive transmitter, using a MEMS chip to accurately measure the system's static pressure. Temperature monitoring utilizes a three-wire PT100 platinum resistance thermometer, eliminating measurement errors based on the four-wire principle. Flow detection is based on Bernoulli's equation, obtaining the flow value through differential pressure measurement and square root calculation.

[0032] Leakage monitoring employs a capacitive sensor array based on the edge electric field effect, with distributed detection nodes deployed at key sealing points such as valve packing and flange connections. When a step change occurs in the dielectric constant, the sensing circuit detects that the capacitance value exceeds a preset threshold, immediately triggering an alarm signal and activating safety interlock protection systems such as electrically operated shut-off valves.

[0033] The valve position monitoring system employs a binary sensing system composed of Hall effect proximity switches. By detecting the displacement trajectory of the cylinder piston rod, it accurately determines the valve's extreme position. This sensor is hardwired to the communication module. When abnormal conditions such as overpressure or overtemperature are detected, an emergency shut-off (ESD) procedure can be triggered within 50ms, driving the solenoid valve to quickly cut off the air supply and simultaneously activating the spring reset mechanism of the pneumatic actuator.

[0034] The system communication network adopts a master-slave topology. Each sensor node is equipped with a serial communication interface conforming to the EIA-RS-232C standard. The physical layer uses a DB9 connector, and the data link layer uses the Modbus RTU protocol frame structure. The communication system uses a cyclic redundancy check (CRC-16) mechanism to ensure data integrity and is equipped with signal conditioning circuits and opto-isolation devices to effectively suppress common-mode interference, fully meeting the real-time and reliability requirements of the process control system.

[0035] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A valve capable of real-time monitoring of fluid state, comprising a mechanical valve (1), a sensor (2), and a communication module (3), characterized in that: The sensor (2) is installed on the outer wall of the mechanical valve (1), and the communication module (3) is connected to the sensor (2) via a signal connection line; The core position of the handwheel transmission mechanism of the mechanical valve (1) is integrated with a sensor (2) as the core valve position feedback unit of the system, which is used to collect the status information of the mechanical valve (1) in real time and convert the precise angular displacement of the valve shaft.

2. The valve for real-time monitoring of fluid state according to claim 1, characterized in that: The mechanical valve (1) is a traditional valve, including emergency shut-off valve, ball valve, butterfly valve, gate valve, unloading valve, unloading valve and combination valves of these valves. The mechanical valve (1) is used to be installed on the top and bottom of the tank.

3. The valve for real-time monitoring of fluid state according to claim 1, characterized in that: The sensor (2) is a waterproof, explosion-proof, and anti-static sensor. The sensor (2) is used to detect the position, pressure, temperature, flow rate, opening and closing status, and leakage of the mechanical valve (1) in real time.

4. A valve capable of real-time monitoring of fluid state according to claim 1, characterized in that: The communication module (3) is used to upload the information collected by the sensor (2) to the external terminal system. The communication module (3) is used to remotely monitor the status of the mechanical valve (1), alarm for abnormal conditions, coordinate cooperation of multiple valves through signals, and perform big data analysis.

5. A valve capable of real-time monitoring of fluid state according to claim 1, characterized in that: The digital position signal output by the core valve position feedback unit is preprocessed and encapsulated by the built-in microprocessor. The core valve position feedback unit follows the frame format and electrical characteristics specified by the RS-232 communication protocol to upload the data packet containing the absolute position information of the mechanical valve (1) to the monitoring terminal in an asynchronous serial transmission mode. The monitoring terminal analyzes this data stream in real time to accurately calculate and display the instantaneous opening of the mechanical valve (1).

6. A valve capable of real-time monitoring of fluid state according to claim 5, characterized in that: The pressure monitoring of the sensor (2) adopts a diffused silicon piezoresistive transmitter, which accurately measures the static pressure of the system through a MEMS chip; the temperature monitoring of the sensor (2) uses a three-wire PT100 platinum resistance thermometer, which eliminates measurement errors based on the four-wire principle; the flow detection of the sensor (2) is based on the Bernoulli equation, and the flow value is obtained by differential pressure measurement and square root calculation; the leakage monitoring of the sensor (2) adopts a capacitive sensing array based on the edge electric field effect, and distributed detection nodes are arranged at the packing and flange connection of the mechanical valve (1).

7. A valve capable of real-time monitoring of fluid state according to claim 6, characterized in that: The valve position status monitoring of the sensor (2) adopts a binary sensing system composed of Hall effect proximity switches. By detecting the displacement trajectory of the cylinder piston rod, it is used to determine the extreme position of the mechanical valve (1). The sensor is hardwired to the communication module (3). The communication network of the core valve position feedback unit adopts a master-slave topology. Each sensing node is equipped with a serial communication interface that conforms to the EIA-RS-232C standard. The physical layer uses a DB9 connector, the data link layer uses a Modbus RTU protocol frame structure, and the communication system of the communication network uses a cyclic redundancy check mechanism to ensure data integrity.

Images