Methods for diagnosing a diaphragm valve, and diagnostic system for a diaphragm valve

Abstract

Method for diagnosing a diaphragm valve (10), comprising the following steps: a) providing to a detection device (46) at least one first parameter characterizing a valve diaphragm (14), at least one second parameter characterizing at least one of the components of the diaphragm valve (10) other than the valve diaphragm (14), and at least one third parameter characterizing an operation of the diaphragm valve (10) and which is a process and / or environmental parameter accumulated in the past during the operation of the diaphragm valve (10); b) determining from the first, second, and third parameters by the detection device (46) using at least one algorithm, a parameter characterizing a current state of the valve diaphragm (14), in particular a current wear.

Description

The invention relates to a method for diagnosing a diaphragm valve according to claim 1.US 2008 / 0 202 606 A1 already discloses a membrane for a process control and methods and devices for monitoring the state of a membrane. A valve also includes a sensor for monitoring the condition associated with membrane wear. A membrane sensor is mounted on the membrane or embedded (e.g. glued or cast) in the membrane. The diaphragm sensor provides a characteristic signal indicative of the status or condition of the diaphragm to an external control unit via sensor leads or wires. In addition, a diaphragm activation switch includes a Hall effect sensor to determine the position of the diaphragm or plunger. DE 10 2013 214 304 A1 describes a diaphragm valve with a valve diaphragm on which a data carrier in the form of an RFID chip is present. Thus, not only data concerning the materials, the dimensions, the production and similar core sizes of the membrane can be stored in the data carrier and / or digitally referenced in the system, but also data concerning the respective customer, the delivery, etc. All these data can be aligned with the respective individual membrane and stored on its associated data carrier.Proceeding from this, the present invention has the object of providing a method for diagnosing a diaphragm valve which increases operating reliability and reduces operating costs.This object is achieved by a method having the features of claim 1. Advantageous refinements of the invention are specified in dependent claims. Features important for the invention are moreover found in the following description and in the attached drawing, wherein these features can be important for the invention both alone and in quite different combinations, without any particular reference being made to them again.According to the invention, three different variables are used to determine the current state of the valve diaphragm. The first variables relate directly to the valve membrane itself, that is to say for example the type and material of the valve membrane. These first variables can be stored and / or referenced directly, for example, during the production of the valve diaphragm in a data carrier assigned to the valve diaphragm and preferably integrated into the latter.The second variables do not characterize the valve diaphragm but rather the diaphragm valve as a whole or its components (apart from the valve diaphragm), that is to say for example the installation situation, the type of drive and the like. These second variables can be stored, for example, during the assembly of the diaphragm valve in a data carrier assigned to the diaphragm valve, preferably integrated in the latter. However, this second data can also be stored in an external data portal, which is arranged at a distance from the diaphragm valve.The third variables characterize the operation of the diaphragm valve and thus contain process and / or environmental variables which have been accumulated in the past during the operation of the diaphragm valve. These third variables can be collected continuously or at specific times and temporarily stored either in a data memory assigned to the diaphragm valve or in an external data portal arranged remote from the diaphragm valve.By combining these three variables, a variable characterizing the current state of the valve diaphragm can be determined very reliably by means of corresponding mathematical algorithms. The algorithms can be used, for example, to determine a remaining service life of the valve diaphragm precisely. For example, the algorithms can be used to specify the expected time of a membrane fracture or the current wear state. The algorithms can thus be used to predict, for example, a time of a necessary replacement of the valve diaphragm. The algorithms can take into account relationships that have been determined, for example, from actually occurring fractures of valve membranes and first, second and third variables present for this purpose by means of a corresponding data analysis.A first development of the method according to the invention includes the fact that the ascertained variable characterizes a remaining service life of the valve diaphragm or an equivalent variable and that, if the ascertained remaining service life or the equivalent variable is less than a limit value, an action is triggered by the ascertainment device. This includes, for example, an automatic creation and / or transmission of status information and / or a replacement part request and / or warning information. This further improves the operational reliability of the diaphragm valve and of the installation in which the diaphragm valve is installed, and possibly interrupts of operation necessary for maintenance and / or repair of the diaphragm valve are reduced to a minimum, specifically both in terms of number and in terms of duration. The status information can comprise, for example, a probable remaining running time of the diaphragm valve or of the valve diaphragm, and / or the warning information can indicate an imminent valve failure.It is further proposed that in step a) a first size is provided by an optical surface inspection. For this purpose, an operator can generate images, for example, via a smartphone or another imaging device. These images can be processed using image processing programs, so that a statement can be made about the state of the valve membrane with the aid of image analysis algorithms. This can take place solely on the basis of defined features and threshold values, but more complex methods such as the classification of the membrane state on the basis of an existing database can also be implemented. A further variable provided by a visual surface inspection is a haptic variable, for example a roughness of a surface of the valve diaphragm, which can additionally be transmitted.It is particularly advantageous if the parameters of the algorithms are changed, in particular optimized, taking into account a first variable provided by an optical surface inspection and / or another analysis of the valve diaphragm and / or a variable characterizing the actual current state of the valve diaphragm. This is particularly useful if the optical surface inspection and or the other analysis is carried out after removal or replacement of the valve membrane. In this way, the algorithms can be continuously optimized and the determination result can thus be improved.The degree of automation of the method according to the invention is increased if, in step a), at least one variable is provided by at least one sensor integrated into the diaphragm valve. Such sensors can, for example, detect a third variable such as an operating temperature or an operating pressure, but optionally also, for example, detect a first variable such as cracks in the valve diaphragm, or detect a leakage.It is likewise possible that in step a) at least one variable is provided by an external device, in particular a controller of a system in which the diaphragm valve is installed, and / or by an external data portal. This can be realized in a simple manner, and when an external data portal is used as or another external device, the data security is improved.At least one of the variables provided in step a) can be a variable from the following group: a variable characterizing swelling and / or lowering of the valve diaphragm; a variable characterizing surface quality of the valve diaphragm; a variable characterizing cracks in the valve diaphragm; a variable characterizing energy consumption of the diaphragm valve; a variable characterizing leakage of the diaphragm valve; a temperature of the fluid flowing through the diaphragm valve; a pressure of the fluid flowing through the diaphragm valve; a type of the fluid flowing through the diaphragm valve; a pH value of the fluid flowing through the diaphragm valve; a profile of the temperature and / or of the pressure of the fluid flowing through the diaphragm valve; a number of switching changes; a frequency of the switching changes; a frequency spectrum of the switching changes; Operating hours of the valve diaphragm and / or of the diaphragm valve; an age of the valve diaphragm and / or of the diaphragm valve; a material of the valve diaphragm and / or of the valve body; a type of seat geometry; a type of the valve diaphragm; a type of valve drive; a date of production of the valve diaphragm; a place of production of the valve diaphragm; quality check variables of the valve diaphragm and / or of the diaphragm valve; a supplier of the valve diaphragm; a delivery path of the valve diaphragm; a storage location of the valve diaphragm and / or of the diaphragm valve; a storage duration of the valve diaphragm and / or of the diaphragm valve; a date of storage of the valve diaphragm and / or of the diaphragm valve; a date of storage of the valve diaphragm and / or of the diaphragm valve; a mounting date of the valve diaphragm and / or the diaphragm valve; a mounting location of the valve diaphragm and / or the diaphragm valve; a name of the assembler; a name of the operator.The method according to the invention can be carried out continuously at least temporarily during the operation of the diaphragm valve. This increases operational reliability, since the current state of the valve diaphragm can be estimated at any point in time.Alternatively, however, the method according to the invention can also be executed at least temporarily only on demand. This saves computing capacity. Such a request can be made at regular times, for example. It is also possible that it is carried out when variables or data stored on a data memory in the valve diaphragm and / or in the diaphragm valve are read out by means of a read-out device. The read-out data can then be transmitted wirelessly, for example, to an external data portal on which variables or data relating to the diaphragm valve are likewise stored, are synchronized there as required with these, and are then processed there by a corresponding determination device by means of the algorithms in order thus to estimate the current state of the valve diaphragm.Carrying out step b) in an external processing portal has the advantage that no corresponding computing capacity has to be reserved for the operator of the diaphragm valve.Hereinafter, an embodiment of the present invention will be explained by way of example with reference to the accompanying drawings. In the drawing, the following are shown: FIG. 1 shows a perspective exploded illustration of a diaphragm valve with a valve diaphragm; FIG. 2 is a schematic illustration of a system including the diaphragm valve of FIG. 1 ; and FIG. 3 is a flow chart of a method for diagnosing the diaphragm valve of FIG. 1.In FIG. 1, a diaphragm valve generally has the reference numeral 10. it comprises a valve body 12 with a seat geometry 13, a valve diaphragm 14, a pressure piece 16 and an intermediate piece 18. The pressure piece 16 serves for connecting the valve diaphragm 14 to a valve drive 20, which is indicated in FIG. 1 merely by a dot-dash line.At the rear edge of the valve diaphragm 14 in FIG. 1, a tab 22 is provided, into which a data storage 24 in the form of an RFID chip is integrated. The housing comprises an inlet connector 26 and an outlet connector 28. However, an arrangement on the inlet connection piece 26 or at another location of the valve body 12 is also possible.The diaphragm valve 10 is installed in a process engineering plant 32, which is indicated here merely symbolically by a box 32 shown. A suitable process engineering plant is, for example, a plant in the pharmaceutical industry for the production of a medicament.In FIG. 2, a system which, among other things, also comprises the diaphragm valve 10 from FIG. 1 bears the overall reference numeral 34. the system 34 also comprises a data input and readout device 36 for reading out data stored on the data memory 24 and the data memory 30 and for inputting further data and variables, which is indicated in FIG. 2 by two lightning-type arrows with the reference numeral 37, furthermore a transmission device 38, which is symbolized in the present case only by a lightning-type arrow, for transmitting data between the data input and readout device 36 and an external data and processing portal 40, which is arranged remote from the data input and readout device 36 and from the diaphragm valve 10 and also belongs to the system 34.The data input and read-out device 36 can be a special device which is designed specifically for the diaphragm valve 10, or, for example, a customary smartphone or a tablet PC, on which special software, for example an app, is loaded and which has a corresponding, for example wireless, transmission possibility of data according to the arrows 37 and 38. The data memory 24, the data memory 30, the data input and read-out device 36, the transmission device 38 and the external data and processing portal 40 are set up and programmed for carrying out a method which will be explained in detail further below.Data relating to first variables which characterize the valve diaphragm 14 are stored in the data memory 24. These variables can be stored as data in the data memory 24, for example, already during the production of the valve diaphragm 14. These first variables can include, for example: a material, a type, a date of manufacture, a place of manufacture, a batch of manufacture, quality test variables recorded during the manufacture of the valve diaphragm 14, for example dimensional tolerances, roughness depths, etc., a supplier, a delivery path, a storage location, a storage duration, an date of storage, a date of storage, a date of installation, a place of installation, a name of the engineer who has installed the valve diaphragm 14 into the diaphragm valve 10, etc.A variable characterizing swelling and / or lowering of the valve diaphragm 14, a variable characterizing a surface quality of the valve diaphragm 14 and a variable characterizing cracks in the valve diaphragm 14 can also be stored in the data memory 24 as the first variable. In particular, the latter variables can, however, also be stored elsewhere. This list is furthermore merely exemplary and is in no way exhaustive. One or more of the first variables listed above can be stored in the data memory 24.Data relating to second variables are stored in the data memory 30 of the housing, which do not relate to the valve diaphragm 14 but in particular to the valve body 12, for example a material, a type, a type of seat geometry, a date of manufacture, a place of manufacture, a batch of manufacture, quality test variables recorded during the manufacture of the valve body 12, for example dimensional tolerances, roughness depths, etc., a supplier, a delivery path, a storage location, a storage duration, an date of storage, a date of storage, a type of valve drive 28, etc. However, this enumeration is also merely exemplary and is in no way exhaustive. The data memory 30 of the housing can store one or more of the second variables listed above.As such, each essential individual part of the diaphragm valve 10 can be equipped with a data memory, for example in the form of an RFID chip, on which the data or second variables relating to this specific component are then stored. However, it is also conceivable for the data memory 30 present on the outlet connector 28 of the housing to store all data on components which are not the valve diaphragm 14.The diaphragm valve 10 also includes a plurality of sensors 42, of which only three are shown here by way of example. These sensors 42 detect third variables which characterize an operation of the diaphragm valve 10. These third variables may include: a variable characterizing an energy consumption of the diaphragm valve 10; a variable characterizing a leak of the diaphragm valve 10; a temperature of the fluid flowing through the diaphragm valve 10; a pressure of the fluid flowing through the diaphragm valve 10; a type of the fluid flowing through the diaphragm valve 10; a pH value of the fluid flowing through the diaphragm valve 10; a profile of the temperature and / or of the pressure of the fluid flowing through the diaphragm valve 10; a number of switching changes of the diaphragm valve 10; a frequency of the switching changes; a frequency spectrum of the switching changes; To carry out the method described below, it is already sufficient to take into account a single third variable, but it is also possible to take into account a plurality of third variables.At least some of the third variables just listed can, however, also be provided by an external device, for example, in the present case, by a controller of the process engineering plant 32 into which the diaphragm valve 10 is installed, and / or by the external data and processing portal 40. The third variables can be temporarily stored on the data memory 24 and / or on the data memory 30.The data and processing portal 40 shown in FIG. 2 includes a data memory 44, on which data, in particular relating to second variables, which characterize the diaphragm valve 10, are stored. Furthermore, the data and processing portal 40 comprises a determination device 46 and an action module 48. the determination device 46 is connected to the action module 48 and the data memory 44. It also receives first, second and third variables, namely from the data input and read-out device 36 by means of the transmission device 38, and from the process engineering plant 32.For the diagnosis of the state of the diaphragm valve 10, in particular of its valve diaphragm 14, the data stored in the data memories 24, 30 and 44 relating to the first, second and third variables are fed to the determination device 46 and are first digitally referenced or synchronized by the latter. This is understood to mean that the data relating to a type of digital identity of the specific individual diaphragm valve 10 and of its valve diaphragm 14 are combined, for example in the sense of: a specific valve diaphragm X having the unique identifier K was produced under specific conditions (raw material, charge, etc.), installed in a specific diaphragm valve V, faced during operation with various physical variables G (switching clearances, temperature, pressure, etc.) and (optionally) evaluated during maintenance or after removal by means of an optical surface inspection (crack formation R, bubble formation B, etc.).Parameterizable algorithms are stored in the determination device 46. The parameters of the algorithms are based at least first on generally known material laws relating to the service life of valve membranes, and on empirical relationships.The synchronized first, second and third variables are now processed in the ascertainment device 46 by the algorithms, specifically in such a way that a variable characterizing the current wear is ascertained. This can be, for example, a remaining service life of the valve diaphragm 14. It is also possible that a time of a probable membrane failure is predicted.The remaining lifetime is compared with a limit value in the determination device 46. If the determined remaining service life of the valve diaphragm 14 is below the limit value, it is assumed that the valve diaphragm 14 is imminent to break. A corresponding status information item is then generated in the action module 48, which alerts the operator of the process engineering plant 32 to the imminent breakage of the valve diaphragm 14. If necessary, a substitute part request can also be automatically generated in the action module 48 and transmitted to a corresponding logistics center. A maintenance request can also be generated automatically, for example, and transmitted to a corresponding maintenance operation.When replacing the valve membrane 14, but optionally also before, an operator can perform an optical surface inspection of the valve membrane 14, as a result of which a corresponding first variable is determined, which relates, for example, to an optical appearance or haptics of the surface of the valve membrane 14. The determined first variable or the determined first variables are then transmitted, for example, to the data input and read-out device 36, from where they are either transmitted directly to the data and processing portal 40 by means of the transmission device 38, or from where they are stored into the data memories 24 or 30 in accordance with the arrows 37 for intermediate storage.The first variables determined by the operator during the optical surface inspection and / or analysis can then be used in the determination device 46, for example, for adapting the parameters of the algorithms, whereby a continuous optimization is achieved. For this purpose, for example, the first quantities determined during the optical surface inspection are compared with corresponding first quantities that the determination device 46 has determined using the previous parameters of the algorithms.However, it is also possible that after an exchange of a valve diaphragm 14, the current state of the removed valve diaphragm 14 is determined, for example, by a corresponding optical surface inspection, and this current determined actual state is compared with the estimated state determined with the aid of the algorithms, taking into account the first, second and third variables. Any difference between the actual state and the estimated state determined by the algorithms can then be used to change the parameters. In the exemplary embodiment described above, the determination device 46 is arranged in the external data and processing portal 40 arranged at a distance from both the diaphragm valve 10 and the data input and readout device 36. For example, the data and processing portal 40 can be provided at a manufacturer 52 of the diaphragm valve 10 or at an external service provider specialized thereto, whereas the diaphragm valve 10 itself is provided at the operator 54 of the process engineering plant 32. In principle, however, it is also possible for the data and processing portal 40 to likewise be present at the operator 54. It is also conceivable that the determination device 46, the action module 48 and the data memory 44 are integrated into the data input and readout device 36, which thus forms a compact and mobile diagnostic system in this respect. Furthermore, it is also conceivable for the third variables to be provided exclusively by the process engineering plant 32.The above-described methods for diagnosing the diaphragm valve 10 may be performed, for example, as follows (FIG. 3 ):After a start block 56, the above-mentioned first, second and third quantities are detected in a block 58, and the corresponding data are stored in the data memories 24, 30 and 44 in the block 60. In block 62, the stored data are read out and the corresponding variables are provided to block 64, in which a current state of the valve diaphragm 14, in particular a current wear of the valve diaphragm 14, is determined or estimated using the provided variables or data by means of algorithms.In block 66, the ascertained current wear of the valve diaphragm 14 is compared with a limit value and, depending on the result of the comparison in block 68, an action, for example an exchange of the valve diaphragm 14, is initiated. In block 70, it is queried whether the valve diaphragm 14 has been replaced. If the result is "yes", the actual wear state of the removed valve diaphragm 14 is compared in block 72 with the estimated wear state "theoretical", namely determined by means of algorithms in block 64. Depending on the result of the comparison in block 72, the parameters of the algorithms are adapted in block 74, i.e. the algorithms are optimized. The method ends in block 76.

Claims

Method for diagnosing a diaphragm valve (10), which comprises the following steps: a) providing - at least one first variable which characterizes a valve diaphragm (14), - at least one second variable which characterizes at least one of the components of the diaphragm valve (10) which are not the valve diaphragm (14), and - at least one third variable which characterizes an operation of the diaphragm valve (10) and which is a process and / or environmental variable which has been accumulated in the past during the operation of the diaphragm valve (10), to a determination device (46); b) determining a variable which characterizes a current state of the valve diaphragm (14), in particular a current wear, from the first, second and third variables by the determination device (46) by means of at least one algorithm.Method according to Claim 1, characterized in that the ascertained variable characterizes a remaining service life of the valve diaphragm (14) or an equivalent variable, and in that, if the ascertained remaining service life or the equivalent variable is less than a limit value, an action is triggered by the ascertainment device (46).Method according to one of the preceding claims, characterized in that in step a) a first size is provided by an optical surface inspection.Method according to one of the preceding claims, characterized in that the at least one algorithm is modified taking into account a first variable provided by an optical surface inspection and / or another analysis of the valve diaphragm (14) and / or a variable characterizing the actual current state of the valve diaphragm (14).Method according to one of the preceding claims, characterized in that, in step a), at least one variable is provided by at least one sensor (42) integrated into the diaphragm valve (10).Method according to one of the preceding claims, characterized in that in step a) at least one variable is provided by an external device, in particular a controller of a plant (32) in which the diaphragm valve (10) is installed, and / or by an external data portal (40).Method according to one of the preceding claims, characterized in that at least one of the variables provided in step a) is a variable from the following group: a variable characterizing swelling and / or lowering of the valve membrane (14); a variable characterizing a surface quality of the valve membrane (14); a variable characterizing cracks in the valve membrane (14); a variable characterizing energy consumption of the membrane valve (10); a variable characterizing leakage of the membrane valve (10); a temperature of the fluid flowing through the membrane valve (10); a pressure of the fluid flowing through the membrane valve (10); a type of the fluid flowing through the membrane valve (10); a pH value of the fluid flowing through the membrane valve (10); a course of the temperature and / or the pressure of the fluid flowing through the diaphragm valve (10); a number of switching changes of the diaphragm valve (10); a frequency of the switching changes of the diaphragm valve (10); a frequency spectrum of the switching changes of the diaphragm valve (10); operating hours of the valve diaphragm (14) and / or of the diaphragm valve (10); an age of the valve diaphragm (14) and / or of the diaphragm valve (10); a material of the valve diaphragm (14) and / or of a valve body (12); a type of seat geometry; a type of the valve diaphragm (14); a type of a valve drive (20); a date of manufacture of the valve diaphragm (14); a place of manufacture of the valve diaphragm (14); a batch of manufacture of the valve diaphragm (14); Quality test variables of the valve diaphragm (14) and / or of the diaphragm valve (10); a supplier of the valve diaphragm (14); a delivery path of the valve diaphragm (14); a storage location of the valve diaphragm (14) and / or of the diaphragm valve (10); a storage duration of the valve diaphragm (14) and / or of the diaphragm valve (10); an insertion date of the valve diaphragm (14) and / or of the diaphragm valve (10); an ejection date of the valve diaphragm (14) and / or of the diaphragm valve (10); an installation date of the valve diaphragm (14) and / or of the diaphragm valve (10); an installation location of the valve diaphragm (14) and / or of the diaphragm valve (10); a name of the assembler; a name of the operator (54) of the diaphragm valve (10).Method according to one of the preceding claims, characterized in that it is carried out continuously at least temporarily during the operation of the diaphragm valve (10).Method according to one of the preceding claims, characterized in that it is executed at least temporarily only on demand.Method according to one of the preceding claims, characterized in that step b) is carried out in an external processing portal (40).Method according to one of the preceding claims, characterized in that the first and second variables are stored in an external data portal (40) arranged remote from the diaphragm valve (10) and the third variables are stored in a data memory (24, 30) integrated into the diaphragm valve (10) and are read out for provision before step b), and in that before step b) the first, second and third variables are synchronized with one another.Diagnostic system for a diaphragm valve (10), comprising: means for obtaining at least one first variable characterizing a valve diaphragm (14), at least one second variable characterizing at least one of the components of the diaphragm valve (10) other than the valve diaphragm (14), and at least one third variable characterizing an operation of the diaphragm valve (10) and being a process and / or environmental variable accumulated in the past during the operation of the diaphragm valve (10); and a determination means (46) determining a current state of the valve diaphragm (14), in particular a variable characterizing a current wear, from the first, second and third variables by the determination means (46) by means of at least one algorithm.

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