Mobile diagnostic device and diagnostic procedure for an actuator

Abstract

A mobile diagnostic device (20) for an actuator (1), in particular for a valve, comprises an interface (21) for establishing a data connection (30), preferably wireless, between the diagnostic device (20) and the actuator (1) and at least one sensor (26). The diagnostic device (20) is configured to acquire diagnostic data from the actuator (1) via the interface (21) and to acquire additional time-varying information data by means of the at least one sensor (26). According to the invention, the diagnostic data comprises data or values ​​of a control variable (s) of the actuator (1), and the information data comprises data or values ​​of a quantity acquired by the sensor (26) on the actuator (1).With the aid of such a diagnostic device (20) and by combining the acquired diagnostic and information data, new diagnostic possibilities arise on site at an actuator, in particular with regard to parameterization of the actuator.

Description

[0001] The invention relates to a mobile diagnostic device for an actuator according to the preamble of patent claim 1 and to a diagnostic method for an actuator according to the preamble of patent claim 9. Such a mobile diagnostic device or such a diagnostic method are known, for example, from DE 10 2016 207 058 A1.

[0002] Process control technology or actuator technology deals with measures for the continuous and discontinuous control of material and energy flows in conjunction with process control technology and sensor technology. The term "actuating device" is often understood to mean a system comprising an actuator, an actuator drive, and components or attachments for signaling and regulating or controlling the actuator. A actuating device is therefore essentially an actuator that comprises a complex mechatronic unit made up of several components. Examples of actuating devices for flowing materials are control valves (e.g., globe valves, ball valves, gate valves, flaps) and actuating machines (e.g., pumps). In more recent literature, the term "asset" is also used to describe a system comprising an actuator, an actuator drive, and associated components / attachments (i.e., to describe the overall mechatronic unit).the term “valve asset” for the control valve.

[0003] The actuator is a mechanical element that is in direct contact with a material flow and includes an actuator for the actual mechanical control of the material flow. In the case of a valve, the actuator comprises a valve body with a valve seat and a closing body, usually a valve cone, that interacts with the valve seat and serves as the actuator.

[0004] Actuators are designed to convert a control signal from an automation device into a movement so that the actuator moves to a position corresponding to the control signal. This can be, for example, a lifting or swiveling movement. Actuators can be designed as pneumatic, electric, or hydraulic drives.

[0005] The components or accessories for signaling and controlling the actuator include, for example, a so-called positioner. These can also include solenoid valves, limit switches, position feedback devices, or volume flow amplifiers. They also include lines (e.g., electrical, pneumatic, and / or hydraulic lines).

[0006] For cost reasons, actuators are often operated without a feedback channel, i.e. they receive a setpoint for a control or regulated variable (e.g. via a fieldbus) and then control or regulate locally to this setpoint.

[0007] Control valves are used in a wide variety of applications where the flow of a medium needs to be controlled. In the process industry, control valves are often controlled by pneumatic actuators. Using an electropneumatic positioner, a control pressure can be generated to actuate the valve depending on a determined valve position, thus moving the valve to a specified target position and holding it there.

[0008] In this case, the flow of the medium is controlled, for example, by a corresponding stroke of a valve cone interacting with the valve seat. The stroke is generated by the pneumatic actuator and transmitted to the valve cone by means of an actuating element (e.g., a valve rod). Such a valve or positioner is known, for example, from DE 10 2019 211 213 A1 and DE 10 2021 211 592 A1.

[0009] The pneumatic actuator can be designed as a linear or rotary actuator. Single- and double-acting pneumatic actuators are also known. As an alternative to pneumatic actuators, other drive types, such as electric motor-driven actuators, are also possible.

[0010] The valve position required for control and / or regulation can be determined in various ways. For example, it is known to transmit the movement of the actuating element (e.g., valve stem) to the interior of the positioner via a mechanical pickup (lever or coupling) on ​​the actuating element. A sensor is then located in the positioner to measure the position of the actuating element. The sensor can then be, for example, a potentiometer, a magnetic sensor, or an inductive sensor. It is also known to arrange a magnet on the actuating element, with a magnetic sensor inside the positioner then determining the position of the magnet.

[0011] Actuators, and especially their positioners, often require manual parameterization on-site or in a workshop. The positioner is usually capable of initiating itself. This process is started locally. Basic actuator parameters, such as limit stops, are automatically detected and stored accordingly. However, all necessary parameters for low-wear and correct operation of the actuator must be entered by the user. These parameters are often set incorrectly or incompletely. Incorrect input cannot be ruled out either.

[0012] Likewise, in the event of on-site service, key performance indicators or specific tests must be performed and read. Positioners already offer a wide range of diagnostics. These include self-diagnostics and diagnostics that provide information about the valve. These include, for example, full-stroke and partial-stroke tests, step response tests, valve performance tests, and valve signature tests. However, even these diagnostics have limitations.

[0013] DE 10 2016 207 058 A1 discloses a mobile diagnostic device and a diagnostic method for a field device. The diagnostic device has an interface, a storage device, and a camera. The diagnostic device is configured to acquire diagnostic data of the field device via the interface and store it in the storage device, as well as to acquire time-varying optical information data of an environment of the field device using the camera, such as the position of an agitator, the fill level of a liquid in a container, or the color of a liquid. Furthermore, the diagnostic device is configured to temporally relate the optical information data to the acquired diagnostic data and store it in the storage device. The diagnostic device is designed to be portable.The diagnostic data may, for example, refer to sensor data, in particular data from a fill level sensor, a level sensor, a temperature sensor, a pressure sensor, a pH sensor, and / or a conductivity sensor. The diagnostic data may also include status data or status values ​​of an actuator, such as a valve position.

[0014] DE 10 2013 019 601 A1 relates to an arrangement with a valve comprising a valve control device and a (static) optical identifier. The arrangement further comprises a mobile device having an optical detection unit for detecting the optical identifier and configured to generate an identifier data set from the image data acquired by the optical detection unit. To simplify the assignment of valve-related data to the valve, a valve data set is transmitted from the valve control device to the mobile device via a wireless communication connection, and a data set group comprising the identifier data set and the valve data set is generated in the mobile device. The valve can comprise a sensor that detects the position of a position sensor connected to a drive rod for the valve.The sensor data provides operating status data, which represents, for example, the open and / or closed positions or intermediate positions of the valve, and is stored in the valve control unit. The mobile device can be used, in a manner not further explained, to read operating states from the valve control unit and transmit them to an external evaluation unit.

[0015] Starting from a mobile diagnostic device according to the preamble of claim 1 or a diagnostic method according to the preamble of claim 9, the object of the present invention is to further improve the diagnosis of actuators.

[0016] This object is achieved in a diagnostic device according to claim 1 and a diagnostic method according to claim 9 by the respective characterizing part. Advantageous embodiments are the subject of the respective subclaims.

[0017] A mobile diagnostic device according to the invention for an actuator, in particular for a valve, comprises: - an interface for establishing a, preferably wireless, data connection between the diagnostic device and the actuator, - at least one sensor, wherein the diagnostic device is configured to - to record diagnostic data of the actuator via the interface and - to collect additional time-varying information data by means of at least one sensor.

[0018] The diagnostic data comprises data or values ​​of a control or regulated variable of the actuator, and the information data comprises data or values ​​of a variable detected by the sensor on the actuator. Preferably, the variable detected on the actuator is a physical variable generated by the actuator itself, e.g., an acceleration, a vibration, a noise, or the like.

[0019] According to the invention, information data is obtained from the actuator itself, and not just information data on the actuator's surroundings as in the prior art (although this can also be additionally recorded within the scope of the invention). Time-varying data or values ​​are recorded, and not just time-invariant static variables such as an optical identifier. Furthermore, the diagnostic data recorded from the actuator via the interface according to the invention comprises data or values ​​of a control or regulated variable of the actuator, in the case of a valve position controller, for example data or measured values ​​of the position of an actuating element for the valve. Thus, not only an operating state (e.g. valve open, valve closed) is recorded, but precise (numerical) data or values ​​of a control or regulated variable.

[0020] It has been discovered that a wide variety of time-varying variables can be measured on a control device. In combination with the data or values ​​of the actuator's control or regulated variable, these variables enable new diagnostic options, particularly for parameterizing the control device or a control and / or regulation device of the control device, or for increasing test reliability, without having to mount additional sensors on the control device itself. Since a mobile, preferably portable, diagnostic device is used, the variables can also be measured on control devices already installed in a system. Examples of variables that can be measured on the control device include vibrations or accelerations, acoustic noise, optical properties, etc.

[0021] In addition to the control or regulated variable, other variables can also be transmitted with the diagnostic data via the interface, e.g. pressures in an actuator or in a pressure supply line, or switch signals.

[0022] The sensor can measure the size on the actuator, for example on its actuator, actuator, positioner, other attachment components or on lines.

[0023] For example, in the case of a ball valve process valve with a magnetic pilot valve, if an acceleration sensor of the diagnostic device is brought into physical contact with the valve body, then small accelerations of the valve body can be measured and thus a switching of the pilot valve can be detected and taken into account in the diagnosis of the valve.

[0024] Using an acoustic sensor (e.g., a microphone) in the diagnostic device, airborne noise generated by vibrations of the actuator during opening and closing operations can be measured. An acoustic sensor can also be used to detect leaks in pneumatically driven actuators, including internal leaks in a control and / or regulating device (e.g., a positioner) of the actuator or leaks in supply lines.

[0025] Furthermore, an acoustic sensor can be used to determine shaft friction and breakaway torque, which can be taken into account when diagnosing an actuator. Such a sensor also makes it possible to determine the minimum force required to tightly close a valve and detect leaks in the valve itself. Through acoustic analysis and targeted control of the actuator, breakages in the springs of pneumatic actuators can also be detected.

[0026] An acceleration sensor can also be used to determine shaft friction and breakaway torque, which can be taken into account when diagnosing the actuator. The acceleration sensor also allows for the determination of the minimum force required to tightly close a valve and for spring break detection. Vibration measurement can also be used to detect cavitation in the valve.

[0027] With the help of an optical sensor (e.g. a camera), for example, the position of a pointer of a pressure gauge attached to the actuator can be detected and its movement on a circular arc can be determined.

[0028] It is particularly advantageous if the diagnostic device comprises several different sensors.

[0029] The interface is preferably a wireless communication interface, in particular an interface based on the Bluetooth standard. However, other interface technologies are also possible, such as a mobile radio-based, WLAN-based, infrared-based, Ethernet-based, and / or fieldbus-based interface.

[0030] The diagnostic device can advantageously be arranged, in particular integrated, at least partially in a smartphone, a mobile device, a notebook, or a tablet. The functions of the diagnostic device can also be implemented as software-based modules, so that the diagnostic device can be advantageously retrofitted. Integration into a smartphone is particularly advantageous, as this often already includes a large number of sensors that can be used for the diagnostic device. Furthermore, it is relatively compact and highly versatile in handling, which means its sensors can be very easily brought into physical contact with the actuator.

[0031] The diagnostic device can in particular be designed or configured to receive the diagnostic data via the interface from the associated actuator, in particular a control and / or regulating device of the actuator, and / or to read them out from the actuator.

[0032] According to a particularly advantageous embodiment, the diagnostic device is configured to control the actuator, preferably via the interface, in order to acquire the diagnostic data and the information data. For example, the control device can be controlled in such a way that it carries out a defined movement process (e.g. first a fast movement, followed by a slow movement) or that it assumes defined positions (e.g. the position end positions). This makes it possible to set a movement or position of the actuator required for a desired diagnostic process and to acquire the associated diagnostic and information data. Advantageously, the control of the actuator takes place simultaneously with the acquisition of the diagnostic data and information data. For this purpose, the diagnostic device can be configured, for example, to generate setpoints for the control or regulating variable and to send them to the actuator via the interface.The target values ​​can then, for example, refer to the defined movement process or the defined positions.

[0033] According to an advantageous embodiment of the invention, the diagnostic device is configured to simultaneously acquire the information data by means of the at least one sensor during acquisition of the diagnostic data.

[0034] The diagnostic device can comprise a storage device and be configured to store the acquired diagnostic data and information data in the storage device. Alternatively, the diagnostic device can also be configured to send the acquired diagnostic data and information data to an external storage device via the aforementioned interface or another interface and to receive them again via the respective interface. The storage device can then be cloud-based, for example. In both cases, the data can be evaluated directly in the diagnostic device.

[0035] The diagnostic device can comprise an evaluation unit configured to temporally associate, in particular synchronize, the information data acquired by the at least one sensor and the diagnostic data acquired via the interface. This can be achieved, for example, by assigning time information to the data (e.g., time stamps) at the time of generation in the actuator itself or during acquisition in the diagnostic device. The interface can also be used to temporally synchronize timers in the actuator and in the diagnostic device.

[0036] The diagnostic device can also be configured to send the acquired diagnostic data and the information data to an external evaluation unit via the said interface or another interface and to receive the diagnostic data and information data via the respective interface with a temporal assignment to one another, in particular temporal synchronization with one another.

[0037] According to a further advantageous embodiment, the diagnostic device comprises a user interface and is configured to output the diagnostic data and information data on the user interface with a temporal association with one another, in particular with a temporal synchronization with one another.

[0038] According to a particularly advantageous embodiment, the user interface is configured to detect a control command from a user for controlling the actuator. A diagnostic process with a targeted, predefined movement or positioning of the actuator can then be initiated directly on site by a user (e.g., a service technician) of the diagnostic device. It is also possible for the user to be offered several different predefined diagnostic processes to choose from on the user interface via a user dialog, and for the user to generate an associated control command by selecting one of the diagnostic processes. The predefined diagnostic processes or associated control commands can either already be stored in the storage device or can be received dynamically from the actuator via the interface, e.g., in a first step after a communication connection has been established with the actuator.

[0039] According to a further very advantageous embodiment, the diagnostic device is configured to output instructions for acquiring the information data by the at least one sensor to a user via the user interface. The instructions can include specific instructions regarding the positioning of the diagnostic device or the sensor on the actuator for acquiring the information data. The instructions can be stored, e.g., as an electronic document, already as a file in a storage device of the diagnostic device, or can be received dynamically from the actuator via the interface, e.g., in the first step after establishing a communication connection with the actuator.

[0040] According to a further advantageous embodiment, the at least one sensor is an acceleration sensor, a microphone, an optical sensor (camera), a humidity sensor, a brightness sensor, a shock sensor and / or a LiDAR sensor.

[0041] According to a further advantageous embodiment, the diagnostic device is configured to parameterize the actuator via the interface (preferably automatically) using the acquired diagnostic data and information data.

[0042] A diagnostic method according to the invention for a control device, in particular for a valve, comprises the steps: - Establishing a, preferably wireless, data connection between a mobile diagnostic device and the actuator, - Collecting diagnostic data of the actuator via the data connection by the mobile diagnostic device; - Capturing, with at least one sensor of the mobile diagnostic device, additional time-varying information data.

[0043] The diagnostic data includes data or values ​​of a control or regulated variable of the actuator and the information data includes data or values ​​of a variable detected by the sensor on the actuator.

[0044] According to an advantageous embodiment, the quantity detected at the actuator is a physical quantity generated by the actuator itself.

[0045] According to a further advantageous embodiment, the diagnostic device controls the actuator for acquiring the diagnostic data and the information data, preferably via the data connection.

[0046] The actuator can comprise a control and / or regulating device for controlling and / or regulating the position of the actuator using the controlled or regulated variable (e.g., by specifying setpoints for the controlled and / or regulated variable). The control and / or regulating device can then also comprise an interface via which the data connection to a corresponding interface of the mobile diagnostic device is established.

[0047] According to a further advantageous embodiment, the acquisition of the diagnostic data in the mobile diagnostic device takes place simultaneously with the acquisition of the information data by means of the at least one sensor.

[0048] The acquired diagnostic data and the information data can be stored in a storage device of the mobile diagnostic device. The storage device can be included in the diagnostic device itself or located externally, e.g., be cloud-based.

[0049] According to an advantageous embodiment, the information data acquired with the at least one sensor and the diagnostic data acquired via the interface are temporally associated with each other, in particular synchronized with each other. This can be done either directly in the mobile diagnostic device or externally, e.g., via a cloud-based system.

[0050] According to a further advantageous embodiment, the diagnostic data and information data that are related to one another in time, in particular that are synchronized in time, are output on a user interface of the mobile diagnostic device.

[0051] A user can also enter a control command for controlling the actuator via the user interface, and the diagnostic device then controls the actuator in accordance with this control command.

[0052] Advantageously, the diagnostic device provides a user with instructions for the acquisition of the information data by the at least one sensor via a user interface.

[0053] The at least one sensor is preferably an acceleration sensor, a microphone, an optical sensor (camera), an optical sensor, a shock sensor and / or a LiDAR sensor.

[0054] According to a further advantageous embodiment, the diagnostic device parameters the actuator (preferably automatically) using the acquired diagnostic data and information data.

[0055] The effects and advantages mentioned for the method according to the invention and its advantageous embodiments apply accordingly to the position controller according to the invention and its advantageous embodiments.

[0056] The invention and further advantageous embodiments of the invention according to the features of the dependent claims are explained in more detail below with reference to exemplary embodiments in the figures. Corresponding parts are provided with identical reference numerals. They show: Fig. 1 a control valve with an actuator, a position controller and a diagnostic device according to the invention, Fig. 2 a flow diagram of a method according to the invention, Fig. 3 a first measurement result on a process valve, Fig. 4 an excerpt from the measurement result of Fig. 3, Fig. 5 a second measurement result on a process valve, Fig. 6 a measuring process using a camera for diagnosis, Fig. 7 a measurement result for the measurement of Fig. 6.

[0057] Fig. 1 shows a simplified schematic diagram of a control device in the form of a control valve 1, which comprises an actuator 2, an electropneumatic actuator 5 and a valve position controller 8.

[0058] The actuator 2 comprises a valve body 4, a valve seat 3 and a closing body in the form of a valve cone 3' which interacts with the valve seat 3.

[0059] The control valve 1 controls the flow of a medium M by a corresponding stroke of the valve cone 3'. The stroke is generated by the electropneumatic actuator 5 and transmitted to the valve cone 3' by means of a control element 6, here a valve rod.

[0060] The actuator 5 is connected to the valve body 4 via a yoke 7. The electropneumatic position controller 8 is attached to the yoke 7 and comprises an electronic control unit 14 which, via a position sensor 9 acting on the actuating element 6, detects a numerical value of a valve position s, compares this with a setpoint S*, and controls the pneumatic actuator 5 via a pneumatic control unit 16 with a compressed air outlet to which a compressed air line 10 is connected, in order to compensate for the control difference.

[0061] The pneumatic actuator 5 shown here is a single-acting diaphragm actuator with spring return and an actuator chamber 11. The actuator chamber 11 is specifically pressurized or vented by the positioner 8 via line 10, so that a control pressure p is generated in it, which acts against the force of a spring 12 on a diaphragm 13 connected to the actuating element 6. Alternatively, a double-acting actuator can be used in conjunction with a double-acting positioner, which generates two opposing control pressures on the two sides of the diaphragm 13. Furthermore, a rotary actuator can be provided instead of a diaphragm actuator if a rotary movement is to be generated for the control valve 1 instead of a linear stroke movement.

[0062] A mobile diagnostic device 20 according to the invention for the control valve 1 comprises a first data interface 21, a second data interface 22, an evaluation unit 23, a storage device 24, a user interface 25 and several different sensors 26, 27 and 28.

[0063] The first data interface 21 serves to establish a data connection 30 between the diagnostic device 20 and a data interface 15 of the position controller 8.

[0064] The diagnostic device 1 is configured to acquire diagnostic data of the control valve 1 via the first interface 21 and to acquire additional time-varying information data using the sensors 26 to 28. The diagnostic data comprise data or values ​​of a control or regulated variable of the actuator 1, here the valve position s, and the information data comprise data or values ​​of a time-varying variable measurable at the control valve 1, in particular a physical variable generated by the control valve 1 itself.

[0065] The diagnostic data may also include further data or values, such as the control pressure p in chamber 11.

[0066] As has been discovered, a wide variety of time-varying variables can be measured at the control valve 1, particularly physical variables generated by the control valve 1 itself. In combination with the data or values ​​of the control or regulated variable s, and possibly also in combination with other variables of the control valve 1 (e.g., pressure in the actuator 5), these variables enable new diagnostic options, particularly for parameterizing the control valve 1 or the position controller 8 or for increasing test reliability, and without having to mount additional sensors on the control valve 1 itself. Examples of physical variables that can be measured at the control valve 1 and generated by the control valve 1 itself are vibrations or accelerations, acoustic noises, optical properties, etc.

[0067] Since a mobile, preferably portable, diagnostic device 20 is used, the measurement of the variables can also be carried out when the control valve 1 is already installed in a system.

[0068] For example, sensor 26 is an acceleration sensor, sensor 27 is an acoustic sensor (microphone) and sensor 28 is an optical sensor (camera).

[0069] The sensors 26 to 28 can detect the time-varying variables on the actuator 1, for example on its actuator 2, on the actuator 5, on the position controller 8, on the line 10 or on other components or lines not shown in detail.

[0070] The interfaces 15, 21 are preferably wireless communication interfaces, in particular interfaces based on the Bluetooth standard. However, other interface technologies are also possible, such as mobile radio-based, WLAN-based, infrared-based, Ethernet-based, and / or fieldbus-based interfaces.

[0071] The diagnostic device 20 can advantageously be arranged, in particular integrated, at least partially in a smartphone, a mobile device, a notebook, or a tablet. The functions of the diagnostic device 20 can also be implemented as software-based modules, so that the diagnostic device can advantageously be retrofitted.

[0072] The diagnostic device 20 is configured to simultaneously acquire the information data by means of the sensors 26 to 28 during acquisition of diagnostic data.

[0073] The diagnostic device 20 is further configured to store the diagnostic data and the information data acquired via the interface 21 in the storage device 24.

[0074] The evaluation unit 23 is configured to temporally associate, in particular synchronize, the information data acquired by the sensors 26-28 and the diagnostic data acquired via the interface 21. This can be achieved, for example, by assigning time information to the data (e.g., time stamps) at the time of generation in the position controller 8 or during acquisition in the diagnostic device 20. The first interface 21 and the interface 15 can also be used to temporally synchronize timers in the control valve 1 or the position controller 8 and in the diagnostic device 20.

[0075] Alternatively or additionally, the diagnostic device 20 can also be configured to send the acquired diagnostic data and the information data via the second interface 22 to an external service facility 40, in particular a cloud-based one.

[0076] For this purpose, the external service device 40 can comprise an interface 41, an evaluation unit 42 and a storage device 43.

[0077] The interfaces 22, 41 are preferably also interfaces for wireless communication, in particular mobile radio-based or WLAN-based interfaces.

[0078] The external service device 40 can only serve to store the diagnostic data and information data in the storage device 43, ie the diagnostic device 20 stores this data in the storage device 43 and retrieves it from there for subsequent evaluation by the evaluation unit 23.

[0079] However, the external service device 40 can also serve to assign the diagnostic data and the information data to one another in time in the evaluation unit 42, in particular to synchronize them with one another in time, and then to send the diagnostic data and information data with a temporal assignment to one another, in particular temporal synchronization with one another, to the diagnostic device 20.

[0080] The diagnostic device 20 is in turn configured to receive the diagnostic data and information data with the temporal assignment to one another, in particular the temporal synchronization with one another, via the second interface 22.

[0081] The user interface 25 is preferably designed as a graphical user interface and the diagnostic device is configured to output the diagnostic data and information data with a temporal association with one another, in particular temporal synchronization with one another, on the user interface 25.

[0082] The control and evaluation unit 23 is further configured to control the control valve 1 via the interface 21 for the acquisition of diagnostic data and information data. For this purpose, it can generate setpoints S* for the control or regulated variable and send them to the position controller 8 via the interface 21. This allows for simultaneous control of the control valve 1 and acquisition of diagnostic data and information data. For example, this can be used to specifically initiate and execute a predefined movement or positioning of the control valve 1 or its valve cone 3' for a diagnostic process.

[0083] For this purpose, the user interface 25 is configured to receive a control command from a user for controlling the control valve 1. A diagnostic process with a targeted, predefined movement or positioning of the control valve can thus be initiated directly on-site by a user (e.g., a service technician) of the diagnostic device 20. It is also possible for the user to be offered several different predefined diagnostic processes to choose from on the user interface 25 via a user dialog, and for the user to generate a control command associated with each of the diagnostic processes by selecting one of the diagnostic processes.

[0084] The predefined diagnostic processes or associated control commands can already be stored in the storage device 24 or can be received dynamically, e.g. in a first step after establishing a communication connection with the control valve 1, via the interface 21 from the control valve 1.

[0085] The diagnostic device 20 is also configured to output instructions for acquiring the information data by the sensors 26 to 28 to a user via the user interface 25. The instructions can include specific instructions regarding the positioning of the diagnostic device 20 or the respective sensor 26 to 28 on the control valve 1 for acquiring the information data. The instructions can be stored, e.g., as an electronic document, already as a file in the storage device 24, or can be received dynamically, e.g., in the first step after establishing a communication connection with the control valve 1, via the first interface 21 from the control valve 1.

[0086] Fig. 2 shows for the embodiment of Fig. 1 shows an example of a flow diagram 50 of a method according to the invention.

[0087] In a first step 51, a command to establish a data connection 30 between the interfaces 15 and 21 is received from a user via the user interface 25 and forwarded to the control and evaluation unit 23.

[0088] The control and evaluation unit 23 then establishes the data connection 30 between the diagnostic device 20 and the position controller 8, more precisely between their interfaces 15, 21, in a second step 52.

[0089] In a third step 53, the user is offered several test and parameterization options for selection on the user interface 25. The options may already be stored in the memory device 24 or may have been retrieved from the position controller 8 via the data connection 30.

[0090] In a fourth step 54, the user selects one of the options via the user interface 25. This selection is recorded by the control and evaluation unit 24 via the user interface 25.

[0091] Depending on this selection, the user is given instructions for using the sensors 26 to 28, e.g., their arrangement on the control valve 1, in a fifth step 55. For example, an instruction could be to bring the sensor into direct physical contact with the valve body 4 of the control valve 1.

[0092] In a sixth step 56, the control and evaluation unit 23 prompts the user via the user interface 25 to enter a start or control command for the selected test or parameterization option. Based on a start or control command received from the user via the user interface 25, the control and evaluation unit generates a control command for actuator 1—here, for example, a setpoint S* for the valve position—and sends it to the positioner 8 via the data connection 30.

[0093] In a seventh step 57, the position controller 8 determines a numerical value of a valve position s detected by the position sensor 9 and compares this with the setpoint S* supplied via the data interface 15. It then controls the pneumatic actuator 5 via the pneumatic control unit 16 and the compressed air line 10 to compensate for the control deviation. Time information (e.g., a time stamp) is optionally assigned to the value of the valve position s detected by the position sensor 9, and the valve position s is transmitted—if necessary, together with the time information—via the interfaces 15 and 21 to the diagnostic device 20. When the valve position s is detected in the interface 15, time information (e.g., a time stamp) can also be assigned.At the same time, the diagnostic device records measurable physical quantities such as accelerations (vibrations), noises or optical properties (e.g. a pressure gauge display) via the sensors 26 to 28 on the outside of the control valve 1 and also assigns time information (e.g. time stamp) to these.

[0094] The control and evaluation unit 23 stores this data together with the time information in the storage device 24. Alternatively or additionally, the data or measured values ​​can be stored in the cloud-based storage device 43.

[0095] In an eighth step 58, the data or measured values ​​acquired with the sensors 26 to 28 and the data or values ​​of the valve position s acquired via the interface 21 are temporally assigned to one another, in particular, synchronized with one another. This can be done directly in the mobile diagnostic device 20 by the control and evaluation unit 23. Alternatively or additionally, this can also be done in the cloud-based control and evaluation unit 42, wherein the data are then transmitted back to the diagnostic device 20 with a temporal assignment to one another, in particular, a temporal synchronization with one another.

[0096] In a ninth step 59, the temporally associated, in particular temporally synchronized, data from the control and evaluation unit 23 are output to the user interface 25 and can be used by the user for parameterization during commissioning and for extended diagnostics or tests. Preferably, the diagnostic device 20 automatically parameters the position controller 8 using the acquired diagnostic data and information data.

[0097] Fig. Figure 3 illustrates new diagnostic options resulting from the invention, using a ball valve process valve as an example. The ball valve process valve comprises a magnetic pilot valve, a double-acting electropneumatic actuator, and a valve position controller.

[0098] The diagnostic device is integrated into a smartphone.

[0099] Time-synchronized measurement results of the following quantities are displayed over time T (in seconds sec): a) Diagnostic data: P1, P2: Values ​​of chamber pressures of the double-acting electro-pneumatic actuator in bar, S: Value of a position S of a valve rod of the actuator (controlled variable) normalized to a maximum value in %, Pz: value of a pressure in a compressed air line from a valve of the valve position controller to the electropneumatic actuator, Ue: Control signal at the solenoid valve normalized to maximum value in %. b) Information data Ax, Ay, Az: Values ​​of acceleration components in x, y and z directions on the valve body in m / s2

[0100] Valve vibrations can be measured based on the accelerations Ax, Ay, and Az. The accelerations Ax, Ay, and Az of the valve can be measured using an acceleration sensor of a diagnostic device according to the invention, which is in direct, physical contact with the valve body and thus essentially measures structure-borne sound from the valve body.

[0101] From the acceleration data of Fig. 3 shows a switching operation in the solenoid valve (designated 60), pressure changes in the chambers (designated 61), breakaway torques of the drive (designated 62) and closing operations of the valve (designated 63).

[0102] The vibrations of the valve body also generate airborne noise, which can then be measured, for example, with a microphone in the diagnostic device. Vibrations that generate airborne noise are Fig. 3 is indicated by the reference number 64.

[0103] The measurement shows that the data or measured values ​​of the accelerations Ax, Ay, Az contain additional information compared to the position and control data, which can be used for automated parameterization or to determine the status of the control valve. Information can even be obtained from the switching of the solenoid valve. 1. Application example using a smartphone microphone

[0104] The smartphone with integrated diagnostic device 20 according to Fig. 1 communicates with the positioner 8 via a wireless Bluetooth connection 30. A user can select assisted parameterization or control valve diagnostics via a menu on a graphical user interface 25 using a smartphone application. The control and evaluation unit 23 provides the user with a graphical representation of the correct position of the smartphone relative to the control valve 1 (alignment and distance from the control valve 1) on the user interface 25. After pressing a corresponding button on the user interface 25, a control command is sent to the positioner 8 via the data connection 30. At the same time, the measurement to determine the acoustic information data starts using the built-in microphone. 1a) Leakage detection:

[0105] By specifically controlling the existing chambers (depending on the actuator variant, single-acting or double-acting), the location of the leak can be detected. Different fault conditions can be distinguished: - Leakage in a supply line (e.g. in line 10) - Leakage in the positioner 8 itself (e.g. diaphragm rupture) - Leakage in actuator 5 (in the case of double-acting actuators, the leakage of both chambers can be determined quantitatively)

[0106] In particular, the identification of the leak is an additional aid during service calls. It can also detect an internal leak in the positioner or a leak in a supply line. 1b) Determination of shaft friction / breakaway torque:

[0107] Some positioners offer two standard diagnostic modes for assessing the friction in the control valve. These include the full-stroke and partial-stroke tests. The number of pressure surges and the temporal behavior of the position change are used for analysis. Additional information can be obtained through acoustic diagnostics to improve the test.

[0108] Partial stroke tests are always performed by a system operator when complete closing or opening is not permitted during operation. In this case, this risk can be minimized using acoustic diagnostics, for example, or even performed without any significant change in position. Fig. 4 shows an excerpt from Fig. 3 shows an enlarged view of the breakaway time period. Here, it can be seen that due to internal stresses and minimal movements of the valve rod, the moment shortly before breakaway (see reference numeral 65) can already be detected through vibration and / or acoustic data.

[0109] Two further particularly advantageous applications for determining the breakaway torque by means of acoustic analysis using a microphone are explained below: Every actuator with a plain bearing has not only a defined sliding friction but also a static friction. The breakaway torque is the moment at which the acting force overcomes this holding force of the static friction and starts the movement. After that, the driving force is only counteracted by an inertial force, internal systemic forces, and the force of sliding friction. In valves, especially safety valves, corrosive or adhesive effects often occur due to the long-term static position. These then largely determine the strength of the static friction. This value is particularly interesting for the user, especially when performing a trend analysis. However, once the valve has been moved once, this value can no longer be determined using conventional methods. With the invention, the breakaway torques can be determined even afterwards.

[0110] In addition to corrosive or adhesive effects after extended periods of inactivity, constant movement in a plain bearing also affects its sliding friction as well as static friction (wear). These two friction values ​​can be determined by repeatedly controlling the drive under realistic conditions at several points within the working range. In addition to the condition of the plain bearing, the condition can also be determined along the length of the shaft's working range. 1c) Determination of the minimum force required for tight closing / leakage detection of the process valve

[0111] The end positions of a control valve can often be detected by the positioner itself. The end positions are defined as the position at which there is no further change in position upon further increase or decrease in pressure. If a plant operator absolutely requires a stable end point for the valve (usually closed state) for their process, they can ensure this by parameterizing the "tight closing" function. The positioner then further increases or decreases the pressure in the actuator. This presses the valve body into the end position or seal with excess force, making it more reliably closed, e.g., against any pressure surges that may occur. However, this method also leads to greater wear on the valve body and seal.

[0112] During penetration, as well as during compression of the valve body into the seal, vibrations occur, even if movement can no longer be detected by the positioner. This fact and the use of the method described here using the smartphone microphone can be used to quantify the strength of the compression. This is illustrated by the enlarged section of the measurement data from Fig. 3 in Fig. 5 visualized.

[0113] 66 indicates the contact between the valve body and the seal. From the moment of contact, a further increase in pressure only results in a change in the position s of the control valve of 0.7% of the total travel. This can no longer be meaningfully resolved by the positioner. The lower diagram shows the vibration data recorded synchronously across the full measuring range. The vibrations generated during compression can still be well resolved, providing additional information.

[0114] In addition to the vibrations from pressing, the flow through the process valve also generates vibrations and thus sound propagation. This means that the moment with zero flow must also be characteristically detected using a microphone.

[0115] By using this information, the plant operator can implement automated parameterization of the tight closure with minimal wear on the process valve. Leak detection of the process valve is also possible. 1d) Spring break detection

[0116] Pneumatic actuators predominantly contain steel springs that guarantee a defined final position of the process valve in the event of a pressure loss. These springs can fatigue or even break, which, depending on the design, means that this function can no longer be guaranteed. Such spring breakages can currently only be detected with considerable effort (disassembly and visual inspection or by trend analysis of pressure surge pulse widths).

[0117] Through acoustic analysis and targeted control, it is possible to detect this type of error due to very characteristic acoustic signatures. 1e) Cavitation detection

[0118] Cavitation is one of the most critical malfunctions in process valves, which plant operators must avoid at all costs. Even short periods of operation under cavitation can lead to the destruction of the process valve. Cavitation generates strong vibrations and thus a characteristic acoustic signature, which can be detected using the concept presented here using a smartphone microphone.

[0119] Based on the plant operator's domain expertise, the process valve design and corresponding parameterization must be such that cavitation is prevented under all process conditions. Targeted parameterization through positioner control in combination with acoustic diagnostics can support the plant operator in this regard. The benefits for the plant operator are: - Avoiding any incorrect parameterization - Protection of the process valve even with widely varying process parameters - Avoiding an oversized and therefore too expensive design of the process valve - Increasing throughput / operating the process at the optimal limit 2. Application example using the smartphone accelerometer

[0120] The cause of airborne sound radiation, and thus the basis for acoustic diagnosis, is vibrations of the control valve. This structure-borne sound also propagates throughout the entire control valve and can be detected using the contact-based method of accelerometer measurement on the surface. The two methods, airborne sound measurement and accelerometer measurement, differ significantly in the frequency ranges in which their highest sensitivity lies. This is due, on the one hand, to the sensors built into smartphones (accelerometer and microphone), as well as to the propagation characteristics of structure-borne sound and its coupling / transmission to airborne sound.

[0121] Thus, frequencies <1kHz can be better detected with the acceleration sensor and frequencies 1-40kHz can be better detected with the microphone.

[0122] However, a combination of both sensors is also possible.

[0123] Possible application examples using the acceleration sensor alone are: - Determination of shaft friction / breakaway torque - Detection and parameterization for tight closing - Spring break detection

[0124] In this application example, the user starts the measurement via the smartphone application as described above. The smartphone must be pressed against specific points on the control valve in a precisely defined orientation. 3. Application example using the smartphone camera

[0125] The smartphone communicates with the positioner via a wireless connection. The user can select a supported parameterization or control valve diagnostic via an application menu. The user is shown a graphical representation of the correct position of the smartphone relative to the control valve (alignment and distance from the control valve). After pressing a corresponding button on the smartphone, a control command is sent to the positioner. At the same time, a recording begins using the smartphone's integrated camera. By processing the image data, the position of the pointer of an attached pressure gauge can be detected, for example, and its movement on the circular arc can be determined. This is demonstrated, for example, in Fig. 6. The control valve 1 comprises a pressure gauge 70 with a pointer 71. Reference numeral 80 denotes a smartphone into which the diagnostic device 20 according to the invention is integrated. The graphical user interface 81 of the smartphone 80 displays an image 83 of the pressure gauge 70 captured by a camera (not shown in detail) of the smartphone, which image is shown even more enlarged in an image section 74. Fig. 7 shows exemplary values ​​of the pressure Pz and the position Z of the pointer 71 over time T.

[0126] The stiffness of the overall system can be estimated from a step response, designated 85, of the movement of the pointer 71 to a defined pressure surge at the supply pressure PZ. However, the stiffness of the pneumatic actuator is dominant here. Thus, the pointer's position signal contains information about the condition of the actuator's diaphragm and spring. In particular, a trend analysis across multiple measurements thus provides information about potential system degradation. Vibrations and deformations of the control valve can also be identified using image processing.

[0127] Combinations of the use cases outlined here, or the simultaneous or sequential use of multiple smartphone sensors, are also possible. One example is the simultaneous use of microphone and vibration data to eliminate the respective spectral insensitivity of the individual sensors. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2016 207 058 A1 [0001, 0013] DE 10 2019 211 213 A1

[0008] DE 10 2021 211 592 A1

[0008] DE 10 2013 019 601 A1

[0014]

Claims

[1] Mobile diagnostic device (20) for an actuator (1), in particular for a valve, comprising: - an interface (21) for establishing a, preferably wireless, data connection (30) between the diagnostic device (20) and the actuator (1), - at least one sensor (26), wherein the diagnostic device (20) is designed to - to record diagnostic data of the actuator (1) via the interface (21) - to detect additional time-varying information data by means of the at least one sensor (26), characterized by , that - the diagnostic data comprise data or values ​​of a control or regulating variable(s) of the actuator (1), - the information data comprise data or values ​​of a variable detected by the sensor (26) on the actuator (1). [2] Mobile diagnostic device (20) according to claim 1, wherein the quantity detected at the actuator (1) is a physical quantity generated by the actuator (1) itself. [3] Mobile diagnostic device (20) according to claim 1 or 2, wherein it is configured to control the actuator (1), preferably via the interface (21), for the acquisition of the diagnostic data and the information data. [4] Mobile diagnostic device (20) according to one of the preceding claims, wherein it is configured to simultaneously acquire the information data by means of the at least one sensor (26) during acquisition of diagnostic data. [5] Mobile diagnostic device (20) according to one of the preceding claims, comprising an evaluation unit (23) which is designed to temporally associate the information data acquired with the at least one sensor (26) and the diagnostic data acquired via the interface (21) with one another, in particular to synchronize them with one another [6] Mobile diagnostic device (20) according to one of the preceding claims, wherein it comprises a user interface (25) and is configured to output the diagnostic data and information data with a temporal association with one another, in particular temporal synchronization with one another, on the user interface (25). [7] Mobile diagnostic device (20) according to one of the preceding claims, wherein the at least one sensor (26) is an acceleration sensor, a microphone, an optical sensor (camera), a humidity sensor, a brightness sensor, a shock sensor and / or a LiDAR sensor. [8] Mobile diagnostic device (20) according to one of the preceding claims, wherein it is configured to parameterize the actuator (1) via the first interface (21) using the acquired diagnostic data and information data. [9] Diagnostic method for a control device (1), in particular for a valve, comprising the steps: - establishing a, preferably wireless, data connection (30) between a mobile diagnostic device (20) and the actuator (1), - Acquiring diagnostic data of the actuator (1) via the data connection by the mobile diagnostic device (20); - detecting, with at least one sensor (26) of the mobile diagnostic device, additional time-varying information data, characterized by , that - the diagnostic data comprise data or values ​​of a control or regulating variable(s) of the actuator (1), - the information data comprise data or values ​​of a variable detected by the sensor (26) on the actuator (1). [10] Diagnostic method according to claim 9, wherein the quantity detected at the actuator (1) is a physical quantity generated by the actuator (1) itself. [11] Diagnostic method according to claim 9 or 10, wherein the diagnostic device (20) controls the actuator (1) for acquiring the diagnostic data and the information data, preferably via the data connection (30). [12] Diagnostic method according to one of claims 9 to 11, wherein the acquisition of the diagnostic data in the mobile diagnostic device (20) takes place simultaneously with the acquisition of the information data by means of the at least one sensor (26). [13] Diagnostic method according to one of claims 9 to 12, wherein the information data acquired with the at least one sensor (26) and the diagnostic data acquired via the interface (21) are temporally associated with one another, in particular synchronized with one another. [14] Diagnostic method according to one of claims 9 to 13, wherein the diagnostic data and information data which are time-aligned with one another, in particular time-synchronized with one another, are output on a user interface (25) of the mobile diagnostic device (20). [15] Diagnostic method according to one of claims 9 to 14, wherein the at least one sensor is an acceleration sensor, a microphone, an optical sensor (camera), a humidity sensor, a brightness sensor, a shock sensor and / or a LiDAR sensor. [16] Diagnostic method according to one of claims 9 to 15, wherein the diagnostic device (20) parameterizes the actuator (1) using the acquired diagnostic data and information data.

Images