Search

CN-121113490-B - Detection method and system for automatic drain valve

CN121113490BCN 121113490 BCN121113490 BCN 121113490BCN-121113490-B

Abstract

The disclosure provides a detection method and a detection system for an automatic drain valve, and relates to the technical field of equipment testing. The method comprises the steps of collecting working data of a drain valve to be detected, determining a flow peak change trend and a drain efficiency attenuation degree based on flow data recorded by continuous drainage for multiple times, generating an impurity deposition index, generating an impurity stripping index based on an instantaneous change rate of flow speed data and a change amount of flow data, determining a first impurity deposition degree in combination with the impurity deposition index, determining vibration abnormal factors and acoustic abnormal factors based on vibration data and acoustic data, determining an impurity abnormal score in combination with the first impurity deposition degree, determining working intensity based on the vibration data, the pressure data and the liquid level data, obtaining drain frequency of the drain valve to be detected after last maintenance, determining fault probability based on the working intensity, the drain frequency and the impurity abnormal score, and predicting fault condition of the drain valve to be detected based on the fault probability. The present disclosure improves fault detection accuracy.

Inventors

  • DU JIANHUA
  • WANG YETAI

Assignees

  • 苏州工学院

Dates

Publication Date
20260508
Application Date
20251111

Claims (9)

  1. 1. A method of detecting an automatic drain valve, the method comprising: Collecting working data of a drain valve to be detected, wherein the working data comprises flow data, flow rate data, vibration data, acoustic data, pressure data and liquid level data, the vibration data is valve vibration data in the drainage process collected by a vibration sensor arranged on the outer wall of the drain valve to be detected, the pressure data is valve inner side pressure data in the drainage process collected by a pressure sensor arranged on the inner side of the drain valve to be detected, and the liquid level data is the liquid level height of accumulated water in a system of the drain valve to be detected, collected by a liquid level sensor arranged in the inner side of the drain valve to be detected; Determining a flow peak value change trend and a drainage efficiency attenuation degree based on flow data recorded by continuous repeated drainage, and generating an impurity deposition index based on the flow peak value change trend and the drainage efficiency attenuation degree; generating an impurity stripping index based on the instantaneous change rate of the flow rate data and the corresponding change amount of the flow rate data, and determining a first impurity deposition degree based on the impurity deposition index and the impurity stripping index; determining a vibration abnormality factor and an acoustic abnormality factor based on the vibration data and the acoustic data, and determining an impurity abnormality score of the drain valve to be detected based on the vibration abnormality factor, the acoustic abnormality factor and the first impurity deposition degree; Determining the operating strength based on the vibration data, the pressure data, and the liquid level data, comprising: For current drainage, acquiring first pressure data acquired by a pressure sensor before the current drainage and second pressure data acquired after the current drainage, and calculating the difference between the first pressure data and the second pressure data to be recorded as a pressure difference before and after the drainage; acquiring a vibration amplitude mean value acquired by a vibration sensor in the current drainage process, and determining the operation strength of equipment based on the vibration amplitude mean value and the pressure difference value before and after drainage; acquiring maximum liquid level data of a water storage device in a system to which a drain valve to be detected belongs and current liquid level data acquired through a liquid level sensor, and determining theoretical drainage based on the maximum liquid level data, the current liquid level data and the volume of the water storage device; acquiring actual drainage amount of current drainage, and recording a difference value between the actual drainage amount and the theoretical drainage amount as an impurity residual value; determining working strength based on effective drainage time, equipment operation strength and impurity residual value, wherein the effective drainage time is determined based on the flow data in the current drainage process; Acquiring the drainage frequency of a drainage valve to be detected after the last maintenance, and determining the fault probability based on the working strength, the drainage frequency and the impurity abnormal score; and predicting the fault condition of the drain valve to be detected based on the fault probability.
  2. 2. The method for detecting an automatic drain valve according to claim 1, wherein the determining a flow peak variation trend and a drain efficiency attenuation degree based on the flow data recorded for a plurality of consecutive drains and generating an impurity deposition index based on the flow peak variation trend and the drain efficiency attenuation degree includes: Acquiring flow peaks in the flow data recorded by continuous repeated drainage, and constructing a flow peak change curve by taking drainage times as independent variables and the flow peaks corresponding to the drainage times as dependent variables; performing straight line fitting on the flow peak change curve, determining the slope of the straight line obtained by fitting, and marking the slope as the flow peak change trend; acquiring primary drainage amount and primary drainage duration of the drainage valve to be detected for primary drainage from the last maintenance, and determining primary drainage efficiency based on the primary drainage amount and the primary drainage duration; acquiring current drainage amount and current drainage duration of the drainage valve to be detected from the current drainage after the last maintenance, and determining current drainage efficiency based on the current drainage amount and the current drainage duration; determining the drainage efficiency attenuation degree based on the primary drainage efficiency, the current secondary drainage efficiency and the effective drainage time; and calculating the product of the absolute value of the flow peak value change trend and the drainage efficiency attenuation degree to generate the impurity deposition index.
  3. 3. The method of detecting an automatic drain valve according to claim 2, wherein determining an effective drain time based on the flow data during the current drain includes: obtaining the system design maximum flow of the drain valve to be detected, and calculating the product of the system design maximum flow and a preset proportion to obtain a flow threshold; and obtaining target flow data which is not smaller than the flow threshold in the current drainage process, determining the sum of drainage time corresponding to the target flow data, and recording the sum as the effective drainage time.
  4. 4. The method of detecting an automatic drain valve according to claim 1, wherein the generating an impurity peeling index based on the instantaneous rate of change of the flow rate data and the corresponding amount of change of the flow rate data, and determining a first impurity deposition degree based on the impurity deposition index and the impurity peeling index, comprises: for each sampling time in the current drainage, acquiring the flow data and the flow velocity data of the current sampling time and the previous sampling time; determining an instantaneous rate of change of the flow rate data at the current sampling time based on the flow rate data at the current sampling time and the previous sampling time and a sampling interval, and determining a flow rate turning point based on the instantaneous rate of change of the flow rate data; Determining the difference between the instantaneous change rates of the flow rate data at the current sampling time and the previous sampling time corresponding to the flow rate turning point, and marking the difference as a first change amount; Determining the difference between the current sampling time corresponding to the flow rate turning point and the flow data of the previous sampling time, and marking the difference as a second variation; Determining the product of the first variation and the second variation to obtain the impurity stripping index; And determining the product of the impurity deposition index and the impurity stripping index to obtain the first impurity deposition degree.
  5. 5. The method for detecting an automatic drain valve according to claim 1, wherein the vibration data is valve vibration data during draining collected by a vibration sensor mounted on an outer wall of the drain valve to be detected, the acoustic data is sound data emitted by a valve during draining collected by an acoustic sensor mounted on an outer wall of the drain valve to be detected, and the determining the vibration abnormality factor and the acoustic abnormality factor based on the vibration data and the acoustic data includes: For each sampling time in the current drainage, acquiring the actual vibration amplitude and the actual vibration frequency acquired by the vibration sensor, and the actual noise intensity and the actual noise frequency acquired by the acoustic sensor; Acquiring a set vibration amplitude upper limit and a set vibration frequency upper limit of the drain valve to be detected, and calculating the difference between the actual vibration amplitude and the vibration amplitude of the set vibration amplitude upper limit and the difference between the actual vibration frequency and the vibration frequency of the set vibration frequency upper limit; Determining the product of the difference between the vibration amplitudes and the difference between the vibration frequencies, and recording the product as the vibration abnormality factor; acquiring a set noise intensity upper limit and a set noise frequency upper limit of the drain valve to be detected, and calculating the difference between the actual noise intensity and the noise intensity of the set noise intensity upper limit and the difference between the actual noise frequency and the noise frequency of the set noise frequency upper limit; Determining the product of the difference between the noise intensities and the difference between the noise frequencies, and recording the product as the acoustic anomaly factor.
  6. 6. The method for detecting an automatic drain valve according to claim 5, wherein the determining the impurity abnormality score of the drain valve to be detected based on the vibration abnormality factor, the acoustic abnormality factor, and the first impurity deposition degree includes: determining the average value of the vibration abnormality factors at each sampling moment in the current drainage process, and marking the average value as the vibration abnormality score of the current drainage; Determining the average value of the acoustic anomaly factors at each sampling moment in the current drainage process, and recording the average value as the acoustic anomaly score of the current drainage; determining an anomaly correlation factor for the vibration anomaly score and the acoustic anomaly score; determining a second impurity deposition level based on the anomaly correlation factor, the vibration anomaly score, and the acoustic anomaly score; and determining the confidence of the first impurity deposition degree based on the first impurity deposition degree and the second impurity deposition degree, and recording the product of the first impurity deposition degree and the confidence as the impurity abnormality score.
  7. 7. The method for detecting an automatic drain valve according to claim 6, wherein the determining the abnormality correlation factor of the vibration abnormality score and the acoustic abnormality score includes: determining the product of the vibration abnormal score and the acoustic abnormal score, and recording the product as a sensor abnormal score product; Determining the absolute value of the difference value of the vibration abnormal score and the acoustic abnormal score, and marking the absolute value as the absolute value of the difference value of the sensor abnormal score; and determining an anomaly correlation factor for the vibration anomaly score and the acoustic anomaly score based on the sensor anomaly score product and the absolute value of the sensor anomaly score difference.
  8. 8. The method for detecting an automatic drain valve according to claim 1, wherein the predicting a fault condition of the drain valve to be detected based on the fault probability includes: acquiring the liquid level data before the next drainage; predicting an increase in the probability of failure of the next drain relative to the current drain based on the liquid level data before the next drain and the probability of failure of the current drain; determining the failure probability of the next drainage based on the failure probability of the current drainage and the failure probability increment; And if the fault probability of the next water discharge is larger than a preset threshold value, sending a stop instruction to the water discharge valve to be detected, and maintaining the water discharge valve to be detected.
  9. 9. A system for detecting an automatic drain valve, the system comprising: The system comprises a data acquisition module, a control module and a control module, wherein the data acquisition module is used for acquiring working data of a drain valve to be detected, the working data comprises flow data, flow rate data, vibration data, acoustic data, pressure data and liquid level data, the vibration data is valve vibration data in the drainage process acquired by a vibration sensor arranged on the outer wall of the drain valve to be detected, the pressure data is valve inner side pressure data in the drainage process acquired by a pressure sensor arranged on the inner side of the drain valve to be detected, and the liquid level data is the liquid level height of accumulated water in the system of the drain valve to be detected acquired by a liquid level sensor arranged in the inner side of the drain valve to be detected; The data processing module is used for determining a flow peak value change trend and a drainage efficiency attenuation degree based on the flow data recorded by continuous drainage for many times, and generating an impurity deposition index based on the flow peak value change trend and the drainage efficiency attenuation degree; the data processing module is further used for generating an impurity stripping index based on the instantaneous change rate of the flow rate data and the corresponding change amount of the flow rate data, and determining a first impurity deposition degree based on the impurity deposition index and the impurity stripping index; The data processing module is further used for determining a vibration abnormality factor and an acoustic abnormality factor based on the vibration data and the acoustic data, and determining an impurity abnormality score of the drain valve to be detected based on the vibration abnormality factor, the acoustic abnormality factor and the first impurity deposition degree; the data processing module is further used for determining working intensity based on the vibration data, the pressure data and the liquid level data, obtaining drainage frequency of the drain valve to be detected after last maintenance, and determining fault probability based on the working intensity, the drainage frequency and the impurity abnormal score; The data processing module is also used for acquiring first pressure data acquired by the pressure sensor before the current drainage and second pressure data acquired after the current drainage aiming at the current drainage, calculating the difference between the first pressure data and the second pressure data, and recording the difference as the pressure difference before and after the drainage; acquiring a vibration amplitude mean value acquired by a vibration sensor in the current drainage process, and determining the operation strength of equipment based on the vibration amplitude mean value and the pressure difference value before and after drainage; acquiring maximum liquid level data of a water storage device in a system to which a drain valve to be detected belongs and current liquid level data acquired through a liquid level sensor, and determining theoretical drainage based on the maximum liquid level data, the current liquid level data and the volume of the water storage device; acquiring actual drainage amount of current drainage, and recording a difference value between the actual drainage amount and the theoretical drainage amount as an impurity residual value; determining working strength based on effective drainage time, equipment operation strength and impurity residual value, wherein the effective drainage time is determined based on the flow data in the current drainage process; and the fault detection module is used for predicting the fault condition of the drain valve to be detected based on the fault probability.

Description

Detection method and system for automatic drain valve Technical Field The invention relates to the technical field of equipment testing, in particular to a detection method and a detection system of an automatic drain valve. Background Automatic drain valves are critical components in industrial fluid systems, the operating state of which directly determines the energy efficiency level and operational safety of the system. In the long-term operation process of an industrial system, condensed water is continuously generated due to temperature fluctuation or medium condensation, and the condensed water is often mixed with dust in the air, rust slag generated by pipeline corrosion, oil mist left by system lubrication, scale formed by medium crystallization and other impurities. If the impurity-containing condensed water is not discharged in time, the impurity-containing condensed water can be continuously accumulated in the system, so that a series of serious problems are caused, namely, on one hand, the corrosion of the inner wall of a pipeline is accelerated, the service life of the pipeline is shortened, and on the other hand, the functional faults such as the clamping failure of a pneumatic element, the remarkable reduction of the heat exchange efficiency of a heat exchanger, the reduction of the vacuum degree of a vacuum pump and the like are caused, and in the extreme case, the whole industrial system is stopped, so that the great economic loss is caused to production operation. The related art generally adopts a traditional manual operation mode to detect an automatic drain valve, and specifically comprises visual inspection of a drain state, manual start-stop test of valve response, judgment of whether working sound of the valve is abnormal or not through hearing, and the like. However, the detection method mainly adopts a strategy of post maintenance or regular inspection, from the aspect of detection timeliness, the post maintenance strategy is only used for intervening in maintenance after the drain valve is blocked or the system is abnormal due to the drainage problem, the early warning capability is lacking, the system loss before the fault is avoided, the regular inspection strategy is used for carrying out detection according to a fixed period, but if the sudden impurities are rapidly accumulated during the interval between the two inspection, a detection blind area is easy to form, and the fault cannot be found in time, so that the influence range is enlarged. Disclosure of Invention In view of the above, the embodiments of the present disclosure provide a method and a system for detecting an automatic drain valve, so as to solve the problems in the related art that a post-maintenance strategy cannot avoid system loss before a fault occurs, and when sudden impurities are rapidly accumulated during a period of two inspection intervals of a periodic inspection strategy, a detection blind area is easily formed, so that the fault cannot be found in time, and the influence range is enlarged. According to a first aspect of the present disclosure, a method for detecting an automatic drain valve is provided, and the adopted technical scheme is as follows: collecting working data of a drain valve to be detected, wherein the working data comprise flow data, flow velocity data, vibration data, acoustic data, pressure data and liquid level data; Determining a flow peak value change trend and a drainage efficiency attenuation degree based on the flow data recorded by continuous and repeated drainage, and generating an impurity deposition index based on the flow peak value change trend and the drainage efficiency attenuation degree; generating an impurity stripping index based on the instantaneous change rate of the flow rate data and the corresponding change amount of the flow rate data, and determining a first impurity deposition degree based on the impurity deposition index and the impurity stripping index; Determining a vibration abnormality factor and an acoustic abnormality factor based on the vibration data and the acoustic data, and determining an impurity abnormality score of the drain valve to be detected based on the vibration abnormality factor, the acoustic abnormality factor and the first impurity deposition degree; determining working intensity based on the vibration data, the pressure data and the liquid level data, acquiring drainage frequency of the drain valve to be detected after last maintenance, and determining fault probability based on the working intensity, the drainage frequency and the impurity abnormal score; And predicting the fault condition of the drain valve to be detected based on the fault probability. The method comprises the steps of determining a flow peak change trend and a drainage efficiency attenuation degree based on flow data recorded by continuous drainage for multiple times, generating an impurity deposition index based on the flow peak change trend and the draina