CN-121977104-A - Valve positioner integrating valve internal leakage self-detection self-compensation self-closing function

CN121977104ACN 121977104 ACN121977104 ACN 121977104ACN-121977104-A

Abstract

The invention relates to a valve positioner integrating a valve internal leakage self-detection self-compensation self-closing function, and belongs to the technical field of intelligent valve control. The method comprises the steps of conducting opening adjustment testing on valve positioners, generating opening-flow curves, obtaining corresponding airtight changes when positioning scales of the valve positioners change, obtaining valve positioner internal leakage self-checking data, constructing an intelligent valve positioner shutdown mapping model, taking the valve positioner internal leakage self-checking data as detection parameters, inputting the valve positioner intelligent shutdown mapping model, conducting numerical simulation on leakage behaviors of the valve positioners after closing based on a fluid seal mutual coupling mechanism, generating a valve positioner closing compensation scheme, executing the valve positioner closing compensation scheme, extracting leakage composition characteristics of corresponding positioning control data, verifying valve positioner sealing compensation periods, constructing a valve positioner shutdown self-checking strategy, setting internal detection updating time, returning the valve positioner internal leakage self-checking data after internal detection updating to the intelligent valve positioner shutdown mapping model based on a recursion execution feedback method, and updating ideal shutdown flow base line.

Inventors

WANG YONGMING

Assignees

汉仲坤（上海）控制系统有限公司

Dates

Publication Date: 20260505
Application Date: 20260122

Claims (12)

1. The valve positioner integrating the valve internal leakage self-detection self-compensation self-closing function is characterized by comprising a valve positioner internal leakage self-detection module, a shut-off mapping compensation module, a sealing compensation period verification module and a shut-off evolution feedback updating module; The valve positioner internal leakage self-checking module is used for acquiring basic function parameters of the valve positioner, carrying out multi-level opening adjustment test on the valve positioner, establishing an opening-flow curve, acquiring corresponding airtight change when the positioning scale of each valve positioner is changed, generating a flow reference in an ideal off state, mapping the flow reference in the ideal off state into a valve positioner sealing index based on a piecewise residual error fitting algorithm, and obtaining valve positioner internal leakage self-checking data; The valve positioner intelligent shut-off mapping compensation module is used for establishing a valve positioner intelligent shut-off mapping model, taking leak self-checking data in the valve positioner as detection parameters, inputting the valve positioner intelligent shut-off mapping model, carrying out numerical simulation on leakage behaviors of the valve positioner after closing based on a fluid sealing mutual coupling mechanism by the valve positioner intelligent shut-off mapping model, outputting valve positioner closing response time and closed flow residual parameters, and attaching valve positioner closing compensation information on model nodes by combining a labeling binding method to generate a valve positioner closing compensation scheme; Executing the valve positioner closing compensation scheme, identifying a region and a time period which are higher than a leakage threshold value in a valve positioner closing state, extracting leakage constituent features of corresponding positioning control data, inquiring residual flow, hysteresis and internal leakage data in a valve positioner self-checking log based on the leakage constituent features, and verifying a valve positioner sealing compensation period; and the turn-off evolution feedback updating module constructs a turn-off self-evolution strategy of the valve positioner, writes the output turn-off response time and flow residues of the valve positioner into a valve positioner sealing compensation period, sets internal detection updating time, returns the internal leakage self-detection data of the valve positioner after internal detection updating to the intelligent turn-off mapping model of the valve positioner, and updates an ideal turn-off flow baseline based on a recursion execution feedback method.
2. The valve positioner according to claim 1, wherein the method for constructing the opening-flow curve comprises the steps of gradually reducing the opening to a real-time flow value corresponding to the fully closed position according to the fully opened position of the valve positioner, calculating a flow steady-state interval of each positioning scale point, extracting flow attenuation characteristics of the flow steady-state interval, and performing sensitivity enhancement on deviation between actual measured flow and theoretical fitting flow to obtain the opening-flow curve.
3. The valve positioner according to claim 1, wherein the piecewise residual fitting algorithm divides the opening-flow curve into opening subintervals including a valve positioner turn-off interval according to a valve positioner positioning scale, performs residual calculation on measured flow data acquired in a multi-stage opening adjustment test in the valve positioner turn-off subinterval, extracts characteristic parameters representing residual concentration degree and fluctuation amplitude as turn-off residual sequences, and maps a flow reference in an ideal turn-off state to a valve positioner sealing index based on a preset sealing reference state, thereby obtaining valve positioner internal leakage self-test data.
4. The valve positioner according to claim 1, wherein the method for constructing the valve positioner intelligent shutdown mapping model comprises the steps of extracting flow residual sequences and attenuation curve characteristics of opening subintervals from the valve positioner internal leakage self-test data received by an input layer, quantifying nonlinear sealing hysteresis characteristics of the valve positioner shutdown intervals, performing numerical simulation on transient flow distribution and pressure fluctuation after the valve positioner is closed by a hidden layer on the basis of a fluid sealing mutual coupling mechanism, establishing a valve positioner response residual mapping matrix, and correspondingly mapping intake leakage data in the matrix, valve positioner shutdown response time and flow residual, thereby constructing the valve positioner intelligent shutdown mapping model.
5. The valve positioner according to claim 2, wherein the valve positioner closing compensation scheme is generated by inputting the valve positioner internal leakage self-check data, the opening-flow curve and the valve positioner closing residual sequence into the valve positioner intelligent closing mapping model, identifying the opening interval and the time period when the flow leakage of the closed valve positioner is higher than the leakage threshold value based on the fluid sealing mutual coupling mechanism, synchronously fusing the leakage simulation data of different sampling frequencies and dynamic response time sequences, and attaching closing speed fine tuning, opening correction and compensation time window parameters on the valve positioner nodes to generate the valve positioner closing compensation scheme.
6. The valve positioner according to claim 5, wherein the valve positioner closing compensation information is provided by constructing a closing compensation table according to the valve positioner opening scale and a time node based on the residual flow and response time data output by the valve positioner intelligent closing mapping model, writing a compensation coefficient in the valve positioner by the labeling binding method, immediately adjusting the corrected opening of the opening subinterval higher than the leakage threshold, and reducing the residual flow and the sealing hysteresis in the next period of operation.
7. The valve positioner according to claim 4, wherein the leakage constituent features are extracted by synchronizing a flow residual in a valve positioner off interval with a closing response time in a valve positioner off state, decomposing a leakage behavior into a transient leakage component, a stable residual component and a hysteresis loop reflux component, and extracting weight proportions of the components in different opening subintervals in combination with an opening scale mapping relation.
8. The valve positioner according to claim 2, wherein the valve positioner seal compensation period verification method comprises the steps of setting a window verification period in combination with the compensated valve positioner seal index, collecting residual flow and internal leakage data of multiple turn-off tests in the window verification period, multiplexing existing leakage constituent feature data through a distributed timing task frame, and judging that the current valve positioner seal compensation period is effective when seal indexes in a plurality of continuous compensation periods are all stably lower than a preset leakage threshold value, otherwise triggering the compensation parameter to recalculate and correct the period.
9. The valve positioner according to claim 4, wherein the valve positioner shut-down self-evolution strategy is constructed by integrating historical valve positioner internal leak self-test data and a closing compensation scheme, establishing a self-evolution hierarchy level comprising an offline training stage and an online updating stage, periodically acquiring valve positioner shut-down response time and a flow residual sequence from a distributed log, performing full-scale modeling on valve positioner shut-down behaviors under different opening intervals and working conditions through a residual error practice regression algorithm, generating initial self-evolution rules and threshold parameters, storing the initial self-evolution rules and threshold parameters in a self-test database, monitoring zone of audibility valve positioner operation events in real time, performing feedback calculation on the basis of recursion, adjusting the recursion feedback rules based on the nearest neighbor principle, creating new rules if the distance between the change vectors and the existing rules exceeds a threshold, archiving low-activity rules, combining similar rules, and updating global self-evolution parameters.
10. The valve positioner according to claim 1, wherein the valve positioner intelligent shut-off mapping model further comprises a mapping index unit and a control decision unit; The mapping index unit is used for establishing a multidimensional index relation among a valve positioner opening subinterval, valve positioner internal leakage self-checking data, valve positioner closing response time and flow residual, positioning corresponding shut-off mapping nodes according to the current opening scale and working condition parameters of the valve positioner, and calling a shut-down compensation parameter associated with the nodes to match the valve positioner shut-off state and compensation strategy; the control decision unit is used for receiving the closing compensation parameter output by the mapping index unit, combining the current valve positioner operation instruction and real-time flow feedback, triggering a recursion execution feedback method when the residual flow or closing deviation exceeding the threshold value is detected, carrying out real-time correction on the closing compensation strategy, and outputting a final valve positioner closing control decision.
11. The valve positioner according to claim 10, wherein the recursively executing feedback method compares the actual closing response time with the residual flow and the predicted value after each valve positioner closing operation is completed, calculates a deviation vector as a recursion feedback input, and writes the feedback result into a self-evolution strategy to correct the valve positioner internal leakage self-checking parameter, update the closing compensation mapping relation, and adjust the leakage threshold value, thereby completing the closed-loop execution of self-checking-compensation-verification.
12. The valve positioner according to claim 9, wherein the airtight change vector adjusts the recursive feedback rules based on nearest neighbor rules, creates new rules if the change vector is more than a threshold from existing rules, archives low-activity rules, merges similar rules, and updates global self-evolution parameters.

Description

Valve positioner integrating valve internal leakage self-detection self-compensation self-closing function Technical Field The invention belongs to the technical field of intelligent valve control, and particularly relates to a valve positioner integrating a valve internal leakage self-detection self-compensation self-closing function. Background The valve is used as a key execution part in an industrial process control system, is widely applied to the fields of petrochemical industry, electric power, metallurgy, water treatment, pharmacy and the like, and the shutdown performance of the valve directly influences the safety, stability and energy efficiency level of the system. In the actual operation process, the valve is easily subjected to internal leakage phenomena with different degrees under the closing state due to the influence of factors such as abrasion of a sealing surface, ageing of materials, flushing of a medium, frequent change of working conditions and the like, so that the medium leakage and the control precision are reduced, and even potential safety hazards are caused. The existing valve internal leakage detection and turn-off control mode is mostly dependent on manual inspection, periodic off-line test or judgment based on a single sensor threshold value, and real-time and fine evaluation of valve sealing performance is difficult to realize. Meanwhile, the conventional valve positioner is usually controlled only according to the target opening degree, and lacks the sensing and compensating capability for nonlinear behaviors such as flow residue, sealing hysteresis and the like in the valve closing process, so that even if a complete closing instruction is executed under actual working conditions, tiny and continuous internal leakage can still exist. In addition, although some models or experience parameters are introduced to correct the valve closing process in the prior art, static compensation strategies are mostly adopted, and the dynamic adjustment cannot be performed according to the valve operation state and historical data, so that the valve sealing performance is difficult to adapt to the time evolution characteristic of the valve. When the valve working condition changes or the sealing state is degraded, the original compensation parameters are often invalid, and the valve is required to be calibrated again manually, so that the maintenance cost is high and the response is lagged. Along with the development of industrial automation and intellectualization, how to realize self-checking identification of the internal leakage state of a valve, intelligent compensation of a shutdown process and self-adaptive evolution of a control strategy on the premise of not increasing a complex hardware structure is a technical problem to be solved in the field of valve control. Therefore, it is necessary to provide a valve intelligent turn-off and seal compensation method and system which can integrate valve operation data, a seal mechanism and an intelligent algorithm, so as to improve the turn-off precision of the valve, prolong the service life and ensure the safe and stable operation of an industrial process. Disclosure of Invention In order to solve the problems in the prior art, the invention provides a valve positioner integrating the functions of self-checking internal leakage and self-compensating and self-closing of a valve, The aim of the invention can be achieved by the following technical scheme: The valve positioner internal leakage self-checking module is used for acquiring basic function parameters of the valve positioner, carrying out multi-level opening adjustment test on the valve positioner, establishing an opening-flow curve, acquiring corresponding airtight change when the positioning scale of each valve positioner is changed, generating a flow reference in an ideal off state, mapping the flow reference in the ideal off state into a valve positioner sealing index based on a piecewise residual error fitting algorithm, and obtaining valve positioner internal leakage self-checking data; The valve positioner intelligent shut-off mapping compensation module is used for establishing a valve positioner intelligent shut-off mapping model, taking leak self-checking data in the valve positioner as detection parameters, inputting the valve positioner intelligent shut-off mapping model, carrying out numerical simulation on leakage behaviors of the valve positioner after closing based on a fluid sealing mutual coupling mechanism by the valve positioner intelligent shut-off mapping model, outputting valve positioner closing response time and closed flow residual parameters, and attaching valve positioner closing compensation information on model nodes by combining a labeling binding method to generate a valve positioner closing compensation scheme; Executing the valve positioner closing compensation scheme, identifying a region and a time period which are higher than a leakage threshold