CN112834208A - Automatic calibration system for pressure of safety valve calibration equipment - Google Patents
Automatic calibration system for pressure of safety valve calibration equipment Download PDFInfo
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Abstract
The invention provides an automatic pressure calibration system of safety valve calibration equipment, which comprises a camera, a pressure gauge, a first air inlet valve, a second air inlet valve, an electromagnetic valve, an exhaust valve, a pressure acquisition card and a computing device, wherein the camera is connected with the pressure gauge; the camera is used for shooting the numerical value of the pressure gauge; the pressure gauge and the first end of the first air inlet valve are respectively connected with an experimental medium storage device; the second end of the first air inlet valve is connected with the second end of the second air inlet valve, the pressure sensor and the first end of the electromagnetic valve respectively; the first end of the second air inlet valve is connected with the safety valve; the second end of the electromagnetic valve is connected with the first end of the exhaust valve; the second end of the exhaust valve is connected with an exhaust system; the pressure acquisition card is respectively and electrically connected with the pressure sensor and the electromagnetic valve; the computing device is electrically connected with the camera and the pressure acquisition card respectively; the computing device runs calibration software. The invention can automatically finish the calibration of the calibration stand on different pressure scales and obtain the determined system error of the calibration stand system, thereby greatly improving the precision of the calibration pressure.
Description
Technical Field
The invention relates to the technical field of pressure detection, in particular to an automatic pressure calibration system for safety valve calibration equipment.
Background
The safety valve is a special device, pressure setting is required to be carried out every other year, namely, a pressure jump test is carried out on a national approved organization, and when the pressure in the safety valve reaches a set pressure value, the safety valve is opened, and the pressure value is reduced. And when the safety valve is correctly opened for three times continuously, and the take-off pressure meets the error range of the set pressure, confirming that the set pressure is effective, otherwise, continuing to teach the safety valve, and repeating the experiment until the requirement is met.
In the process of setting the safety valve, the accuracy of pressure data is the most important parameter, and the tripping pressure of the safety valve can be correctly judged only by accurate pressure. There are generally two methods for obtaining pressure in current safety valve verification devices: the accurate manometer is judged by the naked eyes of people and the pressure is obtained by the pressure sensor. In any case, a complex nonlinear system is formed due to the gas source-pipe-pressure gauge (or sensor). This characteristic causes the pressure to be acquired with a definite systematic error, an uncertain systematic error and a random error, and thus the acquired data is inaccurate. These errors are expressed as:
1. systematic error
Because of the non-linear system of the calibration stand, the final pressure value has a definite system error, which is different at different pressure calibration points, such as a zero pressure point and a 10MPa pressure point. Determining the systematic error has a relationship with the overall system. The systematic errors appear as deterministic systematic errors and indeterminate systematic errors.
2. Random error
In the setting process, random errors occur in the acquired values of the sensors due to various mechanical and electrical factors; or in reading meter data, various random errors are caused due to operator factors.
Of the above errors, the most important is to determine systematic errors, which are the main sources of inaccuracy in the pressure measurement data. Therefore, effective calibration is required for safety valve verification equipment before work.
There is little literature relating to safety valve calibration stand pressure calibration methods or modules. In the published papers and patents, only the method of single sensor calibration, or the structural design of the calibration stage, is discussed, and there is no method or module of pressure calibration based on the safety valve calibration stage as a whole.
Aiming at the situation, the invention designs the automatic calibration module of the safety valve calibration equipment, which is composed of hardware and software and can automatically complete the calibration of the calibration table on different pressure scales and obtain the determined system error of the calibration table system, thereby greatly improving the precision of the calibration pressure.
Disclosure of Invention
The invention aims to solve the technical problem that the pressure in the setting process of the safety valve in the prior art has a determined system error, an uncertain system error and a random error when being obtained, so that the obtained data is inaccurate.
The invention provides an automatic pressure calibration system of safety valve calibration equipment, which comprises a camera, a pressure gauge, a first air inlet valve, a second air inlet valve, an electromagnetic valve, an exhaust valve, a pressure acquisition card and a computing device, wherein the camera is connected with the pressure gauge;
the camera is used for shooting the numerical value of the pressure gauge;
the pressure gauge and the first end of the first air inlet valve are respectively connected with an experimental medium storage device;
the second end of the first air inlet valve is connected with the second end of the second air inlet valve, the pressure sensor and the first end of the electromagnetic valve respectively;
the first end of the second air inlet valve is connected with the safety valve;
the second end of the electromagnetic valve is connected with the first end of the exhaust valve;
the second end of the exhaust valve is connected with an exhaust system;
the pressure acquisition card is respectively and electrically connected with the pressure sensor and the electromagnetic valve;
the computing device is electrically connected with the camera and the pressure acquisition card respectively;
the computing device runs calibration software.
Further, the automatic calibration system realizes automatic calibration through the following steps:
s1) initialization processing;
s2), after initialization is completed, opening an air source, slowly adjusting the opening degree of an electromagnetic valve by an acquisition card, slowly boosting the pressure of a pipeline to be less than 0.01MPa/S, and stopping the electromagnetic valve and keeping the pressure of the system if the difference between the average value of 1024 tested data and the first pressure scale value to be calibrated is within 5% according to the data acquired by the acquisition card;
s3) triggering the camera to collect the image of the precision instrument, and measuring and processing the measured value obtained by the pressure sensor while obtaining the pressure meter value;
s4) the result of the calibration on the first nominal pressure set point is: delta1=P21-P11,P11For the pressure value, P, obtained from the first nominal pressure set point pressure gauge test21Testing the pressure value obtained by the pressure sensor of the first nominal pressure setting point;
s5) the calculating device adjusts the opening of the electromagnetic valve through the calibration software to reach a second nominal setting point, and repeats the steps from S3 to S4 to obtain a calibration result delta of the second nominal pressure setting point2=P22-P12,P12For a pressure value, P, obtained by a second nominal pressure set point pressure gauge test22Continuously repeating the steps from S3 to S4 for the pressure value obtained by the second nominal pressure setting point pressure sensor test to obtain all nominal setting point calibration error values and actual calibration points;
s6) completing the calibration.
Further, the step S3 includes triggering the camera to collect the image of the precision instrument, and performing triggering collection every t, where t is between 0.5 second and 1 second according to the situation, so as to continuously collect 20 sheets.
For each picture, according to the algorithm of the previous preprocessing part, the circle center position C (x) is obtained0,y0) (ii) a The longest line segment is detected by Hough detection, and whether the line segment should pass through C (x) is checked0,y0) (ii) a Calculating the included angle alpha between the line segment and the horizontal linecComparing the pressure value with different alpha obtained by pretreatment, and obtaining an accurate pressure value P 'according to a linear interpolation method'1iI is the inside of 20 picturesThe average and standard deviation of 20 accurate pressure values are calculated, if the standard deviation meets the following 5% of the arithmetic average:
if the actual value of the instrument measured currently is valid and reliable, the actual pressure value P is obtained11If not, triggering to acquire 20 pictures again, calculating the formula (1) again, and if the requirement cannot be met after 10 times of circulation, checking hardware to ensure the stability of an air source, wherein sigma is a standard deviation;
measuring and processing the measured value obtained by the pressure sensor while obtaining the pressure gauge value,
the acquired data is required to be larger than 4096 points, 128 points are divided into one section, so that at least 40 sections of data are processed by adopting median filtering at first, the middle value is taken as the pressure value of the section, the pressure values of all the sections are arithmetically averaged to obtain the pressure measurement value P calculated by the sensor at present21', if the standard deviation satisfies 5% or less of the arithmetic mean:
determining that the current acquisition value of the sensor is obtained to obtain the true pressure value P21If not, the above calculation for 4096 points is repeated until it is satisfied.
The safety valve calibration equipment has the advantages that the safety valve calibration equipment automatic calibration module is designed, is composed of hardware and software, can automatically complete calibration of the calibration table on different pressure scales, and can obtain a determined system error of the calibration table system, so that the precision of the calibration pressure is greatly improved.
1) The module has an automatic workflow. In order to realize automatic calibration and remove manual interference, a scientific and appropriate process should be designed to meet the requirements. The process comprises proper hardware and software, the working sequence of hardware in the module and the like; the invention designs a reasonable flow;
2) the calibration can accurately obtain the true value and the measured value of the pressure. The true value is usually displayed on a precision pressure gauge. However, the precision pressure gauge has the problem of pointer fluctuation, and how to obtain a credible precision value through a jittered pointer is one of key technologies; the method is obtained through an image processing algorithm;
3) the calibration can accurately obtain the pressure value of the sensor. The invention obtains the measurement data by methods of removing random errors and the like.
Drawings
FIG. 1 is a diagram of the system connection relationship of the present invention.
Fig. 2 is a flow chart of the intelligent automatic calibration method of the invention.
In the figure, 1 is a camera, 2 is a precision pressure gauge, 3 is a first air inlet valve, 4 is a second air inlet valve, 5 is an electromagnetic valve, and 6 is an exhaust valve.
Detailed Description
The invention provides an automatic pressure calibration system for safety valve calibration equipment, which is shown in figure 1 and comprises a camera, a pressure gauge, a first air inlet valve, a second air inlet valve, an electromagnetic valve, an exhaust valve, a pressure acquisition card and a computing device, wherein the camera is connected with the pressure gauge;
the camera is used for shooting the numerical value of the pressure gauge;
the pressure gauge and the first end of the first air inlet valve are respectively connected with an experimental medium storage device;
the second end of the first air inlet valve is connected with the second end of the second air inlet valve, the pressure sensor and the first end of the electromagnetic valve respectively;
the first end of the second air inlet valve is connected with the safety valve;
the second end of the electromagnetic valve is connected with the first end of the exhaust valve;
the second end of the exhaust valve is connected with an exhaust system;
the pressure acquisition card is respectively and electrically connected with the pressure sensor and the electromagnetic valve;
the computing device is electrically connected with the camera and the pressure acquisition card respectively;
the computing device runs calibration software.
The intelligent automatic calibration process of the present invention as shown in FIG. 2 is as follows
S1) initialization processing
In the shutdown state, the solenoid valve is opened, the intake valve 1 is closed, the intake valve 2 is closed, and the exhaust valve is opened.
The initialization process includes two tasks, one is to divide the pressure scale value to be calibrated, and the other is to prepare the pressure scale value before the dynamic image processing of the instrument.
Suppose the maximum test pressure of the verification device is PmaxThe pressure scale range to be calibrated is 0-PmaxIf the number of points to be calibrated is N (N is more than or equal to 10), the interval value of each scale point is PmaxAnd the established nominal pressure value sequence needing calibration is Pc={0,PmaxmaxmaxThe pressure to be calibrated can be a floating point number, according to the national standard, the 2 bits behind the decimal point are reserved, and the last bit is carried out according to the principle of 'four-round six-in five-hash double'.
Calibrating the camera image: the hardware type selection of the camera and the connection mode of the camera and the computer are irrelevant to the invention, only a few parameters are needed, the camera CCD is a color area array CCD, the camera is fixedly arranged right in front of the precision pressure gauge, and the camera can be taken away after the calibration is finished. The imaging of the camera needs to be clear and stable, and a sufficient light source is ensured. When the calibration stand is not started, the pointer rotation center of the pressure gauge is marked by 2mm by special color2Left and right circles.
Software collects one image, judges the center of a circle of the instrument pointer through color, finds a special color area in the image and requires that the center of the imaged circle is not less than the range of 4 x 4 pixels. Calculating the geometric center C (x) of the circle center in the image0,y0) The unit is a pixel; the line segment of each scale of the instrument is determined by utilizing Hough linear detection, the line segment is connected with the circle center to form a line, the included angle between the line and the horizontal line is calculated, the accurate pressure value alpha represented by each scale is determined, and the real and accurate pressure values corresponding to different alpha are determined.
The initialization operation further includes zero pressure point calibration. In the shutdown state, the data obtained by the sensor is collected by the acquisition card, and the length of 4096 is calculatedIs arithmetically averaged to obtain P20That is, the system error Δ at 0 pressure point0;
S2), after the initialization is finished, opening an air source, slowly adjusting the opening degree of an electromagnetic valve by an acquisition card, slowly boosting the pressure of a pipeline to be less than 0.01MPa/S, and if the average value of 1024 tested data and the first pressure scale value P to be calibrated are continuously measured according to the data acquired by the acquisition cardc1When the difference is within 5%, the electromagnetic valve is stopped, and the system maintains pressure;
and S3) triggering the camera to acquire the image of the precision instrument. According to the situation, trigger collection is carried out every t (0.5 s-1 s), and 20 pieces of the blood are continuously collected.
The positions of the pointers in the 20 sheets are different due to the fluctuation of the pressure; meanwhile, due to the vibration of the verification table, the position of the instrument in the image is different every time. But the relative position of the pointer and the center of rotation of the pointer is unchanged.
For each picture, according to the algorithm of the previous preprocessing part, the circle center position C (x) is obtained0,y0) (ii) a The Hough detection is used for detecting the longest line segment, namely the pointer, and checking whether the line segment should pass through C (x)0,y0) (ii) a Calculating the included angle alpha between the line segment and the horizontal linecComparing the pressure value with different alpha obtained by pretreatment, and obtaining an accurate pressure value P 'according to a linear interpolation method'1iI is the serial number in 20 pictures; calculating the average value and standard deviation of 20 accurate pressure values, and if the standard deviation meets the following 5% of the arithmetic average value:
the actual value of the instrument measured currently is determined to be effective and reliable, and the actual pressure value P is obtained11(ii) a Otherwise, triggering to collect 20 pictures again, and calculating again (1); if the requirement cannot be met after 10 times of circulation, hardware needs to be checked, and the stability of an air source is ensured;
s3) measuring and processing the measurement values obtained by the pressure sensor while obtaining the pressure gauge value.
The data collected requires more than 4096 points. Due to the influence of pressure fluctuations and pulses, 128 points are divided into segments, so that at least 40 segments of data exist. And (4) processing each section by adopting median filtering, and taking the intermediate value as the pressure value of the section. The pressure values of all the sections are arithmetically averaged to obtain the pressure measurement value P calculated by the current sensor21'; if the standard deviation satisfies 5% or less of the arithmetic mean:
determining that the current acquisition value of the sensor is obtained to obtain the true pressure value P21(ii) a If not, the above calculation for 4096 points is repeated until satisfied.
S4) the result of calibrating the first nominal pressure calibration point is: delta1=P21-P11The actual revision of the real pressure punctuation is P21;
S5) the software adjusts the opening of the electromagnetic valve to reach the second nominal set point, and repeats the steps from S3 to S4 to obtain delta2,P22(ii) a Repeating continuously to obtain all calibration error values and actual calibration points;
s6) completing the calibration. After calibration is completed, the camera can be removed, the electromagnetic valve is fully opened, and the normal setting work of the calibration equipment is not influenced. In the actual test data, the pressure value P obtained by each sensor is subjected to error correction by adopting a linear interpolation method, namelyAnd then, obtaining an error revision value delta by utilizing linear interpolation:
s denotes the number of the nominal setpoint.
The safety valve calibration equipment has the advantages that the safety valve calibration equipment automatic calibration module is designed, is composed of hardware and software, can automatically complete calibration of the calibration table on different pressure scales, and can obtain a determined system error of the calibration table system, so that the precision of the calibration pressure is greatly improved.
1) The module has an automatic workflow. In order to realize automatic calibration and remove manual interference, a scientific and appropriate process should be designed to meet the requirements. The process comprises proper hardware and software, the working sequence of hardware in the module and the like; the invention designs a reasonable flow;
2) the calibration can accurately obtain the true value and the measured value of the pressure. The true value is usually displayed on a precision pressure gauge. However, the precision pressure gauge has the problem of pointer fluctuation, and how to obtain a credible precision value through a jittered pointer is one of key technologies; the method is obtained through an image processing algorithm;
3) the calibration can accurately obtain the pressure value of the sensor. The invention obtains the measurement data by methods of removing random errors and the like.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (3)
1. The automatic pressure calibration system of the safety valve calibration equipment is characterized by comprising a camera, a pressure gauge, a first air inlet valve, a second air inlet valve, an electromagnetic valve, an exhaust valve, a pressure acquisition card and a computing device;
the camera is used for shooting the numerical value of the pressure gauge;
the pressure gauge and the first end of the first air inlet valve are respectively connected with an experimental medium storage device;
the second end of the first air inlet valve is connected with the second end of the second air inlet valve, the pressure sensor and the first end of the electromagnetic valve respectively;
the first end of the second air inlet valve is connected with the safety valve;
the second end of the electromagnetic valve is connected with the first end of the exhaust valve;
the second end of the exhaust valve is connected with an exhaust system;
the pressure acquisition card is respectively and electrically connected with the pressure sensor and the electromagnetic valve;
the computing device is electrically connected with the camera and the pressure acquisition card respectively;
the computing device runs calibration software.
2. The automatic calibration system for pressure of a safety valve calibration device according to claim 1, wherein the automatic calibration system realizes automatic calibration by the following steps:
s1) initialization processing;
s2), after initialization is completed, opening an air source, slowly adjusting the opening degree of an electromagnetic valve by an acquisition card, slowly boosting the pressure of a pipeline to be less than 0.01MPa/S, and stopping the electromagnetic valve and keeping the pressure of the system if the difference between the average value of 1024 tested data and the first pressure scale value to be calibrated is within 5% according to the data acquired by the acquisition card;
s3) triggering the camera to collect the image of the precision instrument, and measuring and processing the measured value obtained by the pressure sensor while obtaining the pressure meter value;
s4) the result of the calibration on the first nominal pressure set point is: delta1=P21-P11,P11For the pressure value, P, obtained from the first nominal pressure set point pressure gauge test21Testing the pressure value obtained by the pressure sensor of the first nominal pressure setting point;
s5) the calculating device adjusts the opening of the electromagnetic valve through the calibration software to reach a second nominal setting point, and repeats the steps from S3 to S4 to obtain a calibration result delta of the second nominal pressure setting point2=P22-P12,P12For a pressure value, P, obtained by a second nominal pressure set point pressure gauge test22Continuously repeating the steps from S3 to S4 for the pressure value obtained by the second nominal pressure setting point pressure sensor test to obtain all nominal setting point calibration error values and actual calibration points;
s6) completing the calibration.
3. The automatic calibration system for pressure of safety valve calibration equipment according to claim 1, wherein the step S3 comprises triggering the camera to collect the image of the precision instrument, and performing triggering collection for 20 consecutive collection at intervals of t, which ranges between 0.5 seconds and 1 second according to the situation.
For each picture, according to the algorithm of the previous preprocessing part, the circle center position C (x) is obtained0,y0) (ii) a The longest line segment is detected by Hough detection, and whether the line segment should pass through C (x) is checked0,y0) (ii) a Calculating the included angle alpha between the line segment and the horizontal linecComparing the pressure value with different alpha obtained by pretreatment, and obtaining an accurate pressure value P 'according to a linear interpolation method'1iAnd i is the serial number in 20 pictures, the average value and the standard deviation of 20 accurate pressure values are calculated, and if the standard deviation meets the condition that the arithmetic average value is less than 5 percent:
if the actual value of the instrument measured currently is valid and reliable, the actual pressure value P is obtained11If not, triggering to acquire 20 pictures again, calculating the formula (1) again, and if the requirement cannot be met after 10 times of circulation, checking hardware to ensure the stability of an air source, wherein sigma is a standard deviation;
measuring and processing the measured value obtained by the pressure sensor while obtaining the pressure gauge value,
the acquired data is required to be larger than 4096 points, 128 points are divided into one section, so that at least 40 sections of data are processed by adopting median filtering at first, the middle value is taken as the pressure value of the section, the pressure values of all the sections are arithmetically averaged to obtain the pressure measurement value P calculated by the sensor at present21', if the standard deviation satisfies 5% or less of the arithmetic mean:
determining that the current acquisition value of the sensor is obtained to obtain the true pressure value P21If not, the above calculation for 4096 points is repeated until it is satisfied.
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Application publication date: 20210525 |