JP6881943B2 - Automatic valve diagnostic system and automatic valve diagnostic method - Google Patents

Description

The present invention relates to a system for diagnosing an automatic valve using an information system and a diagnostic method.

Conventionally, a system for remotely monitoring a piping member such as a valve by using a sensor and an information communication system has been known (see Patent Document 1). Further, there is known a method of diagnosing a deteriorated state of a piping system by analyzing a sample collected by cutting a part of the surface of the piping system (see Patent Document 2).

Special Table 2010-515144 Japanese Unexamined Patent Publication No. 2016-33507

According to the invention described in Patent Document 1 described above, the state of the piping member (valve) can be grasped to some extent by the sensor, but it does not reach the point of predicting the failure or determining the deterioration of the valve or the piping member. .. On the other hand, the invention described in Patent Document 2 discloses that only when the piping member is a resin or the like, a part of the surface is cut and collected to diagnose the deterioration state, but the piping member itself Need to be cut. Therefore, deterioration may be accelerated depending on the cutting method.
Therefore, an object of the present invention is to provide a system for predicting failure and determining deterioration of an automatic valve and a diagnostic method by utilizing an information processing system including a sensor.

In order to achieve the above object, the diagnostic system of the present invention receives a sensor that detects information about an automatic valve that can be opened and closed by receiving a predetermined signal, and various data obtained by the sensor, and automatically receives the information. A diagnostic device that performs comparative analysis with past accumulated data on valve deterioration and transmits an open / close signal to the automatic valve, and can communicate with the diagnostic device to open / close the automatic valve and open / close the opening / closing. output means for accepting an input operation, and means for transmitting a switching signal for closing accepting the input operation to the diagnostic device, the current value in order to confirm the input operation value and if the current value or the same The diagnostic device includes, and a communication terminal having the output means, and the diagnostic apparatus performs failure prediction and deterioration determination of the automatic valve based on the comparative analysis, and obtains the results of the failure prediction and deterioration determination and the various data. The first feature is to output to the communication terminal.

Also, the diagnostic system of the present invention, in the first aspect, the communication terminal is open or closed state of the automatic valve, the opening and closing times, and the second being to output at least one of the cumulative operation time.

Also, the diagnostic system of the present invention, in the first or second feature, a third feature in that the sensor is installed around the automatic valve.

Also, the diagnostic system of the present invention, in the features of the first three, the fourth, wherein the automatic valve is made of resin.

Further, in the diagnostic system of the present invention, in the first to fourth features, the automatic valve is a ball valve, a diaphragm valve, a gate valve, a butterfly valve, a control valve, an automatic flow rate control valve, an automatic pressure control valve, a check valve, and the like. The fifth feature is that the valve is at least one selected from a stop valve, a constant flow rate valve, an electromagnetic valve and a pinch valve.

Further, in the diagnostic system of the present invention, in the first to fifth features, the sensor is at least one sensor selected from a limit switch, a position detection sensor, an angle sensor, a temperature sensor, a strain sensor, a liquid leakage sensor, and a vibration sensor. The sixth feature is that.

Further, in the diagnostic method of the present invention, in an automatic valve diagnostic system having a sensor, a diagnostic device, and a communication terminal , the sensor detects information about an automatic valve that can be opened and closed by receiving a predetermined signal, and the sensor detects information about the automatic valve. obtained various data transmitted to the diagnostic device, said perform diagnostic device storing data and comparative analysis on the deterioration of the automatic valve in, have rows failure prediction and the deterioration determination of the automatic valve, the communication terminal, the diagnostic Communicating with the device, it receives an input operation of opening / closing of the automatic valve and the opening / closing of the opening / closing, and transmits an opening / closing signal of the opening / closing that receives the input operation to the diagnostic device. A seventh feature is that an open / close signal is transmitted to the communication terminal, and the current value is confirmed at the communication terminal to see if it is the same as the input operation value.

According to the present invention, a lot of information about piping members can be obtained through various sensors, and by using accumulated data on deterioration of piping members in the past, it is possible to perform more accurate failure prediction and deterioration judgment. Become. In addition, a large-scale network system is not required, and a diagnostic system for piping members can be easily constructed using an information terminal or the like.

It is a system block diagram of the diagnostic system 1 in embodiment of this invention. It is a block diagram of the structure of the diagnostic apparatus 60 in embodiment of this invention. It is a data table figure of the accumulated data in embodiment of this invention. It is a data table figure of the accumulated data in embodiment of this invention. It is a screen image figure of the communication terminal 10 in embodiment of this invention.

Hereinafter, the present invention will be described in more detail with reference to preferred embodiments. However, the following embodiments are merely examples that embody the present invention, and the present invention is not limited thereto.

FIG. 1 is a system configuration diagram of a piping member diagnostic system 1 according to an embodiment of the present invention. The piping member diagnostic system 1 is a system attached to a piping member installed in a factory, facility, or the like, and is composed of at least a diagnostic device 60 and a piping member. The communication terminal 10 is used to output various data of the diagnostic device 60, and it is desirable that the communication terminal 10 is provided in this system.

The piping member is not particularly limited as long as it is a member for flowing a liquid or gas inside, but may be, for example, a valve 50, a pipe 5, a joint (not shown), and a flange (not shown). ), Tank 1000, and a flow meter (not shown).

The valve 50 is a device or device that manually or automatically adjusts the flow rate of a liquid or gas flowing inside, and is, for example, a ball valve, a diaphragm valve, a gate valve, a butterfly valve, a control valve, an automatic flow rate control valve, or an automatic valve. Examples thereof include, but are not limited to, pressure control valves, check valves, stop valves, constant flow rate valves, electromagnetic valves and pinch valves. The valve 50 is preferably an automatic valve that automatically opens and closes the valve by receiving a predetermined signal and automatically adjusts the opening degree of the valve. The automatic valve may be either an air type in which the valve for adjusting the flow rate is driven by air, an electric type in which the valve is electrically driven, or an electromagnetic type in which the valve is driven by an electromagnet.

The material of the valve 50 is not particularly limited, but is preferably a resin, for example, polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (PVC-C), polystyrene. (PS), Polycarbonate (PC), Acrylonitrile butadiene styrene resin (ABS resin), Polyvinyl chloride (PVDF), Polytetrafluoroethylene (PTFE), Polyphenylene oxide (PPO), Polyphenylene ether (PPE), Tetrafluoroethylene per Fluoroalkyl vinyl ether copolymer (PFA) or the like can be used. Further, polyvinyl chloride (PVC) also includes hard polyvinyl chloride and hard impact resistant polyvinyl chloride. Further, a rubber material, for example, ethylene propylene rubber, fluororubber, or polytetrafluoroethylene may be partially used for the sealing portion.

The diagnostic device 60 is fixedly installed on the upper part of the piping member (valve 50 and tank 1000 in the example of FIG. 1), and various sensors, an open switch 40, and a close switch 41 are communicably connected to each other. The diagnostic device 60 is a device that receives data obtained by various sensors and performs comparative analysis with past accumulated data on deterioration of piping members. Further, the diagnostic device 60 performs failure prediction and deterioration determination of the piping member based on this comparative analysis.

FIG. 2 is an electrical block diagram of the diagnostic device 60. The diagnostic device 60 is connected to a control unit 61 that calculates and controls various data, a wireless communication unit 65 that performs wireless communication with the communication terminal 10, a storage unit 62 that stores various data and past accumulated data, various sensors, and the like. It includes an external input / output unit 64, a counter unit 67 that counts opening and closing when the piping member is a valve 50, and a timer unit 66 that measures the time when the valve 50 is opened.

The control unit 61 may be a microcomputer, a CPU (Central Processing Unit), or a programmable controller (PLC) that performs arithmetic control of various data. In order to perform wireless communication with the communication terminal 10, the wireless communication unit 65 is a device for realizing communication such as WiFi (Wireless Fitness), Bluetooth (registered trademark), Heart, ISA100, Zigbee (registered trademark), for example, BLE. (Bluetooth Low Energy) It may be a module communication kit. The storage unit 62 may be a memory, a hard disk, or the like on which various data can be written.

Various sensors, an open switch 40, and a close switch 41 are communicably connected to the external input / output unit 64. The external input / output unit 64 includes, for example, an analog-to-digital conversion (ADC), a digital-to-analog conversion (DAC), a comparator for insulation conversion, an analog input / output circuit (AIO), an amplifier circuit (AMP), and a pulse modulation circuit. (PWM), serial communication port (SIO), USB circuit, etc. may be used.

The sensor is a device for detecting information about the piping member, for example, a temperature sensor 33 for measuring the temperature inside the valve 50, the surrounding environment, flowing gas or liquid, the ground, etc., and the humidity for measuring the humidity of the environment or soil. Sensors (not shown), leak sensors 31 and 74 that detect liquid leaks inside and outside the valve, pressure sensors that measure the pressure and impact pressure of flowing gas and liquid (not shown), atmospheric pressure sensors (not shown), A strain sensor 30 that detects distortion of a piping member, a vibration sensor that detects vibration of a piping member (not shown), a flow sensor that measures flow rate and flow velocity (not shown), rotation angle, flow speed, and PWM modulation are measured. Pulse sensor (not shown), limit switch to detect open / close position (not shown), position detection sensor to detect open / close angle (not shown), densitometer to measure liquid concentration (not shown), flowing liquid Alternatively, a PH sensor 71 that measures the PH of the surrounding environment, a gas detection sensor that measures the flowing gas and the surrounding environment (not shown), a UV illuminance sensor 70 that measures the intensity of ultraviolet rays, and an illuminance sensor that detects the brightness (not shown). , Magnetic sensor (not shown), infrared sensor to detect human body and obstacles (not shown), optical sensor to detect nighttime (not shown), flame sensor to detect fire (not shown), contact Touch sensor for detection (not shown), microphone sound sensor for detecting the sound and noise of flowing liquid (not shown), ultrasonic sensor for non-destructive measurement (not shown), liquid for detecting the amount of liquid The surface sensor 73, the soil analysis sensor 32 that analyzes the water quality of the soil, and the like may be used.

The location of the sensor is not particularly limited as long as it can collect the desired data, but it may be installed inside or around the valve body, or may be installed near the valve. Further, it may be installed on a piping member other than the valve. As shown in FIG. 1, the strain sensor 30, the liquid leakage sensor 31, the temperature sensor 33, and the pressure sensor 35 are installed in a piping member, for example, a valve 50, and the temperature sensor 33 and the vibration meter sensor 34 are installed in a pipe 5. Will be done. The UV illuminance sensor 70 is installed in the tank 1000 and the upper part of the piping member (where the sun shines), the PH meter sensor 71 and the temperature sensor 33 are installed inside the tank 1000, and the liquid level sensor 75 and the optical sensor 73 are , Installed inside the tank 1000 and at the bottom of the tank 1000. The soil analysis sensor 32 is installed inside the lower soil where the piping member is arranged in the vicinity of the valve 50.

The communication terminal 10 is a terminal capable of wireless communication with at least the diagnostic device 60, and includes an input unit that receives an operation input such as a touch from an operator, and a display unit that outputs a result such as data or an output unit that outputs voice. Be prepared. The communication terminal 10 may be a computer terminal, a smartphone, or a tablet terminal. Further, the communication terminal 10 may be connected to another communication terminal 300 or a control system, and may send and receive data from the communication terminal 10 to and from each other.

The diagnostic device 60 receives the data detected by various sensors and stores the received data in the storage unit 62. The accumulated data is, for example, in a table as shown in FIGS. 3 and 4, and the result received from each sensor is accumulated together with the received time and date.

Then, the diagnostic device 60 performs comparative analysis with the newly received data with the data stored in the storage unit 62. As an example of the comparative analysis here, for example, a certain piping member accumulates past data with a specific valve, and the data newly received from the specific valve is "abnormal" with the information detected by the vibration sensor and the strain sensor. If it is "Yes" (for reasons such as an earthquake), it is analyzed that it is the same as the data at 11 o'clock in Fig. 3, and there is a possibility that liquid leakage will start so that it will occur after 11:15. There is. Therefore, as a failure prediction, it is predicted that liquid leakage may occur in the future.

Further, as an example of deterioration determination, for example, when the pressure sensor detects that the newly received data of the above-mentioned specific valve is 0.1 Pa less than the previous day, it is April 9 in FIG. It is analyzed that there is a possibility of being the same as the data, and it is determined that the piping member may be deteriorated and there is a possibility of liquid leakage.

The diagnostic device 60 transmits the results of these failure predictions and deterioration determinations to the communication terminal 10 and outputs them. As an output example, the results of these failure predictions and deterioration determinations may be associated with a message, an icon, or the like in advance, and the message or the like may be displayed at the time of this result. The message is, for example, "Because the valve has detected vibration and distortion, it is likely to leak in the past experience", "The valve has deteriorated and may leak in the near future. Is displayed.

When the failure prediction and deterioration judgment are performed as described above, since the failure or deterioration has occurred, some measures are required, and it is desirable to take predetermined measures. Here, for example, when the piping member is a valve 50, for the time being, the valve 50 may be opened and closed to see if a failure or deterioration has actually occurred. Therefore, in the following, when the valve 50 is an automatic valve, the operator opens and closes the valve 50 from the communication terminal 10.

When the piping member is a valve 50 and the valve 50 is an automatic valve, the diagnostic device 60 can open and close the valve of the automatic valve by transmitting predetermined signals to the open switch 40 and the close switch 41. it can. Here, since the automatic valve is opened and closed by the rotation or vertical movement of the valve, the rotation position information of the angle sensor and the limit switch is used in the case of rotation, and the position sensor and limit are used in the case of vertical movement. The opening degree, which is the degree of valve opening, is determined from the vertical movement position information of the switch.

FIG. 5 is a screen image diagram when the communication terminal 10 displays the screen. As shown in FIG. 5, the operator selects a predetermined valve from several valves such as A-type VALVE, B-type VALVE, and C-type VALVE, and inputs operations such as invalidation and valid for each valve. Is performed, selection of fully open or fully closed, and adjustment of the opening degree with the opening degree control 80. That is, by operating the operation switch 81 of the opening degree control 80 left and right, it is possible to determine what percentage the opening degree should be. The communication terminal 10 transmits the determined opening degree to the diagnostic device 60, and the diagnostic device 60 transmits an open / close signal to the automatic valve. The automatic valve that receives this signal physically opens and closes the valve.

Then, it is possible to confirm whether the actual opening degree is the same as the value input and operated by the numerical value of the current value monitor 82. In this case, for example, if the operator stops at 75% even though the opening is operated at 60%, it can be predicted that this valve is out of order. Further, the valve opening / closing number 83 is counted by the counter unit 67 of the diagnostic device 60 receiving a signal from the valve, and the result is displayed on the communication terminal 10. Further, in the operating time 84, the timer unit 66 of the diagnostic device 60 receives a signal from the valve, clocks the time, and displays the result on the communication terminal 10. Whether the automatic valve should "open" or "close" is determined by the opening of the current value of the automatic valve and the magnitude of the opening value that the operator has just input. It's just that. That is, if the opening degree of the current value (for example, 60%) is smaller than the opening degree (for example, 75%) of the input operation, a signal of the "opening" motion is sent, and the opening degree of the current value (for example, 75%) is sent. If 75%) is greater than the input-operated opening (eg, 60%), it sends out a "close" motion signal.

According to the above embodiment, by using the accumulated data on the deterioration of the piping member in the past, it is possible to predict the failure of the piping member and determine the deterioration, and the operator knows the status of the piping member and operates the piping member. It becomes possible to do.

1 Diagnostic system, 5 Pipes, 10 Communication terminal 30 Strain sensor, 31 Leakage sensor, 32 Soil analysis sensor 33 Temperature sensor, 35 Pressure sensor 40 Open switch, 41 Close switch 50 Valve, 60 Diagnostic device 61 Control unit, 62 Storage unit 64 External input / output unit, 66 Timer unit, 67 Counter unit 70 UV illuminance sensor, 71 PH sensor, 73 Optical sensor 74 Leakage sensor, 75 Liquid level sensor 1000 Tank

Claims (7)

A sensor that detects information about an automatic valve that can be opened and closed by receiving a predetermined signal,
A diagnostic device that receives various data obtained by the sensor, performs comparative analysis with past accumulated data on deterioration of the automatic valve, and transmits an open / close signal to the automatic valve.
A means that can communicate with the diagnostic device and accepts an input operation of opening / closing the automatic valve and an opening / closing opening degree, and a means of transmitting an opening / closing signal of the opening / closing that receives the input operation to the diagnostic device. a communication terminal and an output means for the output current value in order to confirm the input operation value and if the current value or the same,
With
The diagnostic device is an automatic valve diagnostic system that performs failure prediction and deterioration determination of the automatic valve based on the comparative analysis, and outputs the results of the failure prediction and deterioration determination and various data to the communication terminal. The automatic valve diagnostic system according to claim 1, wherein the communication terminal outputs at least one of the open / closed state, the number of times of opening / closing, and the cumulative operating time of the automatic valve. The automatic valve diagnostic system according to any one of claims 1 or 2, wherein the sensor is installed around the automatic valve. The automatic valve diagnostic system according to any one of claims 1 to 3, wherein the automatic valve is made of resin. The valve is at least one selected from a ball valve, a diaphragm valve, a gate valve, a butterfly valve, a control valve, an automatic flow rate control valve, an automatic pressure control valve, a check valve, a stop valve, a constant flow rate valve, an electromagnetic valve and a pinch valve. The automatic valve diagnostic system according to any one of claims 1 to 4, wherein the automatic valve diagnostic system is characterized by the above. Any one of claims 1 to 5, wherein the sensor is at least one sensor selected from a limit switch, a position detection sensor, an angle sensor, a temperature sensor, a strain sensor, a liquid leakage sensor, and a vibration sensor. The automatic valve diagnostic system described in. In an automatic valve diagnostic system that has a sensor, a diagnostic device, and a communication terminal.
The sensor detects information about an automatic valve that can be opened and closed by receiving a predetermined signal, and transmits various data obtained by the sensor to a diagnostic device.
The diagnostic device performs comparative analysis with accumulated data on deterioration of the automatic valve, predicts failure of the automatic valve, and determines deterioration.
The communication terminal communicates with the diagnostic device, receives an input operation for opening / closing the automatic valve and the opening / closing opening degree, and transmits an opening / closing signal for receiving the input operation to the diagnostic device.
In the diagnostic device, an open / close signal is transmitted to the automatic valve,
In the communication terminal, check the current value to see if it is the same as the input operation value.
A diagnostic method for automatic valves.

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