WO2014161303A1 - 一种用于变压器的压力释放阀的校验方法及装置 - Google Patents

一种用于变压器的压力释放阀的校验方法及装置 Download PDF

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Publication number
WO2014161303A1
WO2014161303A1 PCT/CN2013/086548 CN2013086548W WO2014161303A1 WO 2014161303 A1 WO2014161303 A1 WO 2014161303A1 CN 2013086548 W CN2013086548 W CN 2013086548W WO 2014161303 A1 WO2014161303 A1 WO 2014161303A1
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Prior art keywords
pressure
solenoid valve
calibration
valve
value
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PCT/CN2013/086548
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English (en)
French (fr)
Inventor
戴缘生
袁志文
童在林
张喆
田肖艳
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State Grid Shanghai Electric Power Co Ltd
State Grid Corp of China SGCC
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State Grid Shanghai Electric Power Co Ltd
State Grid Corp of China SGCC
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K17/00—Safety valves; Equalising valves, e.g. pressure relief valves
    • F16K17/02—Safety valves; Equalising valves, e.g. pressure relief valves opening on surplus pressure on one side; closing on insufficient pressure on one side
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K37/00—Special means in or on valves or other cut-off apparatus for indicating or recording operation thereof, or for enabling an alarm to be given
    • F16K37/0075—For recording or indicating the functioning of a valve in combination with test equipment
    • F16K37/0091—For recording or indicating the functioning of a valve in combination with test equipment by measuring fluid parameters

Definitions

  • the present invention relates to the field of pressure relief valves, and more particularly to a method and apparatus for verifying a pressure relief valve for a transformer. Background technique
  • Off-line detection is a direct measurement method.
  • the pressure relief valve needs to be removed and sent to the test bench for testing. This measurement method cannot simulate the effect of the actual temperature on the pressure relief valve setting pressure.
  • the pressure relief valve that has been verified on the calibration table may change its setting pressure and sealing performance due to installation and transportation reasons, which may bring safety hazards, thus affecting the safe and reliable operation of the transformer.
  • the existing online detection can not achieve real-time measurement without releasing the transformer oil completely. If the actual jump measurement is used, the outlet pressure is directly increased, and the pressure release valve is opened to record the action parameters, which not only causes actual damage to the equipment, but also has the same measurement. Poor performance and low measurement accuracy.
  • the instrument measurement methods developed by pressure relief valve manufacturers in Japan and the United States are only indirect measurement.
  • the hydraulic pump is used as the power source.
  • the external force curve is manually adjusted to control the pressure release valve opening process.
  • the human influence is large during the measurement process. Personnel need professional training and experience accumulation, need to compare the verification results, control the uncertainty, and the verification results are also highly susceptible to the use of the on-site environment.
  • the hardware and software related to data acquisition is simple in structure, and it is difficult to adapt to the increasing level of pressure relief valve verification.
  • the pressure relief valve is one of the important means of internal fault protection of the transformer. As the age increases, the aging of the various components of the pressure relief valve, especially the spring, will affect the accuracy of the pressure relief valve action.
  • all pressure relief valves have been unable to be effectively inspected and verified after installation due to restrictions on site conditions. There are no online calibrators at home and abroad, and the corresponding off-line calibrators are also lacking.
  • the pressure relief valve calibration method is mainly a method of suddenly releasing the impact after gas pressure storage.
  • This method has a cumbersome calibration device (the whole device has a mass greater than 300 kg), and can only be verified in the laboratory, and the calibration process noise and The energy consumption is high, and there is a safety hazard due to high-pressure gas storage, and the pressure relief valve field verification cannot be realized.
  • An object of the present invention is to overcome the deficiencies of the prior art and to provide a method and apparatus for verifying a pressure relief valve for a transformer.
  • a method for verifying a pressure relief valve of a transformer the specific step of which is
  • the pre-pressure calibration function measures the pressure value through the pre-pressure end pressure sensor. Before the pressure value measurement, in order to ensure the accuracy of the measured value, the pressure value needs to be calibrated.
  • the process block diagram is as shown in Figure 3;
  • the exhaust solenoid valve, the pressure control solenoid valve and the pre-pressure exhaust solenoid valve allow the pre-pressure end pressure sensor to directly communicate with the outside atmosphere. After a period of time has elapsed, record the AD code of the pre-pressurized sensor as the AD code at zero calibration; then perform full-scale calibration.
  • Digital module calibration includes zero calibration and full calibration, as shown in Figure 4.
  • the digital modules are factory calibrated with a standard pressure source. During use, if the pressure value needs to be recalibrated, the digital module can be directly connected to the standard pressure source for calibration. When calibrating, first connect the digital module to the atmosphere, and then send a zero calibration command to the digital module after stabilization. After the digital module finishes processing the zero calibration instruction, the microcontroller The moving digital module sends a read pressure value command, and the digital module returns the current pressure value. Adjust the pressure value of the standard pressure source to 0. 25MPa, and send a full-scale calibration command to the digital module after stabilization.
  • the MCU After the digital module processes the full-range calibration command, the MCU automatically sends a pressure value command to the digital module, and the digital module returns the current one. Pressure value.
  • the digital module can restore the calibration parameters to the factory state by restoring factory settings.
  • the pressure value is automatically uploaded about 10 seconds after the execution of the factory reset command.
  • the MCU communicates with the digital module and ARM through the RS232 interface.
  • the ARM zero-point calibration command and the full-range calibration command are received according to the communication protocol, and the command is transmitted to the digital module according to the communication protocol of the digital module.
  • the digital module After the digital module processes the zero calibration and the full-range calibration command, it will send the zero-point calibration and the full-frame calibration completion frame to the MCU.
  • the MCU After receiving the calibration completion frame, the MCU sends the read pressure value command to the digital module according to the communication protocol.
  • the pressure value read by the digital module is transmitted to the host computer through the single chip microcomputer.
  • the pressure measurement at the preloading end converts the pressure signal into a mv signal through a preload pressure sensor, and sends it to the AD7714 chip as a differential signal for AD conversion to convert the analog signal into a 24-bit digital signal.
  • the sensor signal is amplified inside the AD chip by configuring the control word with a magnification of 32.
  • the AD value is then converted to a pressure value by calculation.
  • the measurement of the AD signal adopts the interrupt mode. When the AD conversion is completed, an interrupt is applied to the microcontroller every 20 ms, and the microcontroller responds to the interrupt reading the AD code of the pressure value.
  • the AD chip and the microcontroller use the same clock source.
  • the pressure value is rapidly reduced and the lower pressure is reduced by controlling the duty ratio of the solenoid valve, and the pressure value is increased by the air pump.
  • the duty cycle of the solenoid valve is adjusted according to the pressure setting value to maintain the stability of the pressure value.
  • the duty ratio of the solenoid valve is large. As the pressure measurement value gets closer to the set value, the duty ratio of the solenoid valve is higher. The smaller it is.
  • the solenoid valve closes.
  • the pressure value is increased by controlling the air pump.
  • the pre-pressure value is firstly higher than the set value of 10 kPa in the boosting phase, and then the pressure value is finely adjusted during the step-down process by adjusting the duty ratio of the solenoid valve.
  • the rate is controlled by adjusting the duty cycle of the solenoid valve.
  • the MCU records the pressure value in real time with 10ms as the control cycle and measurement cycle, and in the data recursive manner, each time a new data is added, an old data is deleted, and the data record of the array is updated.
  • the pressure data value in the array is always the pressure value of the last 6 points.
  • the pressure relief valve is actuated, the pressure continues to decrease.
  • Slow output pressure if the pressure of the monitoring pressure release valve becomes larger, complete a detection process, open the solenoid valve of the inspection end, and the gas path of the pressure release valve directly communicates with the atmosphere, and simultaneously uploads the opening pressure value and the return pressure value.
  • the preload control is first performed. After the pressure value reaches the set value, the preload control is stopped. After the set time, the initial pressure value is recorded, and then the end pressure value after a period of time is recorded, and the air leak rate of the detected end is measured by the pressure leak rate.
  • the air tightness detection process of the pressure relief valve is shown in Figure 5 above. Open the air pump, pre-press the intake solenoid valve, close the pre-pressure exhaust solenoid valve, open the pressure control solenoid valve, close the exhaust solenoid valve to be inspected, and measure the pressure value of the pre-pressed end and the tested end through the digital module.
  • the pressure value is higher than the pressure set value lOkPa, close the air pump and pre-press the intake solenoid valve.
  • the pressure is adjusted by pre-pressing the exhaust solenoid valve to bring the pressure value close to the pressure set point.
  • the stop control command is received, the control pressure is stopped.
  • the change in the pressure value of the digital module reflects the tightness of the air circuit.
  • the communication function includes the communication between the lower computer and the upper computer, the communication between the lower computer and the FPGA, and the communication between the lower computer and the digital module.
  • the communication between the lower computer and the upper computer is realized through the RS232 interface, and the communication between the lower computer and the FPGA is realized.
  • the communication between the lower computer and the digital module is realized through the RS232 interface.
  • a calibration device for a pressure relief valve of a transformer comprising a mechanical part and a control system, wherein the mechanical part comprises a gas pump, a pre-pressed intake solenoid valve, a pre-pressure end gas volume and a pressure control electromagnetic Wide, the pressure relief valve to be verified is connected to the pressure control solenoid valve, and the pressure control solenoid valve is connected to the preload air intake solenoid valve through the preload end air capacity, and the preload air intake solenoid valve is connected to the air pump.
  • the mechanical part comprises a gas pump, a pre-pressed intake solenoid valve, a pre-pressure end gas volume and a pressure control electromagnetic Wide
  • the pressure relief valve to be verified is connected to the pressure control solenoid valve
  • the pressure control solenoid valve is connected to the preload air intake solenoid valve through the preload end air capacity
  • the preload air intake solenoid valve is connected to the air pump.
  • the pre-pressure end gas volume is connected to the pre-pressure end pressure sensor.
  • the pre-pressure end gas volume is connected to the pre-pressure exhaust solenoid valve.
  • the pressure relief valve to be verified is connected to the exhaust gas solenoid to be inspected.
  • the components of the mechanical portion are connected by a common interface.
  • the control system is composed of four parts, the first part is the calibration module, the second part is the pressure release valve detection module, the third part is the air tightness detection module, the fourth part is the communication module, and the four modules are respectively the lower position machine.
  • the program is connected.
  • the calibration module is preload calibration and digital module calibration.
  • the pressure release valve detection module is divided into three parts: preload control, pressure control, and reading action pressure value.
  • the air tightness detecting module is divided into two parts: pressure control and pressure value uploading.
  • the communication module is divided into two parts: 232 communication and SPI communication.
  • the modules of the described control system are mature technologies and can be purchased directly in the market.
  • the calibration device is verified by the quasi-static pressure process test and the gas controllable pressure rate output, so as to achieve the same verification purpose as the laboratory calibration device, and the gas storage pressure is small (the gas storage pressure is less than 300 kPa),
  • the miniature pressure pump builds the gas storage and the quick solenoid valve control output, making the power much smaller than the laboratory calibration device. It can easily realize on-site calibration (the whole set of device quality is less than 10kg), which has a good effect on the rapid diagnosis and action performance judgment of the pressure relief valve.
  • Figure 1 is a schematic structural view of the present invention.
  • FIG. 2 is a block diagram of the control system of the present invention.
  • FIG. 1 Schematic diagram of pre-compaction calibration
  • Figure 5 is a block diagram of the air tightness detection structure
  • Figure 6 shows the block diagram of the communication function
  • FIG. 8 The flow control main program function running process
  • Figure 9 receives the detected preload value setting communication event driving process
  • Figure 10 Receive the detected preload value setting main program function operation flow. detailed description
  • a specific embodiment of a pressure relief valve verification device of the present invention is provided below.
  • a pressure relief valve verification device includes a gas pump, a pre-pressure intake solenoid valve, a pre-pressure end gas volume, a pre-pressure exhaust solenoid valve, a pre-pressure end pressure sensor, and a pre-pressure control.
  • Solenoid valve, PC machine, the pressure release valve to be verified is connected to the pressure control solenoid valve through a universal interface, and the pressure control solenoid valve is connected to the preload air intake solenoid valve through the preload end air capacity, and the preload air intake solenoid valve passes
  • the air pump is connected to the control unit of the PC.
  • the pre-pressure end gas volume is connected to the pre-pressure end pressure sensor.
  • the pre-pressure end gas volume is connected to the pre-pressure exhaust solenoid valve.
  • the pressure relief valve to be verified is connected to the exhaust gas solenoid to be inspected.
  • the pressure relief valve to be verified is connected to the control unit of the PC through a digital module.
  • a method for verifying a pressure relief valve of a transformer the specific step of which is
  • the pre-pressure calibration function measures the pressure value through the pre-pressure end pressure sensor. Before the pressure value measurement, in order to ensure the accuracy of the measured value, the pressure value needs to be calibrated.
  • the process block diagram is as shown in Figure 3;
  • the exhaust solenoid valve, the pressure control solenoid valve and the pre-pressure exhaust solenoid valve allow the pre-pressure end pressure sensor to directly communicate with the outside atmosphere. After a period of time has elapsed, record the AD code of the pre-pressurized sensor as the AD code at zero calibration. Then perform full scale calibration. Open the air pump, pre-press the intake solenoid valve, close the pre-pressure exhaust solenoid valve, open the pressure control solenoid valve, and close the exhaust solenoid valve to be inspected.
  • the pressure value is measured by the digital module. When the pressure value reaches l lOkPa, the air pump and the pre-pressure intake solenoid valve are closed; the pressure value is adjusted by the pre-pressure exhaust solenoid valve, and when the pressure value is stabilized at 100 kPa, the pre-pressure end sensor is
  • the AD code is recorded as the AD code at the time of full-scale calibration. The pressure value is calculated based on the current AD code, the zero AD code, and the AD code at 100 kPa. Get the current pressure value.
  • Digital module calibration includes zero calibration and full calibration, as shown in Figure 4.
  • the digital modules are factory calibrated with a standard pressure source. During use, if the pressure value needs to be recalibrated, the digital module can be directly connected to the standard pressure source for calibration. When calibrating, first connect the digital module to the atmosphere, and then send a zero calibration command to the digital module after stabilization. After the digital module finishes processing the zero calibration command, the microcontroller automatically sends a pressure value command to the digital module, and the digital module returns the current pressure value. Adjust the pressure value of the standard pressure source to 0. 25MPa, and send a full-scale calibration command to the digital module after stabilization.
  • the MCU After the digital module processes the full-range calibration command, the MCU automatically sends a pressure value command to the digital module, and the digital module returns the current one. Pressure value.
  • the digital module can restore the calibration parameters to the factory state by restoring factory settings.
  • the pressure value is automatically uploaded about 10 seconds after the execution of the factory command is resumed.
  • the MCU communicates with the digital module and ARM through the RS232 interface. According to the communication protocol, the ARM zero calibration command and the full calibration command are received, and the command is transmitted to the digital module according to the communication protocol of the digital module. After the digital module processes the zero calibration and the full-range calibration command, it will send the zero-point calibration and the full-frame calibration completion frame to the MCU. After receiving the calibration completion frame, the MCU sends the read pressure value command to the digital module according to the communication protocol. The pressure value read by the digital module is transmitted to the host computer through the single chip microcomputer. (2) Detection of pressure relief valve
  • the pressure measurement at the preloading end converts the pressure signal into a mv signal through a preload pressure sensor, and sends it to the AD7714 chip as a differential signal for AD conversion to convert the analog signal into a 24-bit digital signal.
  • the sensor signal is amplified inside the AD chip by configuring the control word with a magnification of 32.
  • the AD value is then converted to a pressure value by calculation.
  • the measurement of the AD signal adopts the interrupt mode. When the AD conversion is completed, an interrupt is applied to the microcontroller every 20 ms, and the microcontroller responds to the interrupt reading the AD code of the pressure value.
  • the AD chip and the microcontroller use the same clock source.
  • the pressure value is rapidly reduced and the lower pressure is reduced by controlling the duty ratio of the solenoid valve, and the pressure value is increased by the air pump.
  • the duty cycle of the solenoid valve is adjusted according to the pressure setting value to maintain the stability of the pressure value.
  • the duty ratio of the solenoid valve is large. As the pressure measurement value gets closer to the set value, the duty ratio of the solenoid valve is higher. The smaller it is.
  • the solenoid valve closes.
  • the pressure value is increased by controlling the air pump.
  • the pre-pressure value is firstly higher than the set value of 10 kPa in the boosting phase, and then the pressure value is finely adjusted during the step-down process by adjusting the duty ratio of the solenoid valve.
  • the rate is controlled by adjusting the duty cycle of the solenoid valve.
  • the MCU records the pressure value in real time with 10ms as the control period and measurement period, and in the data recursive manner, each time a new data is added, an old data is deleted, and the data record of the array is updated.
  • the pressure data value in the array is always the pressure value of the last 6 points.
  • the pressure relief valve is actuated, the pressure continues to decrease. At this time, the pressure is slowly outputted. If the pressure of the pressure relief valve is increased, a detection process is completed, and the solenoid valve of the inspection end is opened, and the gas passage of the pressure relief valve is directly connected to the atmosphere. Simultaneously upload the opening pressure value and the return pressure value.
  • the preload control is first performed. After the pressure value reaches the set value, the preload control is stopped. After the set time, the initial pressure value is recorded, and then the end pressure value after a period of time is recorded, and the air leak rate of the detected end is measured by the pressure leak rate.
  • the airtightness detecting process of the pressure release valve is as shown in FIG. Open the air pump, pre-press the intake solenoid valve, close the pre-pressure exhaust solenoid valve, open the pressure control solenoid valve, close the exhaust solenoid valve to be inspected, and measure the pressure value of the pre-pressed end and the tested end through the digital module.
  • the pressure value is higher than the pressure set value lOkPa
  • the air pump and the pre-pressure intake solenoid valve are closed.
  • the pressure is adjusted by pre-pressing the exhaust solenoid valve to bring the pressure value close to the pressure set point.
  • the stop control command is received, the control pressure is stopped.
  • the change in the pressure value of the digital module reflects the tightness of the air circuit.
  • the communication function includes the communication between the lower computer and the upper computer, the communication between the lower computer and the FPGA, and the communication between the lower computer and the digital module.
  • the communication between the lower computer and the upper computer is realized through the RS232 interface, and the communication between the lower computer and the FPGA is realized.
  • the communication between the lower computer and the digital module is realized through the RS232 interface.
  • the rate control communication event driven process is shown in Figure 7.
  • the device repeatability test is to verify the consistency of the device's multiple measurements and is the basic metrology of the device.
  • the measurement method is to perform multiple measurements on a stable same object to be measured, and the results conform to the design specifications.
  • the device performs 15 separate measurements on two different pressure relief valves of different values. The results are shown in Tables 8 and 9 (unit: kPa). After testing, it was verified that the repeatability of the device met the design requirements.
  • the device stability test is to verify the long-term consistency of the device measurements and is the basic metering feature of the device.
  • the measurement method is to perform multiple measurements on a stable same object under test for a period of time, and the results conform to the design specifications.
  • the device performs five separate measurements on two different pressure relief valves of different values within two months. The results are as follows. After testing, the stability of the device is verified to meet the design requirements.

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Abstract

一种用于变压器的压力释放阀的校验方法及校验装置，校验方法的具体步骤为，（一）校准为预压校准和数字模块校准；（二）压力释放阀的检测，检测分为预压控制和压力控制；（三）气密性的检测：打开气泵，预压进气电磁阀，关闭预压排气电磁阀，打开压力控制电磁阀，关闭被检排气电磁阀，通过数字模块测量预压端和被检端的压力值；当压力值高于压力设定值10kPa时，关闭气泵和预压进气电磁阀；通过预压排气电磁阀调节压力，使压力值接近压力设定值；当接收到停止控制指令后，停止控制压力；（四）通讯功能的实现。所述的校验方法及校验装置可以实现现场校验，对于压力释放阀故障的快速诊断和动作性能判定具有良好的作用。

Description

一种用于变压器的压力释放阀的校验方法及装置
技术领域
本发明涉及压力释放阀技术领域， 具体的说， 是一种用于变压器的压力释放 阀的校验方法及装置。 背景技术
国内外相关机构对压力释放阀的测试和技术手段的实施作过许多研究， 方法 上主要是离线检测和在线检测两种。
离线检测是一种直接测量方式， 需要将压力释放阀拆下后送到检验台上进行 测试， 这种测量方法不能模拟运行中实际温度对压力释放阀整定压力的影响。 除 此之外， 考虑到国内变电站中投运的变压器种类各异， 设备和装置的安装和使用 条件的限制， 压力释放阀的拆卸、 安装及运输较为困难， 因此还存在着校验时间 长、 综合成本高等问题。 另外， 在校验台上已校验合格的压力释放阀， 由于安装 运输等方面的原因， 其整定压力及密封性能可能发生变化， 带来了安全隐患， 从 而影响变压器的安全和可靠运行。
现有的在线检测， 无法做到完全不用释放变压器油进行实时测量， 如果采用 实跳测量， 直接提高出口压力使压力释放阀开启来记录动作参数， 不仅对设备造 成实际上的伤害， 而且测量一致性差， 且测量精度低。 日本、 美国等压力释放阀 生产厂家开发的仪器测量方式也只是间接测量， 主要以液压泵为动力源， 人工调 整外加力变化曲线来控制压力释放阀开启过程， 测量过程中人为影响大， 校验人 员需要专业的培训和经验积累， 需要比对校验结果， 控制不确定度， 其校验结果 也极易受使用现场环境等的影响。 同时数据采集相关的软硬件结构简单， 难以适 应压力释放阀校验水平的日益提高。
针对上述问题， 如考虑在变压器不放油的情况下， 开发研制出新型的在线校 验装置， 实现压力释放阀的快速在线检测， 同时根据面向对象技术研发相应的压 力释放阀管理软件平台， 对在线校验过程实现数据采集、 处理和分析功能， 同时 具备日常检验和维护信息管理功能， 从而满足变压器运行周期长， 检修时间短， 工况条件复杂的特殊要求， 将在提升电力变压器非电量保护校验技术方面具有十 分广阔的应用前景。
压力释放阀是变压器内部故障保护的重要手段之一。随着年限的增加， 压力 释放阀各部件尤其是弹簧的老化， 将影响压力释放阀动作的准确性。 而现今所有 压力释放阀在安装完毕后， 受现场条件的限制等原因一直无法进行有效的检修和 校验， 国内外尚既无在线校验仪， 相应的离线校验仪也比较缺乏。 目前压力释放 阀校验方法主要是采用气体压力储气后突然释放冲击的方法， 此方法存在校验装 置笨重 （整套装置质量大于 300kg) ， 只能在试验室完成校验， 校验过程噪音及 能耗均较高， 且由于高压储气而存在安全隐患， 无法实现压力释放阀现场校验。 发明内容
本发明的目的在于克服现有技术的不足， 提供一种用于变压器的压力释放阀 的校验方法及装置。
本发明的目的是通过以下技术方案来实现的：
一种用于变压器的压力释放阀的校验方法， 其具体步骤为，
(一） 校准，
校准为预压校准和数字模块校准：
预压校准功能通过预压端压力传感器进行压力值的测量， 在进行压力值测量 之前， 为了保证测量值的准确性， 需要对压力值进行校准， 过程框图如下图 3所 示； 首先打开被检排气电磁阀， 压力控制电磁阀和预压排气电磁阀， 使预压端压 力传感器直接与外界大气相通。 待稳定一段时间后， 把预压端传感器的 AD码记 录下来， 作为零点校准时的 AD码； 然后进行满度校准。 打开气泵， 预压进气电 磁阀， 关闭预压排气电磁阀， 打开压力控制电磁阀， 关闭被检排气电磁阀； 通过 数字模块测量压力值， 当压力值达到 l lOkPa 时， 关闭气泵和预压进气电磁阀； 通过预压排气电磁阀调节压力值， 当压力值稳定在 lOOkPa 时， 把预压端传感器 的 AD码记录下来，作为满程校准时的 AD码；根据当前 AD码，零点 AD码和 lOOkPa 时的 AD码进行压力值的计算； 得到当前压力值。
数字模块校准：
数字模块校准包括零点校准和满程校准， 如图 4所示。数字模块在出厂时已 经用标准压力源进行过校准。 在使用过程中， 如果压力值需要重新校准， 可把数 字模块与标准压力源直接相连进行校准。 校准时先把数字模块与大气相通， 稳定 后向数字模块发零点校准命令。 数字模块完成处理完零点校准指令后， 单片机自 动向数字模块发读取压力值指令， 数字模块返回当前的压力值。 把标准压力源的 压力值调到 0. 25MPa,稳定后向数字模块发满程校准命令，数字模块处理完满程校 准指令后， 单片机自动向数字模块发读取压力值指令， 数字模块返回当前的压力 值。 数字模块可通过恢复出厂设置命令使校准参数恢复为出厂时的状态。 执行恢 复出厂命令后 10秒钟左右自动上传压力值。
单片机通过 RS232接口与数字模块和 ARM进行通讯。按通讯协议接收 ARM的 零点校准指令和满程校准指令， 把指令按数字模块的通讯协议传给数字模块。 数 字模块处理完零点校准和满程校准指令后会给单片机发送零点校准和满程校准 完成的应答帧， 单片机接收到校准完成的应答帧后， 按通讯协议向数字模块发送 读取压力值指令， 把数字模块读取的压力值通过单片机传给上位机。
(二） 压力释放阀的检测
预压控制：
预压端的压力测量通过预压压力传感器把压力信号转变为 mv信号， 以差分 信号的形式送给 AD7714芯片进行 AD转换把模拟信号转换为 24位的数字信号。 传感器信号通过配置控制字在 AD芯片内部实现放大，放大倍数为 32.然后通过计 算把 AD值换算为压力值。 AD信号的测量采用中断的方式， 当 AD转换完成后， 每 隔 20ms向单片机申请一次中断， 单片机响应中断读取压力值的 AD码。 AD芯片和 单片机采用同一时钟源。
压力控制过程中， 通过控制电磁阀的占空比实现压力值的快速降压和慢速降 压， 通过气泵实现压力值的增加。 电磁阀的占空比根据压力设定值的要求， 按规 律调节， 维持压力值的稳定。 在降压控制过程中， 当压力设定值和压力测量值相 差较大时， 电磁阀的占空比较大， 随着压力测量值越来越接近设定值， 电磁阀的 占空比则越来越小。 当压力设定值和压力测量值相等时， 电磁阀关闭。 在升压过 程中， 通过控制气泵使压力值增加。 为了避免气泵流量大造成的压力值波动， 在 升压阶段先使预压值高于设定值 10kPa，然后通过调节电磁阀的占空比，在降压过 程中实现压力值的微调。
压力控制：
采用调节电磁阀占空比的方式控制速率。 在压力控制过程中， 单片机以 10ms 为控制周期和测量周期， 实时记录压力值， 并且以数据递推的方式， 每加入一个 新的数据， 就去掉一个旧的数据， 更新数组的数据记录， 使数组里的压力数据值 始终为前最近的 6个点的压力值。 在压力释放阀动作后， 压力持续降低， 此时缓 慢输出压力， 监测压力释放阀压力如果变大， 则完成一次检测过程， 打开被检端 电磁阀，压力释放阀的气路直接与大气相通，同时上传开启压力值和返回压力值。
(三） 气密性的检测：
在气密性检测过程中， 首先进行预压控制。 在压力值达到设定值后， 停止预 压控制。经过设定时间后， 记录起始压力值，然后记录一段时间后的结束压力值， 通过压力泄漏率衡量被检端气密性情况。
压力释放阀的气密性检测过程如上图 5所示。 打开气泵， 预压进气电磁阀， 关闭预压排气电磁阀， 打开压力控制电磁阀，关闭被检排气电磁阀， 通过数字模 块测量预压端和被检端的压力值。 当压力值高于压力设定值 lOkPa时， 关闭气泵 和预压进气电磁阀。 通过预压排气电磁阀调节压力， 使压力值接近压力设定值。 当接收到停止控制指令后， 停止控制压力。 数字模块压力值的变化则反映气路的 密封性。
(四） 通讯功能的实现
如下图 6所示， 通讯功能包括下位机和上位机的通讯， 下位机和 FPGA的通 讯， 下位机和数字模块的通讯； 下位机和上位机的通讯通过 RS232接口实现， 下 位机和 FPGA的通讯通过 SPI接口实现， 下位机和数字模块的通讯通过 RS232接 口实现。
一种用于变压器的压力释放阀的校验装置， 其包含机械部分和控制系统， 其 特征在于， 所述的机械部分包含气泵， 预压进气电磁阀， 预压端气容和压力控制 电磁阔， 将待校验的压力释放阀与压力控制电磁阀相连， 压力控制电磁阀通过预 压端气容与预压进气电磁阀相连， 预压进气电磁阀与气泵相连。
所述的预压端气容与预压端压力传感器相连。
所述的预压端气容与预压排气电磁阀相连。
所述的待校验的压力释放阀与被检排气电磁阀相连。
所述的机械部分的各部件之间通过通用接口连接。
所述的控制系统为四部分组成， 第一部分为校准模块， 第二部分为压力释放 阀检测模块， 第三部分为气密性检测模块， 第四部分为通讯模块， 四个模块分别 与下位机程序相连。
所述的校准模块为预压校准和数字模块校准。
所述的压力释放阀检测模块分为预压控制， 压力控制， 读取动作压力值三部 分。 所述的气密性检测模块分为压力控制和压力值上传二部分。
所述的通讯模块分为 232通讯和 SPI通讯二部分。
所述的控制系统的模块均为成熟的技术， 在市场可以直接购买。
与现有技术相比， 本发明的积极效果是：
本校验装置， 通过准静态压力的过程测试验证及气体可控压速率输出， 从而 达到与实验室校验装置相同的校验目的， 同时储气压力较小 （储气压力小于 300kPa) ， 通过微型压力泵造压储气及快速电磁阀控制输出， 使得功率远远小于 实验室校验装置。 且可以轻易实现现场校验（整套装置质量小于 10kg ) ， 对于压 力释放阀故障的快速诊断和动作性能判定具有良好的作用。 附图说明
图 1 本发明的原理结构图。
图 2 本发明的控制系统结构图。
图 3 预压校准示意图；
图 4 数字模块校准框图；
图 5 气密性检测结构框图；
图 6 通讯功能结构框图；
图 7 速率控制通讯事件驱动流程；
图 8 速率控制主程序功能运行流程；
图 9接收被检预压值设定通讯事件驱动流程；
图 10 接收被检预压值设定主程序功能运行流程。 具体实施方式
以下提供本发明一种压力释放阀校验装置的具体实施方式。
实施例 1
请参见附图 1和 2， 一种压力释放阀校验装置， 其包含气泵， 预压进气电磁 阀， 预压端气容， 预压排气电磁阀， 预压端压力传感器， 预压控制电磁阀， PC机， 将待校验的压力释放阀通过通用接口与压力控制电磁阀相连， 压力控制电磁阀通 过预压端气容与预压进气电磁阀相连， 预压进气电磁阀通过气泵与 PC机的控制 单元连接。
所述的预压端气容与预压端压力传感器相连。 所述的预压端气容与预压排气电磁阀相连。
所述的待校验的压力释放阀与被检排气电磁阀相连。
所述的待校验的压力释放阀通过数字模块与 PC机的控制单元连接。
一种用于变压器的压力释放阀的校验方法， 其具体步骤为，
(一） 校准，
校准为预压校准和数字模块校准：
预压校准功能通过预压端压力传感器进行压力值的测量，在进行压力值测量 之前， 为了保证测量值的准确性， 需要对压力值进行校准， 过程框图如下图 3所 示； 首先打开被检排气电磁阀， 压力控制电磁阀和预压排气电磁阀， 使预压端压 力传感器直接与外界大气相通。 待稳定一段时间后， 把预压端传感器的 AD码记 录下来， 作为零点校准时的 AD码。 然后进行满度校准。 打开气泵， 预压进气电 磁阀， 关闭预压排气电磁阀， 打开压力控制电磁阀， 关闭被检排气电磁阀。 通过 数字模块测量压力值， 当压力值达到 l lOkPa 时， 关闭气泵和预压进气电磁阀； 通过预压排气电磁阀调节压力值， 当压力值稳定在 lOOkPa 时， 把预压端传感器 的 AD码记录下来，作为满程校准时的 AD码。根据当前 AD码，零点 AD码和 lOOkPa 时的 AD码进行压力值的计算。 得到当前压力值。
数字模块校准：
数字模块校准包括零点校准和满程校准， 如图 4所示。数字模块在出厂时已 经用标准压力源进行过校准。 在使用过程中， 如果压力值需要重新校准， 可把数 字模块与标准压力源直接相连进行校准。 校准时先把数字模块与大气相通， 稳定 后向数字模块发零点校准命令。 数字模块完成处理完零点校准指令后， 单片机自 动向数字模块发读取压力值指令， 数字模块返回当前的压力值。 把标准压力源的 压力值调到 0. 25MPa,稳定后向数字模块发满程校准命令，数字模块处理完满程校 准指令后， 单片机自动向数字模块发读取压力值指令， 数字模块返回当前的压力 值。 数字模块可通过恢复出厂设置命令使校准参数恢复为出厂时的状态。 执行恢 复出厂命令后 10秒钟左右自动上传压力值。
单片机通过 RS232接口与数字模块和 ARM进行通讯。按通讯协议接收 ARM的 零点校准指令和满程校准指令， 把指令按数字模块的通讯协议传给数字模块。 数 字模块处理完零点校准和满程校准指令后会给单片机发送零点校准和满程校准 完成的应答帧， 单片机接收到校准完成的应答帧后， 按通讯协议向数字模块发送 读取压力值指令， 把数字模块读取的压力值通过单片机传给上位机。 (二） 压力释放阀的检测
预压控制：
预压端的压力测量通过预压压力传感器把压力信号转变为 mv信号， 以差分 信号的形式送给 AD7714芯片进行 AD转换把模拟信号转换为 24位的数字信号。 传感器信号通过配置控制字在 AD芯片内部实现放大，放大倍数为 32.然后通过计 算把 AD值换算为压力值。 AD信号的测量采用中断的方式， 当 AD转换完成后， 每 隔 20ms向单片机申请一次中断， 单片机响应中断读取压力值的 AD码。 AD芯片和 单片机采用同一时钟源。
压力控制过程中，通过控制电磁阀的占空比实现压力值的快速降压和慢速降 压， 通过气泵实现压力值的增加。 电磁阀的占空比根据压力设定值的要求， 按规 律调节， 维持压力值的稳定。 在降压控制过程中， 当压力设定值和压力测量值相 差较大时， 电磁阀的占空比较大， 随着压力测量值越来越接近设定值， 电磁阀的 占空比则越来越小。 当压力设定值和压力测量值相等时， 电磁阀关闭。 在升压过 程中， 通过控制气泵使压力值增加。 为了避免气泵流量大造成的压力值波动， 在 升压阶段先使预压值高于设定值 10kPa，然后通过调节电磁阀的占空比，在降压过 程中实现压力值的微调。
压力控制：
采用调节电磁阀占空比的方式控制速率。在压力控制过程中，单片机以 10ms 为控制周期和测量周期， 实时记录压力值， 并且以数据递推的方式， 每加入一个 新的数据， 就去掉一个旧的数据， 更新数组的数据记录， 使数组里的压力数据值 始终为前最近的 6个点的压力值。 在压力释放阀动作后， 压力持续降低， 此时缓 慢输出压力， 监测压力释放阀压力如果变大， 则完成一次检测过程， 打开被检端 电磁阀，压力释放阀的气路直接与大气相通，同时上传开启压力值和返回压力值。
(三） 气密性的检测：
在气密性检测过程中， 首先进行预压控制。 在压力值达到设定值后， 停止预 压控制。经过设定时间后， 记录起始压力值，然后记录一段时间后的结束压力值， 通过压力泄漏率衡量被检端气密性情况。
压力释放阀的气密性检测过程如上图 5所示。 打开气泵， 预压进气电磁阀， 关闭预压排气电磁阀， 打开压力控制电磁阀，关闭被检排气电磁阀， 通过数字模 块测量预压端和被检端的压力值。 当压力值高于压力设定值 lOkPa时， 关闭气泵 和预压进气电磁阀。 通过预压排气电磁阀调节压力， 使压力值接近压力设定值。 当接收到停止控制指令后， 停止控制压力。 数字模块压力值的变化则反映气路的 密封性。
(四） 通讯功能的实现
如下图 6所示， 通讯功能包括下位机和上位机的通讯， 下位机和 FPGA的通 讯， 下位机和数字模块的通讯； 下位机和上位机的通讯通过 RS232接口实现， 下 位机和 FPGA的通讯通过 SPI接口实现， 下位机和数字模块的通讯通过 RS232接 口实现。
压力释放阀检定校验控制程序：
速率控制通讯事件驱动流程， 见图 7。
速率控制主程序功能运行流程见图 8，
接收被检预压值设定通讯事件驱动流程见图 9，
接收被检预压值设定主程序功能运行流程见图 10，
压力释放阀校验装置的调试及验证
在压力释放阀校验装置完成出厂调试验收后，项目组在实验室也进行了大量 测试研究， 对装置的特性和压力释放阀的特性进行了全面的了解， 也验证了装置 的可靠性。 具体方法和数据如下：
重复性测试：
装置重复性测试是为了验证装置多次测量结果的一致性，是装置的基本计量 特性。测量方法是对稳定的同一被测对象进行多次测量，结果符合设计技术指标。 本装置对 2只不同定值的压力释放阀分别进行了 15次单独测量， 结果分别如下 表 8、 9 (单位： kPa) 。 经过测试， 验证了装置的重复性符合设计要求。
表 8 重复性测试 -1
Figure imgf000010_0001
标准偏差 0.616; 平均值 57.06 表 9重复性测试 -2
Figure imgf000011_0001
标准偏差 0.52; 平均值 81.9 稳定性测试：
装置稳定性测试是为了验证装置测量结果的长期一致性， 也是装置的基本计 量特性。 测量方法是对稳定的同一被测对象在一段时间内进行多次测量， 结果符 合设计技术指标。 本装置对 2只不同定值的压力释放阀在 2个月内分别进行了 5 次单独测量， 结果分别如下， 经过测试， 验证了装置的稳定性符合设计要求。
表 10稳定性测试数据 -1
Figure imgf000011_0002
标准偏差 0.68; 平均值 81.7 以上所述仅是本发明的优选实施方式， 应当指出， 对于本技术领域的普通技 术人员， 在不脱离本发明构思的前提下， 还可以做出若干改进和润饰， 这些改进 和润饰也应视为本发明的保护范围内。

Claims

权利要求书
1. 一种用于变压器的压力释放阀的校验方法， 其特征在于， 具体步骤为，
(一） 校准
校准为预压校准和数字模块校准：
(二） 压力释放阀的检测
检测分为预压控制和压力控制，
(三） 气密性的检测：
气密性的检测过程为： 打开气泵， 预压进气电磁阀， 关闭预压排气电磁阀， 打开压力控制电磁阀， 关闭被检排气电磁阀， 通过数字模块测量预压端和被检端 的压力值； 当压力值高于压力设定值 lOkPa时， 关闭气泵和预压进气电磁阀； 通 过预压排气电磁阀调节压力， 使压力值接近压力设定值； 当接收到停止控制指令 后， 停止控制压力； 数字模块压力值的变化则反映气路的密封性；
(四） 通讯功能的实现
通讯功能包括下位机和上位机的通讯， 下位机和 FPGA的通讯， 下位机和数 字模块的通讯； 下位机和上位机的通讯通过 RS232接口实现， 下位机和 FPGA的 通讯通过 SPI接口实现， 下位机和数字模块的通讯通过 RS232接口实现。
2. 如权利要求 1所述的一种用于变压器的压力释放阀的校验方法，其特征在 于， 所述的预压校准过程为： 首先打开被检排气电磁阀， 压力控制电磁阀和预压 排气电磁阀， 使预压端压力传感器直接与外界大气相通。 待稳定一段时间后， 把 预压端传感器的 AD码记录下来，作为零点校准时的 AD码；然后进行满度校准。 打开气泵， 预压进气电磁阀， 关闭预压排气电磁阀， 打开压力控制电磁阀， 关闭 被检排气电磁阀； 通过数字模块测量压力值， 当压力值达到 l lOkPa时， 关闭气 泵和预压进气电磁阀； 通过预压排气电磁阀调节压力值， 当压力值稳定在 lOOkPa 时，把预压端传感器的 AD码记录下来，作为满程校准时的 AD码；根据当前 AD 码， 零点 AD码和 lOOkPa时的 AD码进行压力值的计算； 得到当前压力值。
3. 一种用于变压器的压力释放阀的校验装置， 其包含机械部分和控制系统， 其特征在于， 所述的机械部分包含气泵， 预压进气电磁阀， 预压端气容和压力控 制电磁阀， 将待校验的压力释放阀与压力控制电磁阀相连， 压力控制电磁阀通过 预压端气容与预压进气电磁阀相连， 预压进气电磁阀与气泵相连； 所述的机械部 分的各部件之间通过通用接口连接。
4. 如权利要求 3所述的一种用于变压器的压力释放阀的校验装置， 其特征 在于， 所述的预压端气容与预压端压力传感器相连。
5. 如权利要求 3所述的一种用于变压器的压力释放阀的校验装置， 其特征 在于， 所述的预压端气容与预压排气电磁阀相连。
6. 如权利要求 3所述的一种用于变压器的压力释放阀的校验装置， 其特征 在于， 所述的待校验的压力释放阀与被检排气电磁阀相连。
7. 如权利要求 3所述的一种用于变压器的压力释放阀的校验装置， 其特征 在于， 所述的控制系统为四部分组成， 第一部分为校准模块， 第二部分为压力释 放阀检测模块， 第三部分为气密性检测模块， 第四部分为通讯模块， 四个模块分 别与下位机程序相连。
8. 如权利要求 7所述的一种用于变压器的压力释放阀的校验装置，其特征在 于， 所述的校准模块为预压校准和数字模块校准； 所述的压力释放阀检测模块分 为预压控制， 压力控制， 读取动作压力值三部分。
9. 如权利要求 7所述的一种用于变压器的压力释放阀的校验装置，其特征在 于， 所述的气密性检测模块分为压力控制和压力值上传二部分； 所述的通讯模块 分为 232通讯和 SPI通讯二部分。
PCT/CN2013/086548 2013-03-30 2013-11-05 一种用于变压器的压力释放阀的校验方法及装置 Ceased WO2014161303A1 (zh)

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