With the rapid development of China’s equipment manufacturing industry, the valve controller controlled by the combination of traditional mechanical devices and simple analog electronic technology can not meet the requirements of industrial automation. In order to improve the intelligent degree of valve controller, it is necessary to study an intelligent electric valve controller. The controller should have a good man-machine interface, be convenient for field personnel to operate, and prompt the valve fault intelligently; support Fieldbus technology, facilitate field personnel to troubleshoot and remote fault diagnosis, the controller is stable and reliable, so as to narrow the gap with foreign valve controller manufacturers. Firstly, the development trend of valve electric controller is introduced, and the working mechanism of its driving motor brushless DC motor is elaborated. Equipment manufacturing industry is an important pillar industry in China’s industrial economy. Valve electric controller, as a device to control valve closure in mechanical industry, can play an important role in chemical production, oil mining, metal smelting, energy generation, coal mine production and other industries. With the rapid development of China’s economy and industrial automation, the degree of development of the valve industry is very important, and the demand for valves in the industrial field is very large. Quality stability, long life, maintenance-free, high technology content these technical indicators become the development trend of the valve industry. At present, the valves manufactured in our country are mainly controlled by mechanical devices and simple analog electronic technology. The technical content of valve controller is relatively low. With the rapid development of modern industrialization, intelligent diagnosis technology, automatic control technology, power electronics technology, communication technology and other technologies have been highly integrated, so the valve equipment needs to improve the degree of intelligence to meet the requirements of industrial automation. As one of the important components of the valve, how to improve the working characteristics of the valve, improve the control accuracy of the valve opening, flexibly adjust the valve switch time, intelligently diagnose the valve failure and increase the remote control mode of the valve has become the focus of the valve industry research.
Therefore, it is particularly important to study the controller as the control valve electric controller. Valves are widely used in the field of industrial control and play an important role in industrial production. With the gradual improvement of industrial automation level, electric valves have gradually replaced the traditional hydraulic and pneumatic valves because of the advantages of simple power supply and convenient on-site maintenance.
They are widely used in the field of industrial control. Especially the emergence of intelligent electric valves has been favored by customers in the industrial field for its advantages of various fault protection modes, high control accuracy, high reliability and small size. With the development of power electronics technology, field bus technology and motor control theory technology, the comprehensive performance index of valve electric controller has been improved continuously, which can meet the requirements of reliable quality, intelligent fault diagnosis and remote control in the field of industrial control.
Therefore, intelligent valve electric controller is widely used.
In view of the key component of valve electric controller – electric controller, a lot of research and development work has been done all over the world. In the early 1990s, many industrial control giants in developed countries in Europe and the United States developed new products of electric valve controllers, which can meet the needs of different industrial occasions. These products have perfect functions, simple operation, stable performance and support a variety of control methods. They all meet the international general standards of electric valve controllers. The comprehensive performance is strong. There are many manufacturers producing electric valve controllers, among which the famous ones in the world are SIEMENS, ZMG, BAILEY, ROTORK, Fuji, Anchuan, etc. The main feature of IQ series intelligent valve device of ROTORK company is to avoid open-cover maintenance. Valve parameters can be set by infrared remote control. LCD display parameters are intuitive and clear. Shell protection level can reach IP68. It is compatible with IrDA standard. It can support computer remote analysis and diagnosis of valve status. Valve control technology is advanced and supports. Various fieldbus communication protocols. Other main representative products are: SIPOS5 series valve electric controller of SIEMENS company, which adopts the idea of simple modular design, realizes the optimal control of motor to make the motor control precision high, uses advanced technology to protect the motor comprehensively and supports various bus communication protocols; besides, ON like ABB company also has the same idea. TRAC intelligent electric valve device, accurate positioning, thermostatic element high reliability, support MODBUS and HART protocol, can receive analog or switching signals to control valve switches, has good mechanical and motor characteristics. Domestic research on valve electric controller started relatively late, and its development was mainly through imitating foreign advanced products, but some core technologies have not yet been mastered. However, some scientific research institutes in China have begun to develop electric valve controllers.
Shanghai Industrial Automation Instrument Research Institute has developed a new type of intelligent electric valve controllers, which have high control accuracy, simple maintenance, high intelligence and support a variety of fieldbus communication protocols. However, the protection level of the outer shell of the device is not high, and the protection side of the valve is low. Style is not as powerful as foreign similar products. After a period of development, the gap between domestic and foreign valve electric controller products is gradually narrowing. The traditional electric valve controller supports the function of setting parameters remotely.
Modifying the value of valve torque protection does not need to adjust the value of torque protection by open-cover regulating circuit elements, nor does it need to change the value of torque protection by mechanical device and set the position of all-open and all-close of the valve. Through infrared remote controller, landmark can be conveniently and quickly achieved. The fixed valve is fully opened and closed, and the torque protection value and communication address of the electric valve controller are set.
This reduces the debugging workload of the field engineers and improves the efficiency of the engineers. Firstly, through the information display window such as liquid crystal display screen or digital tube, the electric valve controller can convey all kinds of status information of the valve to the field controller. When the valve fails, it can display the fault quickly through the information display window.
The field controller can solve the problem quickly according to the fault prompt, thus reducing the field dimension. Repair diagnostic time, can quickly resume normal production. Secondly, the valve electric controller has a variety of protection functions. For example, the gear box of the valve is often damaged because of the untimely torque protection function. The intelligent valve electric controller can detect the value of the valve torque in real time, and provide protection in time when the value of the torque is abnormal. In addition, the valve electric controller also has a powerful fault self-diagnosis function. It can detect the valve fault in real time at each stage of the valve operation, prompt the staff in time when there is a fault, so as to facilitate the staff to solve the problem in time. If it can not be solved, the valve electric controller also has the function of remote diagnosis, and can diagnose the fault through the intelligent network. The information is uploaded to the controller manufacturer to facilitate the experts of the manufacturer to analyze and solve the problem in time, which also improves the efficiency of problem solving and reduces the cost of valve manufacturer’s later maintenance. Intelligent valve electric controller can be connected with the host computer through industrial field bus technology to support the remote control of the valve, so that the staff can monitor the status information of the valve remotely through the computer, modify the opening of the valve, the control mode of the valve and the communication address of the valve controller. Therefore, the application prospect of intelligent valve electric controller is broad. Fieldbus control is also in line with the development trend of intelligent and networked electric valve control devices.