Investigation of the relationship between internal fluid leakage through a valve and the acoustic emission generated from the leakage

The detection of acoustic emission (AE) signals produced by liquid and gas leakage through valves can be related directly to the qualitative leakage rate. This allows for cost estimation of losses in processes for several industries. However, to find out the relationship between qualitative leakage rate and AE signal large amounts of experimental data is needed. This paper presents a theoretical investigation of the acoustic emission to detect the internal leakage rate through a valve and experimental validation. The AE signals generated by internal liquid and gas leakage through valves were characterised. The effect of the influenced factors of leakage rates, inlet pressure levels, valve sizes and valve types, on AE parameter, AE_RMS, were studied and explained. The results of theoretical and experimental showed that AE signal power computed from the power spectral density (PSD) correlated well with influenced factors of leakage rates. Finally, a novel and inexpensive AE instrument has been invented for predicting qualitative leakage rate using a micro processor and derived relationship.     

Prediction method of ball valve internal leakage rate based on acoustic emission technology

Valves on natural gas transmission pipelines are prone to internal leakage due to the influence of environment, transportation medium, misoperation and other factors. Therefore, timely and accurate detection of valve internal leakage is of great significance to the safe operation of the pipelines. As a non-destructive testing method, acoustic emission (AE) technology can be used for online detection of internal leakage of valve. In order to improve the accuracy of AE technology for detecting valve internal leakage, a ball valve internal leakage detection method based on acoustic emission technology is proposed. Firstly, the AE signal generated by the internal leakage of the ball valve is detected by AE sensor, and the AE signal is denoised by wavelet packet threshold denoising. Secondly, the characteristic parameters with high correlation with the internal leakage rate of the ball valve are selected by using the correlation coefficient method to form the sample feature set. Finally, the mathematical model between the internal leakage rate of the ball valve and the characteristic parameters is established by using the sparrow search algorithm to optimize the backpropagation neural network, and to predict the internal leakage rate of the ball valve. An experimental platform is built to verify that the proposed method can predict the internal leakage rate of the ball valve more accurately. It provides strong technical support for the safe operation of natural gas transmission pipelines.     

基于声发射的阀门泄漏检测及标定方法的研究

基于阀门泄漏产生声发射信号的原理,建立了可用于测试阀门泄漏率低于0.1Pa.m3/s的微小泄漏状态的声发射检测系统,采用气泡法对阀门微小泄漏进行标定。针对声发射信号在检测中易受环境噪声干扰的问题,设计了信号调理电路来降低各种噪声,并编制了LabVIEW程序对采集的声发射信号进行分析和处理。以手动球阀为被测对象,在建立的系统上进行了大量泄漏检测实验,结果表明,该系统能快速方便地对阀门微小泄漏做出定性分析。     

A relative calibration method for a valve leakage rate measurement system

This paper presents a relative calibration method for an internal valve leakage rate measurement system using both microcontroller and acoustic emission (AE) methods. An air jet was selected to calibrate because it provides a frequency spectrum similar to the AE spectrum obtained from the valve leak, especially in the frequency range of 100-300 kHz. Three AE sensors mounted on a valve were used to validate the system calibration. Ratios between the average energy (AErms) were obtained from each pair of sensors, and these ratios were used to transfer the leakage AErms value. Subsequence, its performance to predict the leakage rate in the laboratory and in the field was tested. The error is less than 5% in almost cases. Its benefit is to reduce the recalibration time when a part of measurement system is changed. Accordingly, inexpensive equipment including an AE sensor was built, and its system performance was revealed.     

天然气管道球阀内漏发声机理及检测试验

球阀作为高压天然气输送管道的主要设备,其内漏时的喷流气体会产生声发射信号,通过研究该声发射信号特征规律将有助于阀门内漏流量量化检测。针对这一问题,进行了天然气输送管道球阀内漏发声机理和检测试验研究,分析了阀门内漏声发射现象产生的机理和内漏流量检测评价方法。在此基础上,应用声发射检测系统对3种不同尺寸内漏球阀进行了检测试验,通过试验分析了球阀在不同内漏流量下的声发射信号频谱特征分布规律,并采用小波包分析方法进行信号特征参数(信息熵、均方根、频域峰值)提取。拟合特征参数与内漏流量关系曲线,采用R~2(确定系数)指标对曲线拟合程度进行评价,评价结果表明,采用均方根值(root mean square,简称RMS)的曲线拟合程度最高(R2为0.979),可以用于天然气输送管道球阀内漏流量的量化检测。     

基于声发射理论的安全阀气体内漏信号特征研究

基于声发射理论,研究安全阀气体内漏情况下的信号特征。设计搭建了安全阀内漏模拟试验台和安全阀内漏声发射信号检测系统,通过理论分析和试验研究的方法,模拟了安全阀密封面划伤、密封面出现单个漏孔、密封面出现多个漏孔等内漏情况,研究了这些情况下声发射信号的频谱特征,泄漏率对于声发射信号特征参数平均信号电平(ASL)的影响,以及泄漏率与平均信号电平之间的量化关系,为实现安全阀内漏在线监测奠定基础。     

基于特征参数和功率谱分析的液压滑阀内漏声发射检测实验研究

内泄漏直接影响液压系统的工作效率，常用的检测方法主观性强、效率低。以5组通径16 mm的三位四通换向滑阀为研究对象，设计并搭建了液压滑阀内泄漏声发射检测实验台。对比声发射信号的幅值域参数大小和响应时间，确定了最佳测量点。结合实验数据，找到了压力、间隙高度对幅值域特征参数的影响规律。运用AR功率谱提取信号的特征频率，发现滑阀内漏的声发射信号基频为40 kHz，泄漏量越大，特征频率越向低频方向偏移；特征频率呈现倍频的关系，内漏滑阀的功率谱曲线有小幅波动，正常滑阀功率谱曲线光滑。所得实验数据和结论对构建滑阀内漏诊断数据库具有重要意义。     

Experimental study of effects of water-cement ratio on the acoustic emission rate “<Emphasis Type="Italic">a</Emphasis>” values in concrete

The critical microcracks make durability of the concrete seriously weakened, and the water-cement (w/c) ratio plays a key role in the durability of concrete, acoustic emission (AE) rate “a” value is an effective parameter to evaluate the amount of critical microcracks quantitatively, so the study on the influence factors and the distribution of w/c ratio on the value “a” can provide a promising reference value for the practical engineering. A total of 90 specimens in different w/c ratio are tested under axial compression in the experiment. The whole damage evolution processes are monitored by fulldigital AE acquisition system. The differences of the amount of critical microcracks in different w/c ratio are explored based on the AE rate process theory, and the rule of the effects of w/c ratio on the rate “a” value is revealed through the analysis of fracture energy and cumulative AE energy in the failure process. The results show that a linear relationship was observed between cumulative AE energy and rate “a” value, the amount of critical microcracks and the rate “a” value increase with the increase of w/c ratio, while the cumulative AE energy and cumulative AE hits are on the contrary.     

一种基于LabVIEW的节气门位置传感器标定系统

为了准确获得节气门位置传感器的输出特性,以具有直观图形化编程和强大数字信号处理功能的虚拟仪器编程语言LabVIEW为开发平台,研制了一种节气门位置传感器标定系统,提高了传感器的标定精度,试验证明该系统可靠性好,达到了调查的要求。     

Novel torque motor model for performance design and analysis of a servo valve with permanent magnets

Servo valves are widely used for modern hydraulic actuator control. This valve consists of a torque motor with permanent magnets. In present study, a novel torque motor model is derived by considering magnetic flux leakage and demagnetization effect of the permanent magnets involved in the servo valve. The derived model was validated by comparing experimental data with the model calculation represented with physical parameters. Since these two important physical phenomena, missing in the previously well-known model, are considered in the newly derived torque motor model, it can be used for the physical parameter design of a torque motor and the analysis of a servo valve controlling electro-hydraulic servo systems.

     

盾构机液压推进系统故障分析与仿真研究

针对盾构机液压推进系统的故障诊断问题,以在芜湖长江隧道项目过程中所使用的大型液压驱动型泥水盾构机为研究对象,分析了盾构机液压推进系统的工作原理,总结了推进系统中液压缸泄漏、换向阀泄漏及溢流阀泄漏故障模式的发生机理及其对推进系统造成的影响。利用AMESim平台建立推进系统模型,对液压缸泄漏、换向阀泄漏及溢流阀泄漏3类故障进行仿真分析,并提取液压缸推进速度、推进行程、无杆腔流量和系统压力4种推进参数的仿真数据。仿真结果表明：发生液压缸泄漏故障时,活塞杆无法伸出,推进速度为0;发生换向阀泄漏故障时,液压缸出现自走现象,推进速度明显降低;发生溢流阀泄漏故障时,系统压力明显降低,液压缸无法克服阻力向前推进。为后续盾构机推进系统的故障诊断和预测提供了有价值的参考。     

基于虚拟仪器的低转速动平衡测量系统

设计了一种基于Labwindows/CVI的动平衡测量系统。微弱振动信号幅值和相位的精确提取是动平衡测量系统的关键,该系统采用了同步整周期采样技术,利用虚拟仪器灵活的设计方法、强大的信号数据处理与运算能力,应用基于最小二乘法拟合修正采样数据求振动幅值、相关法求相位差的软件设计方法,保证采集信号的精度,简化硬件电路设计,降低了系统成本。现场实验结果表明:该系统实现了对微弱振动信号的高精度测量,已在工程实践中应用于测量1Hz左右、质量大于300kg转子的动不平衡。     

基于机器视觉的液压阀阀芯关键尺寸的自动检测系统

提出一种基于机器视觉的阀芯的关键性尺寸检测的非接触型自动检测系统。该系统针对某液压阀阀芯关键几何量进行测量,测量过程实现自动化,测量精度高。系统采用高精度绝对式圆光栅记录液压阀的角度信号,同时通过误差补偿来减小空回影响和定位误差,再由高分辨力的CCD图像采集系统进行图像处理,最终得出测量结果。以该系统为指导研制的检测仪能自动保存历史数据和生成报表,研制结果表明,仪器的不确定度优于5μm。     

Internal leakage rate prediction and failure diagnosis of buried pipeline ball valve based on valve cavity pressure detection

— Ball valve is a key fluid control equipment used extensively in oil and gas pipelines. The online detection and failure diagnosis of the internal leakage of the ball valve is of great significance to ensure the safety operation of natural gas transmission pipelines. This paper proposes a prediction method of the internal leakage rate and a diagnosis method of the failure mode of the buried pipeline ball valve based on valve cavity pressure detection. Firstly, the valve cavity pressure signal generated by the internal leakage of the ball valve is detected by the pressure sensor, and the valve cavity pressure signal is denoised by wavelet threshold denoising. Then, the back propagation (BP) neural network has the disadvantage of unstable learning ability, so the BP neural network is optimized by chaos sparrow search optimization algorithm (CSSOA-BP). Finally, the prediction model of the ball valve internal leakage rate and the diagnosis model of the ball valve failure mode are established by using CSSOA-BP neural network and the characteristic parameters of the valve cavity pressure signal. To verify the performance of the prediction model and the diagnosis model of CSSOA-BP neural network, the predictive results and diagnostic results are compared with those of the sparrow search algorithm optimization BP (SSA-BP) neural network and BP neural network. The experimental results show that the maximum prediction error of CSSOA-BP neural network is the smallest, which is 13.6%. The accuracy of the diagnostic results of CSSOA-BP neural network is the highest, which is 83.3%. It indicates that the proposed method can achieve better predictive results of the ball valve internal leakage rate and more accurate diagnostic results of the ball valve failure mode.     

智能型电子舌的虚拟仪器构建技术

基于虚拟仪器平台,研制了一种新的伏安型电子舌--智舌,主要由特定的传感器阵列模块、自行设计的信号调理模块、数据采集卡及其软件开发平台 LabVIEW 4部分构成.系统主要实现了激励信号生成、多通道信号采集和实时显示、特征值提取及共享样品数据库等功能.对5种康师傅茶饮料进行检测并应用主成分分析对实验数据进行处理,取得了良好的区分效果,验证了基于虚拟仪器技术构建智舌的方案是行之有效的.     

基于虚拟仪器的扫描阀风洞数据采集系统研究

针对增压连续式风洞扫描阀测量系统的实验,设计了一种基于虚拟仪器LabWindows/CVI开发环境下的风洞扫描阀系统实验数据采集系统,阐述了该系统的方案设计,给出了系统的主要软件涉及构成及采集流程图。该系统为用户提供友好的人机交互界面和易操作性,完成对扫描阀测试实验系统模块参数、系统扫描参数、触发模式的信息配置,实现了对压力测试各通道数据的实时测量、显示、保存及打印输出。实验结果证实该系统提高了测量的有效性和可靠性。     

A study of hydraulic seal integrity

The work described in this paper involved on-line detection of seal defects in a water hydraulic cylinder. An obvious effect of seal defect is internal leakage. Therefore, the approach used was to detect the internal leakage using suitable technique. The technique used involved detecting the acoustic emission (AE) due to the internal leakage. This paper evaluated various parameters of AE signals in terms of their capability in estimating the internal leakage rate in a water hydraulic cylinder. Experiments were carried out to study the characteristics of AE parameters at different internal leakage rates, the parameters including the root-mean-square (rms) value, the count rate, the peak magnitude of power spectral density and the energy. The correlations between these parameters and the internal leakage rate were analysed carefully. The results show that energy-based AE parameters, especially the rms value, are more suitable to interpret AE signals generated by internal leakage.     

基于超声阻抗识别的阀门填料密封气体泄漏在线检测

目前阀门填料密封缺乏一种适用面广、成本低、精度高的气体泄漏在线检测技术,为此提出一种基于超声阻抗识别的阀门填料密封气体泄漏在线检测方法,该方法通过收集阀杆处泄漏的气体,使之通入检测液体中产生气泡,通过超声传感器识别气泡的阻抗来对气泡进行计数,从而实现气体泄漏量的测量。搭建基于高速摄像的气泡上浮动力学实验装置,系统研究采用水和离子液体作为检测液体对气体泄漏检测精度的影响,设计了超声传感信号采集和无线通信的软硬件系统,编制了APP程序,实现了阀门填料密封气体泄漏远程在线检测,检测值的误差小于5%。     

AN ONLINE MONITORING AND ALARMING INSTRUMENT FOR OIL LEAKAGE BASED ON ULTRASONIC EMULSIFYING TECHNOLOGY

An online monitoring and alarming instrument, based on ultrasonic emulsifying technology for measuring oil leakage of circulating cooling systems is put forward in this paper. The instrument consists of a data acquisition circuit which is based on a single chip microprocessor, ultrasonic emulsifiers, photoelectric probes, and remote alarming devices.

The key parts of the instrument are the ultrasonic emulsifier and the photoelectric probe. The former changes oil concentration in a sampled solution of cooling water into turbidity, and the latter detects the turbidity. Precision and reliability of the instrument depends on the function of the ultrasonic emulsifier and the photoelectric probe. Different types of oil need different input power of the ultrasonic emulsifier to yield full emulsification. Input power selections for the ultrasonic emulsifier driver, the structure of sampling tank, and the instrumentation static modeling results are presented in this paper.     

基于ARM_Linux的次声数据采集系统

提出了一种基于ARM9和嵌入式Linux的次声数据采集系统的设计方案。采用以ATMELAT91SAM9263微处理器和LatticeXP2系列FPGA为核心的架构,基于双扭环技术、套接字编程等实现了高速多通道数据采集、高精度数据采集、海量存储、远程传输等功能,已经在管道泄漏次声测试实验中投入使用。