Disclosure of Invention
The invention aims to provide a composite pilot device, a system and an unloading valve for a coal mine emulsion pump station, which provide a plurality of switchable liquid path channels, so that once the liquid path in the unloading valve is blocked, the liquid path can be automatically switched to a smooth channel to continue normal operation.
The invention aims to achieve the aim, and the aim is achieved by the following technical scheme:
The composite pilot device for the coal mine emulsification pump station comprises an electromagnetic proportional valve and a three-way pilot valve;
The electromagnetic proportional valve is provided with a proportional push rod for output in a matching way, and the proportional push rod realizes the expansion and the contraction of at least three gears on a linear stroke through the electromagnetic control of the electromagnetic proportional valve;
The three-channel pilot valve is characterized in that a pilot valve core with linear reciprocating stroke is arranged in the three-channel pilot valve, one end of the pilot valve core is connected with the outer end of a proportional push rod to enable the strokes of the pilot valve core and the proportional push rod to be synchronous, a first liquid flow channel, a second liquid flow channel and a third liquid flow channel are arranged on a valve body of the three-channel pilot valve in parallel, an external medium interface is arranged at the outer end of the pilot valve core, a medium channel communicated with the external medium interface is arranged in the pilot valve core, a communication channel communicated with the medium channel is arranged on the side wall of the pilot valve core, and the three-gear stroke of the proportional push rod enables the communication channel to be communicated with the first liquid flow channel, the second liquid flow channel and the third liquid flow channel respectively.
The external medium interface is connected with a pressure medium pipe which is used for communicating with a liquid path of the unloading valve.
The input voltage of the electromagnetic proportional valve is DC24V, the power is not more than 3W, and the highest surface temperature of the proportional electromagnet of the electromagnetic proportional valve under the condition that coal dust is accumulated on the surface of the proportional electromagnet is not more than 150 ℃.
The composite pilot system for the coal mine emulsion pump station comprises the composite pilot device, a pressure acquisition module and a PLC control module;
The pressure acquisition module is configured on the pressure medium channel of the unloading valve and is used for acquiring the pressure in the channel and the valve cavity and the PLC control module feeds back a pressure signal;
The PLC control module is used for acquiring pressure data of the pressure acquisition module, converting the pressure data into electric signals in a proportional mode, and controlling gears of the electromagnetic proportional valve according to the electric signals.
The pressure acquisition module comprises an explosion-proof intrinsically safe pressure sensor.
The unloading valve for the coal mine emulsion pump station comprises a main valve and a mechanical pilot valve which are matched for use, and further comprises the composite pilot device, a pressure sensor and a PLC control module;
The pressure sensor is arranged on the pressure medium pipe channel of the main valve and is used for acquiring pressure data in the main valve;
the PLC control module is used for receiving the pressure data, directly converting the pressure data into an electric signal, and controlling the gear of the electromagnetic proportional valve according to the electric signal;
the main valve is communicated with the liquid path passage of the mechanical pilot valve through the pilot valve core of the three-channel pilot valve, and is communicated with one of the first liquid flow channel, the second liquid flow channel and the third liquid flow channel.
Compared with the prior art, the invention has the beneficial effects that:
The technology can realize automatic conversion of a liquid flow channel through the composite pilot device, can realize response to voltage change of a liquid channel in a valve body of an unloading valve through an electromagnetic proportional valve, namely, the main valve, the electromagnetic proportional valve and a three-channel pilot valve are mutually matched, and once the channel is blocked, the other channel can be automatically switched to work normally, and the operating principle is as follows: the pressure is collected by an explosion-proof intrinsically safe pressure sensor, the pressure is transmitted to a PLC system through an intrinsically safe explosion-proof circuit chip, the PLC sends different current instructions to an electromagnetic proportional valve according to the pressure, the proportional electromagnet realizes proportional movement of a valve core of the electromagnetic proportional valve according to the received current, the valve core of the electromagnetic proportional valve pushes a pilot valve push rod to realize linear travel position switching of three gears, once the pressure is increased, the movement distance is directly proportional to the ratio of the current to the pressure according to the current, and the butt joint of a first liquid flow channel, a second liquid flow channel and a third liquid flow channel and a communication channel is switched, so that the valve core is shifted to realize that an opening is kept smooth for a long time, and the loading or unloading function of a main valve is maintained.
Detailed Description
The application will be further illustrated with reference to specific examples. It is to be understood that these examples are illustrative of the present application and are not intended to limit the scope of the present application. Further, it will be understood that various changes and modifications may be made by those skilled in the art after reading the teachings of the application, and equivalents thereof fall within the scope of the application as defined by the claims.
The instruments, reagents, materials, etc. used in the examples described below are conventional instruments, reagents, materials, etc. known in the art, and are commercially available. The experimental methods, detection methods, and the like in the examples described below are conventional experimental methods, detection methods, and the like that are known in the prior art unless otherwise specified.
Example 1 unloading valve with composite Pilot plant for coal emulsion Pump station
The traditional mining electromagnetic/mechanical unloading valve (hereinafter referred to as main valve 1) adopts a single flow channel electromagnetic pilot valve in a matched manner, or adopts a mechanical pilot valve instead of an electromagnetic pilot valve, the biggest drawback of both of these conventional forms is that once the pilot valve flow passage is blocked, the entire main valve 1 fails to operate. In order to overcome the blocking problem, the design scheme of the example is as follows:
the main structure comprises a main valve 1 and a mechanical pilot valve 2 which are matched for use, wherein the main valve 1 is consistent with an unloading valve of a traditional emulsion pump station for coal mines. The novel hydraulic control system is characterized by further comprising a composite pilot system for ensuring smooth passages of the main valve 1 and the mechanical pilot valve 2, namely an electromagnetic proportional valve 3, a three-way pilot valve 4, a pressure sensor and a PLC control module.
The electromagnetic proportional valve 3 is connected with a power line, a proportional electromagnet and a proportional valve core 5 are arranged in the electromagnetic proportional valve 3, the proportional valve core 5 is connected with a proportional push rod 6 synchronous with the proportional valve core 5, one end of the proportional push rod 6 extends out of the electromagnetic proportional valve 3 and is used as an output component of the electromagnetic proportional valve, and the proportional push rod 6 realizes the expansion and the contraction of at least three gears on a linear stroke through electromagnetic control of the electromagnetic proportional valve 3;
the design high pressure ratio of the electromagnetic proportional valve 3 meets the GB3836.4 standard requirement, and the design key points and difficulties are as follows:
a. The device can be suitable for high-pressure occasions (the pressure is between 32 and 40 Mpa) and can convert pressure signals into current signals in proportion;
b. The valve is different from a common pressure pilot valve, and compared with the hydraulic pressure on a valve core, the electromagnetic attraction of the proportional electromagnet is compared, and the electromagnetic force can be changed by changing the current of the proportional electromagnet, so that the moving distance of the proportional push rod 6 is changed, as shown in fig. 2,3 and 4;
c. The application occasion of the valve is positioned underground in a coal mine, belongs to flammable and explosive occasions, and therefore the requirement of GB3836.4 standard specification must be met. The input voltage DC24V, the power is not more than 3W, and the highest surface temperature of the proportional electromagnet when coal dust possibly accumulates on the surface of the proportional electromagnet is not more than 150 ℃.
The main valve 1 is communicated with a liquid path of the mechanical pilot valve 2 through a pilot valve core 7 of the three-channel pilot valve 4, and is communicated with a first liquid flow channel 8, a second liquid flow channel 9 and a third liquid flow channel 10. The specific structure is as follows:
The three-channel pilot valve 4 is internally provided with a pilot valve core 7 with linear reciprocating travel, one end of the pilot valve core 7 is connected with the outer end of the proportional push rod 6 to enable the travel of the pilot valve core 7 and the travel of the pilot valve core 7 to be synchronous, the pilot valve also has linear travel output with three gears, a valve body of the three-channel pilot valve 4 is provided with a first liquid flow channel 8, a second liquid flow channel 9 and a third liquid flow channel 10 in parallel, the outer end of the pilot valve core 7 is provided with an external medium interface 12, the external medium interface is connected with a pressure medium pipe 13, and the pressure medium pipe 13 is used for communicating with a liquid path of an unloading valve. The pilot valve core 7 is internally provided with a medium channel 11 communicated with an external medium interface, the side wall of the pilot valve core 7 is provided with a communication channel communicated with the medium channel 11, and the three-gear stroke of the proportional push rod 6 can enable the communication channel to be respectively communicated with the first liquid flow channel 8, the second liquid flow channel 9 and the third liquid flow channel 10. Through the follow-up of the pilot valve core 7 on the proportional push rod 6, the switching and alternative communication of the first liquid flow channel 8, the second liquid flow channel 9, the third liquid flow channel 10 and the communication channel are respectively realized on three stroke gears. The communication passage and the external medium interface are respectively used as two inlet and outlet ports of the medium passage 11 and are used for being connected to the liquid passage of the main valve 1 and the mechanical pilot valve 2, so that the liquid passage of the main valve 1 and the liquid passage of the mechanical pilot valve 2 are communicated in series through the medium passage, and the switching of the three passages of the first liquid passage 8, the second liquid passage 9 and the third liquid passage 10 can ensure that the liquid passage of the main valve 1 and the liquid passage of the mechanical pilot valve 2 can obtain the communication guarantee of the three parallel passages.
The pressure sensor is arranged on a pressure medium channel of the main valve 1 (an unloading valve) and used for acquiring pressure data in the main valve 1, and the pressure sensor is used for acquiring the pressure data in the pressure medium channel of the main valve 1 and can intuitively respond whether the liquid path is blocked or not according to the pressure data.
The PLC control module is used for acquiring pressure data of the pressure acquisition module, converting the pressure data into electric signals in a proportional manner, and controlling the gear of the electromagnetic proportional valve 3 according to the electric signals. The main valve 1 and the pilot valve change the strokes of the proportional valve core 5 and the proportional push rod 6 according to the magnitude of a current signal converted from a pressure ratio by the electromagnetic proportional valve 3, so that the displacement of the pilot valve core 7 and the push rod is realized, and once a liquid flow channel is blocked, the other channel can be automatically switched to work normally.
The working principle of the unloading valve is as follows:
a. Proportional control is adopted, wherein the proportional control is a control mode for continuously controlling hydraulic pressure and displacement of an executing element in proportion according to a current signal converted from the hydraulic pressure;
b. the composite pilot mechanism is an electrohydraulic conversion element and a power amplification element, wherein the electronic proportional amplifier converts an input electric signal voltage value into a corresponding current signal, the current signal is used as an input quantity of the electromagnetic proportional valve 3 to be sent to the proportional electromagnet, the electromagnet converts the current into a force acting on the proportional valve core 5, the current is increased, the output force is correspondingly increased, the force pushes the valve core and acts on the proportional push rod 6, channel conversion is realized, and through the conversion process, the displacement of an executing element (push rod) can be controlled by the change of one input electric signal.
Example 2 performance testing of the unloader valve described in example 1
1. Detection basis
MT/T188.3 emulsion pump station unloading valve technical condition stipulated test method for coal mine.
2. Detection method
2.1 Assembling the pilot System with the Main valve 1 according to the requirement of FIG. 1, opening the first flow passage 8 as shown in FIG. 2 (where all three flow passages are non-blocked) for performance testing, the test results are shown in Table 1
TABLE 1 Performance test results
Project name |
Technical requirement chapter number |
Test method chapter number |
Test results |
External leakage test |
4.5.2 |
5.2.1 |
Meets the requirements |
Internal leakage test |
4.5.3 |
5.2.2 |
Meets the requirements |
Nominal pressure unloading test |
4.5.4 |
5.2.3 |
Meets the requirements |
Nominal pressure recovery test |
4.5.4 |
5.2.4 |
Meets the requirements |
Pressure adjustment range test |
4.5.4 |
5.2.5 |
Meets the requirements |
Pressure loss test |
4.5.4 |
5.2.6 |
Meets the requirements |
Overpressure relief test |
4.5.6 |
5.2.7 |
Meets the requirements |
Dynamic characteristic test |
4.5.4 |
4.2.9 |
Meets the requirements |
2.2 The pilot system is assembled with the main valve 1 as required in fig. 1, the valve core is moved forward to open the second flow channel 9 (the first flow channel 8 is in a blocked state at this time), and a performance test is performed in fig. 3, and the test results are shown in table 2.
TABLE 2 Performance test results
Project name |
Technical requirement chapter number |
Test method chapter number |
Test results |
External leakage test |
4.5.2 |
5.2.1 |
Meets the requirements |
Internal leakage test |
4.5.3 |
5.2.2 |
Meets the requirements |
Nominal pressure unloading test |
4.5.4 |
5.2.3 |
Meets the requirements |
Nominal pressure recovery test |
4.5.4 |
5.2.4 |
Meets the requirements |
Pressure adjustment range test |
4.5.4 |
5.2.5 |
Meets the requirements |
Pressure loss test |
4.5.4 |
5.2.6 |
Meets the requirements |
Overpressure relief test |
4.5.6 |
5.2.7 |
Meets the requirements |
Dynamic characteristic test |
4.5.4 |
4.2.9 |
Meets the requirements |
2.3 The pilot system is assembled with the main valve 1 according to the requirement of fig. 1, the valve core moves forward to open the third fluid flow channel 10 (the first fluid flow channel 8 and the second fluid flow channel 9 are in a blocking state at this time), the performance test is carried out in fig. 4, and the test result is shown in table 3.
TABLE 3 Performance test results
Project name |
Technical requirement chapter number |
Test method chapter number |
Test results |
External leakage test |
4.5.2 |
5.2.1 |
Meets the requirements |
Internal leakage test |
4.5.3 |
5.2.2 |
Meets the requirements |
Nominal pressure unloading test |
4.5.4 |
5.2.3 |
Meets the requirements |
Nominal pressure recovery test |
4.5.4 |
5.2.4 |
Meets the requirements |
Pressure adjustment range test |
4.5.4 |
5.2.5 |
Meets the requirements |
Pressure loss test |
4.5.4 |
5.2.6 |
Meets the requirements |
Overpressure relief test |
4.5.6 |
5.2.7 |
Meets the requirements |
Dynamic characteristic test |
4.5.4 |
4.2.9 |
Meets the requirements |
3. Evaluation of technical Effect
According to the technical condition test requirements of the unloading valve of the emulsion pump station for the MT/T188.3 coal mine, the test of the stipulated provisions of the tables 1,2 and 3 are carried out according to the positions of the liquid flow channels stipulated by the figures 2,3 and 4, and the test results all meet the standard stipulated requirements.