CN110823482A - Early warning method for abnormal liquid level of oil tank of hydraulic lubricating system - Google Patents
Early warning method for abnormal liquid level of oil tank of hydraulic lubricating system Download PDFInfo
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- G—PHYSICS
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- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M3/00—Investigating fluid-tightness of structures
- G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
- G01M3/26—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors
- G01M3/32—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for containers, e.g. radiators
- G01M3/3236—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for containers, e.g. radiators by monitoring the interior space of the containers
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- G—PHYSICS
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- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F23/00—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
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Abstract
The invention discloses a liquid level abnormity early warning method for an oil tank of a hydraulic lubrication system, which comprises the following steps: s1, determining the maximum liquid level difference H of each oil tankc(ii) a S2, filtering the oil tank level value collected by the liquid level meter, namely correcting the mutation level value; s3, when the oil pump runs normally and the pressure accumulator is in a non-oil return state, periodically calculating the difference value H between the maximum value and the minimum value of the liquid level of the oil tankmAnd judging the difference value HmWhether or not the maximum liquid level difference H is exceededcAnd if the detection result is yes, judging that the oil leakage exists in the oil tank. The oil leakage detection device can timely and accurately detect oil leakage of the hot rolling hydraulic lubricating system, automatic detection of oil leakage of the hot rolling hydraulic lubricating system is realized, abnormal liquid level change is timely found, pretreatment can be carried out on the premise of major failure, the failure time is reduced, and oil loss is greatly reduced.
Description
Technical Field
The invention belongs to the technical field of monitoring of the liquid level of an oil tank of a hot rolling hydraulic lubricating oil station, and particularly relates to an early warning method for the liquid level abnormity of the oil tank of a hydraulic lubricating system.
Background
In the production process of the hot rolling production line, oil leakage of a hydraulic and lubricating system often occurs. Due to the fact that the number of points of the pipeline is large, oil leakage is not easy to find out in time, the reason is often found after the system is shut down passively, and huge direct and indirect economic losses are caused.
In order to find the abnormal change of the liquid level, the most common traditional mode is to adopt a manual meter reading mode to observe the change of the liquid level. The main working content is that according to a certain time period, the liquid level reading of each oil tank is recorded and compared, and if the difference is large, the abnormality is judged. There are also some methods of alarming with high and low switching level. The common defects of the two early warning modes are slow reaction and incapability of finding oil leakage quickly.
In some plants, the slope of the liquid level change is also used to reflect the leakage of the oil tank, but the slope method is not suitable for hot rolling production lines, because most of the oil leakage occurs in the pipeline, and the liquid level is basically unchanged when the hydraulic cylinder does not act; after the hydraulic cylinder acts, the liquid level has a sudden change, and then the sudden change can be reflected in the liquid level of the oil tank. The slope of the level reading does not reflect the leak situation well.
Disclosure of Invention
The invention provides an oil tank liquid level abnormity early warning method for a hydraulic lubrication system, and aims to solve the problem that the abnormal change of the liquid level of oil cannot be accurately and timely found out by a hot rolling hydraulic lubrication system.
The invention is realized in this way, a liquid level abnormity early warning method for a hydraulic lubrication system oil tank, the method specifically comprises the following steps:
s1, determining the maximum liquid level difference H of each oil tankc；
S2, filtering the oil tank level value collected by the liquid level meter, namely correcting the mutation level value;
s3, when the oil pump runs normally and the pressure accumulator is in a non-oil return state, periodically calculating the difference value H between the maximum value and the minimum value of the liquid level of the oil tankmAnd judging the difference value HmWhether or not the maximum liquid level difference H is exceededcAnd if the detection result is yes, judging that the oil leakage exists in the oil tank.
Further, the method for determining the maximum liquid level difference of each oil tank specifically comprises the following steps:
s11, after the liquid level of the oil tank is stable, giving the maximum value H of the liquid levelmaxAnd minimum value of liquid level HminAssigning an initial value;
s12, comparing the current liquid level value H with the maximum liquid level value H of the last scanning timemaxAnd minimum level value HminComparing;
s13, if the current liquid level value H is larger than the maximum liquid level value H of the last scanning timemaxAssigning the current liquid level value H to the maximum liquid level value HmaxIf the current level value H is less than the minimum level value H of the last scanning timeminAssigning the current level value H to the minimum level value Hmin；
S14, under the condition that oil leakage exists in the oil tank and water does not enter, if the maximum value H of the liquid level ismaxAnd minimum value of liquid level HminIf there is no change in the set time length, the maximum value H of the liquid levelmaxAnd minimum value of liquid level HminDifference value of (H)mI.e. the maximum level difference H of the oil tankcI.e. Hm＝Hmax-Hmin＝Hc。
Further, the method for filtering the liquid level value specifically comprises the following steps:
d + D1 + D, Yn＝IN；
+|D|<D1, then Yn＝Yn-1+|D|；
–|D|>D1, then Yn＝Yn-1-|D|；
Wherein IN-the detected actual value of the liquid level; y isn-1-the level value of the previous scan; y isn-the level value after filtration; d-the maximum variable quantity of the liquid level value of the PLC in the adjacent two scanning times; d1- -the actual change of the level value of the PLC controller in two adjacent scanning time.
Further, within a set time length after the oil pump stops running to start, the maximum value H of the liquid level is determinedmaxAnd minimum value of liquid level HminThe value being the current level H, i.e. Hmax＝HminAnd H, judging that the oil pump normally operates until the oil pump is started for a set time.
Further, when the pressure accumulator is in an oil return state, the maximum liquid level difference H is achievedcCompensating to form a compensated maximum liquid levelDifference Hco，Hco＝Hc+HosWherein the compensation value HosAre empirical values.
Further, the method further comprises:
and S4, detecting whether the oil tank is in the oiling state in real time, and if the detection result is yes, detecting oil leakage of the oil tank in the oiling state.
Further, the method for detecting oil leakage of the oil tank in the refueling state and the refueling state specifically comprises the following steps:
comparing the real-time level value H with the level value H before n x t millisecondsPA continuous comparison is carried out, and,
at Hm>HcoWhen, if H>HPJudging that the oil tank is filled with oil, and assigning the maximum value H of the liquid levelmaxAnd a minimum value HminIs the current level value H, if H<HPJudging that the oil tank leaks oil;
wherein, the scanning speed of the PLC controller is t milliseconds per time.
The hydraulic lubrication system oil tank liquid level abnormity early warning method provided by the embodiment of the invention has the following beneficial technical effects: the oil leakage detection device can timely and accurately detect oil leakage of the hot rolling hydraulic lubricating system, automatic detection of oil leakage of the hot rolling hydraulic lubricating system is realized, abnormal liquid level change is timely found, pretreatment can be carried out on the premise of major failure, the failure time is reduced, and oil loss is greatly reduced.
Drawings
Fig. 1 is a flowchart of an early warning method for abnormal liquid level in an oil tank of a hydraulic lubrication system according to an embodiment of the present invention.
Detailed Description
The following detailed description of the embodiments of the present invention will be given in order to provide those skilled in the art with a more complete, accurate and thorough understanding of the inventive concept and technical solutions of the present invention.
This unusual early warning system of hydraulic lubrication system oil tank liquid level includes: the PLC controller, the oil pump communication connection of PLC controller and each oil station, during the oil pump was gone into oil pipe with lubricating oil from the oil tank mesopump, was equipped with the level gauge in the oil tank, and the level gauge is connected with the PLC controller communication, and the pressure accumulator in the oil station is connected with the PLC controller communication.
Fig. 1 is a flowchart of a hydraulic lubrication system oil tank liquid level abnormality early warning method provided by an embodiment of the present invention, and the method specifically includes the following steps:
s1, determining the maximum liquid level difference H of each oil tankc；
In general, the liquid level of the oil tank can normally float up and down along with the action of each hydraulic cylinder. However, because of the complexity of the process requirements, the float for a certain period of time cannot be taken as its maximum float value. To calibrate the maximum float of the level of a separate hydraulic or lubricating system, a long acquisition and processing time is necessary, the specific length of time being dependent on the specific conditions at each station.
In the embodiment of the present invention, the method for determining the maximum liquid level difference of each oil tank specifically includes the following steps:
s11, after the liquid level of the oil tank is stable, giving the maximum value H of the liquid levelmaxAnd minimum value of liquid level HminAssigning an initial value;
s12, comparing the current liquid level value H with the maximum liquid level value H of the last scanning timemax1And minimum level value HminComparing;
s13, if the current liquid level value H is larger than the maximum liquid level value H of the last scanning timemaxAssigning the current liquid level value H to the maximum liquid level value HmaxIf the current level value H is less than the minimum level value H of the last scanning timeminAssigning the current level value H to the minimum level value Hmin；
If H is>HmaxThen let HmaxAssigning the current liquid level value H to the maximum liquid level value Hmax；
If H is<HminThen let HminAssigning the current liquid level value H to the minimum liquid level value Hmin。
S14, under the condition that oil leakage exists in the oil tank and water does not enter, if the maximum value H of the liquid level ismaxAnd minimum value of liquid level HminIf there is no change in the set time length, the maximum value H of the liquid levelmaxAnd minimum value of liquid level HminDifference value of (H)mI.e. the maximum level difference H of the oil tankcI.e. Hm＝Hmax-Hmin＝Hc。
S2, filtering the oil tank liquid level collected by the liquid level meter, namely correcting the collected sudden change liquid level value;
since there may be electromagnetic interference in the vicinity of the hydraulic station (e.g., intercom, etc. used nearby), resulting in a sudden change in the level reading, which is not caused by a true level fluctuation, the change is first filtered as follows:
if the liquid level has actual fluctuation, the variation of the liquid level in a short time is not very large, and sudden jump cannot occur, and filtering judgment is carried out based on the thought:
d + D1 + D, Yn＝IN；
+|D|<D1, then Yn＝Yn-1+|D|；
–|D|>D1, then Yn＝Yn-1-|D|；
Wherein IN-the detected actual value of the liquid level; y isn-1-the level value of the previous scan; y isn-the level value after filtration; d-the maximum variable quantity of the liquid level value of the PLC in the adjacent two scanning times; d1 — the actual change of the level value of the PLC controller in two adjacent scanning times, the scanning time of the PLC controller is fast, usually several tens of milliseconds.
S3, when the oil pump normally operates and the pressure accumulator is in a non-oil return state, periodically calculating the difference value H between the maximum value and the minimum value of the liquid level of the oil tankmAnd judging the difference value HmWhether or not the maximum liquid level difference H is exceededcAnd if the detection result is yes, judging that the oil leakage exists in the oil tank.
In the embodiment of the invention, the maximum value H of the liquid level is compared with the minimum value of the liquid level within the set time length after the oil pump stops running and startsmaxAnd minimum value of liquid level HminThe value being the current level, i.e. Hmax＝HminAnd H, judging that the oil pump normally operates until the oil pump is started for a set time, and restarting sampling monitoring.
In the embodiment of the invention, when the pressure accumulator is in an oil return state, the oil return of the pressure accumulator causes a little floating of the liquid level, namely the floating of the normal liquid level, and the maximum liquid level difference H iscCompensating to form a compensated maximum liquid level difference Hco，Hco＝Hc+HosWherein the compensation value HosThe oil leakage detection method is an empirical value, and the value of the empirical value is small so as to avoid influencing the oil leakage detection speed.
In the embodiment of the invention, the liquid level is normally increased due to the fact that the oil tank is supplemented with new oil, and the liquid level is increased to enable HmaxThe value becomes larger, causing the difference value between the maximum liquid level and the minimum liquid level to exceed the calibration value HcoTherefore, the situation of refueling the oil tank needs to be identified, and the method for judging whether the oil tank is in a refueling state specifically comprises the following steps:
s4, detecting whether the oil tank is in an oil filling state in real time, and if so, detecting oil leakage of the oil tank in the oil filling state, wherein the implementation method comprises the following specific steps:
the scanning speed of the PLC controller is t milliseconds per time, n liquid level recording intermediate variables, H, are registeredX1、HX2、HX3、HX4、HX5、HX6、…...、HXn-1、Hp。
The PLC assigns the value of the current liquid level height value H to H every time of scanningX1Is prepared from HX1Is given as HX2Is prepared from HX2Is given as HX3Is prepared from HX3Is given as HX4Is prepared from HX4Is given as HX5Is prepared from HX5Is given as HX6By analogy, HXn-2Is given as Hn-1Is prepared from HXn-1Is given as HP，。
HPThe reading is a liquid level value before n x t milliseconds recorded by the PLC controller, and the real-time liquid level value H and the liquid level value H before n x t milliseconds are recordedPCarry out holdingAnd the comparison is continued,
at Hm＝Hmax-Hmin>HcoWhen, if H>HPJudging that the oil tank is filled with oil, and assigning the maximum value H of the liquid levelmaxAnd a minimum value HminIs the current level value H, if H<HPIf the oil is leaked, the alarm is given out immediately.
In another embodiment, a detection limit switch is additionally arranged at the oil filling valve of the oil tank and used for detecting whether the oil filling valve is in an open state or not, when the oil filling valve is opened, the PLC judges that the oil tank is in the oil filling state, and assigns a maximum value H of the liquid levelmaxAnd a minimum value HminIs the current level H, i.e. Hmax＝HminAnd H, when oiling is stopped, restarting sampling monitoring.
The hydraulic lubrication system oil tank liquid level abnormity early warning method provided by the embodiment of the invention has the following beneficial technical effects: the oil leakage detection device can timely and accurately detect oil leakage of the hot rolling hydraulic lubricating system, automatic detection of oil leakage of the hot rolling hydraulic lubricating system is realized, abnormal liquid level change is timely found, pretreatment can be carried out on the premise of major failure, the failure time is reduced, and oil loss is greatly reduced.
The invention has been described above with reference to the accompanying drawings, it is obvious that the invention is not limited to the specific implementation in the above-described manner, and it is within the scope of the invention to apply the inventive concept and solution to other applications without substantial modification.
Claims (7)
1. The early warning method for the abnormal liquid level of the oil tank of the hydraulic lubrication system is characterized by comprising the following steps:
s1, determining the maximum liquid level difference H of each oil tankc；
S2, filtering the oil tank level value collected by the liquid level meter, namely correcting the mutation level value;
s3, when the oil pump is in normal operation and the pressure accumulator is in non-oil return state, the periodThe difference value H between the maximum value and the minimum value of the liquid level of the oil tank is calculatedmAnd judging the difference value HmWhether or not the maximum liquid level difference H is exceededcAnd if the detection result is yes, judging that the oil leakage exists in the oil tank.
2. The hydraulic lubrication system oil tank liquid level abnormity early warning method according to claim 1, wherein the method for determining the maximum liquid level difference of each oil tank specifically comprises the following steps:
s11, after the liquid level of the oil tank is stable, giving the maximum value H of the liquid levelmaxAnd minimum value of liquid level HminAssigning an initial value;
s12, comparing the current liquid level value H with the maximum liquid level value H of the last scanning timemaxAnd minimum level value HminComparing;
s13, if the current liquid level value H is larger than the maximum liquid level value H of the last scanning timemaxAssigning the current liquid level value H to the maximum liquid level value HmaxIf the current level value H is less than the minimum level value H of the last scanning timeminAssigning the current level value H to the minimum level value Hmin；
S14, under the condition that oil leakage exists in the oil tank and water does not enter, if the maximum value H of the liquid level ismaxAnd minimum value of liquid level HminIf there is no change in the set time length, the maximum value H of the liquid levelmaxAnd minimum value of liquid level HminDifference value of (H)mI.e. the maximum level difference H of the oil tankcI.e. Hm＝Hmax-Hmin＝Hc。
3. The hydraulic lubrication system oil tank liquid level abnormity early warning method according to claim 1, wherein the liquid level value filtering method specifically comprises the following steps:
d + D1 + D, Yn＝IN；
+|D|<D1, then Yn＝Yn-1+|D|；
–|D|>D1, then Yn＝Yn-1-|D|；
Wherein IN- -detected liquidA bit actual value; y isn-1-the level value of the previous scan; y isn-the level value after filtration; d-the maximum variable quantity of the liquid level value of the PLC in the adjacent two scanning times; d1- -the actual change of the level value of the PLC controller in two adjacent scanning time.
4. The method for early warning of abnormal liquid level in an oil tank of a hydraulic lubricating system as claimed in claim 1, wherein the maximum value H of the liquid level is determined within a set time period after the oil pump stops operating and starts operatingmaxAnd minimum value of liquid level HminThe value being the current level H, i.e. Hmax＝HminAnd H, judging that the oil pump normally operates until the oil pump is started for a set time.
5. The method of claim 1, wherein the maximum level difference H is determined when the pressure accumulator is in an oil return statecCompensating to form a compensated maximum liquid level difference Hco，Hco＝Hc+HosWherein the compensation value HosAre empirical values.
6. The hydraulic lubrication system oil tank liquid level abnormality warning method as recited in claim 1, further comprising:
and S4, detecting whether the oil tank is in the oiling state in real time, and if the detection result is yes, detecting oil leakage of the oil tank in the oiling state.
7. The hydraulic lubrication system oil tank liquid level abnormality early warning method according to claim 6, wherein the oil tank oil leakage detection method in the refueling state and the refueling state is as follows:
comparing the real-time level value H with the level value H before n x t millisecondsPA continuous comparison is carried out, and,
at Hm>HcoWhen, if H>HPJudging that the oil tank is filled with oil, and assigning the maximum value H of the liquid levelmaxAnd a minimum value HminIs the current level value H, ifH<HPJudging that the oil tank leaks oil;
wherein, the scanning speed of the PLC controller is t milliseconds per time.
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Cited By (3)
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| CN112033496A (en) * | 2020-09-10 | 2020-12-04 | 上海星融汽车科技有限公司 | Method for judging fuel quantity abnormal change based on fuel tank liquid level monitoring |
| CN112065820A (en) * | 2020-10-10 | 2020-12-11 | 攀钢集团攀枝花钢钒有限公司 | Dynamic control method for oil in oil tank of hot continuous rolling hydraulic system |
| CN112833067A (en) * | 2021-01-22 | 2021-05-25 | 山信软件股份有限公司 | Method and device for detecting oil leakage of oil tank of hydraulic station |
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