CN113294406A - Hydraulic cylinder state monitoring system and method and hydraulic clamp system - Google Patents
Hydraulic cylinder state monitoring system and method and hydraulic clamp system Download PDFInfo
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- CN113294406A CN113294406A CN202010107538.8A CN202010107538A CN113294406A CN 113294406 A CN113294406 A CN 113294406A CN 202010107538 A CN202010107538 A CN 202010107538A CN 113294406 A CN113294406 A CN 113294406A
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- hydraulic cylinder
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- pipeline
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B19/00—Testing; Calibrating; Fault detection or monitoring; Simulation or modelling of fluid-pressure systems or apparatus not otherwise provided for
- F15B19/005—Fault detection or monitoring
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B21/00—Common features of fluid actuator systems; Fluid-pressure actuator systems or details thereof, not covered by any other group of this subclass
- F15B21/08—Servomotor systems incorporating electrically operated control means
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B2211/00—Circuits for servomotor systems
- F15B2211/80—Other types of control related to particular problems or conditions
- F15B2211/857—Monitoring of fluid pressure systems
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B2211/00—Circuits for servomotor systems
- F15B2211/80—Other types of control related to particular problems or conditions
- F15B2211/87—Detection of failures
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Analytical Chemistry (AREA)
- Fluid-Pressure Circuits (AREA)
Abstract
The invention discloses a hydraulic cylinder state monitoring system, which comprises a hydraulic pump, a reversing valve and a hydraulic cylinder which are sequentially connected through a pipeline, and further comprises a flow meter arranged between the reversing valve and the hydraulic cylinder and a control unit electrically connected with the flow meter, wherein the flow meter is used for detecting the flow of hydraulic oil in the pipeline and sending the detected flow value to the control unit; before the hydraulic cylinder reaches a preset position, the control unit compares the flow value with a preset standard value, and if the difference value between the flow value and the preset standard value exceeds a preset tolerance range, the hydraulic cylinder or the pipeline is judged to be abnormal; after the hydraulic cylinder reaches a preset position, if the flow value exceeds a preset variation range, the hydraulic cylinder is judged to have passive action or the pipeline is abnormal. In addition, the monitoring system is adopted to monitor the state of the hydraulic cylinder, and the hydraulic clamp comprising the monitoring system is also provided.
Description
Technical Field
The invention relates to the technical field of hydraulic pressure, in particular to a hydraulic cylinder state monitoring system and method and a hydraulic clamp system.
Background
The hydraulic clamp has gradually become a mainstream clamping and positioning device with the advantages of high machining efficiency, high clamping precision and the like, but an effective automatic monitoring method is not available in the aspect of real-time monitoring of actuating elements such as a hydraulic cylinder and an auxiliary supporting cylinder, so that oil leakage and pressure relief of the hydraulic cylinder cannot be found in time in the clamping working process, and various problems such as unstable size of a machined workpiece, tool shake, oil leakage and cutting fluid pollution are finally caused.
Some detection methods aiming at the clamping state in China generally adopt pressure detection and final contact type detection methods for detecting the state of a hydraulic cylinder pressure plate, but the detection methods have certain defects, such as:
1) the pressure detection method is simple in structure and can be realized only by a pressure gauge. But it is only monitored once during clamping. The self fluctuation of the hydraulic system cannot be monitored in real time, and the abnormity of the clamped point cannot be found, so that the hydraulic cylinder cannot be executed in place. In addition, if the pipeline leaks, the detection method cannot find the pipeline leakage in time.
2) The final contact type detection method can directly detect the pressing state of a part of execution hydraulic cylinders, but if the situation that the pressing head is not moved after the hydraulic cylinders are decompressed occurs, the detection method cannot find the pressing state in time.
Disclosure of Invention
Aiming at the problems in the prior art, a first object of the invention is to provide a hydraulic cylinder state monitoring system, which is used for monitoring the states of a hydraulic execution element and a hydraulic pipeline in real time, feeding back abnormal conditions such as liquid leakage and pressure release in time and improving the processing quality of products in the production process.
A second object of the present invention is to provide a hydraulic cylinder state monitoring method using the hydraulic cylinder state monitoring system.
A third object of the present invention is to provide a hydraulic clamp system including the hydraulic cylinder condition monitoring system.
The invention provides a hydraulic cylinder state monitoring system, which comprises a hydraulic pump, a reversing valve and a hydraulic cylinder which are sequentially connected through a pipeline, and further comprises a flow meter arranged between the reversing valve and the hydraulic cylinder and a control unit electrically connected with the flow meter, wherein the flow meter is used for detecting the flow of hydraulic oil in the pipeline and sending the detected flow value to the control unit;
before the hydraulic cylinder reaches a preset position, the control unit compares the flow value with a preset standard value, and if the difference value between the flow value and the preset standard value exceeds a preset tolerance range, the hydraulic cylinder or the pipeline is judged to be abnormal;
after the hydraulic cylinder reaches a preset position, if the flow value exceeds a preset variation range, the hydraulic cylinder is judged to have passive action or the pipeline is abnormal.
Further, the flow value is the volume of hydraulic oil flowing through the flowmeter, and the preset standard value is the product of the stroke of the hydraulic cylinder and the area of the piston of the hydraulic cylinder.
And the alarm unit is electrically connected with the control unit and used for alarming according to the alarm instruction of the control unit.
Further, the reversing valve is an electromagnetic reversing valve.
Further, the control unit is a PLC control system or a numerical control system.
Further, the flowmeter is a standard gear flowmeter.
A hydraulic cylinder state monitoring method is carried out by adopting the hydraulic cylinder state monitoring system.
A hydraulic clamp system comprises the hydraulic cylinder state monitoring system.
The hydraulic cylinder state monitoring system can monitor the states of the hydraulic actuating elements and the pipelines in real time, judge whether the hydraulic cylinders or the pipelines are abnormal or not in time, and alarm the abnormality of the hydraulic cylinders and the pipelines to remind operators to deal with the abnormality in time.
The hydraulic cylinder state monitoring method by adopting the hydraulic cylinder state monitoring system can monitor the hydraulic cylinder and the pipeline in real time, and can feed back whether the clamping is reliable or not in time and monitor whether the hydraulic cylinder has abnormal actions in the machining process or not.
By adopting the hydraulic clamp system of the hydraulic cylinder state monitoring system, the use stability of the hydraulic clamp and the processing quality of processing parts can be effectively improved; the leakage of a hydraulic pipeline, particularly a rotary distributor joint of a machining center clamp and the like can be fed back in time, and the cutting fluid and the environment are prevented from being polluted by hydraulic oil.
The oil supply and drainage quantity in the hydraulic cylinder and the pipeline are measured by adopting a precise standard gear flowmeter, the change of the flow is monitored in real time by the control unit, and the alarm unit gives an alarm to abnormal changes in time.
Compared with the prior art, the method has the following advantages:
1) the in-place and clamping conditions of the actuating element are automatically detected and fed back to an operator in time.
2) Abnormal pollution conditions such as pipeline leakage can be found in time.
3) Abnormal bulges and abnormal depressions of the clamping points of the processed part can be found.
Drawings
The invention will be described in more detail hereinafter on the basis of embodiments and with reference to the accompanying drawings. Wherein:
FIG. 1 is a schematic diagram of a hydraulic cylinder condition monitoring system.
In the figure: the hydraulic control system comprises a hydraulic cylinder 1, a PLC control system 2, a hydraulic oil tank 3, a hydraulic pump 4, a reversing valve 5 and a flow meter 6.
In the drawings, like parts are designated with like reference numerals, and the drawings are not to scale.
Detailed Description
In order to clearly illustrate the idea of the present invention, the present invention is described below with reference to the following embodiments.
In the description of the present invention, it should be noted that the terms "upper", "lower", "horizontal", "top", "bottom", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
As shown in fig. 1, the present invention provides a hydraulic cylinder state monitoring system, which includes a hydraulic pump 4, a directional valve 5 and a hydraulic cylinder 1 connected in sequence through a pipeline, a flow meter 6 for detecting the flow rate of hydraulic oil in the pipeline and a control unit electrically connected to the flow meter 6 are installed between the directional valve 5 and the hydraulic cylinder 1, and the flow meter 6 sends the detected flow rate value to the control unit in real time.
Before the hydraulic cylinder 1 reaches a preset position, the control unit compares the flow value with a preset standard value, and if the difference value between the flow value and the preset standard value exceeds a preset tolerance range, the hydraulic cylinder 1 or the pipeline is judged to be abnormal;
after the hydraulic cylinder 1 reaches the preset position, if the flow value exceeds the preset variation range, the hydraulic cylinder 1 is judged to have passive action or abnormal pipeline.
The hydraulic cylinder state monitoring system also comprises an alarm unit electrically connected with the control unit, if the control unit judges that the hydraulic cylinder 1 or a pipeline is abnormal, an alarm instruction is sent to the alarm unit, and the alarm unit gives an alarm after receiving the alarm instruction so as to timely feed back the abnormal condition to an operator.
The hydraulic cylinder state monitoring system can monitor the states of the execution elements such as the hydraulic cylinder 1 and the like and the hydraulic pipeline in real time, feed back whether the clamping state of the clamp is reliable or not in real time through the flow change fed back by the flow meter 6 and the real-time monitoring of the flow meter 6 by the control unit, and monitor whether the hydraulic cylinder 1 has abnormal actions in the machining process, such as sudden abnormal vibration of looseness and reclamping; and whether leakage of hydraulic oil exists in a pipeline system can be judged through the flow fed back in time, so that the cutting fluid is prevented from being polluted by the hydraulic oil, and the pollution to the external environment is avoided.
The flowmeter 6 in the present embodiment is a standard gear flowmeter and is an electronic remote flowmeter; the control unit is a PLC control system 2, the PLC control system 2 is electrically connected with an electronic remote transmission flowmeter, the electronic remote transmission flowmeter transmits a flow value to the PLC control system 2 in real time, whether the executing element and the hydraulic pipeline leak or not is judged according to the flow value fed back to the flowmeter 6 by the PLC control system 2 in real time, and the flow value is fed back to an operator in time. The flow value delivered by the flow meter 6 in real time is the volume of hydraulic oil flowing through the flow meter.
In the embodiment, the hydraulic cylinder 1 is used as an actuating element to mainly drive the clamp to perform clamping, supporting and other actuating actions; the PLC control system 2 plays a role in setting standard flow and flow range, monitoring flow in real time and giving an alarm; the hydraulic oil tank 3 and the hydraulic pump 4 form a hydraulic oil supply system, and hydraulic oil is mainly output to the hydraulic cylinder 1 through a pipeline; the reversing valve 5 is responsible for switching an oil supply inlet loop of the hydraulic cylinder 1 to achieve the effects of clamping, general opening, supporting and the like; the flow meter 6 is responsible for precisely detecting the flow rate of the supplied oil or the returned oil.
In the monitoring of the hydraulic cylinder state monitoring system, the PLC control system 2 mainly monitors the hydraulic cylinder 1 in two states before the hydraulic cylinder reaches the preset position and after the hydraulic cylinder reaches the preset position. Particularly, for the hydraulic clamp, the clamping process of the hydraulic clamp and the monitoring after the clamping is finished are mainly carried out.
Before the PLC control system 2 reaches a preset position of the hydraulic cylinder 1, namely when the clamp monitors the clamping process of a machined workpiece, the flow meter 6 feeds back the accumulated hydraulic oil flow value in the clamping process to the PLC control system 2; after the hydraulic cylinder 1 is in place, the PLC control system 2 processes the flow value to judge the states of the hydraulic cylinder 1 and the pipeline. The PLC control system 2 is set with a preset standard value of the hydraulic cylinder 1, and the difference value of the flow value and the preset standard value is compared with the judgment tolerance range set by the PLC control system 2 to judge the states of the hydraulic cylinder 1 and the pipeline. The working principle of the monitoring process is as follows: after the equipment is started, the PLC control system 2 is responsible for giving a starting signal to a reversing valve 5 in the form of an electromagnetic reversing valve, the reversing valve 5 is communicated with a hydraulic pump 4 and a pipeline of the hydraulic cylinder 1, and the hydraulic cylinder 1 starts to act; at the same time the flow meter 6 will feed back in real time a volume of hydraulic oil supplied to the hydraulic cylinder 1. After the hydraulic cylinder 1 is executed in place, the PLC control system 2 calculates a received final accumulated flow value fed back by the flowmeter 6, calculates a difference value between the received final accumulated flow value and a preset standard value, and gives an alarm to prompt that the hydraulic cylinder 1 or a pipeline is abnormal or leaks if the difference value exceeds a preset judgment tolerance range.
It should be noted that, in the monitoring process, the preset standard value can be set to the standard volume by the product of the stroke of the hydraulic cylinder 1 and the piston area of the hydraulic cylinder 1 for the first time, and the standard volume can be finely adjusted according to the actual situation in the use process. The volume tolerance in the monitoring process is related to the tolerance of the pipeline and the clamped workpiece, and the real-time monitored volume tolerance can be set by counting a certain number of clamping processes and observing the change value of the flow.
After the PLC control system 2 reaches the preset position of the hydraulic cylinder 1, namely when the clamp finishes clamping the machined workpiece, the PLC control system 2 monitors the flow meter 6 in real time, and the flow value fed back to the PLC control system 2 through the flow meter 6 judges the states of the hydraulic cylinder 1 and the pipeline. The PLC control system 2 is set with a flow change range after clamping is completed, and the flow value fed back to the PLC control system 2 by the flowmeter 6 in real time is compared with a preset flow change range so as to judge the states of the hydraulic cylinder 1 and the pipeline. The working principle of the monitoring process is as follows: after the hydraulic cylinder 1 is in place, theoretically, no hydraulic oil flows through the flowmeter 6, and at the moment, whether passive action exists in the hydraulic cylinder 1 or whether a pipeline leaks can be judged by monitoring the feedback flow of the flowmeter 6 in real time. Under normal conditions, the PLC control system 2 sets the flow change range after clamping, the PLC control system 2 monitors the flow value fed back by the flowmeter 6 in real time after the hydraulic cylinder 1 is in place, if the flow value is larger than the preset change range, the PLC control system 2 judges that the hydraulic cylinder 1 has passive action or oil leakage occurs in a pipeline, and the PLC control system 2 immediately sends an alarm instruction.
In order to understand the technical solution of the present invention in more detail, the following description is made by using the hydraulic cylinder state monitoring system to perform a state monitoring method for a hydraulic cylinder:
monitoring leakage before the hydraulic cylinder reaches a preset position (in a clamping process): the PLC control system is used for setting a flow initial value Q and a fluctuation range delta Q of the clamping hydraulic cylinder, controlling the reversing valve to supply oil to the hydraulic cylinder by the PLC control system, controlling the clamping and the loosening of the hydraulic cylinder, simultaneously recording the flow of the hydraulic oil supplied to the hydraulic cylinder by the flowmeter, and feeding back the measured flow Q by the flowmeter in real time. And the PLC control system compares the difference delta Q between the actually measured flow Q and a set value Q, judges the difference between the delta Q and the delta Q, and if the delta Q is larger than the delta Q, proves that the process has leakage or the clamping is not in place.
Leakage monitoring after the hydraulic cylinder reaches a preset position (in a clamping state): the PLC control system is used for setting the fluctuation range delta Q1 of the initial clamping hydraulic cylinder, after the clamping of the hydraulic cylinder is controlled by the machine tool or the PLC control system to supply oil to the hydraulic cylinder through the reversing valve, the flow of the hydraulic oil which flows through the flow meter again in the process from the completion of the clamping action to the machining of the device under the clamping state of the clamp is recorded by the flow meter, and the flow rate is fed back to the PLC control system. And comparing the difference between the measured flow Q1 and the set value delta Q1 by the PLC control system, and if Q1 is larger than delta Q1, proving that leakage exists after clamping or the clamping hydraulic cylinder has action fluctuation.
It is important to point out that by adopting the hydraulic clamp system of the hydraulic cylinder state monitoring system, the hydraulic cylinder, the auxiliary supporting cylinder and other executive components and the hydraulic pipeline can be monitored in real time, the problem that the leakage of the executive components or the pipeline cannot be found in time is fundamentally avoided, and the processing quality and the accuracy of the hydraulic clamp system on processing devices are improved.
It should be noted that the control unit may adopt a form of a numerical control system in addition to the PLC control system, so as to meet specific use requirements of different working conditions. It should be pointed out that the monitoring system in the invention has the characteristics of simple structure and strong flexibility, has the advantage of modularization, and can be expanded to a plurality of modules in parallel, namely, the technical effect of monitoring a plurality of hydraulic cylinders is achieved through one total control integration.
Finally, it is to be understood that the above embodiments are merely exemplary embodiments taken to illustrate the principles of the present invention, which is not intended to be limiting. It will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention, and these changes and modifications are to be considered as within the scope of the invention.
Claims (8)
1. A hydraulic cylinder state monitoring system comprises a hydraulic pump, a reversing valve and a hydraulic cylinder which are sequentially connected through a pipeline, and is characterized by also comprising a flow meter arranged between the reversing valve and the hydraulic cylinder and a control unit electrically connected with the flow meter, wherein the flow meter is used for detecting the flow of hydraulic oil in the pipeline and sending the detected flow value to the control unit;
before the hydraulic cylinder reaches a preset position, the control unit compares the flow value with a preset standard value, and if the difference value between the flow value and the preset standard value exceeds a preset tolerance range, the hydraulic cylinder or the pipeline is judged to be abnormal;
after the hydraulic cylinder reaches a preset position, if the flow value exceeds a preset variation range, the hydraulic cylinder is judged to have passive action or the pipeline is abnormal.
2. The hydraulic cylinder condition monitoring system of claim 1, wherein the flow value is a volume of hydraulic fluid flowing through the flow meter, and the predetermined reference value is a product of a cylinder stroke and a cylinder piston area.
3. The hydraulic cylinder state monitoring system according to claim 1, further comprising an alarm unit, wherein the alarm unit is electrically connected with the control unit and used for giving an alarm according to an alarm instruction of the control unit.
4. Hydraulic cylinder condition monitoring system according to claim 1, characterized in that the directional valve is a solenoid directional valve.
5. Hydraulic cylinder condition monitoring system according to any of claims 1-4, characterized in that the control unit is a PLC control system or a numerical control system.
6. Hydraulic cylinder condition monitoring system according to any of claims 1-4, characterized in that the flow meter is a standard gear flow meter.
7. A hydraulic cylinder condition monitoring method characterized by employing the hydraulic cylinder condition monitoring system according to any one of claims 1 to 6.
8. A hydraulic clamp system, characterized in that it comprises a hydraulic cylinder condition monitoring system according to any one of claims 1-6.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010107538.8A CN113294406A (en) | 2020-02-21 | 2020-02-21 | Hydraulic cylinder state monitoring system and method and hydraulic clamp system |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010107538.8A CN113294406A (en) | 2020-02-21 | 2020-02-21 | Hydraulic cylinder state monitoring system and method and hydraulic clamp system |
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| CN113294406A true CN113294406A (en) | 2021-08-24 |
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| CN202010107538.8A Pending CN113294406A (en) | 2020-02-21 | 2020-02-21 | Hydraulic cylinder state monitoring system and method and hydraulic clamp system |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114088140A (en) * | 2021-11-27 | 2022-02-25 | 东莞市深亚精密机械有限公司 | Oil way detection control system and working method thereof |
| CN117404370A (en) * | 2023-12-15 | 2024-01-16 | 常州市武进安圩液压件制造有限公司 | Hydraulic cylinder pressure test detecting system based on artificial intelligence |
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Application publication date: 20210824 |