CN209875614U - Hydraulic pump health diagnosis system - Google Patents
Hydraulic pump health diagnosis system Download PDFInfo
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- CN209875614U CN209875614U CN201920038496.XU CN201920038496U CN209875614U CN 209875614 U CN209875614 U CN 209875614U CN 201920038496 U CN201920038496 U CN 201920038496U CN 209875614 U CN209875614 U CN 209875614U
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- 230000036541 health Effects 0.000 title claims abstract description 11
- 238000003745 diagnosis Methods 0.000 title abstract description 8
- 238000001514 detection method Methods 0.000 claims abstract description 29
- 238000004891 communication Methods 0.000 claims abstract description 23
- 230000005540 biological transmission Effects 0.000 claims abstract description 5
- 238000000034 method Methods 0.000 claims description 10
- 238000012545 processing Methods 0.000 claims description 10
- 238000007405 data analysis Methods 0.000 abstract description 4
- 239000003921 oil Substances 0.000 description 24
- 239000004973 liquid crystal related substance Substances 0.000 description 3
- 238000012423 maintenance Methods 0.000 description 3
- 238000005070 sampling Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 238000002405 diagnostic procedure Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 206010033799 Paralysis Diseases 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 238000013500 data storage Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000003862 health status Effects 0.000 description 1
- 239000010720 hydraulic oil Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
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- Control Of Positive-Displacement Pumps (AREA)
- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
Abstract
The utility model discloses a hydraulic pump health diagnosis system, which comprises a communication module, an oil temperature detection circuit, and an oil circuit blockage detection module controller module, wherein the communication module is in data communication with a controller of a hydraulic system to be diagnosed; the oil temperature detection circuit is used for measuring oil temperature, the oil path blockage detection module is used for detecting oil path blockage conditions, the oil temperature detection circuit, the oil path blockage detection module and the communication module are all in data transmission with the controller module, the communication module obtains data about the rotating speed and the output pressure of a hydraulic pump in a controller of a hydraulic system to be diagnosed, and the controller performs data analysis according to the obtained data.
Description
Technical Field
The utility model relates to a hydraulic pump health diagnosis system belongs to hydraulic pressure technical field.
Background
The core component in a hydraulic system is a hydraulic pump. The hydraulic pump is the power source of the whole hydraulic system, and once the hydraulic pump is broken, the whole hydraulic system can be immediately paralyzed. The hydraulic pumps have a certain life cycle, which may vary from several months to several years due to different working conditions, environments and maintenance methods. Although the performance of the hydraulic pump of Japan Dajin is excellent, the price is expensive, the purchase period is long (generally 2-3 months), so how to predict the life cycle of the hydraulic pump in advance, especially to put forward a warning before the hydraulic pump will go wrong, so as to remind a user to stock as soon as possible and avoid influencing production is a very good subject.
Existing pump controllers themselves provide a lot of information such as pressure, flow, load rate, rotational speed, etc., and also provide some fault information in real time. This only shows the current operating condition and does not predict when the pump will be late in life and when the pump is no longer capable of pressure delivery.
SUMMERY OF THE UTILITY MODEL
Utility model purpose: for solving the problem that current hydraulic pump can't carry out the health prediction, the utility model discloses a hydraulic pump health diagnosis system can effectively predict the life of hydraulic pump. The method specifically comprises the following steps:
a hydraulic pump diagnosis system comprises a communication module, an oil temperature detection circuit, an oil path blockage detection module and a controller module, wherein the communication module is in data communication with a controller of a hydraulic system to be diagnosed; the oil temperature detection circuit is used for measuring oil temperature, the oil circuit blockage detection module is used for detecting oil circuit blockage conditions, the oil temperature detection circuit, the oil circuit blockage detection module and the communication module are all in data transmission with the controller module, the communication module acquires data about the rotating speed and output pressure of a hydraulic pump in a controller of a hydraulic system to be diagnosed, and the controller module performs data analysis according to the acquired data; the controller module comprises a data processing module and an alarm module, and when the controller module receives that the current output pressure of the hydraulic pump meets the following requirements: p0*95％≤P≤P0*105％，P0The data processing module records the rotating speed corresponding to the current output pressure and the corresponding days as reference voltage, and performs function fitting on the recorded rotating speed n and the corresponding days to obtain a trend curve with the day number on the horizontal axis and the rotating speed on the vertical axis, and the alarm module calculates according to the trend curveAnd obtaining the running days for alarming when the rotating speed is increased to the pre-alarming rotating speed.
Further, the oil path blockage detection module is realized through a blockage sensor.
Further, the data processing module performs function fitting on the recorded rotating speed n and the corresponding days for a plurality of times by adopting a least square method to obtain a trend curve with the horizontal axis as days and the vertical axis as rotating speed.
The utility model also discloses a hydraulic pump diagnostic method, including following step:
s1: according to the factory rated speed n0Setting a reference voltage P for testing0；
S2: setting a pre-warning speed n1；
S3: the pressure, the flow, the temperature and the rotating speed of the hydraulic pump are sampled in real time through a communication module;
s4: when the current output pressure of the hydraulic pump meets the following conditions: p0*95％≤P≤P0105%, and when the output pressure lasts for at least more than 10s, recording the rotating speed n corresponding to the current output pressure and the corresponding days;
s5: performing function fitting for a plurality of times by adopting a least square method according to the recorded rotating speed n and the corresponding days to obtain a trend curve with the horizontal axis as days and the vertical axis as the rotating speed;
s6: calculating the current rotating speed to the pre-alarming rotating speed n according to the trend curve1The running days of the system realize pre-alarming.
Has the advantages that: compared with the prior art, the utility model, have following advantage:
1. the method comprises the steps of monitoring the pressure, the flow, the oil temperature, the pump rotating speed and the like of the hydraulic pump in real time on line, recording a historical curve according to historical data such as the pressure, the pump rotating speed and the like, gradually drawing the change trend of the hydraulic pump, diagnosing the health condition of the hydraulic pump according to the historical data, prejudging the service life end point of the hydraulic pump, reminding a user of entering a high-risk period of the hydraulic pump, and preparing goods in advance.
2. Technical parameters such as pressure, flow and oil temperature of the hydraulic pump are monitored on line, and maintenance personnel can intuitively know the operating condition of the hydraulic system through a liquid crystal picture.
3. The USB interface is provided for data storage, the Bluetooth is provided for wireless data transmission, the field data can be stored in a U disk or a computer in the two modes and then sent to the hydraulic station after-sales technicians, and therefore the operation data of the hydraulic station can be remotely mastered, and maintenance and fault judgment of the hydraulic station can be conveniently and remotely carried out.
4. The touch liquid crystal screen is used as a man-machine interaction means, so that various data are more visual and are easier to understand and master by field operators.
Drawings
Fig. 1 is a block diagram of the display structure of the present invention;
FIG. 2 is a trend curve of the example.
Detailed Description
The method of the present invention will be further explained with reference to the drawings and examples.
The utility model discloses a hydraulic pump diagnosis system, which comprises a communication module, an oil temperature detection circuit, an oil circuit blockage detection module and a controller module, wherein the communication module is in data communication with a controller of a hydraulic system to be diagnosed; the oil temperature detection circuit is used for measuring oil temperature, the oil circuit blockage detection module is used for detecting oil circuit blockage conditions, the oil temperature detection circuit, the oil circuit blockage detection module and the communication module are all in data transmission with the controller module, the communication module acquires data about the rotating speed and output pressure of a hydraulic pump in a controller of a hydraulic system to be diagnosed, and the controller module performs data analysis according to the acquired data; the controller module comprises a data processing module and an alarm module, and when the controller module receives that the current output pressure of the hydraulic pump meets the following requirements: p0*95％≤P≤P0*105％，P0The data processing module records the rotating speed corresponding to the current output pressure and the corresponding days as reference voltage, and performs function fitting on the recorded rotating speed n and the corresponding days to obtain a trend curve with the horizontal axis being days and the vertical axis being rotating speed, and the alarm module calculates the running days when the rotating speed is increased to the pre-alarm rotating speed according to the trend curve to report the running daysAnd the data processing module performs function fitting on the recorded rotating speed n and the corresponding days for a plurality of times by adopting a least square method to obtain a trend curve with the horizontal axis as days and the vertical axis as rotating speed.
Examples
The diagnostic system of the embodiment is used in cooperation with a hydraulic station and is designed into an embedded installation scheme, a panel of the display controller adopts a touch liquid crystal screen and is provided with keys and an indicator light, and a USB port is arranged on the panel to be matched with a USB flash disk for data recording.
The display controller of the embodiment comprises a touch screen for realizing human-computer interaction, a CPU module, a power module, a relay for outputting a diagnosis result and an LED indicator lamp for providing an alarm signal, wherein the relay is provided with a constant current source temperature measuring circuit for measuring the oil temperature. The oil temperature measuring precision of the display controller of the embodiment is 1 ℃, and the fastest speed of data acquisition is sampling once every 200 ms.
Description of main working principle:
the CPU collects main data from communication data with the hydraulic pump, oil temperature detection is based on PT100 thermal resistance detection, and oil circuit blockage detection is detected through a blockage sensor.
The hydraulic pump is characterized in that: in the initial stage of use, the leakage rate of the hydraulic pump is relatively small, and when the hydraulic pump outputs hydraulic oil, the pump has a rotating speed. The oil pressure at this time was recorded as P and the rotational speed was recorded as n0. At the initial stage, n0Is a lower value. The reason is that the leakage rate of the hydraulic pump is relatively small, and all work is used for forming pressure, so the efficiency is relatively high, the required power is relatively small, and the rotating speed is low. N at the time of shipment0Typically between 100 and 400 turns.
After the pump is used for a period of time, due to factors such as mechanical vibration and abrasion, the leakage rate of the pump is gradually increased, higher energy is needed for forming the same large pressure P, namely, higher rotating speed is achieved, the heating is caused by the increase of the rotating speed, the long-term rotating speed is high, and the service life of the pump is ended due to the heating. The utility model discloses a diagnostic method passes through the health status of data analysis processing in order to diagnose the hydraulic pump through the health data of collection pump, prejudges the life-span terminal point of hydraulic pump. The method specifically comprises the following steps:
s1: setting a reference pressure P for testing0Setting a factory rated rotation speed n0，n0When the hydraulic pump leaves the factory, the output pressure reaches P0The rotational speed of the pump.
S2: setting a nominal speed neAnd a pre-warning speed n1In general, n1＝80％*ne。
S3: and RS232 or RS422 is utilized to carry out data communication with the hydraulic pump, and data such as pressure, flow, temperature, load rate, rotating speed and the like of the pump are sampled in real time.
S4: when the hydraulic station works, the output pressure P and the rotating speed n of the sampling pump are sampled, and when the output pressure meets the requirement of P0*95％≤P≤P0105%, when the pressure value lasts for at least 10s, considering the pressure value at the moment as an effective pressure value, and recording the rotating speed n at the moment;
s5: and (3) performing 4 times of function fitting on the recorded data by using a least square method to obtain a trend curve with the horizontal axis as days and the vertical axis as rotating speed.
S6: the increase of the rotating speed to n can be calculated according to the trend curve1(n1＝ne80%) of the number of days of the run. Along with the accumulation of time and the increase of sampling data, the fitting curve is closer to the real situation, and when n is calculated1When the actual operation days and the actual operation rotating speed are matched, a pre-alarm can be provided.
Claims (3)
1. A hydraulic pump health diagnostic system characterized by: the system comprises a communication module, an oil temperature detection circuit, an oil path blockage detection module and a controller module, wherein the communication module is in data communication with a controller of a hydraulic system to be diagnosed; the oil temperature detection circuit is used for measuring oil temperature, the oil circuit blockage detection module is used for detecting oil circuit blockage conditions, the oil temperature detection circuit, the oil circuit blockage detection module and the communication module are all in data transmission with the controller module, and the communication module acquires the state of a switch in a controller of a hydraulic system to be diagnosedThe controller module analyzes data according to the acquired data according to the rotating speed and the output pressure data of the hydraulic pump; the controller module comprises a data processing module and an alarm module, and when the controller module receives that the current output pressure of the hydraulic pump meets the following requirements: p0*95％≤P≤P0*105％，P0The data processing module records the rotating speed corresponding to the current output pressure and the corresponding days as reference voltage, and performs function fitting on the recorded rotating speed n and the corresponding days to obtain a trend curve with the horizontal axis being days and the vertical axis being rotating speed, and the alarm module calculates the running days when the rotating speed is increased to the pre-alarm rotating speed according to the trend curve to alarm.
2. The hydraulic pump health diagnostic system of claim 1, wherein: the oil circuit blockage detection module is realized through a blockage sensor.
3. The hydraulic pump health diagnostic system of claim 1, wherein: and the data processing module performs function fitting on the recorded rotating speed n and the corresponding days for a plurality of times by adopting a least square method to obtain a trend curve with the horizontal axis as days and the vertical axis as rotating speed.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201920038496.XU CN209875614U (en) | 2019-01-09 | 2019-01-09 | Hydraulic pump health diagnosis system |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201920038496.XU CN209875614U (en) | 2019-01-09 | 2019-01-09 | Hydraulic pump health diagnosis system |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN209875614U true CN209875614U (en) | 2019-12-31 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201920038496.XU Withdrawn - After Issue CN209875614U (en) | 2019-01-09 | 2019-01-09 | Hydraulic pump health diagnosis system |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109630503A (en) * | 2019-01-09 | 2019-04-16 | 无锡诚勇自动化技术有限公司 | A kind of hydraulic pump health diagnosis system and its diagnostic method |
-
2019
- 2019-01-09 CN CN201920038496.XU patent/CN209875614U/en not_active Withdrawn - After Issue
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109630503A (en) * | 2019-01-09 | 2019-04-16 | 无锡诚勇自动化技术有限公司 | A kind of hydraulic pump health diagnosis system and its diagnostic method |
| CN109630503B (en) * | 2019-01-09 | 2024-02-06 | 无锡诚勇自动化技术有限公司 | Hydraulic pump health diagnosis system and diagnosis method thereof |
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