CN102721536B - Method for detecting and positioning clamping fault of hydraulic valve - Google Patents
Method for detecting and positioning clamping fault of hydraulic valve Download PDFInfo
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- CN102721536B CN102721536B CN201210173996.7A CN201210173996A CN102721536B CN 102721536 B CN102721536 B CN 102721536B CN 201210173996 A CN201210173996 A CN 201210173996A CN 102721536 B CN102721536 B CN 102721536B
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Abstract
The invention relates to a method for detecting and positioning a clamping fault of a hydraulic valve. The hydraulic valve comprises a valve element and a valve body; and the valve body comprises a valve wall and a valve cavity. The method comprises an installing step, a step of calibrating a normal reference, a step of calibrating a clamping reference and a detecting step, or comprises the installing step, the step of calibrating the reference and the detecting step. After the technical scheme is adopted, the clamping fault of the valve element of a slide valve can be conveniently and accurately forecast and detected in real time and the clamping position can be conveniently and accurately judged in real time.
Description
Technical field
The present invention relates to a kind of clamping fault of hydraulic valve, particularly a kind of detection and localization method of hydraulic valve clamping fault.
Background technology
Sliding valve core mechanism adopts maximum a kind of version in all kinds of hydraulic valves.Guiding valve generally comprises spool and valve body, and valve body comprises valve wall and valve pocket.Guiding valve clamping fault is one of fault the most common in hydraulic system and failure mode.Hydraulic system is as high-power topworks, once there is clamping fault, the lighter's thrashing, also even personal safety of entail dangers to equipment of severe one.Therefore, first, find that in time clamping fault is most important to the safe operation of hydraulic system; Secondly, to the forecast of clamping fault, more fault can be nipped in the bud, significant to the reliability of raising whole system; The 3rd, if clamping fault occurs, that lateral location that judgement spool is clamped in valve pocket is also very crucial for the eliminating of clamping fault.
Obtaining of existing guiding valve clamping information, is mainly by the detection of hydraulic system pressure, flow, displacement equivalent is realized, and belongs to the method for indirect detection diagnosis, cannot directly obtain spool duty.Especially, the factor that affects the parameters such as pressure, flow, displacement is a lot, and clamping is one of them, and the accuracy that therefore clamping detects needs to be weighed.
Also the scholar who has proposes to utilize the variation that is superimposed upon the vibrating signal on spool to detect clamping bite fault, this method can realize detection and the forecast of clamping fault to a certain extent, but because it is also to change indirect detection spool mechanical motion state by electromagnetic field, exist judgement influence factor many, judgment threshold is difficult to the problems such as unified demarcation.
In addition, for the decision method of clamping back valve core clamping position, the less report that is seen in.
In view of this, the inventor, in conjunction with being engaged in hydraulic valve area research work experience for many years, studies for a long period of time to the defect of above-mentioned technical field, and this case produces thus.
Summary of the invention
The object of the present invention is to provide detection and the localization method of a kind of hydraulic valve simple in structure, with low cost clamping fault, can facilitate, accurate, real-time forecast, detect valve core of the spool valve clamping fault, judgement clamps position.
To achieve these goals, technical scheme of the present invention is as follows:
Detection and the localization method of hydraulic valve clamping fault, hydraulic valve comprises spool and valve body, valve body comprises valve wall and valve pocket.Comprise installation steps, demarcate normal benchmark step, demarcate clamping benchmark step and detecting step, specific as follows:
Wherein installation steps, refer to the lateral surface that a plurality of ultrasonic transducers is fixedly installed in to hydraulic valve body, and the axis of the axial line of ultrasonic transducer and valve body internal valve cavity intersects vertically;
Wherein demarcate normal benchmark step, refer to hydraulic valve is adjusted to nominal situation, be about to spool and adjust to the axis coincidence of spool and valve pocket, Ultrasonic Detection by intelligent controller is controlled, and the output of the amplitude of intelligent controller is controlled, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place nominal situation, repeats aforesaid operations, the complete reference signal amplitude while finally obtaining monitoring point, a plurality of ultrasonic transducers place nominal situation;
Wherein demarcate clamping benchmark step, refer to hydraulic valve is adjusted to clamping operating mode, Ultrasonic Detection by intelligent controller is controlled, and the output of the amplitude of intelligent controller is controlled, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place clamping operating mode, repeat aforesaid operations, the complete reference signal amplitude while finally obtaining monitoring point, a plurality of ultrasonic transducers place clamping operating mode;
Detecting step wherein, refer to the general operating mode for hydraulic valve, Ultrasonic Detection by intelligent controller is controlled, and the detection of intelligent controller output control, obtains the gripping orientation information whether this monitoring point exists clamping fault and clamping fault light and heavy degree etc.; Repeat aforesaid operations, whether the final monitoring point, a plurality of ultrasonic transducers place that obtains there is the comprehensive gripping orientation information that clamps fault and clamping fault light and heavy degree etc., by fuzzy algorithm, process, show whether relevant hydraulic valve exists the clamping test result of clamping fault and clamping fault light and heavy degree;
Described intelligent controller comprises CPU module, high-speed a/d modular converter, echoed signal filter and amplification module, ultrasound emission module and multichannel handover module; CPU module is connected with high-speed a/d modular converter, can process the echoed signal of collection; CPU module is connected with ultrasound emission module, can control ultrasonic pulse and produce; CPU module is connected with multichannel handover module, is used between a plurality of ultrasonic transducers, to switch ultrasound emission, receive object; Ultrasound emission module is connected with multichannel handover module, and high-speed a/d modular converter is connected with echoed signal filter and amplification module, and echoed signal filter and amplification module is connected with multichannel handover module, and multichannel handover module is connected with a plurality of ultrasonic transducers;
Described ultrasonic transducer and valve body lateral surface directly scribble acoustic coupling medium;
The Ultrasonic Detection of described intelligent controller is controlled, and refers to ultrasonic transducer is connected with multichannel handover module, starts CPU module work, first CPU module follow procedure is controlled multichannel handover module and is connected a certain ultrasonic transducer, then starting ultrasound emission module sends electric signal and is added on this ultrasonic transducer, the ultrasonic pulse that this ultrasonic transducer is excited to produce is entered valve wall and is propagated therein by acoustic coupling medium, gap location between valve wall and spool, because the hydraulic oil in gap is different with the acoustic impedance of valve wall, ultrasound wave produces transmitting at gap location, part reflected energy returns to this ultrasonic transducer along former incident approach, this ultrasonic transducer is changed again into electric pulse, this electric impulse signal is input to high-speed a/d modular converter after by echoed signal filter and amplification module and is converted to digital quantity and sends to CPU module, CPU module records the reflection wave electric pulse of this collection preserve,
The amplitude output of described intelligent controller is controlled, refer to the CPU module follow procedure of intelligent controller, first the reflection wave electric pulse that records and preserve in the Ultrasonic Detection of intelligent controller being controlled, burst as this monitoring point, secondly according to hydraulic valve and ultrasound parameter, calculate the echo position in gap between spool valve wall, finally the signal amplitude as this monitoring point according to the corresponding amplitude in this positional information extraction burst;
The detection output of described intelligent controller is controlled, refer to the CPU module follow procedure of intelligent controller, the reflection wave electric pulse that records and preserve during the Ultrasonic Detection of intelligent controller is controlled, after amplitude-frequency analyzing and processing and when this monitoring point clamps operating mode, corresponding reference signal amplitude is compared, and show whether this monitoring point exists the gripping orientation information of clamping fault and clamping fault light and heavy degree etc.
Further, in described installation steps, a plurality of ultrasonic transducers are six above even numbers, are divided into two rows, are parallel on adjacent two lateral surfaces that are arranged on valve body of valve body internal valve cavity axis, and each ultrasonic transducer on each side is uniformly-spaced arranged.Thereby convenient, accurate, real-time forecast, detection valve core of the spool valve clamping fault, judgement clamping position, and cost is cheaper, and structure is simpler.
Further, also comprise positioning step, described positioning step refers to, when described detecting step show that hydraulic valve exists clamping fault, the CPU module follow procedure of described intelligent controller, according to comprehensive gripping orientation information of the monitoring point, a plurality of ultrasonic transducers place obtaining in detecting step, obtain three-dimensional clamping information after comprehensive, can draw the clamping position of spool.
Further, the frequency of described ultrasonic transducer is more than 10MHz.This design be consider spool and valve wall gap less, thereby more economical realize above-mentioned technique effect.
Further, the A/D converter in described intelligent controller high speed A/D modular converter is selected the A/D chip of ADS5485 or equal performance, and described ultrasonic transducer is selected normal probe, and described acoustic coupling medium is machine oil.Thereby more economical realize above-mentioned technique effect.
Detection and the localization method of hydraulic valve clamping fault, hydraulic valve comprises spool and valve body, valve body comprises valve wall and valve pocket.Comprise installation steps, reference-calibrating step and detecting step, specific as follows:
Wherein installation steps, refer to the lateral surface that a plurality of ultrasonic transducers is fixedly installed in to hydraulic valve body, and the axis of the axial line of ultrasonic transducer and valve body internal valve cavity intersects vertically;
Reference-calibrating step wherein, refer to hydraulic valve is adjusted to nominal situation, be about to spool and adjust to the axis coincidence of spool and valve pocket, Ultrasonic Detection by intelligent controller is controlled, and the amplitude of intelligent controller output controls, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place nominal situation; Hydraulic valve is adjusted to clamping operating mode, by the Ultrasonic Detection of intelligent controller, control, and the amplitude of intelligent controller output controls, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place clamping operating mode; Repeat aforesaid operations, the complete reference signal amplitude while finally obtaining monitoring point, a plurality of ultrasonic transducers place nominal situation and while clamping operating mode;
Detecting step wherein, refer to the general operating mode for hydraulic valve, Ultrasonic Detection by intelligent controller is controlled, and the detection of intelligent controller output control, obtains the gripping orientation information whether this monitoring point exists clamping fault and clamping fault light and heavy degree etc.; Repeat aforesaid operations, whether the final monitoring point, a plurality of ultrasonic transducers place that obtains there is the comprehensive gripping orientation information that clamps fault and clamping fault light and heavy degree etc., by fuzzy algorithm, process, show whether relevant hydraulic valve exists the clamping test result of clamping fault and clamping fault light and heavy degree;
Described intelligent controller comprises CPU module, high-speed a/d modular converter, echoed signal filter and amplification module, ultrasound emission module and multichannel handover module; CPU module is connected with high-speed a/d modular converter, can process the echoed signal of collection; CPU module is connected with ultrasound emission module, can control ultrasonic pulse and produce; CPU module is connected with multichannel handover module, is used between a plurality of ultrasonic transducers, to switch ultrasound emission, receive object; Ultrasound emission module is connected with multichannel handover module, and high-speed a/d modular converter is connected with echoed signal filter and amplification module, and echoed signal filter and amplification module is connected with multichannel handover module, and multichannel handover module is connected with a plurality of ultrasonic transducers;
Described ultrasonic transducer and valve body lateral surface directly scribble acoustic coupling medium;
The Ultrasonic Detection of described intelligent controller is controlled, and refers to ultrasonic transducer is connected with multichannel handover module, starts CPU module work, first CPU module follow procedure is controlled multichannel handover module and is connected a certain ultrasonic transducer, then starting ultrasound emission module sends electric signal and is added on this ultrasonic transducer, the ultrasonic pulse that this ultrasonic transducer is excited to produce is entered valve wall and is propagated therein by acoustic coupling medium, gap location between valve wall and spool, because the hydraulic oil in gap is different with the acoustic impedance of valve wall, ultrasound wave produces transmitting at gap location, part reflected energy returns to this ultrasonic transducer along former incident approach, this ultrasonic transducer is changed again into electric pulse, this electric impulse signal is input to high-speed a/d modular converter after by echoed signal filter and amplification module and is converted to digital quantity and sends to CPU module, CPU module records the reflection wave electric pulse of this collection preserve,
The amplitude output of described intelligent controller is controlled, refer to CPU module 1 follow procedure of intelligent controller, first the reflection wave electric pulse that records and preserve in the Ultrasonic Detection of intelligent controller being controlled, burst as this monitoring point, secondly according to hydraulic valve and ultrasound parameter, calculate the echo position in gap between spool valve wall, finally the signal amplitude as this monitoring point according to the corresponding amplitude in this positional information extraction burst;
The detection output of described intelligent controller is controlled, refer to CPU module 1 follow procedure of intelligent controller, the reflection wave electric pulse that records and preserve during the Ultrasonic Detection of intelligent controller is controlled, after amplitude-frequency analyzing and processing and when this monitoring point clamps operating mode, corresponding reference signal amplitude is compared, and show whether this monitoring point exists the gripping orientation information of clamping fault and clamping fault light and heavy degree etc.
Further, in described installation steps, a plurality of ultrasonic transducers are six above even numbers, are divided into two rows, are parallel on adjacent two lateral surfaces that are arranged on valve body of valve body internal valve cavity axis, and each ultrasonic transducer on each side is uniformly-spaced arranged.Thereby convenient, accurate, real-time forecast, detection valve core of the spool valve clamping fault, judgement clamping position, and cost is cheaper, and structure is simpler.
Further, also comprise positioning step, described positioning step refers to, when described detecting step show that hydraulic valve exists clamping fault, the CPU module follow procedure of described intelligent controller, according to comprehensive gripping orientation information of the monitoring point, a plurality of ultrasonic transducers place obtaining in detecting step, obtain three-dimensional clamping information after comprehensive, can draw the clamping position of spool.
Further, the frequency of described ultrasonic transducer is more than 10MHz.This design be consider spool and valve wall gap less, thereby more economical realize above-mentioned technique effect.
Further, the A/D converter in described intelligent controller high speed A/D modular converter is selected the A/D chip of ADS5485 or equal performance, and described ultrasonic transducer is selected normal probe, and described acoustic coupling medium is machine oil.Thereby more economical realize above-mentioned technique effect.
The present invention compared with the existing technology has following advantage and effect: 1, the principle of ultrasonic inspection is applied to the fault detect of hydraulic valve clamping, method simplicity of design is ingenious, and effect is remarkable; 2, above-mentioned detection method is Non-Destructive Testing, without changing hydraulic valve structure; 3, can realize forecast, detection and the abort situation location of clamping fault; 4, directly feed back spool positional information, than indirect detection better reliability; 5, single as the signal of clamping fault detect, accuracy is high, and being disturbed property is little.
In order further to explain, below in conjunction with drawings and Examples, the present invention is described in further detail technical scheme of the present invention.
Accompanying drawing explanation
Fig. 1 is the structure flow chart of intelligent controller and ultrasonic transducer in the present invention;
Fig. 2 is ultrasonic transducer installation site schematic diagram in the present invention;
Fig. 3 clamps fault detect principle of work schematic diagram in the present invention.
Embodiment
The present invention uses for reference the principle of ultrasonic inspection, has provided a kind of detection and localization method of hydraulic valve clamping fault.As shown in Figure 1 to Figure 3, be the preferred embodiment that adopts equipment therefor of the present invention.
The principle of work of the technical program is as follows:
Ultrasound wave is frequency higher than the mechanical wave of 20 kilo hertzs, and this mechanical wave can be propagated with certain speed and direction in material, runs into the heterogeneous interface that acoustic impedance is different (as the bottom surface of defect or measured object etc.) and will produce reflection.This reflex can be used to carry out UT (Ultrasonic Testing), and the most frequently used is pulse echo defectoscopy.During flaw detection, the voltage that pulse oscillator sends is added in ultrasonic transducer (ultrasonic probe in other words, the detecting element made from piezoelectric ceramics or quartz wafer) on, the ultrasonic pulse that ultrasonic transducer sends is entered material and is propagated therein by acoustic coupling medium (as machine oil or water etc.), run into after defect, part reflected energy returns to ultrasonic transducer along former approach, and ultrasonic transducer is changed again into electric pulse.According to the position of flaw echo electric pulse and amplitude (making comparisons with the reflection wave amplitude of artificial defect in reference block), can measure position and the approximate size of defect.
The present invention uses for reference the mechanism of above-mentioned ultrasonic inspection, utilizes ultrasound wave in heterogeneous interface reflex, to realize forecast, detection and the location of spool clamping.Hydraulic valve is as shown in Figure 3 when normal work, in spool 9 and valve body 8, the axis of valve pocket overlaps, the electric signal that ultrasound emission module is sent is added on ultrasonic transducer 6, then the ultrasonic pulse producing is entered valve wall and is propagated therein by acoustic coupling medium (machine oil), gap location between valve wall and spool, because the hydraulic oil in gap is different with the acoustic impedance of valve wall, ultrasound wave produces transmitting at gap location.Part reflected energy returns to ultrasonic transducer along former incident approach, ultrasonic transducer is changed again into electric pulse, CPU module is according to position t1 and the amplitude v1 of the reflection wave electric pulse gathering, carry out fuzzy judgment with reference position t and reference amplitude v, and then obtain now, for nominal situation, not having the judgement information of clamping fault; And when hydraulic valve is due to hydraulic lock or machinery clamping, make spool depart from position, valve pocket axis.The gap smaller between spool and valve wall (the bite operating mode in Fig. 3) now, CPU module is constant according to the position of reflection wave electric pulse or the boundary position of t1(valve wall that gather), and amplitude becomes v2, v1 during with nominal situation compares significantly and reduces, and can forecast that thus clamping fault has the trend of generation; When clamping fault occurs, now spool departs from axis far away, and between valve wall almost (the bite operating mode in Fig. 3) very close to each other, CPU module is according to position or the t1 of the reflection wave electric pulse gathering, and amplitude has become v3, if v3 value is made as to the detection threshold of clamping fault, can be by judging whether reflex amplitude judges lower than v3 the generation that clamps fault.Otherwise, if the ultrasonic transducer in Fig. 3 is arranged on opposite one side, in the process that hydraulic valve changes to clamping operating mode at nominal situation, the value of v1 v2 v3 is to increase progressively relation, can be by judging whether reflex amplitude judges higher than v3 the generation that whether side is had to clamping fault.
As preferably, for more accurate forecast, detection and location clamping fault, on the axial cross section of spool, the position (having 8 kinds of possibility orientation at least) that at least needs two ultrasonic transducers can judge that clamping occurs on this cross section; Because spool is axially having certain length, clamping likely occurs in any one axial position, and at least 3 transducers on axis can be used for detecting clamping position in the axial direction.
Detection and the localization method of hydraulic valve clamping fault, hydraulic valve comprises spool and valve body, valve body comprises valve wall and valve pocket.Above-mentioned is the state of the art, repeats no more herein.
The course of work of clamping failure prediction and detection is as follows:
Hydraulic valve is installed to that side surface wiped clean of ultrasonic transducer, spread acoustic coupling medium (being machine oil in the present embodiment), a plurality of ultrasonic transducers are placed along the equidistant average line in axis of hydraulic valve.Be about to the lateral surface that a plurality of ultrasonic transducers are fixedly installed in hydraulic valve body, the axis of the axial line of ultrasonic transducer and valve body internal valve cavity intersects vertically.Quantity, the concrete distribution of ultrasonic ring energy device can have multiple.As shown in Figure 2, a plurality of ultrasonic transducers 6 are six above even numbers, are divided into two rows, are parallel on adjacent two lateral surfaces that are arranged on valve body 8 of valve body internal valve cavity axis, and each ultrasonic transducer on each side is uniformly-spaced arranged.In the present embodiment, as shown in Figure 2, totally six ultrasonic transducers, by central piezo ceramic element, front and back metal cover board, prestress screw rod, electrode slice and insulation tube form, and are divided into outer upper side and external right side face that two rows are installed on hydraulic valve body, ultrasonic transducer on each side is three and falls point-blank, this straight line is parallel with valve body internal valve cavity axis, and ultrasonic transduction implement body installation site is in this surperficial both sides and centre position, and three ultrasonic transducers are uniformly-spaced arranged.Thereby convenient, accurate, real-time forecast, detection valve core of the spool valve clamping fault, judgement clamping position, and cost is cheaper, and structure is simpler.
While using for the first time, hydraulic valve is adjusted to nominal situation, be about to spool and adjust to the axis coincidence of spool and valve pocket, Ultrasonic Detection by intelligent controller is controlled, and the output of the amplitude of intelligent controller is controlled, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place nominal situation, repeats aforesaid operations, the complete reference signal amplitude while finally obtaining monitoring point, a plurality of ultrasonic transducers place nominal situation; Hydraulic valve is adjusted to clamping operating mode, Ultrasonic Detection by intelligent controller is controlled, and the output of the amplitude of intelligent controller is controlled, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place clamping operating mode, repeat aforesaid operations, the complete reference signal amplitude while finally obtaining monitoring point, a plurality of ultrasonic transducers place clamping operating mode;
Said method is while adjusting to nominal situation, to demarcate one by one whole ultrasonic transducers, demarcates one by one whole ultrasonic transducers while then adjusting to clamping operating mode.Can certainly take following method, ultrasonic transducer one by one, each ultrasonic transducer is first demarcated nominal situation, then demarcates clamping operating mode.Specific as follows:
While using for the first time, hydraulic valve is adjusted to nominal situation, be about to spool and adjust to the axis coincidence of spool and valve pocket, Ultrasonic Detection by intelligent controller is controlled, and the amplitude of intelligent controller output controls, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place nominal situation; Hydraulic valve is adjusted to clamping operating mode, by the Ultrasonic Detection of intelligent controller, control, and the amplitude of intelligent controller output controls, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place clamping operating mode; Repeat aforesaid operations, the complete reference signal amplitude while finally obtaining monitoring point, a plurality of ultrasonic transducers place nominal situation and while clamping operating mode.
In addition, the step of above-mentioned reference-calibrating, for the hydraulic valve an of the unknown, if the hydraulic valve of a certain identical type or a certain same batch is detected, the reference value of using for the first time this similar hydraulic valve to obtain by this two step before can directly copying, but obviously: first, this measuring method is not to have omitted this two step, but directly copying on the basis of measuring process before; Secondly, be judgement more accurately, our suggestion or each hydraulic valve are demarcated better one by one, there is no after all complete living hydraulic valve.
As shown in Figure 1, intelligent controller comprises CPU module 1, high-speed a/d modular converter 2, echoed signal filter and amplification module 3, ultrasound emission module 4 and multichannel handover module 5; CPU module 1 is connected with high-speed a/d modular converter 2, can process the echoed signal of collection; CPU module 1 is connected with ultrasound emission module 4, can control ultrasonic pulse and produce; CPU module 1 is connected with multichannel handover module 5, is used between a plurality of ultrasonic transducers 6, to switch ultrasound emission, receive object; Ultrasound emission module 4 is connected with multichannel handover module 5, and high-speed a/d modular converter 2 is connected with echoed signal filter and amplification module 3, and echoed signal filter and amplification module 3 is connected with multichannel handover module 5, and multichannel handover module 5 is connected with a plurality of ultrasonic transducers 6.Realize the modules of above-mentioned functions, the structures such as its concrete circuit, components and parts owing to belonging to prior art, just repeat no more herein.Intelligent controller 15 adopts the aviation plug of 2 cores or 4 cores to be connected by multichannel handover module 5 with ultrasonic transducer 6.
The Ultrasonic Detection of intelligent controller is controlled, and refers to ultrasonic transducer is connected with multichannel handover module 5, starts CPU module 1 work, first CPU module 1 follow procedure is controlled multichannel handover module 5 and is connected a certain ultrasonic transducer, then starting ultrasound emission module 4 sends electric signal and is added on this ultrasonic transducer, the ultrasonic pulse that this ultrasonic transducer is excited to produce is entered valve wall and is propagated therein by acoustic coupling medium, gap location between valve wall and spool, because the hydraulic oil in gap is different with the acoustic impedance of valve wall, ultrasound wave produces transmitting at gap location, part reflected energy returns to this ultrasonic transducer along former incident approach, this ultrasonic transducer is changed again into electric pulse, this electric impulse signal is input to high-speed a/d modular converter 2 after by echoed signal filter and amplification module 3 and is converted to digital quantity and sends to CPU module 1, CPU module 1 records the reflection wave electric pulse of this collection preserve.
The amplitude output of intelligent controller is controlled, refer to CPU module 1 follow procedure of intelligent controller, first, secondly the reflection wave electric pulse that records and preserve during the Ultrasonic Detection of intelligent controller is controlled, as the burst of this monitoring point,, according to hydraulic valve and ultrasound parameter, calculate the echo position in gap between spool valve wall, last, the signal amplitude according to the corresponding amplitude in this positional information extraction burst as this monitoring point.
General operating mode for hydraulic valve, when clamping fault may occur (while occurring judging the clamping failure message of hydraulic valve in other words), Ultrasonic Detection by intelligent controller is controlled, and the detection of intelligent controller output control, can obtain the gripping orientation information whether this monitoring point exists clamping fault and clamping fault light and heavy degree etc.; Repeat aforesaid operations, whether the final monitoring point, a plurality of ultrasonic transducers place that obtains there is the comprehensive gripping orientation information that clamps fault and clamping fault light and heavy degree etc., by fuzzy algorithm, process, show whether relevant hydraulic valve exists the clamping test result of clamping fault and clamping fault light and heavy degree.Above-mentioned fuzzy algorithm belongs to prior art, repeats no more herein.
The detection output of intelligent controller is controlled, refer to CPU module 1 follow procedure of intelligent controller, the reflection wave electric pulse that records and preserve during the Ultrasonic Detection of intelligent controller is controlled, after amplitude-frequency analyzing and processing and when this monitoring point clamps operating mode, corresponding reference signal amplitude is compared, and show whether this monitoring point exists the gripping orientation information of clamping fault and clamping fault degree etc.Above-mentioned amplitude-frequency analyzing and processing, is specially frequency-domain analysis and amplitude analysis, and these analytical technologies all belong to prior art, repeat no more herein.
When there is clamping fault, now, show as spool and a certain side valve wall contacts, the gap between this side valve core and valve wall is close to and disappears.When CPU module 1 follow procedure carries out Ultrasonic Detection to this monitoring point, the echoed signal collecting (being reflection wave electric pulse) is compared with the reference signal amplitude of clamping operating mode after treatment, by fuzzy algorithm, process the generation that can forecast and detect clamping fault, its order of severity etc.
Consider that spool and valve wall gap are less, the frequency of ultrasonic transducer is at least more than 10MHz.This design be consider spool and valve wall gap less, thereby more economical realize above-mentioned technique effect.
Ultrasonic transducer is selected normal probe, and couplant is machine oil; A/D converter in high-speed a/d modular converter is selected the A/D chip of ADS5485 or equal performance.Thereby more economical realize above-mentioned technique effect.
The course of work of clamping localization of fault is as follows:
Aforementioned in steps and device with above-mentioned.Also comprise as follows:
When detecting step show that hydraulic valve exists clamping fault, the CPU module follow procedure of intelligent controller, according to comprehensive gripping orientation information of the monitoring point, a plurality of ultrasonic transducers place obtaining in detecting step, after comprehensive, obtain three-dimensional clamping information, can draw the clamping position of spool.
The principle of work of above-mentioned location is as follows: when clamping occurs, a part for spool and valve wall pressure are tight, almost there is no space between the two; And leave space between remainder and valve wall.When ultrasonic echo detects, the size in space can be by ultrasonic echo feature, analysis draws like this.Bull ultrasonic probe along from poppet shaft to distributing installation can obtain the clamping information of this tangent plane.If along the more ultrasonic probe of spool circumferencial direction distributing installation, just can obtain the steric information about clamping, the position of spool clamping also can accurately be located in three dimensions.
The foregoing is only specific embodiments of the invention, the not restriction to this case design, all equivalent variations of doing according to the design key of this case, all fall into the protection domain of this case.
Claims (10)
1. hydraulic valve clamps detection and a localization method for fault, and hydraulic valve comprises spool and valve body, and valve body comprises valve wall and valve pocket, it is characterized in that, comprises installation steps, demarcates normal benchmark step, demarcates clamping benchmark step and detecting step, specific as follows:
Wherein installation steps, refer to the lateral surface that a plurality of ultrasonic transducers is fixedly installed in to hydraulic valve body, and the axis of the axial line of ultrasonic transducer and valve body internal valve cavity intersects vertically;
Wherein demarcate normal benchmark step, refer to hydraulic valve is adjusted to nominal situation, be about to spool and adjust to the axis coincidence of spool and valve pocket, Ultrasonic Detection by intelligent controller is controlled, and the output of the amplitude of intelligent controller is controlled, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place nominal situation, repeats aforesaid operations, the complete reference signal amplitude while finally obtaining monitoring point, a plurality of ultrasonic transducers place nominal situation;
Wherein demarcate clamping benchmark step, refer to hydraulic valve is adjusted to clamping operating mode, Ultrasonic Detection by intelligent controller is controlled, and the output of the amplitude of intelligent controller is controlled, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place clamping operating mode, repeat aforesaid operations, the complete reference signal amplitude while finally obtaining monitoring point, a plurality of ultrasonic transducers place clamping operating mode;
Detecting step wherein, refer to the general operating mode for hydraulic valve, Ultrasonic Detection by intelligent controller is controlled, and the detection of intelligent controller output control, obtains the gripping orientation information whether this monitoring point exists clamping fault and clamping fault light and heavy degree; Repeat aforesaid operations, whether the final monitoring point, a plurality of ultrasonic transducers place that obtains there is the comprehensive gripping orientation information that clamps fault and clamping fault light and heavy degree, by fuzzy algorithm, process, show whether relevant hydraulic valve exists the clamping test result of clamping fault and clamping fault light and heavy degree;
Described intelligent controller comprises CPU module, high-speed a/d modular converter, echoed signal filter and amplification module, ultrasound emission module and multichannel handover module; CPU module is connected with high-speed a/d modular converter, can process the echoed signal of collection; CPU module is connected with ultrasound emission module, can control ultrasonic pulse and produce; CPU module is connected with multichannel handover module, is used between a plurality of ultrasonic transducers, to switch ultrasound emission, receive object; Ultrasound emission module is connected with multichannel handover module, and high-speed a/d modular converter is connected with echoed signal filter and amplification module, and echoed signal filter and amplification module is connected with multichannel handover module, and multichannel handover module is connected with a plurality of ultrasonic transducers;
Described ultrasonic transducer and valve body lateral surface directly scribble acoustic coupling medium;
The Ultrasonic Detection of described intelligent controller is controlled, and refers to ultrasonic transducer is connected with multichannel handover module, starts CPU module work, first CPU module follow procedure is controlled multichannel handover module and is connected a certain ultrasonic transducer, then starting ultrasound emission module sends electric signal and is added on this ultrasonic transducer, the ultrasonic pulse that this ultrasonic transducer is excited to produce is entered valve wall and is propagated therein by acoustic coupling medium, gap location between valve wall and spool, because the hydraulic oil in gap is different with the acoustic impedance of valve wall, ultrasound wave produces transmitting at gap location, part reflected energy returns to this ultrasonic transducer along former incident approach, this ultrasonic transducer is changed again into electric pulse, this electric impulse signal is input to high-speed a/d modular converter after by echoed signal filter and amplification module and is converted to digital quantity and sends to CPU module, CPU module records the reflection wave electric pulse of this collection preserve,
The amplitude output of described intelligent controller is controlled, refer to CPU module (1) follow procedure of intelligent controller, first the reflection wave electric pulse that records and preserve in the Ultrasonic Detection of intelligent controller being controlled, burst as this monitoring point, secondly according to hydraulic valve and ultrasound parameter, calculate the echo position in gap between spool valve wall, finally the signal amplitude as this monitoring point according to the corresponding amplitude in this positional information extraction burst;
The detection output of described intelligent controller is controlled, refer to CPU module (1) follow procedure of intelligent controller, the reflection wave electric pulse that records and preserve during the Ultrasonic Detection of intelligent controller is controlled, after amplitude-frequency analyzing and processing and when this monitoring point clamps operating mode, corresponding reference signal amplitude is compared, and show whether this monitoring point exists the gripping orientation information of clamping fault and clamping fault light and heavy degree.
2. a kind of hydraulic valve as claimed in claim 1 clamps detection and the localization method of fault, it is characterized in that: in described installation steps, a plurality of ultrasonic transducers are six above even numbers, be divided into two rows, be parallel on adjacent two lateral surfaces that are arranged on valve body of valve body internal valve cavity axis, each ultrasonic transducer on each side is uniformly-spaced arranged.
3. a kind of hydraulic valve as claimed in claim 2 clamps detection and the localization method of fault, it is characterized in that: also comprise positioning step, described positioning step refers to, when described detecting step show that hydraulic valve exists clamping fault, the CPU module follow procedure of described intelligent controller, according to comprehensive gripping orientation information of the monitoring point, a plurality of ultrasonic transducers place obtaining in detecting step, obtain three-dimensional clamping information after comprehensive, can draw the clamping position of spool.
4. detection and the localization method of a kind of hydraulic valve clamping fault as described in claim 1 or 2 or 3, is characterized in that: the frequency of described ultrasonic transducer is more than 10MHz.
5. a kind of hydraulic valve as described in claim 1 or 2 or 3 clamps detection and the localization method of fault, it is characterized in that: the A/D converter in described intelligent controller high speed A/D modular converter is selected the A/D chip of ADS5485 or equal performance, described ultrasonic transducer is selected normal probe, and described acoustic coupling medium is machine oil.
6. hydraulic valve clamps detection and a localization method for fault, and hydraulic valve comprises spool and valve body, and valve body comprises valve wall and valve pocket, it is characterized in that: comprise installation steps, reference-calibrating step and detecting step, specific as follows:
Wherein installation steps, refer to the lateral surface that a plurality of ultrasonic transducers is fixedly installed in to hydraulic valve body, and the axis of the axial line of ultrasonic transducer and valve body internal valve cavity intersects vertically;
Reference-calibrating step wherein, refer to hydraulic valve is adjusted to nominal situation, be about to spool and adjust to the axis coincidence of spool and valve pocket, Ultrasonic Detection by intelligent controller is controlled, and the amplitude of intelligent controller output controls, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place nominal situation; Hydraulic valve is adjusted to clamping operating mode, by the Ultrasonic Detection of intelligent controller, control, and the amplitude of intelligent controller output controls, corresponding reference signal amplitude while obtaining signal amplitude as monitoring point, particular ultrasound transducer place clamping operating mode; Repeat aforesaid operations, the complete reference signal amplitude while finally obtaining monitoring point, a plurality of ultrasonic transducers place nominal situation and while clamping operating mode;
Detecting step wherein, refer to the general operating mode for hydraulic valve, Ultrasonic Detection by intelligent controller is controlled, and the detection of intelligent controller output control, obtains the gripping orientation information whether this monitoring point exists clamping fault and clamping fault light and heavy degree; Repeat aforesaid operations, whether the final monitoring point, a plurality of ultrasonic transducers place that obtains there is the comprehensive gripping orientation information that clamps fault and clamping fault light and heavy degree, by fuzzy algorithm, process, show whether relevant hydraulic valve exists the clamping test result of clamping fault and clamping fault light and heavy degree;
Described intelligent controller comprises CPU module, high-speed a/d modular converter, echoed signal filter and amplification module, ultrasound emission module and multichannel handover module; CPU module is connected with high-speed a/d modular converter, can process the echoed signal of collection; CPU module is connected with ultrasound emission module, can control ultrasonic pulse and produce; CPU module is connected with multichannel handover module, is used between a plurality of ultrasonic transducers, to switch ultrasound emission, receive object; Ultrasound emission module is connected with multichannel handover module, and high-speed a/d modular converter is connected with echoed signal filter and amplification module, and echoed signal filter and amplification module is connected with multichannel handover module, and multichannel handover module is connected with a plurality of ultrasonic transducers;
Described ultrasonic transducer and valve body lateral surface directly scribble acoustic coupling medium;
The Ultrasonic Detection of described intelligent controller is controlled, and refers to ultrasonic transducer is connected with multichannel handover module, starts CPU module work, first CPU module follow procedure is controlled multichannel handover module and is connected a certain ultrasonic transducer, then starting ultrasound emission module sends electric signal and is added on this ultrasonic transducer, the ultrasonic pulse that this ultrasonic transducer is excited to produce is entered valve wall and is propagated therein by acoustic coupling medium, gap location between valve wall and spool, because the hydraulic oil in gap is different with the acoustic impedance of valve wall, ultrasound wave produces transmitting at gap location, part reflected energy returns to this ultrasonic transducer along former incident approach, this ultrasonic transducer is changed again into electric pulse, this electric impulse signal is input to high-speed a/d modular converter after by echoed signal filter and amplification module and is converted to digital quantity and sends to CPU module, CPU module records the reflection wave electric pulse of this collection preserve,
The amplitude output of described intelligent controller is controlled, refer to CPU module (1) follow procedure of intelligent controller, first the reflection wave electric pulse that records and preserve in the Ultrasonic Detection of intelligent controller being controlled, burst as this monitoring point, secondly according to hydraulic valve and ultrasound parameter, calculate the echo position in gap between spool valve wall, finally the signal amplitude as this monitoring point according to the corresponding amplitude in this positional information extraction burst;
The detection output of described intelligent controller is controlled, refer to CPU module (1) follow procedure of intelligent controller, the reflection wave electric pulse that records and preserve during the Ultrasonic Detection of intelligent controller is controlled, after amplitude-frequency analyzing and processing and when this monitoring point clamps operating mode, corresponding reference signal amplitude is compared, and show whether this monitoring point exists the gripping orientation information of clamping fault and clamping fault light and heavy degree.
7. a kind of hydraulic valve as claimed in claim 6 clamps detection and the localization method of fault, it is characterized in that: in described installation steps, a plurality of ultrasonic transducers are six above even numbers, be divided into two rows, be parallel on adjacent two lateral surfaces that are arranged on valve body of valve body internal valve cavity axis, each ultrasonic transducer on each side is uniformly-spaced arranged.
8. a kind of hydraulic valve as claimed in claim 7 clamps detection and the localization method of fault, it is characterized in that: also comprise positioning step, described positioning step refers to, when described detecting step show that hydraulic valve exists clamping fault, the CPU module follow procedure of described intelligent controller, according to comprehensive gripping orientation information of the monitoring point, a plurality of ultrasonic transducers place obtaining in detecting step, obtain three-dimensional clamping information after comprehensive, can draw the clamping position of spool.
9. detection and the localization method of a kind of hydraulic valve clamping fault as described in claim 6 or 7 or 8, is characterized in that: the frequency of described ultrasonic transducer is more than 10MHz.
10. a kind of hydraulic valve as described in claim 6 or 7 or 8 clamps detection and the localization method of fault, it is characterized in that: the A/D converter in described intelligent controller high speed A/D modular converter is selected the A/D chip of ADS5485 or equal performance, described ultrasonic transducer is selected normal probe, and described acoustic coupling medium is machine oil.
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