CN105241370A - Cubic press health monitoring method and system - Google Patents
Cubic press health monitoring method and system Download PDFInfo
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- CN105241370A CN105241370A CN201510674673.XA CN201510674673A CN105241370A CN 105241370 A CN105241370 A CN 105241370A CN 201510674673 A CN201510674673 A CN 201510674673A CN 105241370 A CN105241370 A CN 105241370A
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Abstract
The invention proposes a cubic press health monitoring method and system. The monitoring system comprises a power management module, a signal processing module and a remote control monitoring module which are serially connected. The signal processing module comprises a strain detection module, a signal conditioning module, a microprocessor, a storage module and a wireless data transmission module; the strain detection module comprises a strain collection sheet, a bridge-type compensation circuit, and an electronic switch; the signal conditioning module comprises a passage amplifier, a filter and an A/D converter; The remote control monitoring module is arranged in a remote monitoring room and acquires the test data through the wireless data transmission module. The aim of online health monitoring of cubic presses is achieved based on an electrical strain measuring method and modern wireless transmission technology. The cubic press health monitoring system can accurately acquire weak strain signal data, has the functions of online monitoring and real-time display and recording of equipment usage status, and can predicate the fatigue life of equipment in actual work conditions, thereby preventing great and malignant accidents and reducing losses.
Description
Technical field:
The present invention relates to cubic hydraulic press monitoring field, particularly a kind of cubic hydraulic press health monitor method and system.
Background technology:
Cubic hydraulic press is the extra-high tension unit of synthesizing superhard material and goods thereof, be mainly used in and manufacture man-made diamond, the monocrystalline of cubic boron nitride and glomerocryst, and synthesize processing and the production in the superhard material such as polycrystalline diamond, polycrystalline cubic boron nitride compound sheets field, working pressure is up to 100MPa.In the hydropress course of work, the impact that its hydraulic-driven part (piston, plunger) commutation and release produce, affect the normal work of equipment, so long-time, regular reciprocation cycle load application, very easily make the fatigue damage of cubic hydraulic press stress concentration point (as hinge beam, working cylinder, hanger stress carrying key point), to crack time serious, even directly cause equipment failure, cause personal injury and economic loss.Therefore, carry out the real time health monitoring of stress concentration point in cubic hydraulic press operation process, correctly effectively disclose the generation of incipient fault, development, can provide accurately for maintenance management, reliable foundation,
Summary of the invention
The technical problem to be solved in the present invention is do not possess on-line monitoring and instant protective capability for above-mentioned prior art, be difficult to the defect of satisfied intelligent cubic hydraulic press health monitoring reliability requirement, and provides that a kind of accuracy of detection is high, efficiency is high, possess on-line monitoring and instant protective capability, the cubic hydraulic press health monitor method that can meet intelligent cubic hydraulic press health monitoring reliability requirement and system.
The technical solution adopted for the present invention to solve the technical problems is:
A kind of cubic hydraulic press health monitoring systems, comprising: power management module, the signal processing module be connected with power management module and the remote monitoring module be connected with signal processing module; Wherein:
Power management module provides power supply by industrial alternating current, and by power supply revolving die block and voltage-reference conversion, obtaining reliable and stable circuit voltage is that signal processing module is powered;
Signal processing module comprises microprocessor and the strain detecting module, Signal-regulated kinase, memory module and the wireless data transfer module that are connected with microprocessor respectively; Strain detecting module is connected with Signal-regulated kinase, and strain detecting module comprises the strain acquirement sheet, bridge-type compensating circuit, the electronic switch that are connected; Signal-regulated kinase comprises the channel amplifier, wave filter and the A/D converter that are connected;
Remote monitoring module comprises upper computer software, display, storer and printer.
The single armed half-bridge circuit that the working strain gauge that described bridge-type compensating circuit is temperature compensation sheet, High Precision Low Temperature floats resistance and multiple foil gauge is formed in parallel connects to form; Each foil gauge of working strain gauge is connected with described electronic switch, form the faint strain signal acquisition zone of hyperchannel, the duty of each passage is controlled by electronic switch, the electricity after stream is expanded as bridge power supply by voltage-reference by triode in the faint strain signal acquisition zone of each hyperchannel, and is welded on and makes thickness on the strain acquirement sheet of 0.2 ~ 3mm by 35GrMo.
Described strain acquirement sheet is made up of material 35GrMo identical with cubic hydraulic press, thickness 0.2 ~ 3mm, is sticked at cubic hydraulic press stress concentrated position, with cubic hydraulic press area of stress concentration, corresponding strain occurs.
Described voltage-reference and bridge-type compensating circuit input end expand to flow by triode and are connected; The each working strain gauge of bridge-type compensating circuit and electronic switch input end pass through connection; Electronic switch output terminal is linked in sequence by microprocessor I/O mouth and channel amplifier, wave filter, A/D converter.
Described microprocessor and strain detecting module, Signal-regulated kinase, memory module and wireless data transfer module pass through connection;
Described strain detecting module is attached to cubic hydraulic press stress concentrated position by described strain acquirement sheet; Power management module and signal processing module are by connection, and remote monitoring module is communicated by wireless data transfer module with signal processing module.
Single-chip microcomputer selected by described microprocessor, memory module selects SD card, display selects LCD display, voltage-reference adopts MAX6175, wireless data transfer module adopts GPRS module, and electronic switch adopts CD4053, and channel amplifier adopts precision instrument amplifier INA114, wave filter adopts RC wave filter, and A/D converter adopts hyperchannel, high precision 24 AD7710 conversion chips.
The method utilizing cubic hydraulic press health monitoring systems of the present invention to monitor, comprises the steps:
(A) initialization cubic hydraulic press health monitoring systems;
(B) strain detecting module acquires often organizes the faint strain signal of corresponding working strain gauge test point on strain acquirement sheet, and is converted to the voltage signal controlled within the scope of certain error;
(C) voltage signal is carried out gain, filtering, conversion by Signal-regulated kinase, and then Microprocessor S3C44B0X memory module stores data, control electronic switch switching simultaneously and often organize the corresponding service aisle of described strain acquirement sheet, return step (B) executable operations, circulation is gone down successively;
(D) memory module data are read in the timing of microprocessor controls wireless data transfer module, are sent to remote monitoring module and wait for timing reading next time;
(E) remote monitoring module is set up wide area by privately owned fixed ip address with described wireless data transfer module and is connected, and carries out data-signal, control signal communication; Receive data, analyze data, store data, simultaneously according to Plotting data passage strain-time history curve map and print analysis result by printer;
(E1) upper computer software is according to data signal analysis equipment use situation and prediction actual condition fatigue lifetime, memory data signal and analysis result.LCD display display channel strain-time history curve map is worth with expection fatigue lifetime simultaneously;
(E2) upper computer software is according to data in passage strain-time history curve map, and contrast sets strain threshold, frequently loads frequency threshold value; If passage strain value is greater than setting strain threshold, then carry out step (E3), remote monitoring module stores this passage strain value and time simultaneously, and send strain feedback signal by wireless data transfer module to microprocessor, microprocessor performs the first alarm; If passage strain value is less than strain threshold, then returns step (E) and perform;
(E3) passage strain value is greater than strain threshold, then upper computer software is drawn and loaded number of times-time history curve map; If loading number of times is greater than setting and frequently loads frequency threshold value, then remote monitoring module stores this loading number of times-time history plot analyses result, and sending frequent loading number of times feedback signal by wireless data transfer module to microprocessor, microprocessor performs the second alarm; If passage strain value is less than setting frequently load frequency threshold value, then returns step (E) and perform.
Cubic hydraulic press health monitor method of the present invention and system, there is following beneficial effect: the data that can obtain faint strain signal accurately and fast, to possess in on-line monitoring, in real time display recording unit behaviour in service, prediction actual condition equipment fatigue lifetime, online send feedback signal and for equipment research and development unit provide due to user frequently transship, high-frequency uses equipment and causes device damage to require the foundation of research and development unit reparation associated loss, effectively avoids the extra loss researching and developing unit.
Accompanying drawing illustrates:
Fig. 1 is system architecture schematic diagram in cubic hydraulic press health monitoring systems of the present invention embodiment;
Fig. 2 is strain acquirement chip architecture figure in described embodiment;
Fig. 3 is strain detecting module concrete structure schematic diagram in described embodiment;
Fig. 4 is method flow diagram in described embodiment.
In figure, 1. power management module 2. signal processing module 3. remote monitoring module 4. industrial alternating current 5. voltage transformation module 6. voltage-reference 7. strain detecting module 8. Signal-regulated kinase 9. microprocessor 10. memory module 11. wireless data transfer module 12. upper computer software 13. display 14. storer 15. printer 16. electronic switch 17. channel amplifier 18. wave filter 19.A/D converter 20. strain acquirement sheet 21. bridge-type compensating circuit;
1 ~ n district: the faint strain signal acquisition zone of hyperchannel;
R
11~ Rn
1, R
12~ Rn
2, R
13~ Rn
3, R
14~ Rn
4: working strain gauge;
R
2: temperature compensation sheet R
3, R
4: High Precision Low Temperature drift resistance R
e: emitter resistance;
U: bridge input voltage Uo: bridge output voltage.
Embodiment:
Below in conjunction with the accompanying drawing in the embodiment of the present invention, be clearly and completely described the technical scheme in the embodiment of the present invention, obviously, described embodiment is only the present invention's part embodiment, instead of whole embodiments.Based on the embodiment in the present invention, those of ordinary skill in the art, not making the every other embodiment obtained under creative work prerequisite, belong to the scope of protection of the invention.
In cubic hydraulic press health monitor method of the present invention and system embodiment, the structural representation of its cubic hydraulic press health monitoring systems as shown in Figure 1.In Fig. 1, this cubic hydraulic press health monitoring systems comprises: power management module 1, signal processing module 2, remote monitoring module 3; Power management module 1 provides power supply by industrial alternating current 4, is changed by power supply revolving die block 5 and voltage-reference 6, and obtaining reliable and stable circuit voltage is that signal processing module 2 is powered; Signal processing module 2 comprises strain detecting module 7, Signal-regulated kinase 8, microprocessor 9, memory module 10 and wireless data transfer module 11; Strain detecting module 7 comprises strain acquirement sheet 20, bridge-type compensating circuit 21, electronic switch 16; Signal-regulated kinase 8 comprises channel amplifier 17, wave filter 18 and A/D converter 19; Remote monitoring module 3 comprises upper computer software 12, display 13, storer 14 and printer 15.
Described voltage-reference 6 and described bridge-type compensating circuit 21 input end expand to flow by triode and are connected; The each working strain gauge of described bridge-type compensating circuit 21 and described electronic switch 16 input end pass through connection; Described electronic switch 16 output terminal by the I/O mouth of described microprocessor 9 be linked in sequence described channel amplifier 17, wave filter 18, A/D conversion/19; Described microprocessor 9 passes through connection with described strain detecting module 7, Signal-regulated kinase 8, memory module 10 and wireless data transfer module 11; Described strain detecting module 7 is attached to cubic hydraulic press stress concentrated position by described strain acquirement sheet 20; Power management module 1 and signal processing module 2 are by connection, and remote monitoring module 3 is communicated by described wireless data transfer module 11 with signal processing module 2.
In the present embodiment, specifically, single-chip microcomputer selected by described microprocessor 9, and memory module 10 selects SD card, and wireless data transfer module 11 selects GPRS module, display 13 selects LCD display, voltage-reference 6 adopts MAX6175, and electronic switch 16 adopts CD4053, and channel amplifier 17 adopts INA114, wave filter 18 adopts RC wave filter, and A/D converter 19 adopts hyperchannel, high precision 24 AD7799 conversion chips.
In the present embodiment, specifically, in figs. 2 and 3, described bridge-type compensating circuit 21 is temperature compensation sheet R
2, High Precision Low Temperature drift resistance R
3, R
4and the single armed half-bridge circuit that the working strain gauge that is formed in parallel of multiple foil gauge connects to form.Each foil gauge of described working strain gauge is connected with described electronic switch 16, forms 1 ~ n district, the faint strain signal acquisition zone of hyperchannel, is controlled the duty of each passage by described electronic switch 16.1 ~ n district, each hyperchannel faint strain signal acquisition zone expands the electricity after stream as bridge power supply by described voltage-reference 6 by triode, and be pasted onto and make thickness on the strain acquirement sheet 20 of 0.2 ~ 3mm by 35GrMo, on described strain acquirement sheet, 20 are welded on cubic hydraulic press stress concentrated position, with cubic hydraulic press area of stress concentration generation corresponding deformation.
The invention still further relates to a kind of cubic hydraulic press health monitor method, its process flow diagram as shown in Figure 4.In Fig. 1 to Fig. 4, this cubic hydraulic press health monitor method comprises the steps:
Gather 1st district as describing object according to the faint strain signal of hyperchannel in the present embodiment, other duplicate.
(A) in step S101, initialization cubic hydraulic press health monitoring systems; In this step, when cubic hydraulic press and health monitoring systems all normally start, described microprocessor 9 is each block configuration initiation parameter.
(B) in step s 102, described strain detecting module 7 gathers often organizes the faint strain signal of corresponding working strain gauge test point on described strain acquirement sheet 20, and is converted to the voltage signal controlled within the scope of certain error; In this step, first R
11~ R
n1time in running order, corresponding electronic switch 16 closes, and gathers R
11~ R
n1the strain signal of the corresponding stress raiser of working strain gauge, by formula: U
0=UK ε/4 (wherein U
0for bridge road output voltage, U is bridge road input voltage, and K is foil gauge sensitivity coefficient, and ε is foil gauge strain) be converted to the voltage signal U controlled within the scope of certain error
11~ U
n1;
(C) in step s 103, described voltage signal is carried out gain, filtering, conversion by described Signal-regulated kinase 7, and then described microprocessor 9 control store module 10 stores data, control electronic switch 16 to switch and often organize the corresponding service aisle of described strain acquirement sheet simultaneously, return step (B) executable operations, circulation is gone down successively; In this step, described voltage signal U
11~ U
n1amplify through Signal-regulated kinase 8, filtering, conversion process obtain corresponding data signal, perform read-write operations by microprocessor 9 pairs of data-signals, store data.Meanwhile, be greater than described electronic switch 16 switching frequency to a certain degree under condition in described A/D converter 19 sample frequency, microprocessor 9 sends switching command by I/O mouth to electronic switch 16, makes 1 ~ n district working strain gauge R
11~ R
n1corresponding electronic switch 16 disconnects, 1 ~ n district working strain gauge R
12~ R
n2corresponding electronic switch 16 closes, and returns step (B) executable operations, and circulation is gone down successively;
(D) in step S104, described microcontroller 9 controls the timing of described wireless data transfer module 11 and reads described memory module 10 data, is sent to described upper computer software module 3 and waits for timing reading next time; In this step, described microcontroller 9 is according to the timer internal time, control the timing of described wireless data transfer module 11 and read described memory module 10 data, and be sent to described upper computer software module 3 and wait for that the new data of described memory module 10 are read in timing next time;
(E) in step S105, described remote monitoring module 3 is set up wide area by privately owned fixed ip address with described wireless data transfer module 11 and is connected, and carries out data-signal, control signal communication.Receive data, analyze data, store data, print analysis result according to Plotting data passage strain-time history curve map and by described printer 15 simultaneously;
(E1) in step S105, described upper computer software 12 is according to data signal analysis equipment use situation and prediction actual condition fatigue lifetime, memory data signal and analysis result.Described LCD display 13 display channel strain-time history curve map is worth with expection fatigue lifetime simultaneously;
(E2) in step S106 to S107, described upper computer software 12 is according to data in passage strain-time history curve map, and contrast sets strain threshold, frequently loads frequency threshold value.If described passage strain value is greater than setting strain threshold, then carry out step (E3), described remote monitoring module 3 stores this passage strain value and time simultaneously, and sending strain feedback signal by described wireless data transfer module 11 to described microprocessor 9, described microprocessor 9 performs the first alarm; If described passage strain value is less than described strain threshold, then returns step (E) and perform;
(E3) in step S108 to S109, described passage strain value is greater than described strain threshold, then described upper computer software 12 is drawn and loaded number of times-time history curve map.If described loading number of times is greater than setting and frequently loads frequency threshold value, then described remote monitoring module 3 stores this loading number of times-time history plot analyses result, and sending frequent loading number of times feedback signal by described wireless data transfer module 11 to described microprocessor 9, described microprocessor performs the second alarm; If described passage strain value is less than setting and frequently loads frequency threshold value, then return step (E) and perform.
The foregoing is only preferred embodiment of the present invention, not in order to limit the present invention, within the spirit and principles in the present invention all, any amendment done, equivalent replacement, improvement etc., all should be included within protection scope of the present invention.
Claims (9)
1. a cubic hydraulic press health monitoring systems, is characterized in that: the remote monitoring module comprising power management module, the signal processing module be connected with power management module and be connected with signal processing module; Wherein:
Signal processing module comprises microprocessor and the strain detecting module, Signal-regulated kinase, memory module and the wireless data transfer module that are connected with microprocessor respectively; Strain detecting module is connected with Signal-regulated kinase, and strain detecting module comprises the strain acquirement sheet, bridge-type compensating circuit, the electronic switch that are connected; Signal-regulated kinase comprises the channel amplifier, wave filter and the A/D converter that are connected.
2. cubic hydraulic press health monitoring systems according to claim 1, it is characterized in that: described power management module provides power supply by industrial alternating current, by power supply revolving die block and voltage-reference conversion, obtaining reliable and stable circuit voltage is that signal processing module is powered.
3. cubic hydraulic press health monitoring systems according to claim 1, is characterized in that: remote monitoring module comprises upper computer software, display, storer and printer.
4. cubic hydraulic press health monitoring systems according to claim 1, is characterized in that: the single armed half-bridge circuit that the working strain gauge that described bridge-type compensating circuit is temperature compensation sheet, High Precision Low Temperature floats resistance and multiple foil gauge is formed in parallel connects to form; Each foil gauge of working strain gauge is connected with described electronic switch, form the faint strain signal acquisition zone of hyperchannel, the duty of each passage is controlled by electronic switch, the electricity after stream is expanded as bridge power supply by voltage-reference by triode in the faint strain signal acquisition zone of each hyperchannel, and is welded on strain acquirement sheet.
5. cubic hydraulic press health monitoring systems according to claim 1, it is characterized in that: described strain acquirement sheet is made up of material 35GrMo identical with cubic hydraulic press, thickness 0.2 ~ 3mm, be sticked at cubic hydraulic press stress concentrated position, with cubic hydraulic press area of stress concentration, corresponding strain occur.
6. cubic hydraulic press health monitoring systems according to claim 1, is characterized in that: described voltage-reference and bridge-type compensating circuit input end expand to flow by triode and be connected; The each working strain gauge of bridge-type compensating circuit and electronic switch input end pass through connection; Electronic switch output terminal is linked in sequence by microprocessor I/O mouth and channel amplifier, wave filter, A/D converter.
7. cubic hydraulic press health monitoring systems according to claim 1, is characterized in that: described strain detecting module is attached to cubic hydraulic press stress concentrated position by described strain acquirement sheet; Power management module and signal processing module are by connection, and remote monitoring module is communicated by wireless data transfer module with signal processing module.
8. cubic hydraulic press health monitoring systems according to claim 1, it is characterized in that: single-chip microcomputer selected by described microprocessor, memory module selects SD card, display selects LCD display, voltage-reference adopts MAX6175, and electronic switch adopts CD4053, and channel amplifier adopts precision instrument amplifier INA114, wave filter adopts RC wave filter, and A/D converter adopts hyperchannel, high precision 24 AD7710 conversion chips.
9. a cubic hydraulic press health monitor method, is characterized in that: comprise the steps:
(A) initialization cubic hydraulic press health monitoring systems;
(B) strain detecting module acquires often organizes the faint strain signal of corresponding working strain gauge test point on strain acquirement sheet, and is converted to the voltage signal controlled within the scope of certain error;
(C) voltage signal is carried out gain, filtering, conversion by Signal-regulated kinase, and then Microprocessor S3C44B0X memory module stores data, control electronic switch switching simultaneously and often organize the corresponding service aisle of described strain acquirement sheet, return step (B) executable operations, circulation is gone down successively;
(D) memory module data are read in the timing of microprocessor controls wireless data transfer module, are sent to remote monitoring module and wait for timing reading next time;
(E) remote monitoring module is set up wide area by privately owned fixed ip address with described wireless data transfer module and is connected, and carries out data-signal, control signal communication; Receive data, analyze data, store data, simultaneously according to Plotting data passage strain-time history curve map and print analysis result by printer;
(E1) upper computer software is according to data signal analysis equipment use situation and prediction actual condition fatigue lifetime, memory data signal and analysis result; LCD display display channel strain-time history curve map is worth with expection fatigue lifetime simultaneously;
(E2) upper computer software is according to data in passage strain-time history curve map, and contrast sets strain threshold, frequently loads frequency threshold value; If passage strain value is greater than setting strain threshold, then carry out step (E3), remote monitoring module stores this passage strain value and time simultaneously, and send strain feedback signal by wireless data transfer module to microprocessor, microprocessor performs the first alarm; If passage strain value is less than strain threshold, then returns step (E) and perform;
(E3) passage strain value is greater than strain threshold, then upper computer software is drawn and loaded number of times-time history curve map; If loading number of times is greater than setting and frequently loads frequency threshold value, then remote monitoring module stores this loading number of times-time history plot analyses result, and sending frequent loading number of times feedback signal by wireless data transfer module to microprocessor, microprocessor performs the second alarm; If passage strain value is less than setting frequently load frequency threshold value, then returns step (E) and perform.
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