CN105241370B - Cubic hydraulic press health monitor method and system - Google Patents
Cubic hydraulic press health monitor method and system Download PDFInfo
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- CN105241370B CN105241370B CN201510674673.XA CN201510674673A CN105241370B CN 105241370 B CN105241370 B CN 105241370B CN 201510674673 A CN201510674673 A CN 201510674673A CN 105241370 B CN105241370 B CN 105241370B
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Abstract
The invention proposes cubic hydraulic press health monitor method and system, monitoring system includes power management module, signal processing module and the long-range monitoring modular being linked in sequence；Signal processing module includes strain detecting module, signal conditioning module, microprocessor, memory module and wireless data transfer module；Strain detecting module includes strain acquirement piece, bridge-type compensation circuit, electronic switch；Signal conditioning module includes channel amplifier, filter and A/D converter；Long-range monitoring modular is mounted on long-range monitoring room and obtains test data by wireless data transfer module.The present invention is based on the purposes that electromotive strain method and modern Radio Transmission Technology realize the monitoring of cubic hydraulic press HEALTH ONLINE, have the advantages that the data that can accurately obtain faint strain signal, have on-line monitoring, real-time display, recording equipment behaviour in service, predict equipment fatigue life in actual condition, it prevents great, serious accident from occurring, reduces loss.
Description
Technical field
The present invention relates to cubic hydraulic press monitor field, in particular to a kind of cubic hydraulic press health monitor method and
System.
Background technique
Cubic hydraulic press is the extra-high tension unit of synthesizing superhard material and its product, is mainly used in manufacture artificial diamond
The superhard materials neck such as monocrystalline and plycrystalline diamond of stone, cubic boron nitride, and synthesis polycrystalline diamond, polycrystalline cubic boron nitride compound sheets
The processing and production in domain, operating pressure are up to 100MPa.In the hydraulic press course of work, hydraulic-driven part (piston, plunger)
The impact that commutation and release generate, influences the normal work of equipment, and so long-time, regular reciprocation cycle are further applied load,
Easily make the fatigue damage of cubic hydraulic press stress concentration point (such as hinge beam, working cylinder, lifting lug stress carrying key point), sternly
It will be cracked when weight, or even directly cause equipment fault, and cause personal injury and economic loss.Therefore, cubic apparatus liquid is carried out
The real time health monitoring of stress concentration point during pressing machine for operation, correctly and efficiently discloses generation, the development of incipient fault, can be with
Accurate, reliable foundation is provided for maintenance management,
Summary of the invention
The technical problem to be solved in the present invention is that not having on-line monitoring and immediately protection energy for the above-mentioned prior art
Power is difficult to meet the defect of intelligent cubic hydraulic press health monitoring reliability requirement, and provides that a kind of detection accuracy is high, efficiency
Height has on-line monitoring and instant protective capability, six faces for being able to satisfy intelligent cubic hydraulic press health monitoring reliability requirement
Push up hydraulic press health monitor method and system.
The technical solution adopted by the present invention to solve the technical problems is:
A kind of cubic hydraulic press health monitoring systems, comprising: power management module, the letter being connect with power management module
Number processing module and the long-range monitoring modular being connect with signal processing module；Wherein:
Power management module provides power supply by industrial alternating current, is converted, is obtained by power supply revolving die block and voltage-reference
Reliable and stable circuit voltage is signal processing module power supply；
Signal processing module includes microprocessor and the strain detecting module connecting respectively with microprocessor, signal condition mould
Block, memory module and wireless data transfer module；Strain detecting module is connect with signal conditioning module, and strain detecting module includes
The strain acquirement piece that is connected, bridge-type compensation circuit, electronic switch；Signal conditioning module include the channel amplifier being connected,
Filter and A/D converter；
Long-range monitoring modular includes upper computer software, display, memory and printer.
The bridge-type compensation circuit is temperature-compensating plate, High Precision Low Temperature floats resistance and multiple foil gauges are formed in parallel
The single armed half-bridge circuit of working strain gauge connection composition；Each foil gauge of working strain gauge is connect with the electronic switch, structure
At the faint strain signal acquisition zone of multichannel, the working condition in each channel is controlled by electronic switch, each multichannel is faint to answer
The electricity after flowing is expanded as bridge power supply by triode by voltage-reference in varying signal acquisition zone, and is welded on by 35GrMo
Thickness is made in the strain acquirement on piece of 0.2~3mm.
By being made with cubic hydraulic press same material 35GrMo, 0.2~3mm's strain acquirement piece of thickness is sticked
With cubic hydraulic press stress concentration region corresponding strain occurs for cubic hydraulic press stress concentrated position.
The voltage-reference and bridge-type compensation circuit input terminal expand stream by triode and connect；Each work of bridge-type compensation circuit
Make foil gauge and electronic switch input terminal passes through connection；Electronic switch output end is put by I/O mouthfuls of microprocessor with channel
Big device, filter, A/D converter are linked in sequence.
The microprocessor and strain detecting module, signal conditioning module, memory module and wireless data transfer module
Pass through connection；
The strain detecting module is attached to cubic hydraulic press stress concentrated position by the strain acquirement piece；Power supply pipe
It manages module and signal processing module and wireless data transmission mould is passed through by connection, long-range monitoring modular and signal processing module
Block communication.
The microprocessor selects single-chip microcontroller, and memory module selects SD card, and display selects LCD display, voltage reference
Source uses MAX6175, and wireless data transfer module uses GPRS module, and electronic switch uses CD4053, and channel amplifier uses
Precision instrument amplifier INA114, filter use RC filter, and A/D converter is turned using 24 multichannel, high-precision AD7710
Change chip.
The method monitored using cubic hydraulic press health monitoring systems of the present invention, is included the following steps:
(A) cubic hydraulic press health monitoring systems are initialized；
(B) strain detecting module acquires every group of strain acquirement on piece and corresponds to the faint strain signal of working strain gauge test point,
And control is converted in the voltage signal of within a certain error range；
(C) voltage signal is carried out gain, filtering, conversion by signal conditioning module, and then microprocessor controls memory module
Storing data, while controlling strain acquirement piece described in every group of electronic switch switching and corresponding to service aisle, return step (B) executes behaviour
Make, circuits sequentially down；
(D) memory module data are read in microcontroller control wireless data transfer module timing, are sent to long-range monitoring mould
Timing is read next time for block and waiting；
(E) long-range monitoring modular is established wide area with the wireless data transfer module by privately owned fixed ip address and is connect,
Carry out data-signal, control signal communication；Data, analysis data, storing data are received, while drawing channel according to data and answering
Change-time history curve graph and pass through printer printing analysis result；
(E1) upper computer software is deposited according to data signal analysis equipment behaviour in service and prediction actual condition fatigue life
Store up data-signal and analysis result.LCD display display channel strain-time history curve graph and expected fatigue life simultaneously
Value；
(E2) upper computer software is according to data in channel strain-time history curve graph, comparison setting strain threshold, frequently
Load frequency threshold value；If channel strain value is greater than setting strain threshold, carry out step (E3), while long-range monitoring modular storage
The channel strain value and time, and strain feedback signal, microprocessor are sent to microprocessor by wireless data transfer module
Execute the first alarm；If channel strain value is less than strain threshold, return step (E) is executed；
(E3) channel strain value is greater than strain threshold, then upper computer software draws load number-time history curve graph；If
It loads number and is greater than setting frequently load frequency threshold value, then long-range monitoring modular stores the load number-time history curve graph
Analysis is as a result, and to microprocessor transmission, frequently load number feedback signal, microprocessor are held by wireless data transfer module
The second alarm of row；If channel strain value is less than setting frequently load frequency threshold value, return step (E) is executed.
Cubic hydraulic press health monitor method of the invention and system, having the advantages that can be accurately and fast
The data for obtaining faint strain signal have on-line monitoring, real-time display recording equipment behaviour in service, predict to set in actual condition
Standby fatigue life sends feedback signal online and provides for equipment research and development unit since user is frequently overloaded, high-frequency makes
It causes equipment damage to require the foundation of research and development unit reparation associated loss with equipment, effectively avoids the additional damage of research and development unit
It loses.
Detailed description of the invention:
Fig. 1 is system structure diagram in cubic hydraulic press health monitoring systems one embodiment of the present invention；
Fig. 2 is strain acquirement chip architecture figure in the embodiment；
Fig. 3 is strain detecting module concrete structure schematic diagram in the embodiment；
Fig. 4 is method flow diagram in the embodiment.
In figure, 1. power management module, 2. signal processing module, 3. industrial 5. power supply of the alternating current conversion of long-range monitoring modular 4.
10. memory module of module 6. voltage-reference, 7. strain detecting module, 8. signal conditioning module, 9. microprocessor, 11. wireless data
The filter of 16. electronic switch of transmission module 12. upper computer software, 13. display, 14. memory, 15. printer, 17. channel amplifier 18.
20. strain acquirement piece of wave device 19.A/D converter, 21. bridge-type compensation circuit；
The area 1~n: the faint strain signal acquisition zone of multichannel；
R11~Rn1、R12~Rn2、R13~Rn3、R14~Rn4: working strain gauge；
R2: temperature-compensating plate R3、R4: High Precision Low Temperature floats resistance RE: emitter resistance；
U: bridge input voltage Uo: bridge output voltage.
Specific embodiment:
Following will be combined with the drawings in the embodiments of the present invention, and technical solution in the embodiment of the present invention carries out clear, complete
Site preparation description, it is clear that described embodiments are only a part of the embodiments of the present invention, instead of all the embodiments.It is based on
Embodiment in the present invention, it is obtained by those of ordinary skill in the art without making creative efforts every other
Embodiment shall fall within the protection scope of the present invention.
In cubic hydraulic press health monitor method of the present invention and system embodiment, cubic hydraulic press health monitoring
The structural schematic diagram of system is as shown in Figure 1.In Fig. 1, the cubic hydraulic press health monitoring systems include: power management module 1,
Signal processing module 2, long-range monitoring modular 3；Power management module 1 provides power supply by industrial alternating current 4, passes through power supply revolving die block
5 and voltage-reference 6 convert, obtain reliable and stable circuit voltage be signal processing module 2 power；Signal processing module 2 wraps
Include strain detecting module 7, signal conditioning module 8, microprocessor 9, memory module 10 and wireless data transfer module 11；Strain inspection
Surveying module 7 includes strain acquirement piece 20, bridge-type compensation circuit 21, electronic switch 16；Signal conditioning module 8 includes channel amplifier
17, filter 18 and A/D converter 19；Long-range monitoring modular 3 includes upper computer software 12, display 13, memory 14 and beats
Print machine 15.
The voltage-reference 6 expands stream connection by triode with 21 input terminal of bridge-type compensation circuit；The bridge-type
Each working strain gauge of compensation circuit 21 and 16 input terminal of electronic switch pass through connection；16 output end of electronic switch
Pass through the I/O mouth sequential connection channel amplifier 17, the filter 18, A/D converter 19 of the microprocessor 9；It is described micro-
Processor 9 passes through with the strain detecting module 7, signal conditioning module 8, memory module 10 and wireless data transfer module 11
Connection；The strain detecting module 7 is attached to cubic hydraulic press stress concentrated position by the strain acquirement piece 20；Electricity
By connection, long-range monitoring modular 3 passes through the nothing with signal processing module 2 for source control module 1 and signal processing module 2
Line data transmission module 11 communicates.
In the present embodiment, specifically, the microprocessor 9 selects single-chip microcontroller, and memory module 10 selects SD card, no line number
GPRS module is selected according to transmission module 11, display 13 selects LCD display, and voltage-reference 6 uses MAX6175, electronic cutting
It closes 16 and uses CD4053, channel amplifier 17 uses INA114, and filter 18 uses RC filter, and A/D converter 19 is using more
24 channel, high-precision AD7799 conversion chips.
In the present embodiment, specifically, in figure 2 and figure 3, the bridge-type compensation circuit 21 is temperature-compensating plate R2, it is high
Precision Low Drift Temperature resistance R3、R4And the working strain gauge that multiple foil gauges are formed in parallel connects the single armed half-bridge circuit formed.Institute
The each foil gauge for stating working strain gauge is connect with the electronic switch 16, constitutes the faint 1~n of strain signal acquisition zone of multichannel
Area is controlled the working condition in each channel by the electronic switch 16.Each faint strain signal acquisition zone of multichannel area 1~n
The electricity after flowing is expanded as bridge power supply by triode by the voltage-reference 6, and is pasted onto and thickness is made by 35GrMo
On the strain acquirement piece 20 of 0.2~3mm, the strain acquirement on piece 20 is welded on cubic hydraulic press stress and concentrates position degree
It sets, corresponding deformation occurs with cubic hydraulic press stress concentration region.
The invention further relates to a kind of cubic hydraulic press health monitor method, flow chart is as shown in Figure 4.In Fig. 1 to Fig. 4
In, which includes the following steps:
1st area is acquired as narration object according to the faint strain signal of multichannel in the present embodiment, other are identical.
(A) in step s101, cubic hydraulic press health monitoring systems are initialized；It is hydraulic in cubic apparatus in this step
In the case that machine and health monitoring systems all normally start, the microprocessor 9 is that each module configures initiation parameter.
(B) in step s 102, the strain detecting module 7 acquire every group described in correspond to work on strain acquirement piece 20 and answer
Become the faint strain signal of built-in testing point, and is converted to control in the voltage signal of within a certain error range；In this step, R first11
~Rn1When in running order, corresponding electronic switch 16 is closed, and acquires R11~Rn1Working strain gauge corresponds to answering for stress raiser
Varying signal, by formula: U0=UK ε/4 (wherein U0For bridge output voltage, U is bridge input voltage, and K is foil gauge sensitivity system
Number, ε are foil gauge strain) control is converted in the voltage signal U of within a certain error range11~Un1；
(C) in step s 103, the voltage signal is carried out gain, filtering, conversion by the signal conditioning module 8, into
And the microprocessor 9 controls 10 storing data of memory module, while control electronic switch 16 switch every group described in strain acquirement
Piece corresponds to service aisle, and return step (B) executes operation, circuits sequentially down；In this step, the voltage signal U11~Un1
Corresponding data signal is obtained by the amplification of signal conditioning module 8, filtering, conversion process, data-signal is executed by microprocessor 9
Read-write operation, storing data.Meanwhile being greater than 16 switching frequency one of electronic switch in 19 sample frequency of A/D converter
Under the conditions of determining degree, microprocessor 9 sends switching command to electronic switch 16 by I/O mouthfuls, makes the area 1~n working strain gauge R11
~Rn1Corresponding electronic switch 16 disconnects, the area 1~n working strain gauge R12~Rn2Corresponding electronic switch 16 is closed, return step (B)
Operation is executed, is circuited sequentially down；
(D) in step S104, the microcontroller 9 control the wireless data transfer module 11 periodically read described in deposit
10 data of module are stored up, the upper computer software module 3 is sent to and timing next time is waited to read；It is described micro- in this step
Controller 9 controls the wireless data transfer module 11 and periodically reads the number of memory module 10 according to the timer internal time
According to, and be sent to the upper computer software module 3 and wait and periodically read the new data of the memory module 10 next time；
(E) in step s105, the long-range monitoring modular 3 passes through privately owned fixed ip address and the wireless data transmission
Module 11 establishes wide area connection, carries out data-signal, control signal communication.Data, analysis data, storing data are received, simultaneously
Channel strain-time history curve graph is drawn according to data and analysis result is printed by the printer 15；
(E1) in step s105, the upper computer software 12 is according to data signal analysis equipment behaviour in service and prediction
Actual condition fatigue life, memory data signal and analysis result.13 display channel strain of the LCD display-time simultaneously
Course curve graph and expected fatigue life value；
(E2) in step S106 into S107, the upper computer software 12 is according in channel strain-time history curve graph
Data, comparison setting strain threshold frequently load frequency threshold value.If the channel strain value is greater than setting strain threshold, into
Row step (E3), while the long-range monitoring modular 3 stores the channel strain value and time, and passes through the wireless data transmission
Module 11 sends strain feedback signal to the microprocessor 9, and the microprocessor 9 executes the first alarm；If the channel is answered
Variate is less than the strain threshold, then return step (E) executes；
(E3) in step S108 into S109, the channel strain value is greater than the strain threshold, then the host computer is soft
Part 12 draws load number-time history curve graph.If the load number is greater than setting frequently load frequency threshold value, described
Long-range monitoring modular 3 stores the load number-time history curve map analysis as a result, and passing through the wireless data transfer module
11 send frequently load number feedback signal to the microprocessor 9, and the microprocessor executes the second alarm；If the load
Number is less than setting frequently load frequency threshold value, then return step (E) executes.
The foregoing is merely illustrative of the preferred embodiments of the present invention, is not intended to limit the invention, all in essence of the invention
Within mind and principle, any modification, equivalent replacement, improvement and so on be should all be included in the protection scope of the present invention.
Claims (1)
1. a kind of cubic hydraulic press health monitoring systems, it is characterized in that: including that power management module and power management module connect
The signal processing module connect and the long-range monitoring modular being connect with signal processing module；Wherein:
Signal processing module include microprocessor and the strain detecting module being connect respectively with microprocessor, signal conditioning module,
Memory module and wireless data transfer module；Strain detecting module is connect with signal conditioning module, and strain detecting module includes phase
The strain acquirement piece of connection, bridge-type compensation circuit, electronic switch；Signal conditioning module includes the channel amplifier being connected, filter
Wave device and A/D converter；
The power management module provides power supply by industrial alternating current, is converted, is obtained by power conversion module and voltage-reference
It is signal processing module power supply to reliable and stable circuit voltage；
Long-range monitoring modular includes upper computer software, display, memory and printer；
The bridge-type compensation circuit is temperature-compensating plate, two High Precision Low Temperatures float resistance and multiple foil gauges are formed in parallel
The single armed half-bridge circuit of working strain gauge connection composition；Each foil gauge of working strain gauge is connect with the electronic switch, structure
At the faint strain signal acquisition zone of multichannel, the working condition in each channel is controlled by electronic switch, each multichannel is faint to answer
The electricity after flowing is expanded as bridge power supply by triode by voltage-reference in varying signal acquisition zone, and is welded on strain acquirement piece
On；
By being made with cubic hydraulic press same material 35GrMo, 0.2 ~ 3mm's strain acquirement piece of thickness is sticked in cubic apparatus
With cubic hydraulic press stress concentration region corresponding strain occurs for hydraulic press stress concentrated position；
The voltage-reference and bridge-type compensation circuit input terminal expand stream by triode and connect；The work of bridge-type compensation circuit is answered
Become piece and electronic switch input terminal passes through connection；Electronic switch output end by microprocessor I/O mouthful and channel amplifier,
Filter, A/D converter are linked in sequence；
The strain detecting module is attached to cubic hydraulic press stress concentrated position by the strain acquirement piece；Power management mould
Block and signal processing module are logical by wireless data transfer module by connection, long-range monitoring modular and signal processing module
Letter；
The microprocessor selects single-chip microcontroller, and memory module selects SD card, and display selects LCD display, and voltage-reference is adopted
With MAX6175, electronic switch uses CD4053, and channel amplifier uses precision instrument amplifier INA114, and filter is filtered using RC
Wave device, A/D converter is using 24 multichannel, high-precision AD7710 conversion chips；
Its monitoring method, includes the following steps:
(A) cubic hydraulic press health monitoring systems are initialized；
(B) strain detecting module acquires every group of strain acquirement on piece and corresponds to the faint strain signal of working strain gauge test point, and turns
Control is changed in the voltage signal of within a certain error range；
(C) voltage signal is carried out gain, filtering, A/D conversion by signal conditioning module, and then microprocessor control memory module is deposited
Data are stored up, while controlling strain acquirement piece described in every group of electronic switch switching and corresponding to service aisle, return step (B) executes behaviour
Make, circuits sequentially down；
(D) microcontroller control wireless data transfer module timing read memory module data, be sent to long-range monitoring modular with
And timing next time is waited to read；
(E) long-range monitoring modular is established wide area with the wireless data transfer module by privately owned fixed ip address and is connect, and carries out
Data-signal, control signal communication；Receive data, analysis data, storing data, while according to data draw channel strain-when
Between course curve graph and pass through printer printing analysis result；
(E1) upper computer software stores number according to data signal analysis equipment behaviour in service and prediction actual condition fatigue life
It is believed that number and analysis as a result, LCD display display channel strain simultaneously-time history curve graph and expected fatigue life value；
(E2) upper computer software is according to data in channel strain-time history curve graph, comparison setting strain threshold, frequently load
Frequency threshold value；If channel strain value is greater than setting strain threshold, carry out step (E3), while long-range monitoring modular stores this and leads to
Road strain value and time, and strain feedback signal is sent to microprocessor by wireless data transfer module, microprocessor executes
First alarm；If channel strain value is less than strain threshold, return step (E) is executed；
(E3) channel strain value is greater than strain threshold, then upper computer software draws load number-time history curve graph；If load
Number is greater than setting frequently load frequency threshold value, then long-range monitoring modular stores the load number-time history curve map analysis
As a result, and frequently load number feedback signal is sent to microprocessor by wireless data transfer module, microprocessor executes the
Two alarms；If loading number is less than setting frequently load frequency threshold value, return step (E) is executed.
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| CN105742767B (en) * | 2016-05-09 | 2018-07-03 | 桂林电子科技大学 | A kind of Terahertz bandpass filter being adjusted by electrostatic drive |
| CN113536060B (en) * | 2021-06-23 | 2024-04-16 | 上海市计算技术研究所有限公司 | Data acquisition device and method, electronic device and computer storage medium |
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