CN105840583A - Liquid level measuring and monitoring device and liquid level measurement method for hydraulic pump - Google Patents
Liquid level measuring and monitoring device and liquid level measurement method for hydraulic pump Download PDFInfo
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- CN105840583A CN105840583A CN201610323893.2A CN201610323893A CN105840583A CN 105840583 A CN105840583 A CN 105840583A CN 201610323893 A CN201610323893 A CN 201610323893A CN 105840583 A CN105840583 A CN 105840583A
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B19/00—Testing; Calibrating; Fault detection or monitoring; Simulation or modelling of fluid-pressure systems or apparatus not otherwise provided for
- F15B19/005—Fault detection or monitoring
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Abstract
The invention relates to the technical field of liquid level detection of liquid, in particular to a liquid level measuring and monitoring device and a liquid level measurement method for a hydraulic pump. The device comprises a hydraulic pump station, an ultrasonic liquid level meter, a signal processing unit, a signal control unit and a signal displayer, and is capable of monitoring the liquid level of as many as 16 sets of hydraulic pump station systems in real time; by adopting the high-precision small-dead-zone ultrasonic liquid level meter, the theoretic precision of the device is 0.3mm, and the actually-measured display precision of the device is 1mm. The device disclosed by the invention is capable of displaying the state of the liquid level in real time and is also capable of intelligently judging change conditions of the liquid level, namely whether the liquid level is drawn down quite quickly or the liquid is gradually leaked. To quite quick drawdown of the liquid level of an oil tank, the device is capable of quickly stopping the work of the hydraulic pump; to slow drawdown of the liquid level, the device is capable of reminding a maintenance man of overhauling and maintenance.
Description
Technical field
The present invention relates to liquid level detection technique field, be concretely a kind of hydraulic pump level gauging supervising device and measuring method.
Background technology
Hydraulic system is by changing pressure increase active force, thus drives the dynamical system of mechanical actuating mechanism or device drives, and particularly significant at modern industry, application is widely.One complete hydraulic system is made up of five parts, i.e. dynamical element, executive component, control element, auxiliary element and hydraulic oil.
Hydraulic Station, as the core drive of hydraulic system, is the heart of hydraulic system.Hydraulic Station is usually the hydraulic power source device being made up of hydraulic pump, drive motor, fuel tank, direction valve, choke valve, overflow valve etc..By the flow direction of driving means requirement, pressure and flow fuel feeding, it is adaptable to what driving means separated with Hydraulic Station various is mechanically connected Hydraulic Station with driving means oil pipe, and hydraulic system can realize the action of various regulation.
The working media of Hydraulic Station is hydraulic oil.In actual use, due to fluid pressure line hydraulic system structure problem, the factor of Hydraulic Station working environment, or hydraulic package such as sealing ring, hydraulic valve or hydraulic joint aging etc. so that Hydraulic Station occurs hydraulic joint seepage, hydraulic fluid leak at work, oil pipe burst, the problem that oil cylinder seepage and burst inefficacy etc. have a strong impact on Hydraulic Station work.The generation of these situations so that the quick loss of Hydraulic Station hydraulic oil, not only produces the biggest economic waste, also contributes to working environment and ecological environment.If Hydraulic Station works long hours in the case of not having hydraulic oil will greatly damage hydraulic oil pump and hydraulic electric motor.Therefore extremely important to the reliable and stable work of whole Hydraulic Station to the liquid level monitoring of Hydraulic Station, simultaneously if able to quickly find seepage or the quickly hydraulic flat surface decline of hydraulic oil, not only can save substantial amounts of hydraulic oil and be also beneficial to environmental protection.
General installation content gauge on Hydraulic Station, this content gauge has upper and lower bound, is used for identifying the minimum fuel needed for the maximum hydraulic pressure oil oil mass of Hydraulic Station fuel tank addition hydraulic power unit and Hydraulic Station steady operation.This content gauge is not provided that information feedback timely, if spot check is not in place or the not careful pole of work, it is more likely that be all to find Hydraulic Station cisco unity malfunction after hydraulic pressure oil leakage is complete, then report for repairment.
Therefore design a kind of supervising device that can reflect Hydraulic Station liquid level real time information in time and detection method is significantly in actual applications.
Summary of the invention
The present invention breaches a difficult problem for prior art and devises a kind of supervising device that can reflect Hydraulic Station liquid level real time information in time and detection method.
In order to achieve the above object, the present invention devises a kind of hydraulic pump level measuring method, it is characterised in that: measure in accordance with the following steps:
Step 1: open hydraulic pump level gauging supervising device, and initialize；
Step 2: set hydraulic pump liquid level extreme higher position as LEVELmax, minimum LEVELmin；
Step 3: hydraulic pump level gauging supervising device starts to measure liquid surface level, and signal measurement obtained is transferred to signal processing unit, signal processing unit by measurement to signal carry out row AD conversion, and obtain preliminary level measurement through over-fitting, and this preliminary level measurement is corrected according to sensor characteristics, it is thus achieved that level gauging data；
Step 4: the storage that level gauging data acquisition DataLoad software carries out data link table processes, and obtains data result one；
Step 5: data result one is transferred to DataCheck and carries out data check, determines that data result one is between LEVELmin to LEVELmax；
Step 6: the data after qualified for verification are smoothed；
Step 7: the data after first time smoothing processing are carried out derivation process；
Step 8: after derivation in step 7 being processed, data are smoothed；
Step 9: the data after second time smoothing processing are carried out again derivation process, obtains liquid level data；
Step 10: liquid level data is carried out liquid level change and differentiates；
Step 11: the differentiation result of step 10 is fed back and stored.
The present invention have also been devised a kind of hydraulic pump level gauging supervising device simultaneously, including hydraulic power unit, ultrasonic liquid leveller, signal processing unit, signaling control unit and Signal Monitor, it is characterized in that: the fixed above of described hydraulic power unit is provided with ultrasonic liquid leveller, one end of ultrasonic liquid leveller uses signal connecting line to be connected with signal processing unit, the side of signal processing unit is provided with Signal Monitor, the lower section of hydraulic power unit is provided with signaling control unit, the side of signaling control unit is provided with signal processing unit, another signal connecting line is used to be connected between signal processing unit with signaling control unit.
During the change of described liquid level differentiates, it determines method is as follows:
Step a: data are weighted average computation:
, wherein liFor the numerical value after being weighted averagely, αiFor weighted average coefficients, the fluid value that wherein the i moment measures；
Step b: data are carried out variance calculating:
, wherein, leveljt' it is the variance of liquid level rate of change, levelavg' it is weighted average rate of change, βiFor weighted variance coefficient.li' it is level change rate；
Step c: integrating step a and step b, differentiates liquid level change.
Described weighted average coefficients；
Described weighted average rate of change；
Described level change rate, the quantity of employing in the frequency i.e. unit interval that wherein Fr is sampling, Δ t is the time interval of sampling, and js is batten parameter.
The step of described smoothing processing is as follows:
Step 1: data or the peak-data jumped occurs in the data after extraction verification is qualified, is set to abnormal data；
Step 2: 5 data front to abnormal data do average treatment, obtain front mean values；
Step 3: after abnormal data 5 data are done average treatment, obtains rear mean values；
Step 4: front mean values is added with rear mean values, is averaging the most again, obtain replacement data；
Step 5: the replacement data utilizing step 4 to draw replaces abnormal data, completes smoothing processing.
The derivation formula that described derivation processes is, the quantity of employing in the frequency i.e. unit interval that wherein Fr is sampling, Δ t is the time interval of sampling, and js is batten parameter.
The L port of described signaling control unit, N-port and electric fuse F2One end be connected, electric fuse F2The other end of double-pole switch is connected with the three phase supply interface of motor, the P of signaling control unitEnullPort ground connection，The L+ port of signaling control unit is connected with the L+ port of signal processing unit，The M port of signaling control unit is connected with the M port of signal processing unit，The MPI port of signal processing unit connects Signal Monitor，The digital output port one of signal processing unit is connected with 24V power supply，The digital output port two of signal processing unit is connected with one end of bulb PL1，The digital output port three of signal processing unit is connected with one end of bulb PL2，The digital output port four of signal processing unit is connected with one end of bulb PL3，The digital output port five of signal processing unit is connected with one end of bulb PL4，The digital output port six of signal processing unit is connected with one end of coil K1，The digital output port seven of signal processing unit is connected with one end of coil K2，The other end of described bulb PL1-PL4 and coil K1、The other end of K2 is all connected with ground，The digital quantity input port one of signal processing unit is connected with the A+ port of ultrasonic liquid leveller，The digital quantity input port two of signal processing unit is connected with the A-port of ultrasonic liquid leveller.
Described K1, K2 are miniature relay.
In described signaling control unit, the three phase supply interface of motor is divided into U1, V1, W1, described U1, V1, W1 all with electric fuse F1One end be connected, electric fuse F1The other end be connected with one end of catalyst KM1 switch contact, the other end of catalyst KM1 switch contact is connected with one end of thermal protector FR1, the other end of thermal protector FR1 is connected with three-phase drive motor, the earth terminal of three-phase drive motor is connected with ground, described U1 port separates a road and is connected with one end of relay switch K, the other end of relay switch K is connected with one end of the normally opened contact of K1, the other end of K1 normally opened contact is connected with one end of K2 normally opened contact, the other end of K2 normally opened contact is connected with one end of catalyst KM1 coil, the other end ground connection of catalyst KM1 coil.
The present invention compared with prior art, can make the liquid level of up to 16 set hydraulic power unit systems monitor in real time；Use high accuracy small blind zone supersonic tank gage, its theoretical precision 0.3mm, actual display precision of measuring is 1mm, and the present invention can not only show fluid level condition in real time, and can intelligent decision liquid level situation of change: it is to decline the most rapidly, or in gradually seepage.Decline to very fast fuel tank liquid level, it is possible to go the work of fast shut-off hydraulic pump；Declining liquid level at a slow speed reminds maintainer overhaul and safeguard.
Accompanying drawing explanation
Fig. 1 is assembly of the invention structural representation.
Fig. 2 is assembly of the invention circuit connection diagram one.
Fig. 3 is assembly of the invention circuit connection diagram two.
Detailed description of the invention
In conjunction with accompanying drawing, the present invention is described further.
Seeing Fig. 1, Fig. 2 and Fig. 3, the present invention devises a kind of hydraulic pump level measuring method, it is characterised in that: measure in accordance with the following steps:
Step 1: open hydraulic pump level gauging supervising device, and initialize；
Step 2: set hydraulic pump liquid level extreme higher position as LEVELmax, minimum LEVELmin；
Step 3: hydraulic pump level gauging supervising device starts to measure liquid surface level, and signal measurement obtained is transferred to signal processing unit, signal processing unit by measurement to signal carry out row AD conversion, and obtain preliminary level measurement through over-fitting, and this preliminary level measurement is corrected according to sensor characteristics, it is thus achieved that level gauging data；
Step 4: the storage that level gauging data acquisition DataLoad software carries out data link table processes, and obtains data result one；
Step 5: data result one is transferred to DataCheck and carries out data check, determines that data result one is between LEVELmin to LEVELmax；
Step 6: the data after qualified for verification are smoothed；
Step 7: the data after first time smoothing processing are carried out derivation process；
Step 8: after derivation in step 7 being processed, data are smoothed；
Step 9: the data after second time smoothing processing are carried out again derivation process, obtains liquid level data；
Step 10: liquid level data is carried out liquid level change and differentiates；
Step 11: the differentiation result of step 10 is fed back and stored.
The present invention have also been devised a kind of hydraulic pump level gauging supervising device, including hydraulic power unit 2, ultrasonic liquid leveller 1, signal processing unit 4, signaling control unit 3 and Signal Monitor 5, the fixed above of described hydraulic power unit 2 is provided with ultrasonic liquid leveller 1, one end of ultrasonic liquid leveller 1 uses signal connecting line to be connected with signal processing unit 4, the side of signal processing unit 4 is provided with Signal Monitor 5, the lower section of hydraulic power unit 2 is provided with signaling control unit 3, the side of signaling control unit 3 is provided with signal processing unit 4, another signal connecting line is used to be connected between signal processing unit 4 with signaling control unit 3.
During liquid level change in the present invention differentiates, it determines method is as follows:
Step a: data are weighted average computation:
, wherein liFor the numerical value after being weighted averagely, αiFor weighted average coefficients, the fluid value that wherein the i moment measures；
Step b: data are carried out variance calculating:
, wherein, leveljt' it is the variance of liquid level rate of change, levelavg' it is weighted average rate of change, βiFor weighted variance coefficient.li' it is level change rate；
Step c: integrating step a and step b, differentiates liquid level change.
Weighted average coefficients in the present invention；
Weighted average rate of change in the present invention；
Level change rate in the present invention, the quantity of employing in the frequency i.e. unit interval that wherein Fr is sampling, Δ t is the time interval of sampling, and js is batten parameter.
In the present invention, the step of smoothing processing is as follows:
Step 1: data or the peak-data jumped occurs in the data after extraction verification is qualified, is set to abnormal data；
Step 2: 5 data front to abnormal data do average treatment, obtain front mean values；
Step 3: after abnormal data 5 data are done average treatment, obtains rear mean values；
Step 4: front mean values is added with rear mean values, is averaging the most again, obtain replacement data；
Step 5: the replacement data utilizing step 4 to draw replaces abnormal data, completes smoothing processing.
The derivation formula that in the present invention, derivation processes is, the quantity of employing in the frequency i.e. unit interval that wherein Fr is sampling, Δ t is the time interval of sampling, and js is batten parameter.
The L port of signaling control unit 3, N-port and electric fuse F in the present invention2One end be connected, electric fuse F2The other end be connected with the three phase supply interface 6 of motor, the P of signaling control unit 3EnullPort ground connection，The L+ port of signaling control unit 3 is connected with the L+ port of signal processing unit 4，The M port of signaling control unit 4 is connected with the M port of signal processing unit 4，The MPI port of signal processing unit 4 connects Signal Monitor 5，Digital output port one 4-1 with the 24V power supply of signal processing unit 4 is connected，One end of digital output port two 4-2 and the bulb PL1 of signal processing unit 4 is connected，One end of digital output port three 4-3 and the bulb PL2 of signal processing unit 4 is connected，One end of digital output port four 4-4 and the bulb PL3 of signal processing unit 4 is connected，One end of digital output port five 4-5 and the bulb PL4 of signal processing unit 4 is connected，One end of digital output port six 4-6 and the coil K1 of signal processing unit 4 is connected，One end of digital output port seven 4-7 and the coil K2 of signal processing unit 4 is connected，The other end of described bulb PL1-PL4 and coil K1、The other end of K2 is all connected with ground，Digital quantity input port one 4-11 of signal processing unit 4 is connected with the A+ port of ultrasonic liquid leveller 1，Digital quantity input port two 4-12 of signal processing unit 4 is connected with the A-port of ultrasonic liquid leveller.
In the present invention, K1, K2 are miniature relay.
The three phase supply interface 6 stating motor in signaling control unit in the present invention is respectively U1, V1, W1, described U1, V1, W1 all with electric fuse F1One end be connected, electric fuse F1The other end be connected with one end of catalyst KM1 switch contact, the other end of catalyst KM1 switch contact is connected with one end of thermal protector FR1, the other end of thermal protector FR1 is connected with three-phase drive motor, the earth terminal of three-phase drive motor is connected with ground, described U1 port separates a road and is connected with one end of relay switch K, the other end of relay switch K is connected with one end of the normally opened contact of K1, the other end of K1 normally opened contact is connected with one end of K2 normally opened contact, the other end of K2 normally opened contact is connected with one end of catalyst KM1 coil, the other end ground connection of catalyst KM1 coil.
In being embodied as, the working hydraulic pressure 7Mpa of hydraulic power unit, single-pump flow are set
50L/min, Electric Machine at Pumping Station 7.5KW, use SHZ-T20 ultrasonic liquid leveller and SIEMENS S7-300 control system.
Open hydraulic pump liquid level detection device of the present invention, and initialize system, then system is configured:
Systematic parameter is set: high level 850mm minimum liquid level 350mm；
System criterion is set: quickly critical point 30000 and at a slow speed critical point 10；
Strategy after warning is set: fast leak then fast shut-off hydraulic pump motor, slow leakage is then reported to the police.
Starting hydraulic pump makes K1, K2 obtain electric, and the work of hydraulic pump liquid level detection device starts.
Starting to measure liquid level data, data measurement obtained are saved in the data storage area of control system through Data correction, then calculate rate of change li ' according to the formula mentioned above-mentioned in the present invention；
Judge li ' rate of change numerical value:
(1) if it exceeds set maximum
30000, then be judged as the fast leak of the situations such as booster, cut off K1, K2, then hydraulic pump motor shuts down, and alarm lamp PL1 flashes；
(2) if it exceeds at a slow speed marginal value 30 and less than set quick marginal value 30000, then be judged as that slow leak, alarm lamp PL1 light, PL2 flash, do not cut off hydraulic pump motor；
(3) judging minimum and high level situation, if it exceeds marginal value, cut off K1, K2, hydraulic pump motor shuts down, and PL1 lights, and PL3 flashes warning.
Carrying out artificial interference process for three of the above alarm condition, after having processed, hydraulic pump liquid level detection device continues to return DATA REASONING.
Claims (10)
1. a hydraulic pump level measuring method, it is characterised in that: measure in accordance with the following steps:
Step 1: open hydraulic pump level gauging supervising device, and initialize；
Step 2: set hydraulic pump liquid level extreme higher position as LEVELmax, minimum LEVELmin；
Step 3: hydraulic pump level gauging supervising device starts to measure liquid surface level, and signal measurement obtained is transferred to signal processing unit, signal processing unit by measurement to signal carry out row AD conversion, and obtain preliminary level measurement through over-fitting, and this preliminary level measurement is corrected according to sensor characteristics, it is thus achieved that level gauging data；
Step 4: the storage that level gauging data acquisition DataLoad software carries out data link table processes, and obtains data result one；
Step 5: data result one is transferred to DataCheck and carries out data check, determines that data result one is between LEVELmin to LEVELmax;
Step 6: the data after qualified for verification are smoothed；
Step 7: the data after first time smoothing processing are carried out derivation process；
Step 8: after derivation in step 7 being processed, data are smoothed；
Step 9: the data after second time smoothing processing are carried out again derivation process, obtains liquid level data；
Step 10: liquid level data is carried out liquid level change and differentiates；
Step 11: the differentiation result of step 10 is fed back and stored.
2. a hydraulic pump level gauging supervising device, including hydraulic power unit, ultrasonic liquid leveller, signal processing unit, signaling control unit and Signal Monitor, it is characterized in that: the fixed above of described hydraulic power unit (2) is provided with ultrasonic liquid leveller (1), one end of ultrasonic liquid leveller (1) uses signal connecting line to be connected with signal processing unit (4), the side of signal processing unit (4) is provided with Signal Monitor (5), the lower section of hydraulic power unit (2) is provided with signaling control unit (3), the side of signaling control unit (3) is provided with signal processing unit (4), another signal connecting line is used to be connected between signal processing unit (4) with signaling control unit (3).
A kind of hydraulic pump level measuring method the most according to claim 1, it is characterised in that: during the change of described liquid level differentiates, it determines method is as follows:
Step a: data are weighted average computation:
, wherein liFor the numerical value after being weighted averagely, αiFor weighted average coefficients, the fluid value that wherein the i moment measures；
Step b: data are carried out variance calculating:
, wherein, leveljt' it is the variance of liquid level rate of change, levelavg' it is weighted average rate of change, βiFor weighted variance coefficient；li' it is level change rate；
Step c: integrating step a and step b, differentiates liquid level change.
A kind of hydraulic pump level measuring method the most according to claim 3, it is characterised in that: described weighted average coefficients；Described weighted average rate of change。
A kind of hydraulic pump level measuring method the most according to claim 3, it is characterised in that: described level change rate, the quantity of employing in the frequency i.e. unit interval that wherein Fr is sampling, Δ t is the time interval of sampling, and js is batten parameter.
A kind of hydraulic pump level measuring method the most according to claim 1, it is characterised in that: the step of described smoothing processing is as follows:
Step 1: data or the peak-data jumped occurs in the data after extraction verification is qualified, is set to abnormal data；
Step 2: 5 data front to abnormal data do average treatment, obtain front mean values；
Step 3: after abnormal data 5 data are done average treatment, obtains rear mean values；
Step 4: front mean values is added with rear mean values, is averaging the most again, obtain replacement data；
Step 5: the replacement data utilizing step 4 to draw replaces abnormal data, completes smoothing processing.
A kind of hydraulic pump level measuring method the most according to claim 1, it is characterised in that: the derivation formula that described derivation processes is, the quantity of employing in the frequency i.e. unit interval that wherein Fr is sampling, Δ t is the time interval of sampling, and js is batten parameter.
A kind of hydraulic pump level gauging supervising device the most according to claim 2, it is characterised in that: the L port of described signaling control unit (3), N-port and electric fuse F2One end be connected, electric fuse F2The other end be connected with the three phase supply interface (6) of motor, the P of signaling control unit (3)EnullPort ground connection，The L+ port of signaling control unit (3) is connected with the L+ port of signal processing unit (4)，The M port of signaling control unit (4) is connected with the M port of signal processing unit (4)，The MPI port of signal processing unit (4) connects Signal Monitor (5)，The digital output port one (4-1) of signal processing unit (4) is connected with 24V power supply，The digital output port two (4-2) of signal processing unit (4) is connected with one end of bulb PL1，The digital output port three (4-3) of signal processing unit (4) is connected with one end of bulb PL2，The digital output port four (4-4) of signal processing unit (4) is connected with one end of bulb PL3，The digital output port five (4-5) of signal processing unit (4) is connected with one end of bulb PL4，The digital output port six (4-6) of signal processing unit (4) is connected with one end of coil K1，The digital output port seven (4-7) of signal processing unit (4) is connected with one end of coil K2，The digital output port nine (4-9) of signal processing unit (4) is connected with one end of coil K4，The digital output port ten (4-10) of signal processing unit (4) is connected with one end of coil K5，The other end of described bulb PL1-PL4 and coil K1、The other end of K2 is all connected with ground，The digital quantity input port one (4-11) of signal processing unit (4) is connected with the A+ port of ultrasonic liquid leveller (1)，The digital quantity input port two (4-12) of signal processing unit (4) is connected with the A-port of ultrasonic liquid leveller.
A kind of hydraulic pump level gauging supervising device the most according to claim 7, it is characterised in that: described K1, K2 are miniature relay.
A kind of hydraulic pump level gauging supervising device the most according to claim 7, it is characterised in that: the three phase supply interface (6) of described motor is divided into U1, V1, W1, described U1, V1, W1 all with electric fuse F1One end be connected, electric fuse F1The other end be connected with one end of catalyst KM1 switch contact, the other end of catalyst KM1 switch contact is connected with one end of thermal protector FR1, the other end of thermal protector FR1 is connected with three-phase drive motor, the earth terminal of three-phase drive motor is connected with ground, described U1 port separates a road and is connected with one end of relay switch K, the other end of relay switch K is connected with one end of the normally opened contact of K1, the other end of K1 normally opened contact is connected with one end of K2 normally opened contact, the other end of K2 normally opened contact is connected with one end of catalyst KM1 coil, the other end ground connection of catalyst KM1 coil.
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Application publication date: 20160810 |