CN109238335B - Sensor fault judgment method - Google Patents
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Abstract
The invention discloses a sensor fault judging method, wherein the sensor is used for a device with a stretching and/or rotating mechanism, and the method comprises the following steps: the device sends an action output signal which can cause the signal change of the sensor to the stretching and/or rotating mechanism, a delay relay is started, the mechanism action time recorded by the delay relay exceeds the delay relay, and the change value of the signal of the sensor is smaller than a first set value, so that the sensor is judged to have a fault. The method can identify the situations that the pulling rope is stuck, the signal detection module has faults or other conditions which cause the output value of the sensor to be kept fixed, wherein the situations cannot be identified by the conventional fault judgment method.
Description
Technical Field
The invention relates to the technical field of automatic control, in particular to a sensor fault judgment method.
Background
During the working process of the aerial work platform, a single (double) channel sensor is usually used for detecting the position of a structural part, and the position is processed by a controller to ensure that the aerial work platform is always in a safe state. In order to meet the requirement, besides real-time monitoring processing of the sensor acquisition value, real-time monitoring of whether the sensor itself has a fault is also needed. When the sensor is detected to have a fault, the controller limits the platform to act and only allows the platform to act towards a safe direction, such as arm support retraction, amplitude-variable falling, slow rotation and the like, so that the platform is separated from an unsafe state, and safe operation is ensured. Thus, sensor fault signals are closely associated with safety control of the aerial work platform.
In the prior art, the fault of the sensor is mainly judged by the following two schemes: 1. when the single (double) channel sensor adopts analog quantity output, the real-time judgment of the sensor fault is carried out by setting an analog digital conversion value (AD value) of the sensor or a limit value (including a minimum value, a maximum value and a tolerance value between two channels) of an actual value, namely when the AD value or the actual value of the sensor is smaller than the minimum value, the AD value or the actual value is larger than the maximum value or the difference between the AD value and the actual value of the two channels is larger than the tolerance value, the sensor is judged to have the fault; 2. when the single (double) channel sensor adopts Controller Area Network (CAN) communication output, the CAN communication heartbeat detection of the sensor is added on the basis of the former scheme to judge the fault of the sensor, namely the Controller judges that the sensor has fault if the CAN communication heartbeat monitored by the Controller is not changed within a certain time (the time CAN be freely set and is generally set within a few seconds).
However, in these determination schemes, the detection device of the sensor itself is not diagnosed, and when the detection device of the sensor itself fails (for example, the rope pulling mechanism of the length sensor is stuck, and the sensor signal detection and processing module fails), so that the AD value remains unchanged during operation, or exceeds the value in the original normal state during operation, but is within the set limit value range, at this time, the controller considers that the sensor is in the normal state, and the operation limitation under the sensor failure is not performed, which will bring great potential safety hazards to the operators and the equipment.
Therefore, the method for realizing real-time judgment of the fault state of the sensor is significant to develop.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the sensor fault judging method is used for realizing the instant fault judgment of the sensor in the abnormal state on the basis of the existing hardware without increasing the cost.
In order to solve the technical problems, the invention adopts the technical scheme that: a sensor fault judging method includes sending out action output signal capable of causing sensor signal change to telescopic and/or rotary mechanism, starting delay relay, judging that sensor fault exists if mechanism action time recorded by delay relay exceeds said delay relay and sensor signal change value is less than first set value.
Further, the method also comprises the step of judging whether to start the time delay relay: when one of the following conditions does not exist in the action output signal causing the sensor signal change, the time delay relay is started:
a. the action output signal is a signal generated after the device action exceeds a safety limit position or is carried out to a limit position of the device structure operation;
b. no signal to start the engine or power unit is detected;
c. the action output current is less than the minimum current.
Further, the extreme positions comprise length extreme positions and/or angle extreme positions.
Further, the setting factor of the first set value includes one or more of safety of the device structure, detection accuracy of the AD value, an actual value, an operation speed, and a response speed corresponding state.
Furthermore, the setting factors of the delay time comprise the safety state before and after the mechanism acts, the action speed and/or the response speed; preferably, the delay time when the action is just started can be slightly prolonged, such as 4-5S, and the delay time after the action is normally operated is about 3S.
Further, when the sensor is a length sensor, the method further comprises the step of increasing the comparison between the real-time AD value of the sensor or the converted real-time actual value and the calibration AD value or the calibration actual value of the sensor during calibration within the angle range in which the telescopic mechanism of the device can be fully extended: and judging whether the difference between the real-time AD value and the calibrated AD value or the difference between the real-time actual value and the calibrated actual value is respectively smaller than the corresponding second set value, and judging that the sensor has a fault.
Further, if the length sensor is used, the second set value can be specifically determined according to the actual condition, and preferably, for the actual value, the second set value is 5-10 cm; for the AD value, the second setting value may be determined with reference to the AD value corresponding to the desired setting actual value. If the angle sensor is used, the second set value can be specifically determined according to the actual condition, and for the actual value, the second set value is preferably 0.3-0.5 degrees; for the AD value, the second setting value may be determined with reference to the AD value corresponding to the desired setting actual value.
Further, when the sensor adopts CAN communication, the method also comprises the step of using the communication function of the controller to carry out real-time data diagnosis on the basis of monitoring the heartbeat of the CAN communication: and when the return value of the communication function is an abnormal value specified by the function, judging that the sensor has a fault.
Further, the device is an aerial work platform and the like.
The invention has the beneficial effects that: the scheme of the invention can diagnose the clamping stagnation of the pull rope, the fault of the signal detection module or other faults which can not be diagnosed by the conventional fault judging method and cause the output value of the sensor to be unchanged (or in a set limit value interval), and the invention increases the real-time fault judging step under the abnormal working state of the sensor on the basis of the conventional judgment, thereby improving the fault judging range of the sensor and ensuring the safe operation of the aerial work platform to be more stable and reliable by improving the fault diagnosing coverage rate of the sensor.
Drawings
Fig. 1 is a diagram illustrating an operation state of a length sensor according to a first embodiment of the present invention;
FIG. 2 is a flowchart illustrating a determination process of the length sensor according to the first embodiment of the present invention;
fig. 3 is a diagram illustrating an operating state of an angle sensor according to a second embodiment of the present invention;
description of reference numerals:
1. a length sensor; 2. a first main arm; 3. a first work bar; 4. an angle sensor; 5. a second main arm; 6. a second work bar; 7. a turntable.
Detailed Description
In order to explain technical contents, achieved objects, and effects of the present invention in detail, the following description is made with reference to the accompanying drawings in combination with the embodiments.
A sensor malfunction determination method for an apparatus having a telescopic and/or rotary mechanism, comprising the steps of: the device sends an action output signal which can cause the signal change of the sensor to the stretching and/or rotating mechanism, a delay relay is started, the mechanism action time recorded by the delay relay exceeds the delay relay, and the change value of the signal of the sensor is smaller than a first set value, so that the sensor is judged to have a fault.
From the above description, the beneficial effects of the present invention are: the scheme of the invention can diagnose the stay cord jamming or the signal detection module fault which cannot be diagnosed by the conventional fault judgment method, and the range of the fault judgment of the sensor is enlarged by adding the step of judging the instant fault under the abnormal working state of the sensor on the basis of the conventional judgment, and the safety operation of the aerial work platform is more stable and reliable by improving the fault diagnosis coverage rate of the sensor.
Further, the method also comprises the step of judging whether to start the time delay relay: when one of the following conditions does not exist in the action output signal causing the sensor signal change, the time delay relay is started: 1) the action output signal is a signal generated after exceeding a safety limit position or proceeding to a limit position of the device structure operation;
2) no signal to start the engine or power unit is detected;
3) and the action output current is less than the minimum current.
Further, the extreme positions comprise length extreme positions and/or angle extreme positions.
Further, the setting factor of the first set value includes one or more of safety of the device structure, detection accuracy of the AD value, an actual value, an operation speed, and a response speed corresponding state.
Furthermore, the setting factors of the delay time comprise the safety state before and after the mechanism acts, the action speed and/or the action speed response speed; preferably, the delay time when the action is just started can be slightly prolonged, such as 4-5S, and the delay time after the action is normally operated is about 3S.
Further, when the sensor is a length sensor, the sensor fault judgment method further comprises a comparison step of increasing a real-time AD value or a converted real-time actual value of the sensor and a calibration AD value or a calibration actual value of the sensor during calibration within an angle range in which a telescopic mechanism of the device can be fully extended: and judging whether the difference between the real-time AD value and the calibrated AD value or the difference between the real-time actual value and the calibrated actual value is smaller than a corresponding second set value, and if so, judging that the sensor has a fault.
From the above description, the beneficial effects of the present invention are: through the comparison step of increasing the AD value or the converted actual value of the sensor and the AD value or the actual value of the sensor during calibration, the problem that the fault judgment cannot be accurately carried out when the sensor is stretched and stuck but can still normally stretch and contract is solved, and other faults causing the output value of the sensor to be unchanged (or in a set limit value interval) can be diagnosed.
Further, if the length sensor is used, the second set value can be specifically determined according to the actual condition, and preferably, for the actual value, the second set value is 5-10 cm; for the AD value, the second setting value may be determined with reference to the AD value corresponding to the desired setting actual value. If the angle sensor is used, the second set value can be specifically determined according to the actual condition, and for the actual value, the second set value is 0.3-0.5 degrees; for the AD value, the second setting value may be determined with reference to the AD value corresponding to the desired setting actual value.
From the above description, the beneficial effects of the present invention are: the second set value is set according to actual needs and is mainly used for reducing the probability of misjudgment, when the second set value is too small, misjudgment is easy to cause, and when the second set value is too large, the safety of the arm support is affected, and when the comparison result is true, a fault is determined to exist, and maintenance is required.
Further, when the sensor adopts CAN communication, the method also comprises the step of using the communication function of the controller to carry out real-time data diagnosis on the basis of monitoring the heartbeat of the CAN communication: and when the return value of the communication function is an abnormal value specified by the function, judging that the sensor has a fault.
From the above description, the beneficial effects of the present invention are: for the sensor adopting CAN communication, on the basis of monitoring CAN communication heartbeat, a communication function of the controller CAN be used for real-time data diagnosis, the diagnosis range is expanded, and when the return value of the communication function is not the normal value specified by the function (under the normal condition, the function returns to the normal value of 0 or 1 to be the normal state, different controllers have different specifications), the communication or the value of the sensor is considered to be abnormal, and the fault judgment of the sensor is made.
Further, the device is an aerial work platform and the like.
The first embodiment of the invention is as follows: a sensor fault judgment method is characterized in that a sensor is a length sensor 1 and is used for an aerial work platform, and the method comprises the following steps: judging whether to start a delay relay according to an action output signal causing the signal change of the sensor; and if the mechanism action time recorded by the time delay relay exceeds the time delay relay and the sensor signal change value is smaller than a first set value after the time delay relay is started, judging that the sensor has a fault.
Referring to fig. 1, if a stay rope is stuck, a signal detection module is failed or other conditions causing a sensor output value to be kept fixed occur at a point a of a length sensor 1 (such as a length sensor 1 for stay rope ranging, laser ranging or magnetic induction ranging) in an aerial work platform (including a first main arm 2 and a first working column 3 which are connected with each other), an AD value or a converted actual value of the sensor is Y1(the value is larger than the limit range), when the arm support of the first main arm 2 extends to the point B, the AD value of the sensor or the actual value after conversion is still Y1(the value of B point in the normal state is Y2) If the sensor is diagnosed according to the scheme in the prior art, the controller cannot judge that the sensor is in the fault state, so that the fault state can be identified only by the judging method of the scheme in the invention.
Normally, when the boom of the first main arm 2 extends from the point a to the point B or retracts from the point B to the point a, the length of the boom inevitably changes. Taking an actual output signal in the extending or retracting process of the arm support as a condition to start the time delay relay t1When the delay time t is exceeded1(setting according to actual conditions, considering boom safety state before and after action, action speed and the like, and setting too long is not suitable, and the value is about 3s generally), A, B points of sensor AD value or converted actual value Y1And Y2The difference is less than the set value K1(generally, 50 to 100 values can be obtained for the AD value and about 10cm can be obtained for the actual value) by setting the value in consideration of the safety of the structure, the detection accuracy of the AD value, the conversion of the length of the actual value, and the like, and it is considered that there is a problem in the sensor value and a sensor failure occurs.
And (3) perfecting judgment conditions, and in order to avoid misjudgment, not judging the fault by considering the following conditions:
1) when the first main arm 2 extends to the maximum operation curve length to limit the action, the fault judgment is not carried out;
2) the first main arm 2 retracts to the fully retracted state, and the fault judgment is not carried out;
3) when the engine or the power unit is not started, the fault judgment is not carried out;
4) the failure determination is not performed when the action output current is less than the minimum current because there is no actual action when the current is less than the minimum current.
When the length sensor 1 is still normally stretched and jammed (the sensor output value changes), the following steps can be added for further discrimination: as shown in fig. 2, the AD value or the converted actual value Y of the sensor is set within the angle range in which the main arm can be fully extended1From the calibrated AD value or actual value Y0Making a comparison, i.e. determining Y1Whether or not Y is greater than or equal to0+K2(K2According to the practical setting, the method is used for reducing the probability of misjudgment, the misjudgment is easily caused when the probability is too small, the safety of the arm support is affected when the probability is too large, generally, the value is preferably 50-100), and when the comparison result is true, the sensor is considered to have a fault, and the requirement for maintenance is prompted.
The second embodiment of the invention is as follows: a method of failure of a sensor, which differs from the first embodiment in that the sensor is an angle sensor 4.
As shown in fig. 3, if the angle sensor 4 in the aerial work platform (including the second main arm 5 and the second work bar 6 connected to each other) installed on the turntable 7 has a signal detection module failure or other conditions causing the sensor output value to remain fixed at the first position point, the sensor AD value or the converted actual value is Y3(the value is in the range of the limit value), when the amplitude of the arm support is increased to the second position point, the AD value of the sensor or the converted actual value is still Y3(assume that the value of the second position point is Y in the normal state4) No change occurs. At this time, if the prior art scheme is still adopted, the controller cannot judge the sensorIs already in a fault state and can therefore only be identified by the inventive solution.
Normally, when the arm support of the second main arm 5 is changed in amplitude from the first position point to the second position point or from the second position point to the first position point, the angle of the arm support of the second main arm 5 is inevitably changed. Taking the actual output signal of the amplitude variation of the second main arm 5 as a condition to start the delay relay t2When the delay time t is exceeded2(setting according to actual conditions, considering boom safety state before and after action, action speed and the like, and setting too long, generally taking about 3 s), AD values of the first position point sensor and the second position point sensor or converted actual value Y3And Y4The difference is less than the set value K3(the value is set by comprehensively considering the conditions of the safety of the structure, the detection precision of the AD value, the corresponding angle of the actual value and the like, the AD value can be taken to be 50-100 under the general condition (different sensors can be distinguished), and the actual value can be taken to be about 0.5 degrees), the problem of the sensor value is considered to exist, and the sensor fault occurs.
And (3) perfecting a judgment condition, and not judging the fault under the following conditions in order to avoid misjudgment: 1) when the amplitude of the main arm is changed to the maximum angle or the minimum angle; 2) when the engine or the power unit is not started; 3) the failure determination is not performed when the action output current is smaller than the minimum current because there is no actual action when the current is smaller than the minimum current.
The third embodiment of the invention is as follows: a sensor failure determination method, which is different from the first embodiment in that: the sensor adopts CAN communication to transmit data, so that the sensor CAN be diagnosed by the following method in the fault judgment process: on the basis of monitoring the CAN communication heartbeat, the communication function of the controller is used for real-time data diagnosis so as to enlarge the diagnosis range. If the return value of the communication function is not the normal value specified by the function (under normal conditions, the return value 0 or 1 of the function is in a normal state, and the normal value can be specified differently according to different controllers), the communication or the value of the sensor is considered to be abnormal, and the sensor fault judgment is made.
The minimum current is the minimum current value required by the mechanism to complete corresponding actions. The first, second and third setting values are not limited to distinguish the setting values, and the values may be the same or different. In the present invention, the operation speed refers to a speed during the operation of the device, and the response speed refers to a speed during the period from the stationary state to before the start of the operation of the device.
In summary, the sensor fault judgment method provided by the invention can identify the situations that the output value of the sensor is kept fixed due to the clamping stagnation of the pull rope, the fault of the signal detection module or other conditions which cannot be identified by the conventional fault judgment method, and the safety of the aerial work platform adopting the scheme of the invention is higher.
The above description is only an embodiment of the present invention, and not intended to limit the scope of the present invention, and all equivalent changes made by using the contents of the present specification and the drawings, or applied directly or indirectly to the related technical fields, are included in the scope of the present invention.
Claims (7)
1. A sensor fault judgment method is characterized by comprising the following steps: the sensor is used for a device having a telescoping and/or rotating mechanism, the method comprising the steps of: the device sends an action output signal which can cause the signal change of the sensor to the stretching and/or rotating mechanism, a delay relay is started, the mechanism action time recorded by the delay relay exceeds the delay time set by the delay relay, and the change value of the signal of the sensor is smaller than a first set value, so that the sensor is judged to have a fault; the method also comprises the step of judging whether to start the time delay relay: when one of the following conditions does not exist in the action output signal causing the sensor signal change, the time delay relay is started:
a. the action output signal is a signal generated after the device action exceeds a safety limit position or is carried out to a limit position of the device structure operation;
b. no signal to start the engine or power unit is detected;
c. the action output current is less than the minimum current.
2. The sensor malfunction determination method according to claim 1, characterized in that: the extreme positions comprise length extreme positions and/or angle extreme positions.
3. The sensor malfunction determination method according to any one of claims 1-2, characterized in that: the setting factors of the first set value include one or more of the safety of the device structure, the detection precision of the AD value, the actual value, the action speed and the response speed corresponding state.
4. The sensor malfunction determination method according to any one of claims 1-2, characterized in that: the setting factors of the delay time comprise the safety state before and after the mechanism acts, the action speed and/or the response speed.
5. The sensor malfunction determination method according to any one of claims 1-2, characterized in that: when the sensor is a length sensor, the sensor fault judgment method further comprises the step of comparing the real-time AD value or the converted real-time actual value of the sensor with the calibrated AD value or the calibrated actual value of the sensor during calibration within the angle range in which the telescopic mechanism of the device can be fully extended: and judging whether the difference between the real-time AD value and the calibrated AD value or the difference between the real-time actual value and the calibrated actual value is smaller than a corresponding second set value, and if so, judging that the sensor has a fault.
6. The sensor malfunction determination method according to any one of claims 1-2, characterized in that: when the sensor adopts CAN communication, the method also comprises the step of using the communication function of the controller to carry out real-time data diagnosis on the basis of monitoring the heartbeat of the CAN communication: and when the return value of the communication function is an abnormal value specified by the function, judging that the sensor has a fault.
7. The sensor malfunction determination method according to any one of claims 1-2, characterized in that: the device is an aerial work platform.
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Address after: 410600 Jinzhou Avenue East 128, Ningxiang hi tech Industrial Park, Changsha, Hunan Applicant after: Hunan Xingbang Intelligent Equipment Co.,Ltd. Address before: 410600 Jinzhou Avenue East 128, Ningxiang hi tech Industrial Park, Changsha, Hunan Applicant before: HUNAN SINOBOOM HEAVY INDUSTRY Co.,Ltd. |
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Denomination of invention: A sensor fault judgment method Effective date of registration: 20220112 Granted publication date: 20210112 Pledgee: Agricultural Bank of China Limited Ningxiang sub branch Pledgor: Hunan Xingbang Intelligent Equipment Co.,Ltd. Registration number: Y2022430000002 |
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Date of cancellation: 20231110 Granted publication date: 20210112 Pledgee: Agricultural Bank of China Limited Ningxiang sub branch Pledgor: Hunan Xingbang Intelligent Equipment Co.,Ltd. Registration number: Y2022430000002 |