CN110857687B - Method and device for monitoring the condition of a hydraulic pump - Google Patents

Method and device for monitoring the condition of a hydraulic pump Download PDF

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Publication number
CN110857687B
CN110857687B CN201810972759.4A CN201810972759A CN110857687B CN 110857687 B CN110857687 B CN 110857687B CN 201810972759 A CN201810972759 A CN 201810972759A CN 110857687 B CN110857687 B CN 110857687B
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hydraulic pump
pressure
pressure line
rotational speed
displacement
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CN110857687A (en
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K·皮希勒
R·哈斯
P·巴德尔
F·J·基利安
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Engel Machinery Shanghai Co Ltd
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Engel Machinery Shanghai Co Ltd
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B51/00Testing machines, pumps, or pumping installations

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

The invention relates to a method for condition monitoring of at least one hydraulic pump (2) of a hydraulic system of a molding machine (1), wherein the at least one hydraulic pump (2) is connected to at least one pressure line (3) and is designed to be operated with a displacement volume (v) or a rotational speed in order to provide a pressure in the at least one pressure line (3), wherein the displacement volume (v) or the rotational speed of the at least one hydraulic pump (2) is abruptly changed and the condition of the at least one hydraulic pump (2) is determined by evaluating a temporal response of the pressure (p) in the at least one hydraulic pump (2) and/or the at least one pressure line (3).

Description

Method and device for monitoring the condition of a hydraulic pump
Technical Field
The invention relates to a method and a device for monitoring the state of at least one hydraulic pump of a hydraulic system of a molding machine.
Background
The hydraulic pump wears for different reasons, in particular due to friction on the contact surfaces and increased abrasion due to different sized particles in the hydraulic oil.
In internal gear pumps, this wear can be, for example
-erosion of the contact surfaces between the teeth of the internal and external gears;
-abrasion of the contact surface between the tooth tip and the shim (villsst ü ck);
-abrasion of the contact surfaces between the internal and external gears and the axial sealing gaskets;
erosion of the contact surfaces between the external gear and the housing (radial and axial).
In piston pumps, erosion occurs, for example, in
-between the piston and the cylinder;
-on the accommodation of the cylinder;
-on the control panel.
Wear of the hydraulic pump is further exacerbated by, inter alia, abrasion of metal particles, high rotational speeds, cavitation (Kavitation), poor oil quality and long operating times. The hydraulic pump is therefore a drive system with a certain service life, which should be replaced after a certain time.
The main effect of increasing wear is an increase in leakage from the hydraulic pump. Leakage occurs due to the aforementioned abrasion, which results in an increase in the size of the gap and thus in a deterioration of the seal between the parts.
Methods and devices of this type are known from the following documents:
DE10156927a1 describes a device for controlling and monitoring pumps, in particular screw pumps, in industrial installations. Different operating parameters related to wear are detected by means of sensors and an expected value of the operating time is calculated on the basis of the detected operating parameters. The operating parameters were:
-temperature difference and absolute temperature;
-differential and absolute pressures;
-a back pressure difference and an absolute back pressure;
-absolute suction pressure;
-a flow rate;
-the rotational speed of the motor and the speed of the motor,
-a torque;
-a flow rate;
viscosity of the (hydraulic) medium;
density of the (hydraulic) medium;
electrical parameters of the pump, such as current, voltage, power consumption, phase shift.
DE102005059564a1 shows a device for condition monitoring in a hydrostatic displacement unit in a special axial piston pump. A large amount of sensor data, monitoring data and operating data are analyzed and the state of the machine is diagnosed as a result. Indicating that maintenance may be about to occur on the machine before the machine life expires. The following parameters were monitored here:
-surface vibration;
-hydraulic fluid temperature and leakage oil temperature;
hydraulic fluid conditions (degree of soiling, viscosity value and dielectric constant value);
-the rotational speed of the cylinder;
-the pressure in the high-pressure line and the low-pressure line.
DE102004028643B3 discloses a device for monitoring a pump system having at least one pump. The state variable of the pump is detected by structure-borne sound vibrations of the pump. Impending or existing faults are identified and predicted by the device. The monitored state variables are:
-cavitation;
-dry running;
air content of the (hydraulic) medium;
the condition of the pressure side of the pump (open or closed).
The mentioned methods and devices all require auxiliary sensing devices which are sometimes very expensive.
The monitoring of the displacement mechanism is described in DE102008035954a 1. In this case, the system pressure profile is detected by means of a piston with a changing position and is subsequently compared with an expected system pressure profile in order to determine a malfunction. Furthermore, the predicted damage to the pump is recognized early. This evaluation method is complicated.
Disclosure of Invention
The object of the invention is to provide a method of this type and a device of this type, in which no auxiliary sensor devices and no complex evaluation methods are required.
The object is achieved by a method according to the invention for condition monitoring a hydraulic pump or by a device according to the invention for condition monitoring a hydraulic pump. The invention relates to a method for monitoring the state of at least one hydraulic pump of a hydraulic system of a molding machine, wherein the at least one hydraulic pump is connected to at least one pressure line and is designed to be operated with a displacement or a rotational speed in order to provide a pressure in the at least one pressure line, characterized in that the displacement or the rotational speed of the at least one hydraulic pump is suddenly changed and the state of the at least one hydraulic pump is determined by evaluating the temporal response of the pressure in the at least one hydraulic pump and/or the at least one pressure line, wherein, in order to determine the state of the at least one hydraulic pump, additionally: how large the displacement or the required rotational speed of the at least one hydraulic pump is required for maintaining the static pressure in the at least one hydraulic pump and/or the at least one pressure line.
According to the invention, the displacement or the rotational speed of the at least one hydraulic pump is suddenly changed and the state of the at least one hydraulic pump is determined by evaluating the temporal response of the pressure in the at least one hydraulic pump and/or in the at least one pressure line.
The invention makes it possible to determine the state of at least one hydraulic pump, in particular the leakage (wear measurement). For this purpose, the at least one hydraulic pump is hydraulically decoupled as well as possible from the remaining hydraulic components of the hydraulic system and a leakage measurement is carried out. The better the hydraulic decoupling (for example by a shut-off mechanism, such as a valve that can be shut off), the more accurate the result of the leakage measurement.
Since the wear measurement according to the invention is a leakage measurement, the wear calculation can be inaccurate if there is an unrecognized leakage in the hydraulic system outside the at least one hydraulic pump (for example a leakage at a shut-off element for disconnecting the at least one hydraulic pump) that is not recognized and taken into account.
For monitoring the at least one hydraulic pump, preferably only the pressure and the displacement or the rotational speed of the at least one hydraulic pump are detected. Since sensors are always provided in conventional hydraulic systems, by means of which the pressure and the displacement or the rotational speed in the at least one hydraulic pump and/or the at least one pressure line (for example, the pressure and the rotational speed or the displacement directly at the at least one hydraulic pump or at the valve block with respect to the motor angle and the time) can be determined, the invention can also be implemented without additional sensor devices.
By means of the invention fault limit values can be defined. This may be achieved, for example, by a value provided by the manufacturer of the at least one hydraulic pump, or may be determined by the manufacturer or operator of the molding machine: from which value of the leakage the at least one hydraulic pump only causes unacceptable power.
The determination of the state can be done in different ways on the basis of the method performed according to the invention, for example (alone or in any combination):
by comparison with earlier measurements on the same molding machine;
by comparison with measurements on other molding machines (preferably by comparison with a statistical mean or median);
by comparison with theoretical calculations or computer simulations;
by comparison with the data page value (of the manufacturer).
In a preferred first exemplary embodiment of the method according to the invention, at least the following steps are provided:
-operating the at least one hydraulic pump with a predetermined, preferably constant, profile of the pressure in the at least one hydraulic pump and/or in the at least one pressure line;
-abruptly reducing the displacement or the rotational speed of the at least one hydraulic pump, preferably to a zero value or to a predetermined value, or according to a profile of the pressure in the at least one hydraulic pump and/or the at least one pressure line, when the pressure line is switched off;
-measuring a pressure drop time or determining a quantity characterizing the pressure drop, which is required for the pressure drop in the at least one hydraulic pump and/or the at least one pressure line;
determining the state of the at least one hydraulic pump by evaluating the pressure drop time or a variable characterizing the pressure drop.
If the measured or determined pressure drop is carried out too quickly (i.e. the measured or determined pressure drop is too short), this indicates a leak, which is the main manifestation of wear. The variable characterizing the pressure drop may be, for example, a combination of time and dynamics, for example, a time derivative of the pressure curve may be considered.
In a particularly preferred second embodiment of the method according to the invention, at least the following steps are provided:
-abruptly increasing the displacement or the rotational speed of the at least one hydraulic pump, preferably from zero to a predetermined value, when the pressure line is switched off, or according to a profile of the pressure in the at least one hydraulic pump and/or the at least one pressure line;
-measuring a pressure build-up time or determining a pressure build-up characterizing variable, which is required for the pressure build-up in the at least one hydraulic pump and/or the at least one pressure line;
-determining the state of the at least one hydraulic pump by analyzing a pressure build-up time or a quantity characterizing a pressure build-up.
If the measured or determined pressure buildup is proceeding too slowly (i.e., the measured or determined pressure buildup is too long), this indicates a leak, which is the primary manifestation of wear. The variable characterizing the pressure buildup can be, for example, a combination of time and dynamics, for example, the time derivative of the pressure curve can be taken into account.
The device according to the invention is characterized in that:
an input to which a pressure signal of a pressure sensor of the hydraulic system can be fed;
-a clock providing a time signal;
an evaluation unit, which is connected or can be connected to the input for data transmission and which is designed to determine the state of the at least one hydraulic pump from the pressure signal and the time signal of the clock, preferably by evaluating the temporal response of the pressure in the at least one hydraulic pump and/or the at least one pressure line, according to one embodiment of the method according to the invention.
The pressure line can be shut off by means of a suitable shut-off mechanism, for example by means of a shut-off valve (or a slide valve or the like), which can be arranged in a valve block.
The method according to the invention can be carried out within a few seconds.
The at least one hydraulic pump is preferably automatically measured within a defined measuring period. The initiation of the measurement cycle can be done in different ways (alone or in any combination):
-triggering by a machine control of the molding machine, for example within a determined time interval of operating hours;
-remotely triggered, for example by a cloud or service APP;
-triggered by a service technician or operator of the forming machine;
-triggered by an algorithm.
In one embodiment of the method according to the invention, it is provided that, for determining the state of the at least one hydraulic pump, additionally: how large the rotational speed or displacement of the at least one hydraulic pump is required for maintaining the static pressure in the at least one hydraulic pump and/or the at least one pressure line. The greater the speed or displacement required to maintain a static pressure, the greater the wear or leakage. A possible leakage during the holding of the static pressure can be calculated by a correlation between the leakage and the rotational speed of the at least one hydraulic pump (since the delivery volume of the at least one hydraulic pump is equal to zero when the pressure line is switched off). This is independent of the pump type (in particular whether the displacement is constant or variable).
The invention can be used in fixed displacement pumps (where only the rotational speed is provided as an intervention parameter, since the displacement is constant) or variable displacement pumps (where there are rotational speeds and displacements that may be influenced by the pivot angle adjustment, for example).
The invention is preferably used in internal gear pumps and/or axial piston pumps.
The invention is preferably used in a hydraulic pump regulated with rotational speed and/or in a hydraulic pump regulated with pressure.
The invention is preferably used in a molding machine in the form of a die casting machine, in particular an injection molding machine.
The results of the wear measurements according to the invention can be recorded.
The results of the wear measurement according to the invention can be used in different ways (alone or in any combination):
display the results to the customer (e.g. in the client, control, as Email, in the cloud, …) who can use this information to automatically take other actions (e.g. plan for disassembly or shutdown);
parameters of a given molding machine (e.g. adjustment or control parameters, delivery characteristics of the pump, pre-control parameters for controlled machine movements, switching times of the valves, …);
parameters of a given forming process (e.g. adjustment or control parameters for modifying the forming process, …);
as input for further algorithms (e.g. wear detection of hydraulic components such as valves, cylinders, etc., oil qualification, …);
… for triggering a service engagement application (Serviceeinsatz) or changing a service period
-for analyzing in detail the status of the at least one hydraulic pump;
-determining the efficiency and thus the wear in the at least one hydraulic pump;
-triggering a business process.
Drawings
Embodiments of the invention are discussed with the aid of figures. In the figure:
FIG. 1 is a first molding machine with an apparatus according to the invention;
FIG. 2 is a second molding machine with an apparatus according to the invention;
FIG. 3 is a device according to the invention;
FIG. 4 is a first pressure profile over time;
fig. 5 is a second pressure profile over time.
Detailed Description
Fig. 1 shows a molding machine 1, in particular a die casting machine, with a hydraulic system. For example, only two branches or circuits in the hydraulic system are shown. Each cycle comprises a supply 7, a hydraulic pump 2 which can be driven by a motor 6, a pressure line 3 connected to the hydraulic pump 2, which leads to a component 9 of the molding machine 1 to be supplied with hydraulic oil, and a circuit 8. Each pressure line 3 can be shut off by a switchable valve 4. The valve 4 is arranged, for example, in a valve block 5. The particular configuration of the hydraulic system is not critical.
What is important is a device 10 according to the invention for monitoring the state of a hydraulic pump 2 of a hydraulic system of a molding machine 1. A possible internal structure of the device is shown in fig. 3.
The device 10 receives signals representing the pressure in the pressure line 3 and the hydraulic pump 2 via signal lines. The device can control the motor 6 of the hydraulic pump 2 and the valve 4 of the valve block 5 via signal lines.
In the embodiment shown, the device 10 forms part of the moulding machine 1 and can be implemented, for example, in a machine control of the moulding machine. As shown in the embodiment of fig. 2, the apparatus 10 may also be arranged separately from the molding machine 1, e.g. remotely from the molding machine, and connected with the molding machine 1 (e.g. with the machine control of the molding machine) by the communication unit 14 via a connection transferring data, e.g. a cloud 15.
The device 10 according to fig. 3 has an input 11 to which a pressure signal of a pressure sensor of the hydraulic system and/or a signal for calculating the rotational speed or the displacement v of the hydraulic pump 2 can be supplied, a clock 12 (each device which can output a time signal is understood here to be a clock 12, which need not be a separate component in the device 10 here), an output 16 and an evaluation unit 13. The evaluation unit 13 is connected to the input 11 or, as shown, can be connected to the input 11 in a data-transmitting manner. The evaluation unit is designed to determine the state of the at least one hydraulic pump 2 from the pressure signal of the pressure sensor and the time signal of the clock 12. This may be done as discussed with reference to fig. 4 and/or 5.
Fig. 4 shows a method for condition monitoring of at least one hydraulic pump 2 of a hydraulic system of a molding machine 1 (as shown in fig. 1 and/or 2), wherein the at least one hydraulic pump 2 is connected to at least one pressure line 3 and is designed to be operated with a displacement volume v in order to provide a pressure p in the at least one pressure line 3. The corresponding control commands can be issued by the machine control of the molding machine 1 or by the device 10. Starting from the operation of the at least one hydraulic pump 2 at a constant pressure p in the at least one hydraulic pump 2 and/or the at least one pressure line 3, at least one connection to the at least one hydraulic pump 2 is switched off at a specific point in timeThe pressure line 3 is connected and the displacement v is suddenly reduced, preferably to the value "zero" (both controlled by the device 10 via corresponding control commands). Measuring the pressure drop time t required for the pressure drop in the at least one hydraulic pump 2 and/or in the at least one pressure line 3ab(in the range of hundreds of milliseconds). This takes place in the evaluation unit 13 of the device 10 on the basis of the time signal of the clock 12 and the pressure signal of the pressure sensor. By analysing the pressure drop time tabThe state of the at least one hydraulic pump 2 can be determined in the evaluation unit 13.
Alternatively or additionally, the processing may be performed as shown in fig. 5. At a specific point in time, at least one pressure line 3 connected to the at least one hydraulic pump 2 is shut off and the displacement volume v, preferably zero, is suddenly increased to a predetermined value v (both of which are controlled by the device 10 by corresponding control commands). Measuring the pressure build-up time t required for the pressure build-up in the at least one hydraulic pump 2 and/or in the at least one pressure line 3auf. This takes place in the evaluation unit 13 of the device 10 on the basis of the time signal of the clock 12 and the pressure signal of the pressure sensor. By analysing the pressure build-up time taufThe state of the at least one hydraulic pump 2 can be determined. Alternatively, the displacement v (or the rotational speed) may be increased until a predetermined value of the pressure p in the at least one hydraulic pump 2 and/or in the at least one pressure line 3 is reached.
Additionally, it can be evaluated in the method of fig. 4 and/or 5 for determining the state of the at least one hydraulic pump 2: how high the rotational speed of the at least one hydraulic pump 2 is required for maintaining the static pressure p in the at least one hydraulic pump 2 and/or the at least one pressure line 3. The higher the rotational speed required for maintaining the static pressure p, the greater the leakage.
List of reference numerals
1 Forming machine
2 Hydraulic pump
3 pressure line
4-way valve
5 valve group
6 Motor of hydraulic pump
7 supply end of hydraulic system
8 hydraulic system circuit
9 parts of the forming machine to be supplied with hydraulic oil
10 device for condition monitoring
11 input terminal of device for condition monitoring
12 clock for condition monitoring device
13 evaluation unit for a condition monitoring device
14 communication unit of forming machine
15 cloud
16 output of a device for condition monitoring
p pressure in the pressure line and/or in the hydraulic pump
v displacement
tabTime of pressure drop
taufTime of pressure build-up

Claims (10)

1. Method for condition monitoring of at least one hydraulic pump (2) of a hydraulic system of a molding machine (1), wherein the at least one hydraulic pump (2) is connected to at least one pressure line (3) and is designed to be operated with a displacement (v) or a rotational speed in order to provide a pressure (p) in the at least one pressure line (3), characterized in that the at least one hydraulic pump (2) is operated with a predetermined profile of the pressure (p) in the at least one hydraulic pump (2) and/or in the at least one pressure line (3) starting from which the at least one hydraulic pump (2) is operated, the at least one pressure line connected to the at least one hydraulic pump is switched off at a specific point in time, the displacement (v) or the rotational speed of the at least one hydraulic pump (2) is abruptly changed and the at least one hydraulic pump (2) and/or the at least one pressure line (2) is/are analyzed (v) or the rotational speed is calculated by analyzing the at least one hydraulic pump (2) and/or the at least one pressure line (3) 3) Determining a state of the at least one hydraulic pump (2) in response to the pressure (p) over time, wherein, for determining the state of the at least one hydraulic pump (2), additionally: how large the required displacement (v) or the required rotational speed of the at least one hydraulic pump (2) is for maintaining the static pressure (p) in the at least one hydraulic pump (2) and/or the at least one pressure line (3).
2. The method of claim 1, comprising the steps of:
-abruptly reducing the displacement (v) or the rotational speed of the at least one hydraulic pump (2) when the pressure line (3) is switched off;
-measuring the pressure drop time (t)ab) Or determining a variable which characterizes a pressure drop, which is required for the pressure drop in the at least one hydraulic pump (2) and/or in the at least one pressure line (3);
by analysing the pressure drop time (t)ab) Or a variable which characterizes the pressure drop, to determine the state of the at least one hydraulic pump (2).
3. A method according to claim 1 or 2, comprising the steps of:
-abruptly increasing the displacement (v) or the rotational speed of the at least one hydraulic pump (2) when the pressure line (3) is switched off;
-measuring the pressure build-up time (t)auf) Or determining a variable characterizing a pressure buildup, which is required for the pressure buildup in the at least one hydraulic pump (2) and/or the at least one pressure line (3);
-establishing a time (t) by analyzing the pressureauf) Or a variable characterizing the pressure build-up, to determine the state of the at least one hydraulic pump (2).
4. The method of claim 2, wherein,
the predetermined variation curve is a constant variation curve; and/or
-abruptly reducing the displacement (v) or the rotational speed of the at least one hydraulic pump (2) to a zero value or to a predetermined value when the pressure line (3) is switched off; or suddenly reducing the displacement or the rotational speed of the at least one hydraulic pump according to a profile of the pressure in the at least one hydraulic pump and/or the at least one pressure line.
5. A method according to claim 3, wherein the displacement (v) or the rotational speed of the at least one hydraulic pump is increased abruptly from zero to a predetermined value when the pressure line (3) is switched off, or is increased abruptly in accordance with a profile of the pressure (p) in the at least one hydraulic pump (2) and/or in the at least one pressure line (3).
6. The method according to claim 1 or 2, wherein the results of the method are used individually or in any combination in the manner specified below:
-displaying the results and/or the derived efficiency of the analysis;
-calculating a power loss;
as decision support for maintenance planning;
-parameters of a given forming machine;
-parameters of a given forming process;
-as input to other algorithms;
-for triggering a service application or changing a service period.
7. An arrangement (10) for condition monitoring of at least one hydraulic pump (2) of a hydraulic system of a molding machine (1), wherein the at least one hydraulic pump (2) is connected to at least one pressure line (3) and is configured to be operated with a displacement (v) or a rotational speed in order to provide a pressure (p) in the at least one pressure line (3), characterized in that:
-an input (11) to which a pressure signal of a pressure sensor of the hydraulic system can be fed;
-a clock (12) providing a time signal;
-an evaluation unit (13) which is connected to the input (11) or can be connected to the input (11) for data transmission and which is designed to determine the state of the at least one hydraulic pump (2) from the pressure signal of the pressure sensor and the time signal of the clock (12) by evaluating the temporal response of the pressure (p) in the at least one hydraulic pump (2) and/or the at least one pressure line (3) according to the method according to any one of claims 1 to 6.
8. The device according to claim 7, wherein the evaluation unit (13) is designed to take into account the displacement (v) or the rotational speed of the at least one hydraulic pump (2) for determining the state of the at least one hydraulic pump (2).
9. A molding machine (1) having a hydraulic system with at least one hydraulic pump (2) connected to at least one pressure line (3) and either having a device according to claim 7 or 8 or being connectable to said device for data transmission.
10. The molding machine (1) according to claim 9, wherein the molding machine is a die casting machine.
CN201810972759.4A 2018-08-24 2018-08-24 Method and device for monitoring the condition of a hydraulic pump Active CN110857687B (en)

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CN110857687B true CN110857687B (en) 2022-05-13

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Publication number Priority date Publication date Assignee Title
DE102004005851A1 (en) * 2004-02-06 2005-09-08 Audi Ag Fuel pumping and injection monitoring system for internal combustion engine has circuit with fuel supply pressure sensor and diagnosis value calculating circuit
CN203184622U (en) * 2012-12-30 2013-09-11 宁波弘讯科技股份有限公司 Servo system of die-casting machine
CN106989004A (en) * 2017-04-14 2017-07-28 北京理工大学 A kind of electro-hydraulic pump diagnostic system and method

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