CN111473021A - Fluid leakage detection method and device - Google Patents
Fluid leakage detection method and device Download PDFInfo
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- CN111473021A CN111473021A CN202010277416.3A CN202010277416A CN111473021A CN 111473021 A CN111473021 A CN 111473021A CN 202010277416 A CN202010277416 A CN 202010277416A CN 111473021 A CN111473021 A CN 111473021A
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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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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M3/00—Investigating fluid-tightness of structures
- G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
- G01M3/26—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors
- G01M3/32—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for containers, e.g. radiators
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Abstract
The invention discloses a fluid leakage detection method, which judges whether leakage exists or not by acquiring the volume increment of oil in an oil tank and the sum of the volume increments of the oil in all oil cylinders within a certain period of time and comparing the volume increments with the allowable leakage. The invention also discloses a fluid leakage detection method and a device, wherein the device comprises a liquid level detection module, a liquid level detection module and a liquid level detection module, wherein the liquid level detection module is arranged in the hydraulic oil tank and is used for detecting the height of oil in the hydraulic oil tank and converting the height of the oil into an electric signal; the displacement detection module is arranged in the hydraulic oil cylinder and used for monitoring the displacement of the hydraulic oil cylinder and converting the displacement into an electric signal; the control module inputs a set value, and calculates and compares the set value with the set value; and the alarm module is connected with the control module and used for alarming. The invention provides a fluid leakage detection method and a device, which can find whether a hydraulic system has leakage and leakage amount in time, are very suitable for equipment with complex systems, more pipelines and poor use working condition environment, and have simple structure and easy realization.
Description
Technical Field
The invention relates to the technical field of leakage testing, in particular to a method and a device for detecting fluid leakage in a hydraulic system.
Background
The hydraulic system is the core of power transmission and automatic control, and generally consists of a hydraulic oil tank, a power element (such as a pump), an actuator (such as a cylinder and a motor), a control element (such as a battery valve) and a hydraulic pipeline. In practical application, the applicant finds that the leakage phenomenon of a hydraulic system which has more hydraulic elements and pipelines and contains an oil cylinder as an execution element is not easy to find, and particularly in a mixed environment of mud, water, oil stain and the like, a plurality of interference elements influence the observation of the leakage phenomenon. Once the leakage phenomenon can be directly observed by naked eyes, the leakage is possibly developed to a serious condition, the maintenance difficulty is increased sharply, and the oil liquid waste is serious.
Based on this, the applicant aims to design and develop a fluid leakage detection method and device, which can detect whether a hydraulic system leaks or not, and timely carry out overhaul and maintenance by prejudging in advance so as to prevent further aggravation of leakage.
Disclosure of Invention
The invention provides a fluid leakage detection method for overcoming the problems in the prior art, which can find whether a hydraulic system has leakage and leakage amount in time, is very suitable for equipment with complex system, multiple pipelines and poor use working condition environment, and has simple structure and easy realization. Meanwhile, the invention also provides a fluid leakage detection method and device, and leakage detection is carried out through cooperation among all the modules.
The technical scheme adopted by the invention is as follows:
the fluid leakage detection method comprises the steps of collecting the oil volume increment of a hydraulic oil tank and the sum of the oil volume increments in all oil cylinders within a certain period of time, and comparing the sum with the allowable leakage amount to judge whether a hydraulic system has a leakage condition.
Further, a method of fluid leak detection comprising the steps of
(1) Obtaining a sampling initial value
Acquiring liquid level height L0 of oil in hydraulic oil tank at initial acquisition timet0；
Acquiring the stroke L1 of all hydraulic cylinders at the initial acquisition timet0、L2t0、···Lnt0；
(2) Sampling
Acquiring liquid level height L0 of oil in hydraulic oil tank at acquisition timet1；
Acquiring the stroke L1 of all hydraulic cylinders at the initial acquisition timet1、L2t1、···Lnt1；
(3) Obtaining total increment of oil volume
Oil increment of hydraulic oil tank
Wherein S is the cross-sectional area of oil at d L;
oil increment of hydraulic oil cylinder
ΔVOil cylinder t1＝(L1t1-L1t0)*S1+(L2t1-L2t0)*S2+(Lnt1-Lnt0)*Sn，
Wherein S1、S2、···SnThe diameter of the piston rod of the corresponding oil cylinder;
total increment of oil delta Vt1＝ΔVOil tank t1+ΔVOil cylinder t1；
(4) Leak determination
Comparison of | Δ Vt1I and VminIn which V isminIs the minimum allowed leakage;
if Δ Vt1|>VminIf the leakage exists, alarming and prompting;
if Δ Vt1|≤VminThere is no leakage.
Further, when leakage occurs, the actual leakage Δ VActual t1≈|ΔVt1|±ΔVAccuracy of measurement，ΔVAccuracy of measurementDependent on hydraulic system construction and sensing elementThe accuracy of (2).
Further, when the hydraulic oil tank is in a rectangular parallelepiped shape, Δ VOil tank t1＝(L0t1-L0t0)*S0Wherein S is0Is the bottom area inside the oil tank.
The fluid leakage detection method and device comprise
The liquid level detection module is arranged in the hydraulic oil tank and used for detecting the height of oil in the hydraulic oil tank and converting the oil into an electric signal;
the displacement detection module is arranged in the hydraulic oil cylinder and used for monitoring the displacement of the hydraulic oil cylinder and converting the displacement into an electric signal;
a control module for inputting a set point including, but not limited to, Vmin、ΔVAccuracy of measurement(ii) a Receiving the signals sent by the liquid level detection module and the displacement detection module, and calculating delta V according to the signalsOil tank t1、ΔVOil cylinder t1And Δ Vt1(ii) a Comparison of Δ Vt1And VminJudging whether leakage occurs and the actual leakage amount
And the alarm module is connected with the control module and used for alarming.
Further, the device also comprises a display module.
Further, the alarm module may be replaced with a display module.
The invention has the beneficial effects that:
(1) in order to solve the problem that leakage of a hydraulic system is not easy to find due to external environment interference in the prior art, the invention designs a fluid leakage detection method, which judges whether leakage exists or not by acquiring the volume increment of oil in a hydraulic oil tank and the sum of the volume increments of oil in all oil cylinders within a certain period of time and comparing the sum with the allowable leakage. The method can find out whether the hydraulic system has leakage and leakage amount in time, is very suitable for equipment with complex system, multiple pipelines and poor use working condition environment, and is simple and easy to realize.
(2) The invention designs a fluid leakage detection device based on a fluid leakage detection method, which comprises a liquid level detection module, a displacement detection module, a control module, an alarm module and the like, and samples and analyzes a hydraulic system in real time through initial value setting, so that the leakage condition of the hydraulic system can be pre-judged in advance, the leakage condition is prevented from being further rapid, and the normal operation of the hydraulic system is also protected.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative efforts.
Fig. 1 is a schematic view of a connection structure of a hydraulic system in embodiment 1 of the present invention.
Fig. 2 is a schematic structural diagram of a propulsion system in embodiment 2 of the present invention.
FIG. 3 is a schematic view of the construction of the hinge system according to embodiment 2 of the present invention
Fig. 4 is a logical structure diagram of a fluid leakage detection apparatus according to embodiment 3 of the present invention.
Detailed Description
In the following, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
In the description of the present invention, it is to be understood that the terms "central," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," and the like are used in the orientations and positional relationships indicated in the drawings for convenience in describing the invention and to simplify the description, and are not intended to indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and are not to be considered limiting of the invention.
The following disclosure provides many different embodiments or examples for implementing different features of the invention. To simplify the disclosure of the present invention, the components and arrangements of specific examples are described below. Of course, they are merely examples and are not intended to limit the present invention.
The following describes in detail embodiments of the present invention with reference to the accompanying drawings.
Example 1
The hydraulic system is the core of power transmission and automatic control, and generally consists of a hydraulic oil tank, power components (such as a pump), actuators (such as a cylinder and a motor), control components (such as a solenoid valve) and a hydraulic pipeline, as shown in fig. 1.
In a common hydraulic system, a hydraulic component causing a liquid level change of a hydraulic oil tank is generally a cylinder, and the rest of power components, control components and pipelines are in a full oil state. If the part of the element is not full of oil, corresponding measures are needed to ensure that the part is full of oil. Based on this, the leakage detection method in this embodiment is applicable, and by acquiring the sum of the oil volume increase of the hydraulic oil tank and the oil volume increases of all the oil cylinders at a certain time and comparing the sum with the allowable leakage amount, whether the hydraulic system has a leakage condition is judged.
Specifically, the fluid leakage detection method of the present embodiment includes
(1) Obtaining a sampling initial value
Acquiring liquid level height L0 of oil in hydraulic oil tank at initial acquisition timet0。
Acquiring the stroke L1 of all hydraulic cylinders at the initial acquisition timet0、L2t0···Lnt0。
(2) Sampling
Acquiring liquid level height L0 of oil in hydraulic oil tank at acquisition timet1。
Acquiring the stroke L1 of all hydraulic cylinders at the initial acquisition timet1、L2t1···Lnt1。
(3) Obtaining total increment of oil volume
Oil increment of hydraulic oil tank
Wherein S is the cross-sectional area of the oil at d L.
If the hydraulic oil tank is in a rectangular parallelepiped shape, Δ VOil tank t1＝(L0t1-L0t0)*S0Wherein S is0Is the bottom area of the oil tank.
Oil quantity increment delta V of hydraulic oil cylinderOil cylinder t1＝(L1t1-L1t0)*S1+(L2t1-L2t0)*S2+(Lnt1-Lnt0)*SnIn which S is1、S2、···SnIs the diameter of the piston rod of the corresponding oil cylinder.
Considering that the inside of other parts, such as a pump, a motor, a control element, a pipeline and the like, is always full of oil during normal operation, the increment change is zero.
Total increment of oil delta Vt1＝ΔVOil tank t1+ΔVOil cylinder t1。
(4) Leak determination
Comparison of | Δ Vt1I and VminIn which V isminThe minimum value of the leakage is allowed, and the design can be carried out according to the requirements of actual requirements and detection precision.
If Δ Vt1|>VminIf the leakage exists, the alarm is given.
Actual leakage Δ VActual t1≈|ΔVt1|±ΔVAccuracy of measurement，ΔVAccuracy of measurementDepending on the hydraulic system configuration and the accuracy of the sensing elements.
If Δ Vt1|≤VminThere is no leakage.
The fluid leakage detection method can be used for monitoring whether leakage and leakage amount exist in the hydraulic system in time, is very suitable for equipment with complex systems, multiple pipelines and poor use working condition environment, and is simple and easy to implement.
Example 2
In the present embodiment, a hydraulic system in a shield machine is taken as an example, and the hydraulic system used for the shield machine is analyzed. The system which can cause the liquid level change of the hydraulic oil tank on the shield machine mainly comprises a propelling system and a hinging system, and the hydraulic oil absorbed or released by other systems is very little, so that only two systems of propelling and hinging need to be considered.
As shown in fig. 2, a propulsion system of a certain shield tunneling machine is composed of 16 groups of 32 oil cylinders, wherein displacement sensors for measuring displacement of the oil cylinders are respectively arranged at the upper, lower, left and right sides of the propulsion system, the specifications of the oil cylinders are 240/200-2250, mounting points of all the oil cylinders are on the same plane, the oil cylinders are perpendicular to the mounting plane, and according to actual working conditions, floating points (oil cylinder supporting surfaces) of all the oil cylinders are also on the same plane basically during normal propulsion operation of the shield tunneling machine.
As shown in fig. 3, the hinged system of the shield tunneling machine is composed of 14 oil cylinders, No. 3, 7, 11, 14 oil cylinders are respectively provided with a displacement sensor for measuring the displacement of the oil cylinder, and the specification of the hinged oil cylinder is 210/100-150; the fixed points at the two ends of all the oil cylinders are respectively positioned in the same plane.
The hydraulic system of the shield machine is provided with a hydraulic oil tank with larger capacity, the oil tank in the embodiment has the specification of 4000mm (length) 1100mm (width) 1200mm (height), a high-precision liquid level sensor is arranged in the oil tank, and a hysteresis type displacement sensor is selected in the embodiment, and the precision is 0.5 per mill.
Because the stroke difference of the propulsion system and the hinging system is small when the shield machine normally tunnels, the calculation can be simplified, and the strokes of all the propulsion and hinging oil cylinders respectively take the average value of 4 displacement sensors and set as LPropulsion by air，LHinge jointOil tank level LOil tank(the propulsion displacement and the hinge displacement are average values of four displacement sensors of a propulsion system and a hinge system).
Cross section area S of oil tankOil tank＝4*1.1＝4.4m2；
Sectional area S of piston rod of propulsion oil cylinderPropulsion rod＝3.1415*(0.2/2)2＝3.142*10-2m2；
Sectional area S of piston rod of articulated oil cylinderHinged rod＝3.1415*(0.1/2)2＝7.854*10-3m2；
(1) Obtaining a sampling initial value
After the equipment is operated and debugged, presetting initial values (the time is T0) through a reset button of a human-computer interaction interface, taking sampling conversion data of propelling displacement, hinging displacement and oil tank liquid level at the time of T0 as initial values, and respectively recording the initial values as LPush t0，LHinge t0，LOil tank t0。
(2) Sampling
After pressing the reset button, the P L C control system begins to sample and calculate in real time.
Setting a time T1 at which the sampling conversion data of the propulsion displacement, the hinge displacement and the oil tank liquid level are LPush t1，LHinge t1，LOil tank t1。
(3) Obtaining oil volume increase
Increment value of volume of oil in hydraulic oil tank at time T1:
ΔVoil tank t1＝(LOil tank t1-LOil tank t0)*SOil tank
Oil volume increment value of the propulsion cylinder at time T1:
ΔVpush t1＝32*(LPush t1-LPush t0)*SPropulsion rod
Oil volume increment value of the hinged oil cylinder at T1:
ΔVhinge t1＝14*(LHinge t1-LHinge t0)*SHinged rod
Total oil increase at time T1:
ΔVtotal increment of＝ΔVOil tank t1+ΔVPush t1+ΔVHinge t1
(4) And (3) measuring and judging oil leakage amount:
|ΔVtotal increment of|>Vmin
VminIf the above formula is established, the oil leakage is judged, and an alarm signal is sent through the man-machine interaction interface to allow the minimum value of the leakageAnd a leakage value of △ VPractice ofTo the operator.
VminAccording to the function of the hydraulic system of the shield machine, except that a propulsion system and an articulation system contain a large number of oil cylinders, the systems of an erector, a sheet feeder, a screw machine and the like contain a small number of oil cylinders with smaller specifications, because the part of the oil cylinders are not provided with stroke detection devices, Vmin is set to be 30L according to the maximum error calculation and the precision of a displacement sensor, and because the total oil quantity of the hydraulic system of the shield machine is about 4500L, the detection sensitivity can reach 6.7 permillage.
Actual leakage amount Δ VPractice of≈|ΔVTotal increment of|±ΔVAccuracy of measurementIn the present embodiment, the leak detection accuracy is about Δ VAccuracy of measurementIs 18L.
If at a certain moment, LPush t0＝1m LHinge t0＝0.08 LOil tank t0＝0.8m
LPush t1＝1.5 LHinge t1＝0.1 LOil tank t1＝0.65m
Then, Δ VOil tank t1＝(LOil tank t1-LOil tank t0)*SOil tank＝-0.66m3
ΔVPush t1＝32*(LPush t1-LPush t0)*SPropulsion rod＝0.503m3
ΔVHinge t1＝14*(LHinge t1-LHinge t0)*SHinged rod＝0.002m3
ΔVTotal increment of＝ΔVOil tank t1+ΔVPush t1+ΔVHinge t1＝-0.155m3I.e. Δ VTotal increment ofis-155L. | Δ VTotal increment of|>VminAnd leakage occurs, alarm prompt is given, and the machine needs to be stopped immediately for maintenance.
The actual leakage △ V is actually ≈ 155L ± 18L.
Example 3
Based on the fluid leakage detecting method in example 1 or example 2, an embodiment of the present invention is a fluid leakage detecting apparatus, as shown in fig. 4, including a liquid level detecting module, a displacement detecting module, a control module, a display module, and an alarm module.
Specifically, the liquid level detection module is installed in the hydraulic oil tank and used for detecting the height of oil in the hydraulic oil tank and converting the oil into an electric signal.
And the displacement detection module is arranged in the hydraulic oil cylinder and used for monitoring the displacement of the hydraulic oil cylinder and converting the displacement into an electric signal.
A control module for inputting a set point including, but not limited to, Vmin、ΔVAccuracy of measurement(ii) a Receiving the signals sent by the liquid level detection module and the displacement detection module, and calculating delta V according to the signalsOil tank t1、ΔVOil cylinder t1And Δ Vt1(ii) a Comparison of | Δ Vt1I and VminAnd judging whether oil leaks or not.
And the display module is connected with the control module and displays the segment judgment result.
And the alarm module is connected with the control module and warns in a sound, light, character and other modes.
The device in the present embodiment operates according to the following principle:
a high-precision liquid level detection module is arranged on a hydraulic oil tank and used for measuring the volume increment change of oil in the hydraulic oil tank, a displacement detection module is additionally arranged on a hydraulic oil cylinder of an execution element and used for measuring the volume increment change of the oil in the oil cylinder, and whether leakage exists or not is judged by calculating the sum of the volume increment changes of the oil and the oil.
Example 4
Based on the fluid leakage detection method in example 1 or example 2, one embodiment of the present invention, a fluid leakage detection apparatus, comprises
And the liquid level sensor is mounted in the hydraulic oil tank, and is used for detecting the oil height in the hydraulic oil tank and converting the oil height into an electric signal.
The oil cylinder displacement sensor is a KYDM type oil cylinder and is arranged in the hydraulic oil cylinder and used for monitoring the displacement of the hydraulic oil cylinder and converting the displacement into an electric signal.
And a P L C controller, model 6ES73121AE140AB0, inputs set values, receives electric signals of the liquid level sensor and the oil cylinder displacement sensor, calculates, compares and judges the electric signals.
And the audible and visual alarm, the type DC-8X, is connected with the P L C controller, and gives an alarm prompt when the P L C controller judges that leakage exists in advance.
And the industrial display, the model P L M-1501T, is connected with the P L C controller and displays the detection result of the image or character mode.
Claims (7)
1. A method of fluid leak detection, characterized by: and in a certain period of time, the sum of the oil volume increment in the oil tank and the oil volume increments in all the oil cylinders is acquired and compared with the allowable leakage amount, and whether the leakage condition exists in the hydraulic system is judged.
2. The fluid leak detection method according to claim 1, characterized in that: the steps include
(1) Obtaining a sampling initial value
Acquiring the liquid level height L0 of oil in the oil tank at the initial acquisition timet0；
Acquiring the stroke L1 of all hydraulic cylinders at the initial acquisition timet0、L2t0、···Lnt0；
(2) Sampling
Acquiring liquid level height L0 of oil in hydraulic oil tank at acquisition timet1；
Acquiring the stroke L1 of all hydraulic cylinders at the initial acquisition timet1、L2t1、···Lnt1；
(3) Obtaining total increment of oil volume
Oil increment of hydraulic oil tank
Wherein S is the cross-sectional area of the oil at d L;
oil increment of hydraulic oil cylinder
ΔVOil cylinder t1＝(L1t1-L1t0)*S1+(L2t1-L2t0)*S2+(Lnt1-Lnt0)*Sn，
Wherein S1、S2、···SnThe diameter of the piston rod of the corresponding oil cylinder;
total increment of oil delta Vt1＝ΔVOil tank t1+ΔVOil cylinder t1；
(4) Leak determination
Comparison of | Δ Vt1I and VminIn which V isminIs the minimum allowed leakage;
if Δ Vt1|>VminIf the leakage exists, alarming and prompting;
if Δ Vt1|≤VminThere is no leakage.
3. The fluid leak detection method according to claim 2, characterized in that: when a leak occurs.
ΔVActual t1≈|ΔVt1|±ΔVAccuracy of measurement，ΔVAccuracy of measurementDepending on the hydraulic system configuration and the accuracy of the sensing elements.
4. The fluid leak detection method according to claim 2, characterized in that: when the hydraulic oil tank is cuboid, delta VOil tank t1＝(L0t1-L0t0)*S0Wherein S is0Is the bottom area inside the oil tank.
5. Fluid leakage detection device, its characterized in that: the device comprises
The liquid level detection module is arranged in the hydraulic oil tank and used for detecting the height of oil in the hydraulic oil tank and converting the oil into an electric signal;
the displacement detection module is arranged in the hydraulic oil cylinder and used for monitoring the displacement of the hydraulic oil cylinder and converting the displacement into an electric signal;
a control module for inputting a set point including, but not limited to, Vmin、ΔVAccuracy of measurement(ii) a Receiving the signals sent by the liquid level detection module and the displacement detection module, and calculating delta V according to the signalsOil tank t1、ΔVOil cylinder t1And Δ Vt1(ii) a Comparison of | Δ Vt1I andVminjudging whether leakage exists or not and the actual leakage amount;
and the alarm module is connected with the control module and used for alarming.
6. The fluid leak detection device according to claim 5, wherein: the device also includes a display module.
7. The fluid leak detection device according to claim 5, wherein: the alarm module can be replaced by a display module.
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Cited By (3)
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| CN112879388A (en) * | 2021-02-04 | 2021-06-01 | 中铁工程装备集团有限公司 | Abnormal leakage detection method for hydraulic system |
| CN112879389A (en) * | 2021-02-04 | 2021-06-01 | 中铁工程装备集团有限公司 | Abnormal leakage detection system of hydraulic system |
| CN114323493A (en) * | 2021-12-29 | 2022-04-12 | 广东南曦液压机械有限公司 | Automatic detection device and detection method for tiny leakage flow |
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| CN114323493A (en) * | 2021-12-29 | 2022-04-12 | 广东南曦液压机械有限公司 | Automatic detection device and detection method for tiny leakage flow |
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Application publication date: 20200731 |