CN112727853A - Early warning system and early warning method for operation faults of air cylinder - Google Patents
Early warning system and early warning method for operation faults of air cylinder Download PDFInfo
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- CN112727853A CN112727853A CN202011550214.8A CN202011550214A CN112727853A CN 112727853 A CN112727853 A CN 112727853A CN 202011550214 A CN202011550214 A CN 202011550214A CN 112727853 A CN112727853 A CN 112727853A
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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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- 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
- F15B21/00—Common features of fluid actuator systems; Fluid-pressure actuator systems or details thereof, not covered by any other group of this subclass
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Abstract
The invention discloses a cylinder operation fault early warning system, which comprises: the data analysis unit comprises a data analysis module and a human-computer interaction module; the first trigger device is arranged at the top dead center of the cylinder piston, the second trigger device is arranged at the bottom dead center of the cylinder piston, the first trigger device and the second trigger device send trigger signals to the data acquisition module, the data acquisition module acquires preset data according to the trigger signals, and the data acquisition module sends the preset data to the data analysis unit; the data analysis module receives preset data and judges whether to send an early warning signal according to a preset judgment rule, and the human-computer interaction module displays early warning information on a human-computer interaction interface according to the early warning signal. The invention also discloses a cylinder operation fault early warning method.
Description
Technical Field
The invention relates to the field of automobiles, in particular to a cylinder operation fault early warning system. The invention also relates to a cylinder operation fault early warning method.
Background
The cylinder is a cylindrical metal part which guides the piston to do linear reciprocating motion in the cylinder, and is a pneumatic actuating element which converts the pressure energy of compressed gas into mechanical energy in pneumatic transmission. From the conventional conception, the cylinder and the electric actuator are always considered to be automatic products belonging to two completely different fields, but in recent years, with the increasing degree of electrification, the electric actuator is slowly immersed into the pneumatic field, and the cylinder and the electric actuator are competitive and complementary in application.
The cylinder can reliably work under severe conditions, is simple to operate and can basically realize maintenance-free operation. The cylinder is good at reciprocating linear motion, and is particularly suitable for linear conveying of workpieces which are the most transmission requirements in industrial automation. Further, stable speed control can be simply achieved by adjusting only the one-way throttle valves installed at both sides of the cylinder, which also becomes the largest feature and advantage of the cylinder driving system. Therefore, for users without multi-point positioning requirements, the cylinder is most preferred from the aspect of convenience in use.
At present, the automatic assembly production line mostly adopts a pneumatic mode to complete required equipment actions, and a control program of the equipment realizes the accurate and orderly operation of the whole set of equipment by acquiring position signals of a driving element or an executing element. The cylinder can not be monitored in the normal production process, and cylinder faults are mostly concentrated on cylinder gas leakage, cylinder operation, cylinder clamping stagnation and the like, but the accurate preventive maintenance can not be carried out on the cylinder faults at present, and the trend management can not be carried out on the operation state of the cylinder.
Disclosure of Invention
The invention aims to provide a cylinder operation fault early warning system. The invention also provides a system and a method for early warning the operation fault of the cylinder.
In order to solve the technical problem, the invention provides a cylinder operation fault early warning system, which comprises: the data analysis unit comprises a data analysis module and a human-computer interaction module;
the first trigger device is arranged at the top dead center of the cylinder piston, the second trigger device is arranged at the bottom dead center of the cylinder piston, the first trigger device and the second trigger device send trigger signals to the data acquisition module, the data acquisition module acquires preset data according to the trigger signals, and the data acquisition module sends the preset data to the data analysis unit;
the data analysis module receives preset data and judges whether to send an early warning signal according to a preset judgment rule, and the human-computer interaction module displays early warning information on a human-computer interaction interface according to the early warning signal.
The cylinder operation fault early warning system is further improved, and the preset data is the time actually required by the cylinder piston stroke to complete one cycle.
The cylinder operation fault early warning system is further improved, and the data analysis module displays the actual time required for completing one cycle of the cylinder piston stroke on the man-machine interaction module through a time curve.
The cylinder operation fault early warning system is further improved, the preset judgment rule comprises the steps of comparing the standard time required by the stroke of the piston of the cylinder to complete one cycle with the actual time required by the stroke of the piston of the cylinder to complete one cycle, judging that the cylinder has no operation fault if the two times are equal, and judging that the cylinder has the operation fault if the actual time required by the stroke of the piston of the cylinder to complete one cycle is longer than the standard time required by the stroke of the piston of the cylinder to complete one cycle, and sending out operation fault early warning.
The cylinder operation fault early warning system is further improved, the preset judgment rule comprises the steps of comparing the standard time required by the stroke of the piston of the cylinder to complete one cycle with the actual time required by the stroke of the piston of the cylinder to complete one cycle, judging that the cylinder has no operation fault if the two times are equal, judging that the cylinder has the operation fault if the actual time required by the stroke of the piston of the cylinder to complete one cycle is longer than the standard time required by the stroke of the piston of the cylinder to complete one cycle and the actual time required by the stroke of the piston of the cylinder to complete one cycle is longer than an early warning threshold value, and sending out.
The cylinder operation fault early warning system is further improved, and the first triggering device and the second triggering device are position sensors.
The cylinder operation fault early warning system is further improved, and data exchange is carried out between the data acquisition unit and the data analysis unit by adopting TCP communication.
Wherein the operation faults include cylinder leakage, cylinder blow-by and cylinder sticking.
The invention provides a cylinder operation fault early warning method, which comprises the following steps:
1) calibrating the standard time required by the stroke of the cylinder piston to complete one cycle;
2) acquiring the actual time required by the stroke of the piston of the cylinder to complete one cycle;
3) and comparing the standard time with the actual time, judging that the cylinder has no operation fault if the actual time is equal to the standard time, and judging that the cylinder operates if the actual time is greater than the standard time to send out an operation fault early warning.
And further improving the early warning method for the operation faults of the cylinder, comparing the standard time with the actual time when the step 3) is executed, judging that the cylinder has no operation faults if the actual time is equal to the standard time, judging that the cylinder has the operation faults if the actual time is greater than the standard time and the actual time is greater than an early warning threshold value, and sending out an operation fault early warning.
Wherein the operation faults include cylinder leakage, cylinder blow-by and cylinder sticking.
The cylinder operation fault early warning system comprises two parts which are named as a data acquisition unit and a data analysis unit respectively, wherein the data acquisition unit comprises a first trigger device, a second trigger device and a data acquisition module, and the data analysis unit comprises a data analysis module and a human-computer interaction module. The data acquisition unit and the data analysis unit adopt TCP communication to carry out data interaction, the communication time is short, the real-time performance is strong, and the application is wide.
The data acquisition unit collects signals of two in-place position sensors (top dead center and bottom dead center) at the front position and the back position of the operating cylinder, the operating time of the cylinder is statistically analyzed through the data analysis unit, the operating time of the cylinder is displayed in a curve mode, the operating time of the cylinder can be prolonged if air leakage, air leakage and air cylinder jamming occur, and the device automatically warns and prompts when the operating time exceeds the set time limit.
In actual production, the Siemens PLC is used for collecting the operation time of each air cylinder during automatic operation, the invention only needs to be developed on the basis of the original program of the equipment, and the original action logic of the equipment cannot be changed. The creation of the dedicated data block stores the device operating state parameters in a format that is shaped (e.g., shown at maximum 32767) to meet the application of all the actuators that can be used in the current manufacturing line. The method uses the labvew2014 as a platform to develop and receive PLC transmitted data through the TCP, processes and applies the PLC transmitted data, and stores and plays back original data and the like; in human-computer interaction, a cylinder action logic diagram can be introduced into software and can be associated with PLC data, so that the operation action of the equipment can be displayed in real time. By acquiring the operation time of each cylinder of the equipment, recording the initial operation time of each cylinder of the equipment and taking the initial operation time as the basis of the whole monitoring, when the operation time of the cylinder exceeds or is lower than the initial operation time by a certain difference value, the early warning system automatically pops up a dialog text through the human-computer interaction module and gives an alarm.
Drawings
The invention will be described in further detail with reference to the following detailed description and accompanying drawings:
fig. 1 is a schematic structural diagram of a cylinder operation fault early warning system of the invention.
Fig. 2 is a schematic flow chart of a cylinder operation fault early warning method according to a first embodiment of the invention.
Fig. 3 is a schematic flow chart of a cylinder operation fault early warning method according to a second embodiment of the invention.
Description of the reference numerals
A is a cylinder
B is cylinder top dead center
C is cylinder bottom dead center
a is a first trigger device
b is a second triggering device
c is a data acquisition module
d data analysis module
e human-computer interaction module
Detailed Description
As shown in fig. 1, a first embodiment of the early warning system for cylinder operation failure according to the present invention includes: the device comprises a data acquisition unit and a data analysis unit, wherein the data acquisition unit comprises a first trigger device a, a second trigger device b and a data acquisition module c, and the data analysis unit comprises a data analysis module d and a human-computer interaction module e;
the first trigger device is arranged at the top dead center of the cylinder piston, the second trigger device is arranged at the bottom dead center of the cylinder piston, the first trigger device and the second trigger device send trigger signals to the data acquisition module, the data acquisition module acquires preset data according to the trigger signals, and the data acquisition module sends the preset data to the data analysis unit; and the data acquisition unit and the data analysis unit exchange data by adopting TCP communication.
The data analysis module receives preset data and judges whether to send an early warning signal according to a preset judgment rule, and the human-computer interaction module displays early warning information on a human-computer interaction interface according to the early warning signal.
In this embodiment, the first trigger device and the second trigger device use position sensors, and when the cylinder piston runs to the top dead center or the bottom dead center to trigger the data acquisition module to perform timing, the time actually required for the cylinder piston to complete one cycle is calculated. Of course, the actual time required for completing more than one cycle of the cylinder piston stroke can be calculated, the accuracy of the early warning system can be reduced by correspondingly counting the actual time required for more than one cycle, the redundancy of the system can be improved, and the selection between the accuracy and the redundancy can be properly selected according to the actual work. And the data analysis module displays the actual time required by the stroke of the piston of the air cylinder to complete one cycle on the man-machine interaction module through a time curve.
And continuously taking the actual time required for completing one cycle as an example, wherein the preset judgment rule comprises the steps of comparing the standard time required by the stroke of the piston of the air cylinder to complete one cycle with the actual time required by the stroke of the piston of the air cylinder to complete one cycle, judging that the air cylinder has no operation fault if the two times are equal, and judging that the air cylinder has the operation fault if the actual time required by the stroke of the piston of the air cylinder to complete one cycle is greater than the standard time required by the stroke of the piston of the air cylinder to complete one cycle, and sending out an operation.
The second embodiment of the cylinder operation fault early warning system provided by the invention comprises the following components: the data analysis unit comprises a data analysis module and a human-computer interaction module;
the first trigger device is arranged at the top dead center of the cylinder piston, the second trigger device is arranged at the bottom dead center of the cylinder piston, the first trigger device and the second trigger device send trigger signals to the data acquisition module, the data acquisition module acquires preset data according to the trigger signals, and the data acquisition module sends the preset data to the data analysis unit; and the data acquisition unit and the data analysis unit exchange data by adopting TCP communication.
The data analysis module receives preset data and judges whether to send an early warning signal according to a preset judgment rule, and the human-computer interaction module displays early warning information on a human-computer interaction interface according to the early warning signal.
In this embodiment, the first trigger device and the second trigger device use position sensors, and when the cylinder piston runs to the top dead center or the bottom dead center to trigger the data acquisition module to perform timing, the time actually required for the cylinder piston to complete one cycle is calculated. Of course, the actual time required for completing more than one cycle of the cylinder piston stroke can be calculated, the accuracy of the early warning system can be reduced by correspondingly counting the actual time required for more than one cycle, the redundancy of the system can be improved, and the selection between the accuracy and the redundancy can be properly selected according to the actual work. And the data analysis module displays the actual time required by the stroke of the piston of the air cylinder to complete one cycle on the man-machine interaction module through a time curve.
And continuously explaining the actual time required for completing one cycle by taking the example as an illustration, wherein the preset judgment rule comprises the steps of comparing the standard time required by the stroke of the piston of the air cylinder to complete one cycle with the actual time required by the stroke of the piston of the air cylinder to complete one cycle, judging that the air cylinder has no operation fault if the two times are equal, judging that the operation fault occurs in the air cylinder if the actual time required by the stroke of the piston of the air cylinder to complete one cycle is greater than the standard time required by the stroke of the piston of the air cylinder to complete one cycle and the actual time required by the stroke of the piston of the air cylinder.
In the second implementation of the invention, the early warning threshold is additionally set, and the operation fault of the cylinder is further judged through the early warning threshold, so that false alarm is avoided, and the stability of the system is improved.
As shown in fig. 2, the present invention provides a first embodiment of a cylinder operation failure early warning method, which comprises the following steps:
1) calibrating the standard time required by the stroke of the cylinder piston to complete one cycle;
2) acquiring the actual time required by the stroke of the piston of the cylinder to complete one cycle;
3) and comparing the standard time with the actual time, judging that the cylinder has no operation fault if the actual time is equal to the standard time, and judging that the cylinder operates if the actual time is greater than the standard time to send out an operation fault early warning.
As shown in fig. 3, the present invention provides a second embodiment of a cylinder operation failure early warning method, which comprises the following steps:
1) calibrating the standard time required by the stroke of the cylinder piston to complete one cycle;
2) acquiring the actual time required by the stroke of the piston of the cylinder to complete one cycle;
3) and comparing the standard time with the actual time, judging that the cylinder has no operation fault if the actual time is equal to the standard time, judging that the cylinder has the operation fault if the actual time is greater than the standard time and the actual time is greater than an early warning threshold value, and sending out an operation fault early warning.
The present invention has been described in detail with reference to the specific embodiments and examples, but these are not intended to limit the present invention. Many variations and modifications may be made by one of ordinary skill in the art without departing from the principles of the present invention, which should also be considered as within the scope of the present invention.
Claims (11)
1. An early warning system for operation failure of a cylinder, comprising: the data analysis unit comprises a data analysis module and a human-computer interaction module;
the first trigger device is arranged at the top dead center of the cylinder piston, the second trigger device is arranged at the bottom dead center of the cylinder piston, the first trigger device and the second trigger device send trigger signals to the data acquisition module, the data acquisition module acquires preset data according to the trigger signals, and the data acquisition module sends the preset data to the data analysis unit;
the data analysis module receives preset data and judges whether to send an early warning signal according to a preset judgment rule, and the human-computer interaction module displays early warning information on a human-computer interaction interface according to the early warning signal.
2. The cylinder operation failure early warning system as set forth in claim 1, wherein: the preset data is the actual time required for the cylinder piston stroke to complete one cycle.
3. The cylinder operation failure early warning system according to claim 2, wherein: and the data analysis module displays the actual time required by the stroke of the piston of the air cylinder to complete one cycle on the man-machine interaction module through a time curve.
4. The cylinder operation failure early warning system according to claim 2, wherein: the preset judgment rule comprises the steps of comparing the standard time required by the stroke of the piston of the air cylinder to complete one cycle with the actual time required by the stroke of the piston of the air cylinder to complete one cycle, judging that the air cylinder has no operation fault if the two times are equal, and judging that the air cylinder has the operation fault if the actual time required by the stroke of the piston of the air cylinder to complete one cycle is longer than the standard time required by the stroke of the piston of the air cylinder to complete one cycle, and sending out operation fault early warning.
5. The cylinder operation failure early warning system according to claim 2, wherein: the preset judgment rule comprises the steps of comparing the standard time required by the stroke of the piston of the air cylinder to complete one cycle with the actual time required by the stroke of the piston of the air cylinder to complete one cycle, judging that the air cylinder has no operation fault if the two times are equal, judging that the air cylinder has the operation fault if the actual time required by the stroke of the piston of the air cylinder to complete one cycle is greater than the standard time required by the stroke of the piston of the air cylinder to complete one cycle, and sending out an operation fault early warning if the actual time required by the stroke of the piston of the air cylinder.
6. The cylinder operation failure early warning system as set forth in claim 1, wherein: the first and second triggering devices are position sensors.
7. The cylinder operation failure early warning system as set forth in claim 1, wherein: and the data acquisition unit and the data analysis unit exchange data by adopting TCP communication.
8. The cylinder operation failure early warning system according to any one of claims 1 to 7, wherein: the operation faults include air leakage of the air cylinder, air leakage of the air cylinder and clamping stagnation of the air cylinder.
9. The early warning method for the operation fault of the cylinder is characterized by comprising the following steps of:
1) calibrating the standard time required by the stroke of the cylinder piston to complete one cycle;
2) acquiring the actual time required by the stroke of the piston of the cylinder to complete one cycle;
3) and comparing the standard time with the actual time, judging that the cylinder has no operation fault if the actual time is equal to the standard time, and judging that the cylinder operates if the actual time is greater than the standard time to send out an operation fault early warning.
10. The cylinder operation failure early warning method as set forth in claim 9, wherein: and 3) comparing the standard time with the actual time when the step 3) is executed, judging that the cylinder has no operation fault if the actual time is equal to the standard time, judging that the cylinder has the operation fault if the actual time is greater than the standard time and the actual time is greater than an early warning threshold value, and sending out an operation fault early warning.
11. The cylinder operation failure warning method according to any one of claims 9 or 10, characterized in that: the operation faults include air leakage of the air cylinder, air leakage of the air cylinder and clamping stagnation of the air cylinder.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202011550214.8A CN112727853A (en) | 2020-12-24 | 2020-12-24 | Early warning system and early warning method for operation faults of air cylinder |
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| CN202011550214.8A CN112727853A (en) | 2020-12-24 | 2020-12-24 | Early warning system and early warning method for operation faults of air cylinder |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114635893A (en) * | 2022-03-02 | 2022-06-17 | 一汽解放汽车有限公司 | Cylinder switching method and device, computer equipment and storage medium |
| CN114876905A (en) * | 2022-04-18 | 2022-08-09 | 珠海趣印科技有限公司 | Cylinder alarm method based on PLC |
| CN115468750A (en) * | 2021-05-24 | 2022-12-13 | 一汽-大众汽车有限公司 | Monitoring method and monitoring system for overturning air cylinder and storage medium |
| CN116976863A (en) * | 2023-09-20 | 2023-10-31 | 福建福清核电有限公司 | Internet-based proportional valve card data analysis system |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110030230A (en) * | 2013-07-08 | 2019-07-19 | Smc 株式会社 | Fault detection system for actuator |
-
2020
- 2020-12-24 CN CN202011550214.8A patent/CN112727853A/en active Pending
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110030230A (en) * | 2013-07-08 | 2019-07-19 | Smc 株式会社 | Fault detection system for actuator |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115468750A (en) * | 2021-05-24 | 2022-12-13 | 一汽-大众汽车有限公司 | Monitoring method and monitoring system for overturning air cylinder and storage medium |
| CN114635893A (en) * | 2022-03-02 | 2022-06-17 | 一汽解放汽车有限公司 | Cylinder switching method and device, computer equipment and storage medium |
| CN114876905A (en) * | 2022-04-18 | 2022-08-09 | 珠海趣印科技有限公司 | Cylinder alarm method based on PLC |
| CN116976863A (en) * | 2023-09-20 | 2023-10-31 | 福建福清核电有限公司 | Internet-based proportional valve card data analysis system |
| CN116976863B (en) * | 2023-09-20 | 2023-12-22 | 福建福清核电有限公司 | Internet-based proportional valve card data analysis system |
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Application publication date: 20210430 |