CN113638937A - Automatic test system of hydraulic source - Google Patents

Automatic test system of hydraulic source Download PDF

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Publication number
CN113638937A
CN113638937A CN202110615584.3A CN202110615584A CN113638937A CN 113638937 A CN113638937 A CN 113638937A CN 202110615584 A CN202110615584 A CN 202110615584A CN 113638937 A CN113638937 A CN 113638937A
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test
pressure
control
automatic
control box
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CN113638937B (en
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朱凤晴
李国强
唐慧慧
俞涛
吴非
岳国森
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Beijing Research Institute of Precise Mechatronic Controls
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Beijing Research Institute of Precise Mechatronic Controls
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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
    • 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
    • F15B19/007—Simulation or modelling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
  • Investigating Strength Of Materials By Application Of Mechanical Stress (AREA)

Abstract

The invention relates to an automatic hydraulic source testing system which comprises a hydraulic load platform, an analog energy control box, an upper computer, an automatic control box, a connecting pipeline, a testing cable and the like, wherein the hydraulic load platform is arranged on the upper computer; the upper computer is communicated with the automatic control box through a bus, test items are selected through the upper computer, the upper computer generates corresponding test data packets according to the test items and sends the test data packets to the automatic control box, the automatic control box analyzes the received test data packets to obtain control instructions, analog quantity control information is output to the analog energy control box, analog signals are processed and amplified through the analog energy control box and are sent to the hydraulic load platform, and the valve switch, the oil line pressure, the flow rate and the like of the hydraulic load platform are controlled; the automatic control box collects the sensor analog signals processed by the analog energy control box in real time, the sensor analog signals are sent to the upper computer through the bus after being packaged, and the upper computer carries out state monitoring and data storage.

Description

Automatic test system of hydraulic source
Technical Field
The invention relates to an automatic test system for a hydraulic source, in particular to a system for realizing automatic and flow test of a hydraulic source product by replacing manual operation.
Background
The hydraulic source test mainly comprises a high-pressure overflow valve test, a low-pressure safety valve test, an oil tank pressurization pressure test, a service life test and the like, and is an important link for testing whether the product performance of valves meets the design requirements.
The current hydraulic source test also has the following problems:
1. in the test process, the knob key needs to be manually adjusted repeatedly for many times, and part of test items (service life test) need to be tested repeatedly for 8 hours and nearly 900 times by an operator every day, so that the labor is seriously consumed;
2. for the interpretation of the parameters and the analysis of the test phenomena, the recorded data consistency is different due to different evaluation standards of different operators;
3. one person is needed to operate the test process, and simultaneously one person records the test process, and part of the test links can be completed only by matching two persons, so that the labor cost is high;
4. the adjusting knob on the energy control box is a potentiometer, the manual operation precision is difficult to guarantee, and the adjustment is easy to overshoot.
Disclosure of Invention
The technical problem solved by the invention is as follows: the defects of the prior art are overcome, and the automatic testing system for the hydraulic source is provided.
The technical scheme of the invention is as follows: an automatic hydraulic source testing system comprises a hydraulic load platform, a simulation energy control box, an upper computer and an automatic control box;
the upper computer is communicated with the automatic control box through a bus, test items are selected through the upper computer, the upper computer generates corresponding test data packets according to the test items and sends the test data packets to the automatic control box, the automatic control box analyzes the received test data packets to obtain control instructions, analog quantity control information is output to the analog energy control box, analog signals are processed and amplified through the analog energy control box and are sent to the hydraulic load platform, and the valve switch, the pressure and the flow of the hydraulic load platform are controlled; the automatic control box collects the sensor analog signals processed by the analog energy control box in real time, the sensor analog signals are sent to the upper computer through the bus after being packaged, and the upper computer carries out state monitoring and data storage.
Furthermore, the test items comprise automatic test of the service life of the valve, automatic test of the pressurization pressure of the oil tank, automatic test of the high-pressure overflow valve and automatic test of the low-pressure safety valve.
Furthermore, the automatic control box comprises an analog quantity acquisition module, a signal conversion module, a DA control module, a V/I module, an I/O control module, a communication module and an automatic test control module;
the communication module is used for realizing communication with an upper computer;
the automatic test control module is used for analyzing the test data packet, generating corresponding control instructions to the I/O control module, the DA control module and the V/I module according to different test items, monitoring sensor signals through the analog quantity acquisition module and the signal conversion module, and performing feedback control;
the I/O control module is used for outputting a switching signal and a pulse signal to the analog energy control box;
the DA control module is used for outputting a 0-10V voltage control signal;
the V/I module is used for converting a 0-10V voltage control signal output by the DA control module into a 0-20mA current signal and sending the current signal to the analog energy control box;
the analog quantity acquisition module is used for acquiring sensor analog signals which are integrated by the analog energy control box and have the voltage of 0-20mA or not more than 10V, and the sensor analog signals comprise pressure signals, oil temperature signals and flow signals;
the signal conversion module is used for converting the acquired sensor analog signals into digital signals and delivering the digital signals to the automatic test module.
Further, the valve service life automatic test implementation method comprises the following steps:
the upper computer sets the test times, sends the life test data packet to the automatic control box, the automatic control box analyzes the life test data packet after receiving the command, and the automatic test control module sends a corresponding control instruction to control as follows:
the main contactor, the auxiliary contactor and the high-voltage switch-on switch in the simulation energy control box are sequentially opened by utilizing the I/O control module;
the DA control module is used for outputting a linearly increased voltage signal to the analog energy control box, and the analog energy control box outputs a current signal to adjust the size of a valve port of the proportional overflow valve of the hydraulic load platform, so that the pressure of a test oil way in the hydraulic load platform is adjusted;
the flowmeter is arranged on the inlet side of a test valve on the hydraulic load platform, the data of the flowmeter is acquired by using the analog quantity acquisition module, the test valve is fully opened when the feedback flow of the flowmeter reaches 30L/min, the output voltage of the DA control module is linearly reduced after 10 seconds, the valve is closed when the feedback flow is 0 and is stabilized for 10 seconds, one-time test is completed, and the automatic control box feeds back the number of times of completing the service life test of the upper computer and adds 1; and the automatic test control module repeats the adjusting process until the set times are finished, feeds back a test completion data packet, and closes the high-voltage switch-on switch, the auxiliary contactor and the main contactor in sequence.
Further, the implementation method for automatically testing the boost pressure of the oil tank comprises the following steps:
the upper computer sends an oil tank pressurization pressure test data packet to the automatic control box, the automatic control box receives the command analysis, and the automatic test control module sends a corresponding control instruction to perform the following control:
opening a main contactor and an auxiliary contactor in the analog energy control box in sequence by using the I/O control module, and starting an auxiliary source;
the method comprises the steps of utilizing a DA control module and a V/I module to lift low pressure to be 0.7Mpa, simulating an energy control box to output current signals to adjust the rotating speed of an auxiliary motor of a hydraulic load platform, starting a main source by utilizing the I/O control module after maintaining for 10 seconds, lifting the high pressure to be 3Mpa by utilizing the DA control module, simulating the energy control box to output current signals to adjust the rotating speed of the main motor of the hydraulic load platform, starting the I/O control module to switch on the high pressure, slowly increasing the high pressure to 16Mpa, slowly lifting the low pressure to be 1Mpa by utilizing the DA control module and the V/I module, returning to 0.7Mpa after maintaining for 10 seconds, reducing the high pressure to be 3Mpa by utilizing the DA module, closing the high pressure switch-on by utilizing the I/O control module, adjusting the high pressure to be 0Mpa, closing the auxiliary source, and completing a pressure test of an oil tank.
Further, the automatic test implementation method of the high-pressure overflow valve comprises the following steps:
the upper computer sends high-pressure overflow valve test data to the automatic control box, the automatic control box receives commands to analyze the high-pressure overflow valve test data, and the automatic test control module sends corresponding control instructions to control as follows:
the I/O control module is utilized to open the main contactor, the auxiliary contactor and the high-voltage switch-on switch in sequence;
the DA control module is used for outputting a linearly increased high-pressure control signal to the energy control box, and the analog energy control box outputs a current signal to adjust the size of a valve port of the proportional overflow valve of the hydraulic load platform, so that the pressure of a test oil way in the hydraulic load platform is adjusted;
the flowmeter is arranged at the inlet end of the test valve, the data of the flowmeter is collected by using the analog quantity collection module, when the feedback flow of the flowmeter reaches 5L/min, the high-pressure overflow valve is opened, the current high-pressure value is stored by the automatic test control module as the opening pressure, the high-pressure control signal is adjusted by using the DA control module by the automatic test control module after the flow is kept for 10 seconds, the feedback flow of the flowmeter exceeds 20L/min, the high-pressure value is in the range of 15.8-17.5 Mpa, the current high-pressure value is stored by the automatic test control module as the rated pressure, the current flow is the rated flow, and the low-pressure value collected by the analog quantity collection module is the return pressure at the moment;
after keeping for 10 seconds, the automatic test control module utilizes the DA control module to adjust up a high-pressure control signal, so that the feedback flow of the flowmeter exceeds 30L/min, the pressure value meets the requirement, and the automatic test control module stores the current pressure value which is the full-open pressure;
after the pressure is kept for 10 seconds, the automatic test control module utilizes the DA control module to adjust down the high-pressure control signal, so that the feedback flow of the flowmeter is not higher than 0.01L/min and lasts for 10 seconds, the automatic test control module stores the current high-pressure value, namely the closing pressure, and after all values are stored, the automatic test control module sends a test data packet to an upper computer through the communication module, namely a test of the high-pressure overflow valve is completed.
Further, the automatic test implementation method of the low-pressure safety valve is as follows:
the upper computer sends a low-pressure safety valve test data packet to the automatic control box, the automatic control box receives the command and analyzes the low-pressure safety valve test data packet, and the automatic test control module sends a corresponding control instruction to perform the following control:
controlling the gas detection preparation switch to be switched on by using the I/O control module;
the DA control module is used for outputting a low-voltage control signal which is linearly increased, the low-voltage control signal is converted by the V/I module to obtain a 0-20mA current signal which is sent to the energy control box, the energy control box outputs the current signal to adjust the rotating speed of an auxiliary motor of the hydraulic loading platform, and therefore the low-voltage pressure of a test oil way in the hydraulic loading platform is adjusted;
the flowmeter for low-pressure test is arranged at the outlet end of the test valve, the data of the flowmeter is collected by an analog quantity collecting module, when the feedback flow reaches 0.1-0.12L/min, the valve is opened, the automatic test control module stores the current pressure value as the opening pressure, the automatic test control module controls the DA control module to adjust the low pressure control signal after keeping for 10 seconds, so that the flow exceeds 0.7L/min, and the pressure value meets the requirement, the automatic test control module stores the current pressure value as the full-open pressure, the current flow is the full-open flow, the automatic test control module controls the DA control module to adjust the low-voltage control signal downwards after keeping for 10 seconds, the flow is enabled to be not higher than 0.01L/min for 10 seconds, the automatic test control module stores the current pressure value which is the closing pressure, and when all values are stored, the automatic test control module sends a test data packet to the upper computer through the communication module.
Furthermore, the DA module outputs any voltage value from 0V to 10V, the high-voltage control signal is 0-10V voltage and corresponds to 0-20 Mpa of high-voltage pressure, and the low-voltage control signal can be converted from 0-10V to 0-20mA current signal and corresponds to 0-2 Mpa of low voltage.
Furthermore, the upper computer is used for setting the pressure, the flow and the holding time in the test items, and the pressure, the flow and the holding time are solidified to the automatic control box in a parameter binding mode, so that the setting and adjustment of the characteristics of different hydraulic source products to be tested are realized, and the test requirements of different products are met.
Furthermore, the simulation energy control box has two working states of remote control and local control and is switched by a two-position switch; under the remote control working state, the test items are completed by matching with the automatic control box, and under the local control working state, the test items are completed by adjusting related parameters in the test items through knobs or buttons.
Compared with the prior art, the invention has the beneficial effects that:
the invention innovatively provides an automatic hydraulic source testing system, aiming at pain spots existing in the current testing process, the operating mode of manually and locally operating and simulating a knob key of an energy control box is innovatively upgraded into an automatic control box and an upper computer for remote automatic control, manual experience is solidified in automatic testing system software, the automatic testing system is simple and easy to use, a testing result report can be automatically stored and printed, and even a primary operator can still independently complete the testing of a hydraulic source product. The automatic modification can improve the testing efficiency of the hydraulic source product, reduce the cost of human resources for testing, and has great social and economic benefits and application and popularization values.
(1) Simplified test operation flow, one-click test
The mode of remote control of the upper computer is adopted to replace local control, the upper computer selects a test project, manual intervention is not needed by one-key operation, automatic test is carried out according to set steps, and the test efficiency is high.
(2) Operation steps of curing test in software
The testing operation steps are solidified in the program in a software mode, even primary operators with insufficient experience can finish the testing of the hydraulic element, and the testing precision is high and the consistency is good.
(3) Automatic storing and printing of test data report
After the test is finished, the test data report can be automatically stored according to different requirements, a specially-assigned person is not required to fill in the data record table manually, the labor cost is saved, and the test efficiency is improved.
Drawings
FIG. 1 is a block diagram of the system of the present invention.
Detailed Description
The invention is further illustrated by the following examples.
The invention aims to provide a device which can realize one-click test for a hydraulic element and can automatically store test data. As shown in fig. 1, the system mainly comprises an upper computer, an automatic control box, an analog energy control box, a hydraulic loading platform, a flowmeter and the like. The hardware equipment comprises an analog quantity acquisition module, a signal conversion module, a DA control module, a V/I module, an I/O control module, a communication module and an automatic test control module. The software running on the automatic test control module mainly comprises an automatic test control algorithm, control command transceiving and test data receiving and storing. The DA module can output any voltage value of voltage from 0 to 10V, and the high-voltage control signal is the voltage of 0-10V, and is corresponding to the high-voltage pressure of 0-20 Mpa, and the low-voltage control signal can be converted into a current signal of 0-20mA from 0-10V, and is corresponding to the low-voltage of 0-2 Mpa.
The working process is as follows: the host computer communicates with the automatic control box through the bus, issues a control instruction data packet to the automatic control box, the automatic control box unpacks to obtain a control instruction, outputs a control signal (voltage, current or pulse) to the simulation energy control box, replaces a front panel of the simulation energy control box, automatically realizes functions such as pressure regulation, key switches and the like, and meanwhile, the automatic control box collects signals of multiple sensors in real time, and sends the signals to the host computer through packaging to realize data storage or printing.
The simulation energy control box can be matched with an automatic control box to remotely control and complete a specific test project, and can also carry out local control, remote control and local control states are switched by two-position switches, the simulation energy control box is provided with a front panel, low voltage, high voltage and oil temperature numerical values can be displayed by nixie tubes, in addition, auxiliary frequency and high voltage can be adjusted by knobs, corresponding nixie tubes are displayed, and a main control contactor, an auxiliary contactor, high voltage connection, an auxiliary source starting, an auxiliary source stopping, a main source starting, a main source stopping, a power supply, buttons such as remote control emergency stop and the like are also arranged, wherein the remote control emergency stop is used for the accident situation of the remote control states, and the hydraulic load platform can not be damaged due to timely stopping and power failure. An experienced worker may also perform the given test items described below locally by adjusting the front panel, and may also perform other tests in addition to the conventional test items described above.
The upper computer can complete the following test items and can set the test times of the test items, and after the test is completed, the upper computer can generate and store an electronic version test record report and can also select whether to print the test report.
Typical test items of the invention comprise automatic test of valve service life, automatic test of oil tank pressurization pressure, automatic test of high-pressure overflow valve and automatic test of low-pressure safety valve.
The implementation method for the automatic test of the service life of the valve comprises the following steps:
the upper computer sets the test times, sends a service life test data packet to the automatic control box, the automatic control box unpacks after receiving a command, the main contactor, the auxiliary contactor switch and the high-voltage switch are opened by the aid of the I/O module, the DA module outputs a linearly increased voltage signal (0-10V) to the simulation energy control box, the simulation energy control box outputs a current signal to adjust the size of a valve port of the proportional overflow valve of the hydraulic load platform, accordingly, the pressure of the test oil path of the hydraulic load platform is adjusted, the test valve is fully opened when the feedback flow of the flowmeter exceeds 30L/min, the DA output voltage is linearly reduced after 10 seconds is kept, the valve is closed when the feedback flow is 0 and stably exceeds 10 seconds, the process is repeated until the set times are completed, and the data packet is fed back and tested.
The implementation method for automatically testing the boost pressure of the oil tank comprises the following steps:
the upper computer sends an oil tank pressurization pressure test data packet to the automatic control box, the automatic control box unpacks after receiving a command, an IO module is used for controlling a main contactor to be connected, an auxiliary contactor is connected, an auxiliary source is started, a DA module and a V/I module are used for slowly increasing the low pressure to 0.7Mpa, an energy control box outputs a current signal to adjust the rotating speed of an auxiliary motor of the hydraulic load platform, an I/O module is used for starting the main source after maintaining for 10 seconds, the DA module is used for slowly increasing the high pressure to 3Mpa, the energy control box outputs a current signal to adjust the rotating speed of the main motor of the hydraulic load platform, the high pressure is started to be connected, the high pressure is slowly increased to 16Mpa, the DA module and the V/I module are used for slowly increasing the low pressure to 1Mpa, the high pressure is slowly decreased to 3Mpa by the DA module, the high pressure is closed by the IO module, the high pressure is adjusted to 0Mpa, the auxiliary frequency is closed, the pressure test of the oil tank is completed once, and the pressure test curve of the oil tank is automatically printed by a printer connected with an industrial personal computer.
The automatic test implementation method of the high-pressure overflow valve comprises the following steps:
the test data packet of the high-pressure overflow valve is sent to an automatic control box, the automatic control box unpacks after receiving a command, an IO module is used for controlling a main contactor to be connected, an auxiliary contactor is connected, the high-pressure connection is carried out, a DA module is used for outputting a linearly increased high-pressure control signal (0-10V) to an energy control box, the energy control box outputs a current signal to adjust the size of a valve port of a hydraulic load-bearing platform proportional overflow valve, when the feedback flow of a flowmeter reaches 5L/min, the high-pressure overflow valve is opened, the automatic control box stores the current pressure value as opening pressure, the automatic control box adjusts the high-pressure control signal on the DA module after keeping for 10 seconds, the flow exceeds 20L/min, the pressure value meets the requirement, the automatic control box stores the current pressure value as rated pressure, the current flow is the rated flow, the low-pressure value is oil return pressure, the automatic control box adjusts the high-pressure control signal on the DA module after keeping for 10 seconds, the flow exceeds 30L/min, the pressure value meets the requirement, the automatic control box stores the current pressure value which is full-open pressure, the automatic control box utilizes a DA module to reduce a high-pressure control signal after keeping for 10 seconds, the flow is approximate to 0L/min, the automatic control box stores the current pressure value which is closing pressure, the automatic control box sends a test data packet to an upper computer after all numerical values are stored, and a test report is automatically generated and stored after unpacking processing of the upper computer.
The automatic test implementation method of the low-pressure safety valve comprises the following steps:
the upper computer sends a low-pressure safety valve test data packet to the automatic control box, the automatic control box unpacks the data packet after receiving a command, an IO module is used for controlling gas measurement to be ready to be connected, a DA module is used for outputting a low-pressure control signal (0-10V) which linearly increases, a V/I module is used for converting the low-pressure control signal into a 0-20mA current signal to be sent to the energy control box, the energy control box outputs the current signal to adjust the rotating speed of an auxiliary motor of the hydraulic load platform, when the feedback flow reaches 0.1L/min, a valve is opened, the automatic control box stores the current pressure value which is opening pressure, the automatic control box controls the DA module to adjust the low-pressure control signal upwards after keeping for 10 seconds, the flow exceeds 0.7L/min, the pressure value meets the requirement, the automatic control box stores the current pressure value which is full-opening pressure, the current flow is full-opening flow, the automatic control box controls the DA module to adjust the low-pressure control signal downwards after keeping for 10 seconds, the flow is approximate to 0L/min, the automatic control box stores the current pressure value which is the closing pressure, the automatic control box sends a test data packet to the upper computer after all the numerical values are stored, and a test report is automatically generated and stored after the unpacking processing of the upper computer.
All pressure, flow and holding time numerical values of the test items can be set through the upper computer, and are solidified to the automatic control box through a parameter binding mode, and the test items can be adjusted according to the characteristics of different to-be-tested hydraulic source products, so that the test requirements of different products are met.
The simulation energy control box can be matched with an automatic control box to remotely control and complete a specific test project, and can also carry out local control, remote control and local control states are switched by two-position switches, the simulation energy control box is provided with a front panel, low voltage, high voltage and oil temperature numerical values can be displayed by nixie tubes, in addition, auxiliary frequency and high voltage can be adjusted by knobs, corresponding nixie tubes are displayed, and a main control contactor, an auxiliary contactor, high voltage connection, an auxiliary source starting, an auxiliary source stopping, a main source starting, a main source stopping, a power supply, buttons such as remote control emergency stop and the like are also arranged, wherein the remote control emergency stop is used for the accident situation of the remote control states, and the hydraulic load platform can not be damaged due to timely stopping and power failure. The experienced worker may also perform all of the above test items locally by adjusting the front panel, and may also perform other tests than the above conventional test items.
The upper computer can complete the test items and can set the test times of the test items, and after the test is completed, the upper computer can generate and store an electronic version test record report and can also select whether to print the test report.
The invention has not been described in detail in part in the common general knowledge of a person skilled in the art.

Claims (10)

1. The utility model provides an automatic test system of hydraulic source, includes hydraulic pressure load platform, simulation energy control box, its characterized in that: the automatic control system also comprises an upper computer and an automatic control box;
the upper computer is communicated with the automatic control box through a bus, test items are selected through the upper computer, the upper computer generates corresponding test data packets according to the test items and sends the test data packets to the automatic control box, the automatic control box analyzes the received test data packets to obtain control instructions, analog quantity control information is output to the analog energy control box, analog signals are processed and amplified through the analog energy control box and are sent to the hydraulic load platform, and the valve switch, the pressure and the flow of the hydraulic load platform are controlled; the automatic control box collects the sensor analog signals processed by the analog energy control box in real time, the sensor analog signals are sent to the upper computer through the bus after being packaged, and the upper computer carries out state monitoring and data storage.
2. The system of claim 1, wherein: the test items comprise automatic test of the service life of the valve, automatic test of the pressurization pressure of the oil tank, automatic test of the high-pressure overflow valve and automatic test of the low-pressure safety valve.
3. The system according to claim 1 or 2, characterized in that: the automatic control box comprises an analog quantity acquisition module, a signal conversion module, a DA control module, a V/I module, an I/O control module, a communication module and an automatic test control module;
the communication module is used for realizing communication with an upper computer;
the automatic test control module is used for analyzing the test data packet, generating corresponding control instructions to the I/O control module, the DA control module and the V/I module according to different test items, monitoring sensor signals through the analog quantity acquisition module and the signal conversion module, and performing feedback control;
the I/O control module is used for outputting a switching signal and a pulse signal to the analog energy control box;
the DA control module is used for outputting a 0-10V voltage control signal;
the V/I module is used for converting a 0-10V voltage control signal output by the DA control module into a 0-20mA current signal and sending the current signal to the analog energy control box;
the analog quantity acquisition module is used for acquiring sensor analog signals which are integrated by the analog energy control box and have the voltage of 0-20mA or not more than 10V, and the sensor analog signals comprise pressure signals, oil temperature signals and flow signals;
the signal conversion module is used for converting the acquired sensor analog signals into digital signals and delivering the digital signals to the automatic test control module.
4. The system of claim 3, wherein: the implementation method for the automatic test of the service life of the valve comprises the following steps:
the upper computer sets the test times, sends the life test data packet to the automatic control box, the automatic control box analyzes the life test data packet after receiving the command, and the automatic test control module sends a corresponding control instruction to control as follows:
the main contactor, the auxiliary contactor and the high-voltage switch-on switch in the simulation energy control box are sequentially opened by utilizing the I/O control module;
the DA control module is used for outputting a linearly increased voltage signal to the analog energy control box, and the analog energy control box outputs a current signal to adjust the size of a valve port of the proportional overflow valve of the hydraulic load platform, so that the pressure of a test oil way in the hydraulic load platform is adjusted;
the flowmeter is arranged on the inlet side of a test valve on the hydraulic load platform, the data of the flowmeter is acquired by using the analog quantity acquisition module, the test valve is fully opened when the feedback flow of the flowmeter reaches 30L/min, the output voltage of the DA control module is linearly reduced after 10 seconds, the valve is closed when the feedback flow is 0 and is stabilized for 10 seconds, one-time test is completed, and the automatic control box feeds back the number of times of completing the service life test of the upper computer and adds 1; and the automatic test control module repeats the adjusting process until the set times are finished, feeds back a test completion data packet, and closes the high-voltage switch-on switch, the auxiliary contactor and the main contactor in sequence.
5. The system of claim 3, wherein: the implementation method for automatically testing the boost pressure of the oil tank comprises the following steps:
the upper computer sends an oil tank pressurization pressure test data packet to the automatic control box, the automatic control box receives the command analysis, and the automatic test control module sends a corresponding control instruction to perform the following control:
opening a main contactor and an auxiliary contactor in the analog energy control box in sequence by using the I/O control module, and starting an auxiliary source;
the method comprises the steps of utilizing a DA control module and a V/I module to lift low pressure to be 0.7Mpa, simulating an energy control box to output current signals to adjust the rotating speed of an auxiliary motor of a hydraulic load platform, starting a main source by utilizing the I/O control module after maintaining for 10 seconds, lifting the high pressure to be 3Mpa by utilizing the DA control module, simulating the energy control box to output current signals to adjust the rotating speed of the main motor of the hydraulic load platform, starting the I/O control module to switch on the high pressure, slowly increasing the high pressure to 16Mpa, slowly lifting the low pressure to be 1Mpa by utilizing the DA control module and the V/I module, returning to 0.7Mpa after maintaining for 10 seconds, reducing the high pressure to be 3Mpa by utilizing the DA module, closing the high pressure switch-on by utilizing the I/O control module, adjusting the high pressure to be 0Mpa, closing the auxiliary source, and completing a pressure test of an oil tank.
6. The system of claim 3, wherein: the automatic test implementation method of the high-pressure overflow valve comprises the following steps:
the upper computer sends high-pressure overflow valve test data to the automatic control box, the automatic control box receives commands to analyze the high-pressure overflow valve test data, and the automatic test control module sends corresponding control instructions to control as follows:
the I/O control module is utilized to open the main contactor, the auxiliary contactor and the high-voltage switch-on switch in sequence;
the DA control module is used for outputting a linearly increased high-pressure control signal to the energy control box, and the analog energy control box outputs a current signal to adjust the size of a valve port of the proportional overflow valve of the hydraulic load platform, so that the pressure of a test oil way in the hydraulic load platform is adjusted;
the flowmeter is arranged at the inlet end of the test valve, the data of the flowmeter is collected by using the analog quantity collection module, when the feedback flow of the flowmeter reaches 5L/min, the high-pressure overflow valve is opened, the current high-pressure value is stored by the automatic test control module as the opening pressure, the high-pressure control signal is adjusted by using the DA control module by the automatic test control module after the flow is kept for 10 seconds, the feedback flow of the flowmeter exceeds 20L/min, the high-pressure value is in the range of 15.8-17.5 Mpa, the current high-pressure value is stored by the automatic test control module as the rated pressure, the current flow is the rated flow, and the low-pressure value collected by the analog quantity collection module is the return pressure at the moment;
after keeping for 10 seconds, the automatic test control module utilizes the DA control module to adjust up a high-pressure control signal, so that the feedback flow of the flowmeter exceeds 30L/min, the pressure value meets the requirement, and the automatic test control module stores the current pressure value which is the full-open pressure;
after the pressure is kept for 10 seconds, the automatic test control module utilizes the DA control module to adjust down the high-pressure control signal, so that the feedback flow of the flowmeter is not higher than 0.01L/min and lasts for 10 seconds, the automatic test control module stores the current high-pressure value, namely the closing pressure, and after all values are stored, the automatic test control module sends a test data packet to an upper computer through the communication module, namely a test of the high-pressure overflow valve is completed.
7. The system of claim 3, wherein: the automatic test implementation method of the low-pressure safety valve comprises the following steps:
the upper computer sends a low-pressure safety valve test data packet to the automatic control box, the automatic control box receives the command and analyzes the low-pressure safety valve test data packet, and the automatic test control module sends a corresponding control instruction to perform the following control:
controlling the gas detection preparation switch to be switched on by using the I/O control module;
the DA control module is used for outputting a low-voltage control signal which is linearly increased, the low-voltage control signal is converted by the V/I module to obtain a 0-20mA current signal which is sent to the energy control box, the energy control box outputs the current signal to adjust the rotating speed of an auxiliary motor of the hydraulic loading platform, and therefore the low-voltage pressure of a test oil way in the hydraulic loading platform is adjusted;
the flowmeter for low-pressure test is arranged at the outlet end of a test valve, an analog quantity acquisition module is used for acquiring data of the flowmeter, the valve is opened when the feedback flow reaches 0.1-0.12L/min, an automatic test control module stores the current pressure value as opening pressure, the automatic test control module controls a DA control module to adjust a low-pressure control signal upwards after keeping for 10 seconds, the flow exceeds 0.7L/min, and the pressure value meets the requirement, the automatic test control module stores the current pressure value as full opening pressure, the current flow is full opening flow, the automatic test control module controls the DA control module to adjust the low-pressure control signal downwards after keeping for 10 seconds, the flow is not higher than 0.01L/min and lasts for 10 seconds, the automatic test control module stores the current pressure value as closing pressure, and sends a test data packet to an upper computer through a communication module after all values are stored, and completing the test of the low-pressure safety valve.
8. The system of claim 3, wherein: the DA module outputs any voltage value of 0-10V internal voltage, the high-voltage control signal is 0-10V voltage, the high-voltage control signal corresponds to 0-20 Mpa of high-voltage pressure, the low-voltage control signal can be converted into 0-20mA current signal from 0-10V, and the low-voltage control signal corresponds to 0-2 Mpa of low voltage.
9. The system according to any one of claims 3-7, wherein: pressure, flow and holding time in the test project are set through the upper computer, and are solidified to the automatic control box through a parameter binding mode, so that setting adjustment according to different to-be-tested hydraulic source product characteristics is realized, and the test requirements of different products are met.
10. The system of claim 1, wherein: the simulation energy control box has two working states of remote control and local control and is switched by a two-position switch; under the remote control working state, the test items are completed by matching with the automatic control box, and under the local control working state, the test items are completed by adjusting related parameters in the test items through knobs or buttons.
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