CN114183334A - Method for suppressing zero drift in debugging of amplification plate of radial plunger pump - Google Patents
Method for suppressing zero drift in debugging of amplification plate of radial plunger pump Download PDFInfo
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- 238000012937 correction Methods 0.000 claims abstract description 25
- 238000001514 detection method Methods 0.000 claims abstract description 14
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- 238000012423 maintenance Methods 0.000 description 10
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- 238000005299 abrasion Methods 0.000 description 2
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- 238000005242 forging Methods 0.000 description 2
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B51/00—Testing machines, pumps, or pumping installations
Abstract
The invention discloses a method for suppressing zero drift in debugging of an amplification plate of a radial plunger pump, which comprises the following steps: analyzing the display condition of a display lamp on a panel of an amplifying plate of the main pump, and determining the reason of the alarm fault; detecting the servo valve of the main pump and the mechanical zero position of the main pump through port communication of the amplification plate; and comparing the measurement data with the standard zero-position data, calculating a deviation value of the detection data and the standard zero-position data, and performing zero-position deviation correction according to the deviation value. According to the invention, the mechanical zero position and the electrical zero position of the equipment are corrected, so that zero drift of the mechanical zero position and the electrical zero position is solved, the accurate corresponding relation between the mechanical zero position and the electrical zero position is restored and maintained, and the accurate control of the main pump is realized.
Description
Technical Field
The invention belongs to the technical field of electro-hydraulic accurate control of heavy industrial forging equipment, and particularly relates to a method for suppressing zero drift in debugging of an amplifying plate of a radial plunger pump.
Background
In the actual production process, the precise matching of the mechanical system and the electrical system of the equipment is an important factor for ensuring the equipment to produce high-quality products, and simultaneously, the accurate matching is also a basic guarantee for ensuring all the functions of the equipment to reach the standard.
The 3000-ton hydraulic press currently used in a special steel workshop is built and used by a German PANK company in 2003, 8 main pumps (750 radial plunger pumps) are always the fundamental guarantee for normal and rapid operation of the hydraulic press, but in the long-term use process, because the mechanical structure abrasion and the compensation deviation of an electric control system are increased day by day, the fault that the 3000-ton hydraulic press cannot be started due to the alarm control deviation of the main pumps occurs in the starting process, so that the machine is stopped and the production is stopped.
Disclosure of Invention
The invention aims to provide a method for suppressing zero drift in debugging of an amplifying plate of a radial plunger pump.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
the method for suppressing zero drift in debugging of the amplification plate of the radial plunger pump comprises the following steps:
analyzing the display condition of a display lamp on a panel of an amplifying plate of the main pump, and determining the reason of the alarm fault;
detecting the servo valve of the main pump and the mechanical zero position of the main pump through port communication of the amplification plate;
and comparing the measurement data with the standard zero-position data, calculating a deviation value of the detection data and the standard zero-position data, and performing zero-position deviation correction according to the deviation value.
Further, detecting a port 1 and a port 2 of the amplifying plate and recording measurement data, wherein the port 1 is used for position feedback of the servo valve and is a voltage signal, and a voltage value represents the position of the servo valve of the main pump; the 2 ports are used for feeding back the rotation angle degree of the main pump, and are voltage signals, and the numerical value of the voltage signals represents the size of the feedback position of the rotation angle degree of the main pump.
Further, when the main pump stops, the servo valve deflects to one side, and if the mechanical zero position exceeds or is less than the position zero data, the main pump is judged to have the offset of the mechanical zero position; and the rotation angle of the main pump deviates to one side, and if the deviation value exceeds or is smaller than the angle zero position signal, the angle zero position is judged to deviate.
And further, adding the deviation value with the current main pump position parameter in the amplification board, communicating with the amplification board by using amplification board communication software REXROTH, inputting the added data parameter into the amplification board, measuring the port 1, detecting a voltage feedback signal of the main pump position parameter, and finishing zero position parameter deviation correction when the voltage feedback signal is returned as position zero position data.
And further, adding the deviation value and the current rotation angle number in the amplification board, communicating with the amplification board by using amplification board communication software REXROTH, inputting the added data parameters into the amplification board, detecting voltage feedback signals of the rotation angle number, and finishing zero parameter correction when the voltage feedback signals are classified as rotation angle zero data.
Further, if the main pump electrical system position zero drift, zero parameter correction of the electrical system position zero drift is required; and detecting and recording measurement data on an Ia port of the amplifying plate, wherein the Ia port is used for feeding back the coil current of the servo valve and is a voltage signal, and the value of the voltage signal represents the coil current of the proportional servo valve.
And further, adding the deviation value with the current servo valve coil current in the amplification board, communicating with the amplification board by using amplification board communication software REXROTH, inputting the added data parameters into the amplification board, measuring the port Ia by using a universal meter, detecting a voltage feedback signal of the servo valve coil current value, and finishing zero parameter correction of the servo valve coil current when the voltage feedback signal is returned to standard current zero data.
Further, the parameters of the amplifying plate are repeatedly finely adjusted for many times until the feedback signals of the mechanical zero position and the electrical zero position are returned to the standard zero data, and at the moment, the mechanical zero position and the electrical zero position of the main pump are completely overlapped with the standard zero data, so that zero correction is completed.
Further, after the zero position deviation correction is completed, the main pump is started, and parameter detection and gradual fine adjustment are respectively carried out on the output opening degree of 50% and the output opening degree of 100%.
The invention has the technical effects that:
1. the method for suppressing zero drift in main pump zero debugging has a complete maintenance basis in the aspect of radial plunger pump debugging through the attack on the debugging technology.
Before the invention, if a main pump (750 radial plunger pump) of a 3000-ton hydraulic press fails to start, technical maintenance personnel do not have complete theoretical support for maintenance, only can replace a servo valve and a sensor at random integrally, and cannot repair a main pump system fundamentally.
2. According to the invention, the mechanical zero position and the electrical zero position of the equipment are corrected, so that zero drift of the mechanical zero position and the electrical zero position is solved, the accurate corresponding relation between the mechanical zero position and the electrical zero position is restored and maintained, and the accurate control of the main pump is realized.
The invention overcomes the problems of the old press that the deviation control error of the main pump is increased and the control precision is reduced due to the use of the old press for many years, so that the pressure of the main cylinder of the oil press is reduced, the precision control of the main pump is realized, and the precision and the production efficiency of forged products are indirectly ensured.
3. When a main pump fails, the fault point can be quickly determined, the maintenance efficiency is improved, the fault rate is reduced, and the maintenance cost is saved.
After the invention is applied, a complete theoretical system for controlling the power Shile 750 plunger pump is established, the original passive maintenance of the main pump is changed into the current active maintenance, the fault repair time caused by the main pump is greatly reduced, the maintenance time is basically changed from the past 3 days to 1 day, meanwhile, the fault point can be quickly determined when the main pump has a fault, the maintenance efficiency is improved, and the mechanical action and the electrical action precision of 3000 tons of main pumps are improved through the autonomous zero position deviation rectification debugging, the input pressure is constant, and the product quality and the production efficiency of the produced products are indirectly ensured.
Before the present invention was applied, the 3000 ton lescent main pump had less than one fifth of this failure recovery probability.
Detailed Description
The following description sufficiently illustrates specific embodiments of the invention to enable those skilled in the art to practice and reproduce it.
The invention carries out careful analysis and debugging on the fault which can not be started due to the deviation of the alarm control of the main pump, carries out actual test on site and carries out statistical measurement on data, thereby successfully solving the technical problem. The accurate matching of the machinery and the electricity of the equipment is firstly in the accuracy and the synchronism of the feedback sampling point, when the mechanical position and the electric detection feedback position are synchronous and are in a completely linear proportion, the perfect matching of the mechanical action and the electric control can be determined, no deviation or delay phenomenon exists, and the accurate corresponding relation of the mechanical zero position and the electric zero position is the foundation and the reference point of the synchronism to realize the synchronism. Because of the influence of field environment factors and mechanical loss caused by long-time use, zero drift of the mechanical zero position and the electrical zero position gradually occurs, and the control deviation cannot be caused, so that the correction of the mechanical zero position and the electrical zero position of the equipment is realized by debugging, and the recovery of the corresponding relation is a key technology of daily maintenance of forging equipment.
1. And (3) theoretically analyzing corresponding starting detection conditions and the reasons of the occurrence of alarm faults when the main pump is started.
Taking 750 radial plunger pumps as main pumps as an example, when the system works and starts, the special VT12350 controls the amplification board to detect the positions of the main pumps, pressures and the positions of the hydraulic servo valves one by one through electrical feedback signals (belonging to negative feedback signals), the actual physical positions and pressures of the main pumps and the hydraulic servo valves at present are judged by detecting the numerical values of the negative feedback signals, then an analog quantity signal is calculated and output through a PID algorithm to drive the coils of the hydraulic servo valves to act and open, negative feedback closed-loop action is executed, corresponding pressures are established by the main pumps in the deflection, and the main pumps are ensured to operate in a self-circulation mode by 5% of the deflection degree under the condition of no load.
In the actual production process, along with the prolonging of the service life of equipment, mechanical abrasion causes the drift of a mechanical zero position, meanwhile, the influence of temperature and environment causes the corresponding drift of a zero position detected by an electric sensor, when the drift deviation value between the mechanical zero position and the zero position is overlarge, the asynchronous phenomenon occurs between the position fed back by the electric sensor and the mechanical position (the instant actual action position), a control amplification board and a PLC upper system can not accurately predict and control the time state point of main pump pressurization deflection and pressure relief deflection, namely the control deviation phenomenon occurs, when the control deviation error is large, the control of the main pump by the PLC system and the main pump amplification board occurs out-of-control state, and the main pump can not normally deflect to establish pressure operation fault error reporting.
2. Analyzing the numerical code meaning of the alarm signal and solving the technical principle of fault idea.
The amplifying plate of the main pump plays a role in controlling the operation of the main pump, the panel of the amplifying plate can prompt alarm information in a mode that a group of four-digit LED indicating lamps are turned on and off in different sequencing modes according to different alarm contents, a conclusion is obtained through on-off sequencing analysis of the indicating lamps, the on-off sequencing is a group of regular binary codes, namely '8421 codes' in an electrical system, and the alarm prompting information is read through fault reporting and error prompting, namely, the response is that 1, 2 and 4LED lamps are turned on the spot, and when 3 lamps are turned off, the alarm prompting contents are that the mechanical zero point and the electrical zero point of the main pump are seriously deviated.
After the alarm content is read, reasoning solution measures from the mechanical aspect and the electrical aspect respectively, firstly, in the mechanical aspect, surveying the mechanical structure state of the actual working condition of the main pump on site, and checking whether the stopped main pump is at the reset mechanical zero point or not, if the main pump is correctly reset and has no obvious stuck trace in the mechanical action aspect, the main pump is proved to have no large mechanical fault; the main pump is used for controlling the system to deviate from parking due to zero drift of the position of the electric system and overlarge deviation of the electric zero. At the moment, the repairing thought needs to adjust zero drift correction of the main pump from the electrical system, the magnitude of a feedback signal of the electrical system is represented by the linear proportion of voltage or current, if the feedback signal needs to be corrected, the difference value of the actual feedback voltage and the feedback voltage of the mechanical zero is calculated, and then the electrical zero can be corrected by eliminating the difference value through corresponding hardware and control quantity.
3. And (4) implementing process principle of zero position deviation correction.
The VT12350 amplification plate end face provides voltage measurement data of a port, the voltage measurement data of a servo valve position, a main pump position and main pump pressure can be detected and fed back in real time, and a universal meter direct current voltage level can be used for detecting the voltage of a port 1 (servo valve position feedback), a port 2 (main pump position feedback), a port Ia (servo valve coil current magnitude) and a < - > end of the amplification plate. The actual feedback value is a direct-current voltage signal of 0-10V, the standard overflow upper limit of an electrical system is 13V, if the feedback voltage exceeds 10V, the feedback overflow is considered to occur, the main pump is required to stop and restore the zero position, and the zero position is corresponding to an electrical zero position-10V signal.
The deviation of the signal value between the actual zero position signal of the electric sensor and the mechanical zero position of the main pump is calculated by comparing the deviation of the measured value with the standard value, the calculation result is pre-estimated in percentage form and is filled into a parameter page and downloaded to an amplification board (in special software REXROTH of the amplification board, the deviation value is compensated in a form of changing the feedback proportion), the deviation value between the mechanical zero position of the main pump and the zero position of the electric appliance on site is tested, the parameter is continuously modified according to the difference value according to the result until feedback signals of a port 1 (valve position feedback) and a port 2 (pump position feedback) of the amplification board are returned to-10V, at the moment, the electric zero position and the pump electric zero position of the valve group are correspondingly matched with the actual zero position of the main pump and the servo valve, at the moment, the main pump is started, and the parameter detection method is respectively carried out step by step fine adjustment setting at 50% and 100% opening degrees, the precise control of the main pump of the Lishile pump can be completely realized.
The amplification board is controlled to communicate with a corresponding main pump by utilizing the amplification board communication software REXROTH special for the Lishile, a parameter setting page is opened, original parameters are uploaded to the amplification board, the zero compensation value 0. x% of the pump and the zero compensation value 0. y% of the proportional servo valve can be obtained, the deviation percentage (deviation percentage is deviation value/total value 0.001) is roughly calculated according to the actual deviation size, and the calculated deviation value result is superposed on the zero compensation value and downloaded to the amplification board. After downloading, electric feedback signals of the servo valve and the main pump are corrected to be close to or equal to-10V, at the moment, the deviation amount of the mechanical zero position of the main pump and the zero position of the electric appliance on site is tested again, parameters are finely adjusted until feedback signals of a port 1 (valve position feedback) and a port 2 (pump position feedback) of the amplification plate are returned to-10V, at the moment, the electric zero position of the valve group and the electric zero position of the pump are correspondingly matched with the actual zero positions of the main pump and the servo valve, and zero position adjustment is successful.
The method for suppressing zero drift in debugging of the amplification plate of the radial plunger pump comprises the following specific steps:
step 1: the method comprises the steps that mechanical and electrical inspection is conducted on a main pump (750 radial plunger pump) in a hydraulic station of the oil press, an amplification plate (a VT12350 amplification plate is selected) of the main pump is observed, and the alarm fault reason is determined through the display condition of a display lamp on a panel of the amplification plate;
step 2: detecting the servo valve of the main pump and the mechanical zero position of the main pump through port communication of the amplification plate;
and detecting the ports 1, 2 and Ia of the amplification board by using a direct-current voltage gear of the universal meter, recording measurement data, and judging whether zero offset occurs or not according to the measurement data.
The 1 port is used for position feedback of the proportional servo valve and is a voltage signal, and a voltage value represents the position of the servo valve (the proportional servo valve) of the main pump; when the main pump stops, the proportional servo valve is biased to one side, the corresponding zero position signal is direct current-10V, and if the zero position signal exceeds or is less than the value, the zero position is shifted.
The port 2 is used for feeding back the rotation angle degree of the main pump, is a voltage signal, and the numerical value of the voltage signal represents the size of the feedback position of the rotation angle degree of the main pump;
the port Ia is used for feeding back the coil current of the proportional servo valve, and is a voltage signal, and the value of the voltage signal represents the coil current of the proportional servo valve (1V represents 1A); when the main pump stops, the corresponding zero position signal is DC-0V, and if the zero position signal exceeds or is less than the value, the zero position is judged to be deviated.
And step 3: and comparing the measurement data with the standard zero-position data, calculating a deviation value of the detection data and the standard zero-position data, and performing zero-position deviation correction according to the deviation value.
When the main pump has the deviation of the mechanical zero position, and the control system deviates from parking due to overlarge deviation, the deviation correction of the mechanical zero position is needed.
And comparing the position zero data (standard zero electrical signals) of the proportional servo valve of the main pump with the main pump position parameters (detection data) of the port 1, calculating the deviation value of the main pump position parameters and the standard position zero data, if the actually measured signals are-11V, indicating that the difference is-1V, namely the deviation value is-1%, and calculating the result to be used for modifying the amplification board to correct the zero parameter of the proportional servo valve.
VT12350 amplifies the specific operation of the plate: adding the deviation value with the current main pump position parameter in the amplification board, communicating with the amplification board by using amplification board communication software REXROTH, inputting the added data parameter into the amplification board, measuring the port 1 by using a universal meter, detecting a voltage feedback signal of the main pump position parameter, finishing zero position parameter correction when the voltage feedback signal is returned to position zero position data (-10V), adding the voltage feedback signal and the deviation value and inputting the sum into the amplification board if the voltage feedback signal is not returned to the position zero position data, and continuing the zero position parameter correction.
And (3) the corner zero position data (standard zero position electrical signal) of the corner degrees of the main pump corner is-10V, the corner degrees (detection data) of the 2 ports are compared, the deviation value of the corner degrees and the standard zero position data is calculated, if the actually measured signal is-9V, the difference is 1V, namely the deviation value is 1%, and the result is calculated and used for correcting the proportional servo valve zero position parameter on the amplification plate.
VT12350 amplifies the specific operation of the plate: adding the deviation value with the current rotation angle number in the amplification board, communicating with the amplification board by using amplification board communication software REXROTH, inputting the added data parameters into the amplification board, measuring the 2-port by using a universal meter, detecting a voltage feedback signal of the rotation angle number, and finishing zero-position parameter rectification when the voltage feedback signal is returned to rotation angle zero-position data (-10V); if the angle zero data is not included, the voltage feedback signal is added with the deviation value and is input into the amplifying plate, and the zero parameter correction is continued.
The voltage corresponding to the rotation angle of a proportional servo valve of a main pump and the rotation angle of the main pump is +10V when the rotation angle is fully deviated, the deviation value can be measured and corrected at the full deviation position, and the feedback signal corresponding to the full deviation voltage is 0V actually because the 3000-ton hydraulic station main pump only performs one-side deviation.
If the position of the main pump electrical system is zero-shifted, the control system deviates from parking due to overlarge deviation of the position of the electrical zero. Detecting the voltage data of the coil of the servo valve, and correcting the zero parameter of the zero drift of the position of the electrical system.
And standard zero position data of coil current of the proportional servo valve is DC-0V, the detection data of the port Ia are compared, the deviation value of the detection data and the standard zero position data is calculated, and zero position parameter correction is carried out according to the deviation value. VT12350 amplifies the specific operation of the plate: adding the deviation value with the current servo valve coil current in the amplification board, communicating with the amplification board by using amplification board communication software REXROTH, inputting the added data parameters into the amplification board, measuring an Ia port by using a universal meter, detecting a voltage feedback signal of the servo valve coil current value, and finishing zero parameter correction of the servo valve coil current when the voltage feedback signal is returned to standard current zero data (-10V); if the zero data is not returned to, the voltage feedback signal is added with the deviation value and input into the amplifying board, and the zero parameter deviation correction is continued.
And repeating the fine adjustment of the parameters of the amplification board for multiple times until the feedback signals of the mechanical zero position and the electrical zero position are all returned to standard zero data (-10V), wherein the mechanical zero position and the electrical zero position of the main pump are completely superposed with the standard zero data, the zero correction debugging is successful, the main pump can be recovered to be normally used, and the main pump is started from the industrial personal computer to finish the repair. And then, the main pump can be started, and the parameter detection method is respectively carried out on the output opening degree of 50% and the 100% opening degree to carry out gradual fine adjustment setting, so that the accurate control of the physical stamina main pump can be completely realized.
The terminology used herein is for the purpose of description and illustration, rather than of limitation. As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the meets and bounds of the claims, or equivalences of such meets and bounds are therefore intended to be embraced by the appended claims.
Claims (9)
1. A method for suppressing zero drift in debugging of an amplifying plate of a radial plunger pump is characterized by comprising the following steps:
analyzing the display condition of a display lamp on a panel of an amplifying plate of the main pump, and determining the reason of the alarm fault;
detecting the servo valve of the main pump and the mechanical zero position of the main pump through port communication of the amplification plate;
and comparing the measurement data with the standard zero-position data, calculating a deviation value of the detection data and the standard zero-position data, and performing zero-position deviation correction according to the deviation value.
2. The method for debugging and suppressing zero drift of the amplification plate of the radial plunger pump according to claim 1, wherein a port 1 and a port 2 of the amplification plate are detected and measured data are recorded, the port 1 is used for position feedback of a servo valve and is a voltage signal, and a voltage value represents the position of the servo valve of a main pump; the 2 ports are used for feeding back the rotation angle degree of the main pump, and are voltage signals, and the numerical value of the voltage signals represents the size of the feedback position of the rotation angle degree of the main pump.
3. The method for debugging and suppressing zero drift of the amplification plate of the radial plunger pump according to claim 2, wherein when the main pump stops, the servo valve is biased to one side, and if the mechanical zero position exceeds or is less than position zero data, the main pump is judged to have the deviation of the mechanical zero position; and the rotation angle of the main pump deviates to one side, and if the deviation value exceeds or is smaller than the angle zero position signal, the angle zero position is judged to deviate.
4. The method for debugging and suppressing zero drift of the amplification plate of the radial plunger pump according to claim 3, wherein the deviation value is added to the current main pump position parameter in the amplification plate, the amplification plate communication software REXROTH is used for communicating with the amplification plate, the added data parameter is input into the amplification plate, the 1 port is measured, the voltage feedback signal of the main pump position parameter is detected, and when the voltage feedback signal is returned to position zero data, zero parameter rectification is completed.
5. The method for debugging and suppressing zero drift of the amplification plate of the radial plunger pump according to claim 3, wherein the offset value is added to the current rotation angle number in the amplification plate, the amplification plate is communicated with the amplification plate by using amplification plate communication software REXROTH, the added data parameters are input into the amplification plate, the voltage feedback signal of the rotation angle number is detected, and when the voltage feedback signal is returned to the rotation angle zero data, zero parameter rectification is completed.
6. The method for debugging and suppressing zero drift of the amplification plate of the radial plunger pump according to claim 1, wherein if the main pump electrical system position zero drifts, correction of zero parameters of the electrical system position zero drift is required; and detecting and recording measurement data on an Ia port of the amplifying plate, wherein the Ia port is used for feeding back the coil current of the servo valve and is a voltage signal, and the value of the voltage signal represents the coil current of the proportional servo valve.
7. The method for debugging and suppressing zero drift of the amplification plate of the radial plunger pump according to claim 6, wherein the offset value is added to the current servo valve coil current in the amplification plate, the amplification plate communication software REXROTH is used for communicating with the amplification plate, the added data parameters are input into the amplification plate, an Ia port is measured by a universal meter, a voltage feedback signal of the servo valve coil current value is detected, and when the voltage feedback signal is returned to standard current zero data, zero parameter correction of the servo valve coil current is completed.
8. The method for debugging and suppressing zero drift of the amplification plate of the radial plunger pump according to claim 1, wherein the fine adjustment of the parameters of the amplification plate is repeated for a plurality of times until the feedback signals of the mechanical zero position and the electrical zero position are both returned to standard zero data, and at the moment, the mechanical zero position and the electrical zero position of the main pump are completely overlapped with the standard zero data, so that zero deviation correction is completed.
9. The method for debugging and suppressing zero drift of the amplification plate of the radial plunger pump according to claim 1, wherein after zero deviation correction is completed, the main pump is started, and parameter detection and gradual fine adjustment are respectively performed at 50% and 100% of output opening.
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