CN114810572A - Hydraulic pump fault diagnosis method and device - Google Patents
Hydraulic pump fault diagnosis method and device Download PDFInfo
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- CN114810572A CN114810572A CN202210411004.3A CN202210411004A CN114810572A CN 114810572 A CN114810572 A CN 114810572A CN 202210411004 A CN202210411004 A CN 202210411004A CN 114810572 A CN114810572 A CN 114810572A
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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 hydraulic pump fault diagnosis method and device, relating to the technical field of hydraulic pump fault diagnosis, wherein the method comprises the following steps: acquiring no-load pressure, no-load flow, actual pressure, actual flow and hydraulic pump performance parameters of an outlet of a hydraulic pump; the performance parameters of the hydraulic pump comprise the discharge capacity, the highest rotating speed, the theoretical flow and the rated pressure of the hydraulic pump; obtaining the volumetric efficiency of the hydraulic pump according to the actual flow and the theoretical flow; obtaining the no-load power of the hydraulic pump according to the no-load pressure and the no-load flow; obtaining the test power of the hydraulic pump according to the displacement, the highest rotating speed and the rated pressure; obtaining the actual power of the hydraulic pump according to the actual pressure and the actual flow; and carrying out fault diagnosis on the hydraulic pump according to the volumetric efficiency, the no-load power, the test power and the actual power to obtain a fault diagnosis result. The invention can efficiently, simply and accurately diagnose the fault of the hydraulic pump.
Description
Technical Field
The invention relates to the technical field of hydraulic pump fault diagnosis, in particular to a hydraulic pump fault diagnosis method and device.
Background
The hydraulic pump is applied to hydraulic systems of equipment such as automobiles, engineering machinery and ships, the working performance of the hydraulic pump directly influences the working state of the hydraulic system, and the fault diagnosis of the hydraulic pump is required to be carried out by improving the running reliability of the hydraulic pump. At present, the engineering machinery advanced in the world uses technologies such as computer management, intelligent fault diagnosis and remote monitoring, most of the Chinese engineering machinery adopts the traditional electric control technology, and the fault diagnosis of the hydraulic pump generally depends on the experience of maintenance personnel.
The conventional common hydraulic pump fault diagnosis method comprises a hydraulic pump fault diagnosis method depending on the experience of technicians, a fault diagnosis method for acquiring hydraulic pump operation parameter signals and a fault prediction diagnosis method for establishing a mathematical model by using acquired data, wherein the hydraulic pump fault diagnosis method depending on the experience of the technicians has high requirements on the technicians and low working efficiency; the method for diagnosing the fault of the signal of the operation parameter of the hydraulic pump is based on measuring the working state parameter of the hydraulic pump, and the characteristic values of frequency spectrum, amplitude, phase and the like are extracted by methods of frequency spectrum analysis, time domain analysis, frequency domain analysis and the like to diagnose the fault of the hydraulic pump, so that the extraction of the characteristic values is difficult, and the method for diagnosing the fault of the hydraulic pump is complicated; the method for predicting and diagnosing the faults of the mathematical model established by using the collected data has the advantages that due to the fact that factors influencing working characteristics of the hydraulic pump are more, coupling effects exist when elements of the hydraulic pump work in a closed hydraulic system, and the accuracy of the model established by collecting the working parameter data of the hydraulic pump is unstable. Therefore, how to efficiently, simply and accurately diagnose the fault of the hydraulic pump becomes a problem to be solved urgently by the technical personnel in the field.
Disclosure of Invention
The invention aims to provide a hydraulic pump fault diagnosis method and device, which can be used for efficiently, simply and accurately diagnosing hydraulic pump faults.
In order to achieve the purpose, the invention provides the following scheme:
a hydraulic pump fault diagnostic method, the method comprising:
acquiring no-load pressure, no-load flow, actual pressure, actual flow and hydraulic pump performance parameters of an outlet of a hydraulic pump; the performance parameters of the hydraulic pump comprise the displacement, the highest rotating speed, the theoretical flow and the rated pressure of the hydraulic pump;
obtaining the volumetric efficiency of the hydraulic pump according to the actual flow and the theoretical flow;
obtaining the no-load power of the hydraulic pump according to the no-load pressure and the no-load flow;
obtaining the test power of the hydraulic pump according to the displacement, the highest rotating speed and the rated pressure;
obtaining the actual power of the hydraulic pump according to the actual pressure and the actual flow;
and carrying out fault diagnosis on the hydraulic pump according to the volumetric efficiency, the no-load power, the test power and the actual power to obtain a fault diagnosis result.
Optionally, the idle load pressure is a pressure at an outlet of the hydraulic pump when the hydraulic pump is set to be in an idle load working condition; the no-load flow is the flow of the outlet of the hydraulic pump when the hydraulic pump is set to be in the no-load working condition.
Optionally, the rated pressure is the highest pressure at which the hydraulic pump is set to operate continuously under normal operating conditions according to a test standard; the displacement is the volume of liquid theoretically discharged by each rotation of the hydraulic pump; the maximum rotating speed is the maximum rotating speed which is allowed to operate for a short time when the hydraulic pump exceeds the rated rotating speed under the rated pressure; the theoretical flow rate is the volume of liquid that the hydraulic pump should theoretically discharge per unit time.
Optionally, the actual pressure is a pressure at an outlet of the hydraulic pump when the hydraulic pump is set to a working condition of actual pressure, actual rotating speed and actual flow; the actual flow is the flow of the outlet of the hydraulic pump when the hydraulic pump is set to the working conditions of actual pressure, actual rotating speed and actual flow.
Optionally, the fault diagnosis result includes that the rotating speed of the hydraulic pump is too high, the pressure of the hydraulic pump is too high, the rotating speed of the hydraulic pump is too low, the working time of the hydraulic pump is too long, the hydraulic oil needs to be replaced, the relative moving parts inside the hydraulic pump are worn, the assembly is in problem, the relative moving parts inside the hydraulic pump are excessively worn, the relative moving parts are blocked by foreign matters, and the hydraulic pump has no fault.
Optionally, the performing fault diagnosis on the hydraulic pump according to the volumetric efficiency, the idle power, the test power, and the actual power to obtain a fault diagnosis result specifically includes:
when the actual power is larger than the test power, determining that the rotating speed of the hydraulic pump is too high or the pressure of the hydraulic pump is too large;
when the actual power is smaller than the no-load power, determining that the rotating speed of the hydraulic pump is too low;
when the volumetric efficiency is reduced by 5% -20% on the basis of 100%, determining that the working time of the hydraulic pump is too long or the hydraulic oil needs to be replaced;
when the volumetric efficiency is reduced by 20-40% on the basis of 100%, determining that the abrasion or assembly of the relative moving parts in the hydraulic pump is in problem;
when the volumetric efficiency is reduced by 40-60% on the basis of 100%, determining that the internal relative moving parts of the hydraulic pump are excessively worn or have foreign matters to block relative movement;
and when the actual power is less than or equal to the test power, the actual power is greater than or equal to the no-load power, and the volumetric efficiency is reduced by 0-5% on the basis of 100%, determining that the hydraulic pump has no fault.
The invention also provides the following scheme:
a hydraulic pump fault diagnosis apparatus that applies the hydraulic pump fault diagnosis method, the apparatus comprising:
the sensor signal node module is arranged at the outlet of the hydraulic pump and used for acquiring the no-load pressure, the no-load flow, the actual pressure and the actual flow of the outlet of the hydraulic pump;
and the data storage processing node module is connected with the sensor signal node module and is used for acquiring the no-load pressure, the no-load flow, the actual pressure, the actual flow, the displacement, the highest rotating speed, the theoretical flow and the rated pressure of the hydraulic pump, obtaining the volumetric efficiency of the hydraulic pump according to the actual flow and the no-load flow, obtaining the no-load power of the hydraulic pump according to the no-load pressure and the no-load flow, obtaining the test power of the hydraulic pump according to the displacement, the highest rotating speed and the rated pressure, obtaining the actual power of the hydraulic pump according to the actual pressure and the actual flow, and diagnosing the fault of the hydraulic pump according to the volumetric efficiency, the no-load power, the test power and the actual power to obtain a fault diagnosis result.
Optionally, the apparatus further comprises:
and the display node module is connected with the data storage processing node module and is used for displaying the fault diagnosis result.
Optionally, the apparatus further comprises:
the storage battery is used for providing voltage for the sensor signal node module, the data storage processing node module and the display node module;
and the power management module is respectively connected with the storage battery, the sensor signal node module, the data storage processing node module and the display node module and is used for converting the voltage provided by the storage battery into the voltage required by the sensor signal node module, the data storage processing node module and the display node module.
Optionally, the data storage processing node module specifically includes:
the actual power and test power comparison unit is used for determining that the rotating speed of the hydraulic pump is too high or the pressure of the hydraulic pump is too high when the actual power is larger than the test power;
the actual power and no-load power comparison unit is used for determining that the rotating speed of the hydraulic pump is too low when the actual power is smaller than the no-load power;
the first volumetric efficiency reduction unit is used for determining that the working time of the hydraulic pump is too long or the hydraulic oil needs to be replaced when the volumetric efficiency is reduced by 5% -20% on the basis of 100%;
the second volumetric efficiency reduction unit is used for determining that the abrasion or assembly of the relative moving parts in the hydraulic pump is in a problem when the volumetric efficiency is reduced by 20% -40% on the basis of 100%;
the third volumetric efficiency reduction unit is used for determining that the internal relative movement parts of the hydraulic pump are excessively worn or have foreign matters to block the relative movement when the volumetric efficiency is reduced by 40-60 percent on the basis of 100 percent;
and the fault-free determining unit is used for determining that the hydraulic pump has no fault when the actual power is less than or equal to the test power, the actual power is greater than or equal to the no-load power, and the volumetric efficiency is reduced by 0-5% on the basis of 100%.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
the hydraulic pump fault diagnosis method and the hydraulic pump fault diagnosis device disclosed by the invention can be used for obtaining the volumetric efficiency, the no-load power, the test power and the actual power of the hydraulic pump only based on the pressure and flow data of the outlet of the hydraulic pump, and carrying out the fault diagnosis of the hydraulic pump according to the volumetric efficiency, the no-load power, the test power and the actual power of the hydraulic pump to obtain a specific fault diagnosis result.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
FIG. 1 is a flow chart of an embodiment of a hydraulic pump fault diagnosis method of the present invention;
FIG. 2 is a block diagram of an embodiment of a hydraulic pump failure diagnosis apparatus according to the present invention;
fig. 3 is a schematic diagram of a hydraulic pump fault diagnosis device based on a CAN bus.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention aims to provide a hydraulic pump fault diagnosis method and device, which can be used for efficiently, simply and accurately diagnosing hydraulic pump faults.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Fig. 1 is a flowchart of an embodiment of a hydraulic pump fault diagnosis method of the present invention. Referring to fig. 1, the hydraulic pump fault diagnosis method includes:
step 101: acquiring no-load pressure, no-load flow, actual pressure, actual flow and hydraulic pump performance parameters of an outlet of a hydraulic pump; the performance parameters of the hydraulic pump comprise the displacement, the maximum rotating speed, the theoretical flow and the rated pressure of the hydraulic pump.
In step 101, the no-load pressure is the pressure at the outlet of the hydraulic pump when the hydraulic pump is set to the no-load working condition of the hydraulic pump; the no-load flow is the flow of the outlet of the hydraulic pump when the hydraulic pump is set to the no-load working condition of the hydraulic pump.
The rated pressure is the highest pressure for setting the hydraulic pump to continuously run under the normal working condition according to the test standard; the displacement is the volume of liquid theoretically discharged by each rotation of the hydraulic pump; the maximum rotating speed is the maximum rotating speed which is allowed to operate for a short time when the hydraulic pump exceeds the rated rotating speed under the rated pressure; the theoretical flow rate is the volume of liquid that the hydraulic pump should theoretically discharge per unit time. The performance parameters of the hydraulic pump can be obtained by inquiring.
The actual pressure is the pressure of the outlet of the hydraulic pump when the hydraulic pump is set to be the working condition of actual pressure, actual rotating speed and actual flow; the actual flow is the flow of the outlet of the hydraulic pump when the hydraulic pump is set to the working conditions of actual pressure, actual rotating speed and actual flow.
Step 102: and obtaining the volumetric efficiency of the hydraulic pump according to the actual flow and the theoretical flow.
The step 102 specifically includes:
using formulas
Calculating the volumetric efficiency of the hydraulic pump; in the formula, eta represents the volumetric efficiency of the hydraulic pump, q Practice of Representing the actual flow, q Theory of the invention Representing the theoretical flow rate.
Step 103: and obtaining the no-load power of the hydraulic pump according to the no-load pressure and the no-load flow.
The step 103 specifically includes:
using the formula P No load ＝p No load ×q No load Calculating the no-load power of the hydraulic pump; in the formula, P No load Indicating the no-load power of the hydraulic pump, p No load Denotes the no-load pressure, q No load Indicating no load flow.
Step 104: and obtaining the test power of the hydraulic pump according to the displacement, the highest rotating speed and the rated pressure.
The step 104 specifically includes:
using the formula P Testing of ＝p Rated value ×V×n max Calculating the test power of the hydraulic pump; in the formula, P Testing Indicating the test power of the hydraulic pump, p Rated value Indicating rated pressure, V indicating displacement, n max Indicating the highest rotational speed.
Step 105: and obtaining the actual power of the hydraulic pump according to the actual pressure and the actual flow.
The step 105 specifically includes:
using the formula P Practice of ＝p Practice of ×q Practice of Calculating the actual power of the hydraulic pump; in the formula, P Practice of Representing the actual power of the hydraulic pump, p Practice of Representing the actual pressure, q Practice of Representing the actual flow rate.
Step 106: and carrying out fault diagnosis on the hydraulic pump according to the volumetric efficiency, the no-load power, the test power and the actual power to obtain a fault diagnosis result.
In step 106, the fault diagnosis result includes that the rotation speed of the hydraulic pump is too high, the pressure of the hydraulic pump is too high, the rotation speed of the hydraulic pump is too low, the working time of the hydraulic pump is too long, hydraulic oil needs to be replaced, relative moving parts inside the hydraulic pump are worn, problems occur in assembly, relative moving parts inside the hydraulic pump are worn excessively, relative movement is blocked by foreign matters, and the hydraulic pump has no fault.
The step 106 specifically includes:
when the actual power is larger than the test power, the rotating speed of the hydraulic pump is determined to be too high or the pressure of the hydraulic pump is determined to be too large.
When the actual power is less than the idling power, it is determined that the rotational speed of the hydraulic pump is too low.
When the volumetric efficiency is reduced by 5% -20% on the basis of 100%, it is determined that the hydraulic pump is operated for an excessively long time or the hydraulic oil needs to be replaced.
When the volumetric efficiency is reduced by 20% -40% on the basis of 100%, it is determined that there is a problem in wear or assembly of the relatively moving parts inside the hydraulic pump.
When the volumetric efficiency is reduced by 40% -60% on the basis of 100%, the excessive wear of the internal relative moving parts of the hydraulic pump or the obstruction of the relative movement by foreign matters is determined.
And when the actual power is less than or equal to the test power, the actual power is greater than or equal to the no-load power, and the volumetric efficiency is reduced by 0-5% on the basis of 100%, determining that the hydraulic pump has no fault.
Wherein 0-5% does not include 5%, 5% -20% does not include 20%, and 20% -40% does not include 40%.
The hydraulic pump fault diagnosis method disclosed by the invention can be used for calculating the volumetric efficiency, the no-load power, the test power and the actual power of the hydraulic pump only based on the pressure and flow data of the outlet of the hydraulic pump, and performing the fault diagnosis of the hydraulic pump according to the volumetric efficiency, the no-load power, the test power and the actual power of the hydraulic pump to obtain a specific fault diagnosis result, and is efficient and simple, because the specific fault diagnosis result (comprising overhigh rotating speed of the hydraulic pump, overlarge pressure of the hydraulic pump, overlow rotating speed of the hydraulic pump, overlong working time of the hydraulic pump, needing to replace hydraulic oil, abrasion of parts and parts moving relatively inside the hydraulic pump, problems of assembly, excessive abrasion of parts and parts moving relatively inside the hydraulic pump, blockage of relative movement by foreign matters and no fault of the hydraulic pump) is determined based on the pressure and flow data of the outlet of the hydraulic pump, the fault diagnosis result is accurate, therefore, the hydraulic pump fault diagnosis can be efficiently, simply and accurately carried out.
Fig. 2 is a structural view of an embodiment of a hydraulic pump failure diagnosis apparatus according to the present invention. Referring to fig. 2, the hydraulic pump failure diagnosis apparatus to which the hydraulic pump failure diagnosis method in the above-described hydraulic pump failure diagnosis method embodiment is applied includes:
and the sensor signal node module 201 is arranged at the outlet position of the hydraulic pump and is used for acquiring the no-load pressure, the no-load flow, the actual pressure and the actual flow of the outlet of the hydraulic pump.
And the data storage processing node module 202 is connected to the sensor signal node module 201, and is configured to obtain the idle pressure, the idle flow, the actual pressure, the actual flow, and the displacement, the maximum rotation speed, the theoretical flow, and the rated pressure of the hydraulic pump, obtain the volumetric efficiency of the hydraulic pump according to the actual flow and the idle flow, obtain the idle power of the hydraulic pump according to the idle pressure and the idle flow, obtain the test power of the hydraulic pump according to the displacement, the maximum rotation speed, and the rated pressure, obtain the actual power of the hydraulic pump according to the actual pressure and the actual flow, and perform fault diagnosis on the hydraulic pump according to the volumetric efficiency, the idle power, the test power, and the actual power, so as to obtain a fault diagnosis result.
The rated pressure is the highest pressure for setting the hydraulic pump to continuously run according to the test standard under the normal working condition; the displacement is the volume of liquid theoretically discharged by each rotation of the hydraulic pump; the maximum rotating speed is the maximum rotating speed which is allowed to operate for a short time when the hydraulic pump exceeds the rated rotating speed under the rated pressure; the theoretical flow rate is the volume of liquid that the hydraulic pump should theoretically discharge per unit time.
The no-load pressure acquired by the sensor signal node module 201 is the pressure at the outlet of the hydraulic pump when the hydraulic pump is set to the no-load working condition of the hydraulic pump; the no-load flow rate obtained by the sensor signal node module 201 is the flow rate of the outlet of the hydraulic pump when the hydraulic pump is set to the no-load working condition of the hydraulic pump.
The actual pressure obtained by the sensor signal node module 201 is the pressure at the outlet of the hydraulic pump when the hydraulic pump is set to the working condition of actual pressure, actual rotating speed and actual flow; the actual flow rate obtained by the sensor signal node module 201 is the flow rate of the outlet of the hydraulic pump when the hydraulic pump is set to the working condition of actual pressure, actual rotating speed and actual flow rate.
The fault diagnosis result obtained by the data storage processing node module 202 includes that the rotating speed of the hydraulic pump is too high, the rotating speed of the hydraulic pump is too low, the working time of the hydraulic pump is too long, the hydraulic oil needs to be replaced, the relative moving parts inside the hydraulic pump are worn, the assembly is in problem, the relative moving parts inside the hydraulic pump are excessively worn, the relative movement is blocked by foreign matters, and the hydraulic pump has no fault.
The data storage processing node module 202 specifically includes:
and the actual power and test power comparison unit is used for determining that the rotating speed of the hydraulic pump is too high or the pressure of the hydraulic pump is too high when the actual power is greater than the test power.
And the actual power and idle power comparison unit is used for determining that the rotating speed of the hydraulic pump is too low when the actual power is less than the idle power.
And the first volumetric efficiency reduction unit is used for determining that the working time of the hydraulic pump is too long or the hydraulic oil needs to be replaced when the volumetric efficiency is reduced by 5% -20% on the basis of 100%.
And a second volumetric efficiency reduction unit for determining that there is a problem in wear or assembly of the relatively moving parts inside the hydraulic pump when the volumetric efficiency is reduced by 20% -40% on the basis of 100%.
And the third volumetric efficiency reduction unit is used for determining that the internal parts of the hydraulic pump which move relatively are excessively worn or have foreign matters to block the relative movement when the volumetric efficiency is reduced by 40-60 percent on the basis of 100 percent.
And the fault-free determining unit is used for determining that the hydraulic pump has no fault when the actual power is less than or equal to the test power, the actual power is greater than or equal to the no-load power and the volumetric efficiency is reduced by 0-5% on the basis of 100%.
Specifically, the hydraulic pump failure diagnosis device further includes:
and the display node module 203 is connected with the data storage processing node module 202 and is used for displaying the fault diagnosis result.
The hydraulic pump failure diagnosis apparatus further includes:
and the storage battery 204 is used for providing voltage for the sensor signal node module 201, the data storage processing node module 202 and the display node module 203.
And the power management module 205 is connected to the storage battery 204, the sensor signal node module 201, the data storage processing node module 202 and the display node module 203, and is configured to convert a voltage provided by the storage battery 204 into a voltage required by the sensor signal node module 201, the data storage processing node module 202 and the display node module 203.
The technical solution of the present invention is illustrated by a specific example below:
fig. 3 is a schematic diagram of a hydraulic pump fault diagnosis device based on a CAN bus. Referring to fig. 3, the hydraulic pump fault diagnosis device of the present invention CAN implement connection of each structure in the device based on the CAN bus, and the present invention provides a hydraulic pump fault diagnosis device based on the CAN bus aiming at meeting the reliability requirement of hydraulic pump fault diagnosis, which comprises a sensor signal node module, a data storage processing node module, a display node module and a power management module. The sensor signal node module, the data storage processing node module and the display node module are connected through a CAN bus, the CAN bus adopts two differential transmission signal lines (differential signal transmission networks) to form a bus network, and two ports of a CAN bus driver PCA82C250 of the sensor signal node module are respectively connected to the two differential signal transmission networks for communication. Two ports of a CAN bus driver PCA82C250 of the data storage processing node module are respectively connected to two differential signal transmission networks for communication. Two ports of a CAN bus driver PCA82C250 of the display node module are respectively connected to two differential signal transmission networks for communication, the input end of the power management module is connected with a storage battery of the equipment (device), the output end of the power management module is connected with power supply ends of the sensor signal node module, the data storage processing node module and the display node module, and the voltage of the storage battery of the equipment is converted into the voltage required by the sensor signal node module, the data storage processing node module and the display node module.
Specifically, the sensor signal node module comprises a single chip microcomputer AT89C52, a CAN controller SJA1000, a CAN driver PCA82C250, an analog-to-digital converter ADC0809, an integrated operational amplifier LM358 and other elements, the sensor signal node module further comprises a pressure detection node (a pressure sensor) and a flow detection node (a flow sensor), the two types of sensors are arranged AT the outlet position of the hydraulic pump, physical pressure and flow signals of the outlet of the hydraulic pump are collected and converted into analog voltage signals, and then the analog voltage signals are converted into digital signals. The input end of the integrated operational amplifier LM358 is connected with the output ends of the pressure sensor and the flow sensor, the output end of the integrated operational amplifier LM358 is connected with the input end of the analog-to-digital converter ADC0809, the output end of the analog-to-digital converter ADC0809 is connected with the input end of the single chip microcomputer AT89C52, the output end of the single chip microcomputer AT89C52 is connected with the input end of the CAN controller SJA1000, the output end of the CAN controller SJA1000 is connected with the input end of the CAN driver PCA82C250, the output end of the CAN driver PCA82C250 is connected with a CAN bus, the integrated operational amplifier LM358 amplifies sensor signals and then transmits the amplified sensor signals to the analog-to-digital converter ADC0809 to convert the analog signals into digital signals, the digital signals are transmitted to the single chip microcomputer AT89C52 to be stored, and the single chip microcomputer 89C52 controls the CAN controller SJA1000 and the CAN driver PCA82C250 to be communicated with the data storage processing node module through the CAN bus.
The data storage processing node module comprises a single chip microcomputer AT89C52, a CAN controller SJA1000, a CAN driver PCA82C250, a memory FRAM1808 and other elements, the output end of the memory FRAM1808 is connected with the input end of the single chip microcomputer AT89C52, the output end of the single chip microcomputer AT89C52 is connected with the input end of the CAN controller SJA1000, the output end of the CAN controller SJA1000 is connected with the input end of the CAN driver PCA82C250, the output end of the CAN driver PCA82C250 is connected with a CAN bus, the single chip microcomputer AT89C52 controls the CAN controller SJA1000 and the CAN driver PCA82C250 to be communicated with the sensor signal node module and the display node module through the CAN bus, and the FRAM1808 memory stores signals transmitted by the sensor signal node module and parameters such as the displacement, the highest rotating speed, the theoretical flow and the rated pressure of a hydraulic pump to be inquired. The data storage processing node module is also provided with a key switch for starting or stopping the hydraulic pump fault diagnosis device.
The display node module comprises a single-chip microcomputer AT89C52, a CAN controller SJA1000, a CAN driver PCA82C250, a liquid crystal display module and other elements, the output end of the single-chip microcomputer AT89C52 is connected with the input end of the CAN controller SJA1000, the output end of the CAN controller SJA1000 is connected with the input end of the CAN driver PCA82C250, the output end of the CAN driver PCA82C250 is connected with a CAN bus, the input end of the liquid crystal display module is connected with the output end of the single-chip microcomputer AT89C52, the liquid crystal display module displays corresponding fault information of a hydraulic pump, and the single-chip microcomputer AT89C52 controls the CAN controller SJA1000 and the CAN driver PCA82C250 to be communicated with the data storage processing node module through the CAN bus.
The power management module comprises a power voltage reduction element PW6206 and other elements, and the power voltage reduction element is used for inputting 24V direct current voltage and outputting 5V direct current voltage.
The data storage processing node module receives digital signals acquired by the sensor signal node module through the CAN bus, the received data are stored, the hydraulic pump fault diagnosis model diagnoses and analyzes faults of the hydraulic pump to obtain fault diagnosis result data (including overhigh rotating speed of the hydraulic pump or overhigh pressure, overlow rotating speed, overlong working time, hydraulic oil needing to be replaced, abrasion of internal relative movement parts, problem in assembly, excessive abrasion of the internal relative movement parts, blockage of relative movement by foreign matters and no fault), the fault diagnosis result data are transmitted to the display node module through the CAN bus, and the display node module displays the fault diagnosis result data of the data storage processing node module.
The invention also provides a hydraulic pump fault diagnosis method, which comprises the following steps:
and pressing a key switch of the data storage processing node module to start the hydraulic pump fault diagnosis device.
1. The sensor signal node module is arranged at the outlet end of the hydraulic pump, collects physical pressure and flow signals of the outlet of the hydraulic pump, converts the physical pressure and flow signals into analog voltage signals, and converts the analog voltage signals into digital signals.
2. In the embodiment, the hydraulic pump configured in the hydraulic system is an electrically-controlled double-acting vane pump, and the theoretical flow q of the hydraulic pump is inquired Theory of the invention 28.0L/min, and the displacement V of the hydraulic pump is 10.74cm 3 /r, maximum speed n of hydraulic pump max When the working condition is 2600r/m, the hydraulic pump is set to work under 3 working conditions, and the output pressure p and the flow rate q of the hydraulic pump under the specified working conditions are obtained.
The specified 1 st working condition refers to that the hydraulic pump is set to be in a no-load working condition of the hydraulic pump, and the output pressure p No load 0.8MPa and flow q No load ＝26L/min。
The specified 2 nd working condition refers to the working condition that the hydraulic pump is set to be at rated pressure and the maximum flow output by the hydraulic pump under the highest rotating speed, and the output pressure p Rated value 5.2MPa and maximum flow q max ＝V×n mTONG x ＝28L/min。
The specified 3 rd working condition refers to the working condition that the hydraulic pump is set to be at the actual pressure, the actual rotating speed and the actual flow, and the output pressure p Practice of And flow rate q Practice of As shown in table 1.
TABLE 1 actual output pressure and flow
| Serial number | Pressure p Practice of (MPa) | Flow rate q Practice of (L/min) |
| 1 | 5.1 | 29.0 |
| 2 | 1.9 | 10.3 |
| 3 | 4.3 | 23.8 |
| 4 | 3.7 | 20.4 |
| 5 | 4.1 | 14.0 |
Calculating the volumetric efficiency of the hydraulic pump according to equation (1), equation (1) being as follows:
calculating the no-load power of the hydraulic pump according to the formula (2), wherein the formula (2) is as follows:
P no load ＝p No load ×q No load (2)
Calculating the test power of the hydraulic pump according to the formula (3), wherein the formula (3) is as follows:
P testing ＝p Rated value ×V×n max (3)
Calculating the actual power of the hydraulic pump according to equation (4), equation (4) being as follows:
P practice of ＝p Practice of ×q Practice of (4)
The output pressure and the flow of the hydraulic pump to be measured under the 3 rd working condition are measured 20 times, and the average value is taken as the final pressure value and flow value.
The data obtained from the number 1 in table 1, the actual power of the hydraulic pump was calculated,
when the actual power p of the hydraulic pump Practice of ＞p Testing This indicates that the rotation speed of the hydraulic pump is too high or the pressure of the hydraulic pump is too high.
The data obtained from the number 2 in table 1, the actual power of the hydraulic pump was calculated,
when the actual power p of the hydraulic pump Practice of ＜p No load Indicating that the speed of the hydraulic pump is too low.
The data obtained from number 3 in table 1, the volumetric efficiency of the hydraulic pump was calculated,
the volume efficiency of the hydraulic pump is reduced by 15% when the volume efficiency of the hydraulic pump is 100% and reduced by 5% -20%, which indicates that the hydraulic pump has too long working time or the hydraulic oil needs to be replaced.
The data obtained from number 4 in table 1, the volumetric efficiency of the hydraulic pump was calculated,
when the volumetric efficiency of the hydraulic pump is 100%, and the volumetric efficiency eta is 73%, the volumetric efficiency eta is reduced by 27%, and when the volumetric efficiency of the hydraulic pump is 100%, and the volumetric efficiency eta is reduced by 20% -40%, the abrasion or assembly problem of the relative moving parts in the hydraulic pump is shown.
The hydraulic pressure was calculated from the data obtained in Table 1, reference number 5The volumetric efficiency of the pump is such that,
the volume efficiency of the hydraulic pump is reduced by 50% when the volume efficiency of the hydraulic pump is 100%, and the volume efficiency eta is reduced by 40% -60% when the volume efficiency of the hydraulic pump is 100%, which indicates that the internal relative moving parts of the hydraulic pump are excessively worn or foreign matters block the relative movement.
And when the conditions are not met, namely when the actual power is less than or equal to the test power, the actual power is greater than or equal to the no-load power, and the volumetric efficiency is reduced by 0-5% on the basis of 100%, determining that the hydraulic pump has no fault, and determining that the diagnosis result is no fault.
And storing the fault data in a data storage processing node module, establishing a hydraulic pump fault diagnosis library by using the fault judgment method, and storing the fault data in the data storage processing node module, wherein the data storage processing node module is installed in an operation cab.
3. And (3) transmitting the data measured in the step (1) to a data storage processing node module through a CAN bus, and analyzing and processing the data by a hydraulic pump fault diagnosis library to obtain hydraulic system fault diagnosis result data.
4. And the fault diagnosis result is transmitted from the data storage processing node module to the display node module through the CAN bus to display the fault data of the hydraulic system, and the display node module is installed in an operation cab.
The invention has the following advantages:
the invention provides a hydraulic pump fault diagnosis device and method aiming at the structural characteristics of a hydraulic pump and a conventional hydraulic pump fault diagnosis method, and provides the hydraulic pump fault diagnosis device based on a CAN bus. The device has simple structure, can carry out the fault diagnosis of the hydraulic pump based on the actually measured pressure and flow data to obtain a specific fault diagnosis result, and realizes the high-efficiency, simple and accurate fault diagnosis of the hydraulic pump.
In the present specification, the embodiments are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (10)
1. A hydraulic pump fault diagnosis method, characterized by comprising:
acquiring no-load pressure, no-load flow, actual pressure, actual flow and hydraulic pump performance parameters of an outlet of a hydraulic pump; the performance parameters of the hydraulic pump comprise the displacement, the highest rotating speed, the theoretical flow and the rated pressure of the hydraulic pump;
obtaining the volumetric efficiency of the hydraulic pump according to the actual flow and the theoretical flow;
obtaining the no-load power of the hydraulic pump according to the no-load pressure and the no-load flow;
obtaining the test power of the hydraulic pump according to the displacement, the highest rotating speed and the rated pressure;
obtaining the actual power of the hydraulic pump according to the actual pressure and the actual flow;
and carrying out fault diagnosis on the hydraulic pump according to the volumetric efficiency, the no-load power, the test power and the actual power to obtain a fault diagnosis result.
2. The hydraulic pump fault diagnosis method according to claim 1, wherein the no-load pressure is a pressure at an outlet of the hydraulic pump when the hydraulic pump is set to the no-load condition of the hydraulic pump; and the no-load flow is the flow of the outlet of the hydraulic pump when the hydraulic pump is set to be in the no-load working condition.
3. The hydraulic pump malfunction diagnosis method according to claim 1, characterized in that the rated pressure is the highest pressure at which the hydraulic pump is set to be continuously operated under normal operating conditions in accordance with a test standard; the displacement is the volume of liquid theoretically discharged by each rotation of the hydraulic pump; the maximum rotating speed is the maximum rotating speed which is allowed to operate for a short time when the hydraulic pump exceeds the rated rotating speed under the rated pressure; the theoretical flow rate is the volume of liquid that the hydraulic pump should theoretically discharge per unit time.
4. The hydraulic pump malfunction diagnosis method according to claim 1, characterized in that the actual pressure is a pressure at an outlet of the hydraulic pump when the hydraulic pump is set to a working condition of the actual pressure, the actual rotational speed, and the actual flow rate; the actual flow is the flow of the outlet of the hydraulic pump when the hydraulic pump is set to the working conditions of actual pressure, actual rotating speed and actual flow.
5. The hydraulic pump fault diagnosis method according to claim 1, wherein the fault diagnosis result includes that the rotation speed of the hydraulic pump is too high, the pressure of the hydraulic pump is too high, the rotation speed of the hydraulic pump is too low, the working time of the hydraulic pump is too long, the hydraulic oil needs to be replaced, the relative moving parts inside the hydraulic pump are worn out, problems occur in assembly, the relative moving parts inside the hydraulic pump are excessively worn out, relative movement is blocked by foreign matters, and the hydraulic pump is not faulty.
6. The hydraulic pump fault diagnosis method according to claim 5, wherein the performing hydraulic pump fault diagnosis based on the volumetric efficiency, the no-load power, the test power, and the actual power to obtain a fault diagnosis result specifically includes:
when the actual power is larger than the test power, determining that the rotating speed of the hydraulic pump is too high or the pressure of the hydraulic pump is too large;
when the actual power is smaller than the no-load power, determining that the rotating speed of the hydraulic pump is too low;
when the volumetric efficiency is reduced by 5% -20% on the basis of 100%, determining that the working time of the hydraulic pump is too long or the hydraulic oil needs to be replaced;
when the volumetric efficiency is reduced by 20-40% on the basis of 100%, determining that the abrasion or assembly of the relative moving parts in the hydraulic pump is in problem;
when the volumetric efficiency is reduced by 40-60% on the basis of 100%, determining that the internal relative moving parts of the hydraulic pump are excessively worn or have foreign matters to block relative movement;
and when the actual power is less than or equal to the test power, the actual power is greater than or equal to the no-load power, and the volumetric efficiency is reduced by 0-5% on the basis of 100%, determining that the hydraulic pump has no fault.
7. A hydraulic pump failure diagnosis apparatus that applies the hydraulic pump failure diagnosis method according to any one of claims 1 to 6, the apparatus comprising:
the sensor signal node module is arranged at the outlet of the hydraulic pump and used for acquiring the no-load pressure, the no-load flow, the actual pressure and the actual flow of the outlet of the hydraulic pump;
and the data storage processing node module is connected with the sensor signal node module and is used for acquiring the no-load pressure, the no-load flow, the actual pressure, the actual flow, the displacement, the highest rotating speed, the theoretical flow and the rated pressure of the hydraulic pump, obtaining the volumetric efficiency of the hydraulic pump according to the actual flow and the no-load flow, obtaining the no-load power of the hydraulic pump according to the no-load pressure and the no-load flow, obtaining the test power of the hydraulic pump according to the displacement, the highest rotating speed and the rated pressure, obtaining the actual power of the hydraulic pump according to the actual pressure and the actual flow, and diagnosing the fault of the hydraulic pump according to the volumetric efficiency, the no-load power, the test power and the actual power to obtain a fault diagnosis result.
8. The hydraulic pump malfunction diagnosis device according to claim 7, characterized in that the device further comprises:
and the display node module is connected with the data storage processing node module and is used for displaying the fault diagnosis result.
9. The hydraulic pump malfunction diagnosis device according to claim 8, characterized in that the device further comprises:
the storage battery is used for providing voltage for the sensor signal node module, the data storage processing node module and the display node module;
and the power management module is respectively connected with the storage battery, the sensor signal node module, the data storage processing node module and the display node module and is used for converting the voltage provided by the storage battery into the voltage required by the sensor signal node module, the data storage processing node module and the display node module.
10. The hydraulic pump fault diagnosis device according to claim 7, wherein the data storage processing node module specifically includes:
the actual power and test power comparison unit is used for determining that the rotating speed of the hydraulic pump is too high or the pressure of the hydraulic pump is too high when the actual power is larger than the test power;
the actual power and no-load power comparison unit is used for determining that the rotating speed of the hydraulic pump is too low when the actual power is smaller than the no-load power;
the first volumetric efficiency reduction unit is used for determining that the working time of the hydraulic pump is too long or the hydraulic oil needs to be replaced when the volumetric efficiency is reduced by 5% -20% on the basis of 100%;
the second volumetric efficiency reduction unit is used for determining that the abrasion or assembly of the relative moving parts in the hydraulic pump is in a problem when the volumetric efficiency is reduced by 20% -40% on the basis of 100%;
the third volumetric efficiency reduction unit is used for determining that the internal relative movement parts of the hydraulic pump are excessively worn or have foreign matters to block the relative movement when the volumetric efficiency is reduced by 40-60 percent on the basis of 100 percent;
and the fault-free determining unit is used for determining that the hydraulic pump has no fault when the actual power is less than or equal to the test power, the actual power is greater than or equal to the no-load power, and the volumetric efficiency is reduced by 0-5% on the basis of 100%.
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