CN114810572B - Hydraulic pump fault diagnosis method and device - Google Patents
Hydraulic pump fault diagnosis method and device Download PDFInfo
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- CN114810572B CN114810572B CN202210411004.3A CN202210411004A CN114810572B CN 114810572 B CN114810572 B CN 114810572B CN 202210411004 A CN202210411004 A CN 202210411004A CN 114810572 B CN114810572 B CN 114810572B
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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
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Abstract
The invention discloses a hydraulic pump fault diagnosis method and device, which relate to the technical field of hydraulic pump fault diagnosis, and the method comprises the following steps: acquiring idle pressure, idle flow, actual pressure, actual flow and hydraulic pump performance parameters of a hydraulic pump outlet; the hydraulic pump performance parameters comprise the displacement, the highest rotating speed, the theoretical flow and the rated pressure of the hydraulic pump; according to the actual flow and the theoretical flow, the volumetric efficiency of the hydraulic pump is obtained; according to the idle pressure and the idle flow, obtaining the idle power of the hydraulic pump; 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 of the hydraulic pump according to the volumetric efficiency, the idle 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, ships and the like, the working performance of the hydraulic pump directly influences the working state of the hydraulic system, and the reliability of the operation of the hydraulic pump is improved, so that fault diagnosis is required to be carried out on the hydraulic pump. Currently, advanced engineering machinery in the world adopts technologies such as computer management, intelligent fault diagnosis, remote monitoring and the like, and most of China engineering machinery adopts traditional electric control technology, and the fault diagnosis of a hydraulic pump generally depends on experience of maintenance personnel.
The current commonly used hydraulic pump fault diagnosis method comprises a hydraulic pump fault diagnosis method which depends on experience of technicians, a hydraulic pump operation parameter signal acquisition fault diagnosis method and a mathematical model fault prediction diagnosis method established by utilizing acquisition data, and the hydraulic pump fault diagnosis method which depends on experience of the technicians has higher requirements on the technicians and has low working efficiency; the fault diagnosis method for collecting the hydraulic pump operation parameter signals is based on measuring the operation state parameters of the hydraulic pump, and uses methods such as frequency spectrum analysis, time domain analysis, frequency domain analysis and the like to extract characteristic values such as frequency spectrum, amplitude, phase and the like to carry out hydraulic pump fault diagnosis, so that the characteristic values are difficult to extract, and the hydraulic pump fault diagnosis method is complex; the mathematical model fault prediction diagnosis method is established by utilizing the collected data, and as the factors influencing the working characteristics of the hydraulic pump are more, the elements of the hydraulic pump work in a closed hydraulic system to have coupling effect, and the accuracy of the model established by collecting the working parameter data of the hydraulic pump is unstable. Based on this, how to efficiently, simply and accurately perform hydraulic pump fault diagnosis is a problem to be solved urgently by those skilled in the art.
Disclosure of Invention
The invention aims to provide a hydraulic pump fault diagnosis method and device, which can efficiently, simply and accurately perform hydraulic pump fault diagnosis.
In order to achieve the above object, the present invention provides the following solutions:
a hydraulic pump fault diagnosis method, the method comprising:
acquiring idle pressure, idle flow, actual pressure, actual flow and hydraulic pump performance parameters of a hydraulic pump outlet; the hydraulic pump performance parameters comprise the displacement, the highest rotating speed, the theoretical flow and the rated pressure of the hydraulic pump;
according to the actual flow and the theoretical flow, the volumetric efficiency of the hydraulic pump is obtained;
according to the idle pressure and the idle flow, obtaining the idle power of the hydraulic pump;
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 performing hydraulic pump fault diagnosis according to the volumetric efficiency, the idle power, the test power and the actual power to obtain a fault diagnosis result.
Optionally, the idle pressure is the pressure of the outlet of the hydraulic pump when the hydraulic pump is set to the idle working condition of the hydraulic pump; the idle flow is the flow of the outlet of the hydraulic pump when the hydraulic pump is set to be in an idle working condition of the hydraulic pump.
Optionally, the rated pressure is the highest pressure of the hydraulic pump which is set to be continuously operated according to the test standard under the normal working condition; the displacement is the volume of liquid which is theoretically discharged per revolution of the hydraulic pump; the maximum rotating speed is the maximum rotating speed of the hydraulic pump which exceeds the rated rotating speed and allows short-time operation under the rated pressure; the theoretical flow is the volume of liquid that the hydraulic pump should theoretically discharge per unit time.
Optionally, the actual pressure is the pressure of the outlet of the hydraulic pump when the hydraulic pump is set to be under the working conditions 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 be under the working conditions of actual pressure, actual rotating speed and actual flow.
Optionally, 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, parts moving relatively in the hydraulic pump are worn out, assembly is problematic, parts moving relatively in the hydraulic pump are worn out excessively, foreign matters prevent relative movement, and the hydraulic pump has no fault.
Optionally, performing fault diagnosis of the hydraulic pump according to the volumetric efficiency, the idle power, the test power and the actual power to obtain a fault diagnosis result, which 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 high;
when the actual power is smaller than the idle power, determining that the rotating speed of the hydraulic pump is too low;
when the volumetric efficiency is reduced by 5% -20% based on 100%, determining that the hydraulic pump has too long working time or hydraulic oil needs to be replaced;
when the volumetric efficiency is reduced by 20% -40% based on 100%, determining that the abrasion or assembly of the relative movement parts in the hydraulic pump is problematic;
when the volumetric efficiency is reduced by 40% -60% based on 100%, determining that the relative movement parts inside the hydraulic pump are excessively worn or foreign matters block the relative movement;
and when the actual power is smaller than or equal to the test power, the actual power is larger than or equal to the idle power and the volumetric efficiency is reduced by 0-5% based on 100%, determining that the hydraulic pump has no fault.
The invention also provides the following scheme:
a hydraulic pump failure diagnosis apparatus to which the hydraulic pump failure diagnosis method is applied, the apparatus comprising:
the sensor signal node module is arranged at the outlet position of the hydraulic pump and used for acquiring the no-load pressure, no-load flow, actual pressure and actual flow of the outlet of the hydraulic pump;
the data storage processing node module is connected with the sensor signal node module and is used for acquiring the idle pressure, the idle flow, the actual pressure, the actual flow, the displacement of the hydraulic pump, the highest rotating speed, the theoretical flow and the rated pressure, obtaining the volumetric efficiency of the hydraulic pump according to the actual flow and the idle flow, obtaining the idle power of the hydraulic pump according to the idle pressure and the idle 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 performing fault diagnosis of the hydraulic pump according to the volumetric efficiency, the idle 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 used for displaying the fault diagnosis result.
Optionally, the apparatus further comprises:
the storage battery is used for providing voltages for the sensor signal node module, the data storage processing node module and the display node module;
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 idle 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 idle power;
the first volumetric efficiency reducing unit is used for determining that the working time of the hydraulic pump is too long or hydraulic oil needs to be replaced when the volumetric efficiency is reduced by 5% -20% based on 100%;
a second volumetric efficiency reduction unit for determining that the abrasion or assembly of the relatively moving parts inside the hydraulic pump is problematic when the volumetric efficiency is reduced by 20% -40% based on 100%;
a third volumetric efficiency reduction unit for determining excessive wear of the parts moving relatively inside the hydraulic pump or that foreign matter is obstructing the relative movement when the volumetric efficiency is reduced by 40% -60% based on 100%;
and the fault-free determining unit is used for determining that the hydraulic pump has no fault when the actual power is smaller than or equal to the test power, the actual power is larger than or equal to the idle power and the volumetric efficiency is reduced by 0-5% based on 100%.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
according to the hydraulic pump fault diagnosis method and device disclosed by the invention, the volumetric efficiency, the idle power, the test power and the actual power of the hydraulic pump are obtained only based on the pressure and flow data of the outlet of the hydraulic pump, and the hydraulic pump fault diagnosis can be performed according to the volumetric efficiency, the idle power, the test power and the actual power of the hydraulic pump, so that a specific fault diagnosis result is obtained.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions of the prior art, the drawings that are needed in the embodiments will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
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 of the present invention;
fig. 3 is a schematic diagram of a hydraulic pump fault diagnosis device based on a CAN bus according to the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention aims to provide a hydraulic pump fault diagnosis method and device, which can efficiently, simply and accurately perform hydraulic pump fault diagnosis.
In order that the above-recited objects, features and advantages of the present invention will become more readily apparent, a more particular description of the invention will be rendered by reference to the appended drawings and appended detailed description.
Fig. 1 is a flowchart of an embodiment of a hydraulic pump failure diagnosis method of the present invention. Referring to fig. 1, the hydraulic pump fault diagnosis method includes:
step 101: acquiring idle pressure, idle flow, actual pressure, actual flow and hydraulic pump performance parameters of a hydraulic pump outlet; hydraulic pump performance parameters include displacement, maximum rotational speed, theoretical flow, and rated pressure of the hydraulic pump.
In the step 101, the idle pressure is the pressure of the outlet of the hydraulic pump when the hydraulic pump is set to the idle working condition of the hydraulic pump; the idle flow is the flow of the outlet of the hydraulic pump when the hydraulic pump is set to the idle working condition of the hydraulic pump.
The rated pressure is the highest pressure of the hydraulic pump which is set to be continuously operated according to the test standard under the normal working condition; the displacement is the volume of liquid which should be theoretically discharged per revolution of the hydraulic pump; the maximum rotation speed is the maximum rotation speed of the hydraulic pump which exceeds the rated rotation speed and allows short-time operation 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 through inquiry.
The actual pressure is the pressure of the outlet of the hydraulic pump when the hydraulic pump is set to be under the working conditions 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 the actual pressure, the actual rotation speed and the 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 the formulaCalculating the volumetric efficiency of the hydraulic pump; wherein η represents the volumetric efficiency of the hydraulic pump, q Actual practice is that of Represents the actual flow rate, q Theory of Indicating the theoretical flow rate.
Step 103: and obtaining the idle power of the hydraulic pump according to the idle pressure and the idle flow.
The step 103 specifically includes:
using formula P No-load ＝p No-load ×q No-load Calculating the idle load of a hydraulic pumpA power; wherein P is No-load Indicating the idle power of the hydraulic pump, p No-load Represents the idle pressure, q No-load Indicating the idle 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 formula P Testing ＝p Rated for ×V×n max Calculating the test power of the hydraulic pump; wherein P is Testing Indicating the test power of the hydraulic pump, p Rated for Represents rated pressure, V represents 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 formula P Actual practice is that of ＝p Actual practice is that of ×q Actual practice is that of Calculating the actual power of the hydraulic pump; wherein P is Actual practice is that of Representing the actual power of the hydraulic pump, p Actual practice is that of Represents the actual pressure, q Actual practice is that of Representing the actual flow.
Step 106: and carrying out fault diagnosis of the hydraulic pump according to the volumetric efficiency, the idle 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, the hydraulic oil needs to be replaced, the parts moving relatively in the hydraulic pump are worn out, the assembly is problematic, the parts moving relatively in the hydraulic pump are worn excessively, foreign matters prevent the relative movement, and the hydraulic pump has no fault.
The step 106 specifically includes:
when the actual power is greater than the test power, it is determined that the rotational speed of the hydraulic pump is too high or that the pressure of the hydraulic pump is too high.
When the actual power is smaller than the idle power, it is determined that the rotational speed of the hydraulic pump is too low.
When the volumetric efficiency is reduced by 5% -20% based on 100%, 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% based on 100%, the abrasion or assembly of the relative motion parts inside the hydraulic pump is determined to be problematic.
When the volumetric efficiency is reduced by 40% -60% based on 100%, the excessive abrasion of the parts moving relatively in the hydraulic pump or the obstruction of the relative movement by foreign matters is determined.
When the actual power is less than or equal to the test power, the actual power is greater than or equal to the idle power and the volumetric efficiency is reduced by 0-5% based on 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%.
According to the hydraulic pump fault diagnosis method disclosed by the invention, the volumetric efficiency, the idle power, the test power and the actual power of the hydraulic pump are calculated only based on the pressure and flow data of the outlet of the hydraulic pump, and the hydraulic pump fault diagnosis can be performed according to the volumetric efficiency, the idle power, the test power and the actual power of the hydraulic pump, so that a specific fault diagnosis result is obtained.
Fig. 2 is a structural view of an embodiment of a hydraulic pump failure diagnosis apparatus of 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:
the sensor signal node module 201 is arranged at the outlet position of the hydraulic pump and is used for acquiring the idle pressure, the idle flow, the actual pressure and the actual flow of the outlet of the hydraulic pump.
The data storage processing node module 202 is connected with the sensor signal node module 201, and is used for obtaining the idle pressure, the idle flow, the actual pressure, the actual flow, the displacement of the hydraulic pump, the highest rotating speed, the theoretical flow and the rated pressure, obtaining the volumetric efficiency of the hydraulic pump according to the actual flow and the idle flow, obtaining the idle power of the hydraulic pump according to the idle pressure and the idle 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 performing fault diagnosis of the hydraulic pump according to the volumetric efficiency, the idle power, the test power and the actual power, and obtaining the fault diagnosis result.
The rated pressure is the highest pressure of the hydraulic pump which is set to be continuously operated according to the test standard under the normal working condition; the displacement is the volume of liquid which should be theoretically discharged per revolution of the hydraulic pump; the maximum rotation speed is the maximum rotation speed of the hydraulic pump which exceeds the rated rotation speed and allows short-time operation under the rated pressure; the theoretical flow rate is the volume of liquid that the hydraulic pump should theoretically discharge per unit time.
The idle pressure obtained by the sensor signal node module 201 is the pressure of the outlet of the hydraulic pump when the hydraulic pump is set to the idle working condition of the hydraulic pump; the idle 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 idle working condition of the hydraulic pump.
The actual pressure obtained by the sensor signal node module 201 is the pressure of the outlet of the hydraulic pump when the hydraulic pump is set to be under the working conditions 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 conditions of the actual pressure, the actual rotation speed and the actual flow rate.
The fault diagnosis results obtained by the data storage processing node module 202 include 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 movement parts in the hydraulic pump are worn out, the assembly is problematic, the relative movement parts in the hydraulic pump are excessively worn out, foreign matters prevent the relative movement, 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 larger 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 smaller than the idle power.
And the first volumetric efficiency reduction unit is used for determining that the hydraulic pump has too long working time or hydraulic oil needs to be replaced when the volumetric efficiency is reduced by 5% -20% based on 100%.
And a second volumetric efficiency reducing unit for determining that the abrasion or assembly of the relatively moving parts inside the hydraulic pump is problematic when the volumetric efficiency is reduced by 20% -40% based on 100%.
And the third volumetric efficiency reducing unit is used for determining that the relative movement parts inside the hydraulic pump are excessively worn or foreign matters block the relative movement when the volumetric efficiency is reduced by 40% -60% based on 100%.
And the fault-free determining unit is used for determining that the hydraulic pump has no fault when the actual power is smaller than or equal to the test power, the actual power is larger than or equal to the idle power and the volumetric efficiency is reduced by 0-5% based on 100%.
Specifically, the hydraulic pump failure diagnosis device further includes:
the display node module 203 is connected to the data storage processing node module 202, and is configured to display a fault diagnosis result.
The hydraulic pump failure diagnosis device further includes:
a battery 204 for providing voltages to the sensor signal node module 201, the data storage processing node module 202, and the display node module 203.
The power management module 205 is respectively connected with 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 used for converting the voltage provided by the storage battery 204 into the voltage required by the sensor signal node module 201, the data storage processing node module 202 and the display node module 203.
The technical scheme of the invention is described in the following by a specific embodiment:
fig. 3 is a schematic diagram of a hydraulic pump fault diagnosis device based on a CAN bus according to the present invention. Referring to fig. 3, the hydraulic pump fault diagnosis device of the invention CAN realize connection of various structures in the device based on a CAN bus, and the invention provides the 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 the 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 singlechip AT89C52, a CAN controller SJA1000, a CAN driver PCA82C250, an analog-to-digital converter ADC0809, an integrated operational amplifier LM358 and other elements, and also comprises a pressure detection node (pressure sensor) and a flow detection node (flow sensor), wherein the two types of sensors are deployed AT the outlet position of the hydraulic pump, collect pressure and flow physical signals AT the outlet of the hydraulic pump, convert the pressure and flow physical signals into analog voltage signals, and then convert the analog voltage signals into digital signals. The input end of the integrated operational amplifier LM358 is connected with the output end 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 the CAN bus, the integrated operational amplifier LM358 amplifies sensor signals and then transmits the sensor signals to the analog-to-digital converter ADC0809 to be converted into digital signals, the digital signals are transmitted to the single-chip microcomputer AT89C52 to be stored, and the single-chip microcomputer AT89C52 controls the CAN controller SJA1000 and the CAN driver PCA82C250 to communicate with each other through the CAN bus and the data storage processing node module.
The data storage processing node module comprises a singlechip 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 singlechip AT89C52, the output end of the singlechip 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 singlechip AT89C52 controls the CAN controllers SJA1000 and the CAN driver PCA82C250 to communicate with the sensor signal node module and the display node module through the CAN bus, and the FRAM1808 memory stores the signals transmitted by the sensor signal node module, the parameters such as the displacement, the highest rotating speed, the theoretical flow, the rated pressure and the like of the inquired hydraulic pump. The data storage processing node module is also provided with a key switch which starts or shuts down the hydraulic pump fault diagnosis device.
The display node module comprises elements such as a singlechip AT89C52, a CAN controller SJA1000, a CAN driver PCA82C250, a liquid crystal display module and the like, wherein the output end of the singlechip 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 singlechip AT89C52, the liquid crystal display module displays corresponding fault information of the hydraulic pump, and the singlechip AT89C52 controls the CAN controller SJA1000 and the CAN driver PCA82C250 to communicate with the data storage processing node module through the CAN bus.
The power management module comprises a power supply voltage-reducing element PW6206 and other elements, wherein the input DC voltage is 24V, and the output DC voltage is 5V.
The data storage processing node module receives the digital signals acquired by the sensor signal node module through the CAN bus, stores the received data, the hydraulic pump fault diagnosis model performs diagnosis analysis on faults of the hydraulic pump to obtain fault diagnosis result data (comprising the fact that the rotating speed of the hydraulic pump is too high or the pressure of the hydraulic pump is too high, the rotating speed is too low, the working time is too long, hydraulic oil needs to be replaced, internal relative movement parts are worn out, assembly is problematic, the internal relative movement parts are worn out excessively, foreign matters prevent relative movement and no faults exist), and transmits the fault diagnosis result data 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 signals of pressure and flow of the outlet of the hydraulic pump, converts the physical signals into analog voltage signals, and then converts the analog voltage signals into digital signals.
2. The hydraulic pump configured in the hydraulic system in the embodiment is an electric control double-acting vane pump, and the theoretical flow q of the hydraulic pump is inquired Theory of The displacement V of the hydraulic pump=10.74 cm=28.0L/min 3 Maximum rotational speed n of hydraulic pump max =2600 r/m, the hydraulic pump is set to operate under the prescribed 3 working conditions, resulting in the output pressure p and flow q of the hydraulic pump under the prescribed working conditions.
The 1 st prescribed condition refers to setting the hydraulic pump to the idle condition of the hydraulic pump, and outputting the pressure p No-load =0.8 MPa and flow q No-load ＝26L/min。
The 2 nd working condition is the working condition that the hydraulic pump is set to rated pressure and the maximum flow rate is output by the hydraulic pump under the highest rotating speed, and the output pressure p Rated for =5.2 MPa and maximum flow q max ＝V×n m is x ＝28L/min。
The 3 rd working condition is the working condition that the hydraulic pump is set to be the actual pressure, the actual rotating speed and the actual flow rate, and the pressure p is output Actual practice is that of And flow rate q Actual practice is that of As shown in table 1.
TABLE 1 output pressure and flow for actual conditions
| Sequence number | Pressure p Actual practice is that of (MPa) | Flow q Actual practice is that 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 |
The volumetric efficiency of the hydraulic pump is calculated according to equation (1), equation (1) being as follows:
the idle power of the hydraulic pump is calculated according to formula (2), 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 for ×V×n max (3)
Calculating the actual power of the hydraulic pump according to formula (4), wherein formula (4) is as follows:
P actual practice is that of ＝p Actual practice is that of ×q Actual practice is that of (4)
And under the 3 rd working condition, the output pressure and the flow of the hydraulic pump to be measured are measured for 20 times, and the average value is taken as a final pressure value and a final flow value.
The data is obtained from the number 1 in table 1, the actual power of the hydraulic pump is calculated, when the actual power p of the hydraulic pump Actual practice is that of ＞p Testing Indicating that the rotational speed of the hydraulic pump is too high or that the pressure of the hydraulic pump is too high.
The data is obtained from the number 2 in table 1, the actual power of the hydraulic pump is calculated, when the actual power p of the hydraulic pump Actual practice is that of ＜p No-load Indicating that the rotational speed of the hydraulic pump is too low.
The data obtained by the number 3 in table 1, the volumetric efficiency of the hydraulic pump was calculated,the volumetric efficiency of the hydraulic pump is 100 percent, the volumetric efficiency eta=85%, the volumetric efficiency is reduced by 15 percent, when the volumetric efficiency of the hydraulic pump is 100 percent, the volumetric efficiency eta is reduced by 5 to 20 percent, which indicates that the working time of the hydraulic pump is overlong or the hydraulic oil needs to be replaced.
The data obtained by the number 4 in table 1, the volumetric efficiency of the hydraulic pump was calculated,the volumetric efficiency of the hydraulic pump is 100% as a reference, the volumetric efficiency eta=73% and is reduced by 27%, when the volumetric efficiency of the hydraulic pump is 100% as a reference, the volumetric efficiency eta is reduced by 20% -40%, which indicates that the abrasion or assembly of the relative motion parts inside the hydraulic pump is problematic.
The data obtained by the number 5 in table 1, the volumetric efficiency of the hydraulic pump was calculated,the volumetric efficiency of the hydraulic pump is 100 percent as a reference, the volumetric efficiency eta=50% and the volumetric efficiency is reduced by 50 percent, when the volumetric efficiency of the hydraulic pump is 100 percent as a reference and the volumetric efficiency eta is reduced by 40% -60%, the relative movement of the parts in the hydraulic pump is excessively worn or blocked by foreign matters.
When the conditions are not satisfied, namely, the actual power is smaller than or equal to the test power, the actual power is larger than or equal to the idle power and the volumetric efficiency is reduced by 0-5% based on 100%, the hydraulic pump is determined to be fault-free, and the diagnosis result is fault-free.
The fault data are stored in a data storage processing node module, a hydraulic pump fault diagnosis library is built by the fault judging method, the fault data are stored in the data storage processing node module, and 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. The fault diagnosis result is transmitted to the display node module from the data storage processing node module through the CAN bus to display fault data of the hydraulic system, and the display node module is arranged in the operation cab.
The invention has the following advantages:
the invention establishes a hydraulic pump fault diagnosis device and method aiming at the structural characteristics of a hydraulic pump and the current commonly used hydraulic pump fault diagnosis method, and provides a hydraulic pump fault diagnosis device based on a CAN bus. The device has a simple structure, can perform hydraulic pump fault diagnosis based on the actually measured pressure and flow data, obtains a specific fault diagnosis result, and realizes efficient, simple and accurate hydraulic pump fault diagnosis.
In the present specification, each embodiment is described in a progressive manner, and each embodiment is mainly described in a different point from other embodiments, and identical and similar parts between the embodiments are all enough to refer to each other.
The principles and embodiments of the present invention have been described herein with reference to specific examples, the description of which is intended only to assist in understanding the methods of the present invention and the core ideas thereof; also, it is within the scope of the present invention to be modified by those of ordinary skill in the art in light of the present teachings. In view of the foregoing, this description should not be construed as limiting the invention.
Claims (7)
1. A method for diagnosing a failure of a hydraulic pump, the method comprising:
acquiring idle pressure, idle flow, actual pressure, actual flow and hydraulic pump performance parameters of a hydraulic pump outlet; the hydraulic pump performance parameters comprise the displacement, the highest rotating speed, the theoretical flow and the rated pressure of the hydraulic pump; the rated pressure is the highest pressure of the hydraulic pump which is set to be continuously operated according to the test standard under the normal working condition; the displacement is the volume of liquid which is theoretically discharged per revolution of the hydraulic pump; the maximum rotating speed is the maximum rotating speed of the hydraulic pump which exceeds the rated rotating speed and allows short-time operation under the rated pressure; the theoretical flow is the volume of liquid which the hydraulic pump theoretically should discharge in unit time;
obtaining the volumetric efficiency of the hydraulic pump according to the actual flow and the theoretical flow, wherein the volumetric efficiency comprises the following specific steps: using the formulaCalculating the volumetric efficiency of the hydraulic pump; wherein η represents the volumetric efficiency of the hydraulic pump, q Actual practice is that of Represents the actual flow rate, q Theory of Representing a theoretical flow rate;
according to the idle pressure and the idle flow, obtaining the idle power of the hydraulic pump;
obtaining test power of the hydraulic pump according to the displacement, the highest rotating speed and the rated pressure, wherein the test power comprises the following specific steps: using formula P Testing ＝p Rated for ×V×n max Calculating the test power of the hydraulic pump; wherein P is Testing Indicating the test power of the hydraulic pump, p Rated for Represents rated pressure, V represents displacement, n max Representing the highest rotational speed;
obtaining the actual power of the hydraulic pump according to the actual pressure and the actual flow;
performing hydraulic pump fault diagnosis according to the volumetric efficiency, the idle power, the test power and the actual power to obtain a fault diagnosis result; the fault diagnosis result comprises 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, hydraulic oil needs to be replaced, parts moving relatively in the hydraulic pump are worn out, assembly is problematic, parts moving relatively in the hydraulic pump are worn excessively, foreign matters prevent relative movement, and the hydraulic pump has no fault;
and performing hydraulic pump fault diagnosis according to the volumetric efficiency, the idle power, the test power and the actual power to obtain a fault diagnosis result, wherein the method specifically comprises the following steps of:
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 high;
when the actual power is smaller than the idle power, determining that the rotating speed of the hydraulic pump is too low;
when the volumetric efficiency is reduced by 5% -20% based on 100%, determining that the hydraulic pump has too long working time or hydraulic oil needs to be replaced;
when the volumetric efficiency is reduced by 20% -40% based on 100%, determining that the abrasion or assembly of the relative movement parts in the hydraulic pump is problematic;
when the volumetric efficiency is reduced by 40% -60% based on 100%, determining that the relative movement parts inside the hydraulic pump are excessively worn or foreign matters block the relative movement;
and when the actual power is smaller than or equal to the test power, the actual power is larger than or equal to the idle power and the volumetric efficiency is reduced by 0-5% based on 100%, determining that the hydraulic pump has no fault.
2. The hydraulic pump failure diagnosis method according to claim 1, wherein the idle pressure is a pressure at an outlet of the hydraulic pump when the hydraulic pump is set to a hydraulic pump idle condition; the idle flow is the flow of the outlet of the hydraulic pump when the hydraulic pump is set to be in an idle working condition of the hydraulic pump.
3. The hydraulic pump failure diagnosis method according to claim 1, wherein 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 rotation 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 be under the working conditions of actual pressure, actual rotating speed and actual flow.
4. A hydraulic pump failure diagnosis apparatus, characterized in that the apparatus applies the hydraulic pump failure diagnosis method according to any one of claims 1 to 3, the apparatus comprising:
the sensor signal node module is arranged at the outlet position of the hydraulic pump and used for acquiring the no-load pressure, no-load flow, actual pressure and actual flow of the outlet of the hydraulic pump;
the data storage processing node module is connected with the sensor signal node module and is used for acquiring the idle pressure, the idle flow, the actual pressure, the actual flow, the displacement of the hydraulic pump, the highest rotating speed, the theoretical flow and the rated pressure, obtaining the volumetric efficiency of the hydraulic pump according to the actual flow and the idle flow, obtaining the idle power of the hydraulic pump according to the idle pressure and the idle 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 performing fault diagnosis of the hydraulic pump according to the volumetric efficiency, the idle power, the test power and the actual power to obtain a fault diagnosis result.
5. The hydraulic pump failure diagnosis apparatus according to claim 4, characterized in that the apparatus further comprises:
and the display node module is connected with the data storage processing node module and used for displaying the fault diagnosis result.
6. The hydraulic pump failure diagnosis apparatus according to claim 5, characterized in that the apparatus further comprises:
the storage battery is used for providing voltages for the sensor signal node module, the data storage processing node module and the display node module;
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.
7. The hydraulic pump fault diagnosis apparatus according to claim 4, 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 idle 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 idle power;
the first volumetric efficiency reducing unit is used for determining that the working time of the hydraulic pump is too long or hydraulic oil needs to be replaced when the volumetric efficiency is reduced by 5% -20% based on 100%;
a second volumetric efficiency reduction unit for determining that the abrasion or assembly of the relatively moving parts inside the hydraulic pump is problematic when the volumetric efficiency is reduced by 20% -40% based on 100%;
a third volumetric efficiency reduction unit for determining excessive wear of the parts moving relatively inside the hydraulic pump or that foreign matter is obstructing the relative movement when the volumetric efficiency is reduced by 40% -60% based on 100%;
and the fault-free determining unit is used for determining that the hydraulic pump has no fault when the actual power is smaller than or equal to the test power, the actual power is larger than or equal to the idle power and the volumetric efficiency is reduced by 0-5% based on 100%.
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| CN116255377B (en) * | 2023-05-11 | 2023-07-18 | 南京蒙福液压机械有限公司 | Servo intelligent machine tool hydraulic station fault analysis system |
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