CN115526211A - Load port independent control-oriented fault diagnosis method for valve-controlled hydraulic cylinder system - Google Patents
Load port independent control-oriented fault diagnosis method for valve-controlled hydraulic cylinder system Download PDFInfo
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Abstract
The invention provides a fault diagnosis method for a valve-controlled hydraulic cylinder system independently controlled by a load port, which comprises the following steps: step S1: establishing a valve control hydraulic cylinder system; step S2: fault injection is carried out to generate eight types of faults; and step S3: acquiring signals to obtain nine types of signals and generate a sample; and step S4: preprocessing a sample; step S5: after the pretreatment is finished, dividing the generated sample into a training set, a verification set and a test set according to a proportion; step S6: the training set and the verification set are used for training a fault diagnosis algorithm; step S7: and judging the performance of the trained algorithm model after the test of the test set. According to the invention, the element characteristics under long time span are excavated by a deep learning algorithm according to the sensor information of a plurality of components of the valve-controlled hydraulic cylinder system which is independently controlled towards the load port, and the specific element with a fault of the system is identified, so that the fault diagnosis work of the valve-controlled hydraulic cylinder system which is independently controlled towards the load port is realized.
Description
Technical Field
The invention relates to the technical field of fault diagnosis and mode identification in industrial processes, in particular to a fault diagnosis method for a valve-controlled hydraulic cylinder system independently controlled for a load port, and particularly relates to a fault diagnosis method for a valve-controlled hydraulic cylinder system independently controlled for a load port based on a one-dimensional large convolution kernel and a residual error network.
Background
The valve-controlled hydraulic cylinder system has the characteristics of high power, high precision, quick response and the like, and is often applied to a typical hydraulic system such as a power gear-shifting transmission system of a tractor, a driving system of a hybrid electric vehicle and the like. The traditional servo control system for the valve-controlled hydraulic cylinder adopts a three-position four-way valve to control the hydraulic cylinder, and the control precision and efficiency are limited by low flexibility and high energy loss caused by a coupled mechanical structure. In contrast, the valve-controlled hydraulic cylinder system facing the load port independent control has the characteristic of independent control of two cavities, so that the system has high precision and high flexibility and simultaneously achieves low energy consumption.
At present, certain research is carried out at home and abroad aiming at the valve-controlled hydraulic cylinder system which is independently controlled by a load port. The technical scheme of the prior art designs an independent control system of a load port with continuously adjustable return oil pressure, and solves the problem of cavitation of an actuator low-pressure cavity in a low-pressure regeneration mode of the control system and the pressure loss in a common mode by adding a structure that an electric proportional overflow valve with adjustable pressure is connected with a check valve in parallel on an oil return path. In the prior art, a hydraulic system and a control method based on two-stage energy supply and independent valve control of a load port are designed, and the control precision of a hydraulic drive unit and the efficiency of the system are improved through a fuzzy sliding mode variable structure control strategy. Meanwhile, certain research is carried out at home and abroad aiming at the fault diagnosis of the valve-controlled hydraulic cylinder system. The pneumatic control valve fault diagnosis method based on the low-deviation random configuration network is designed in the prior art, the fault diagnosis work of the pneumatic control valve is realized by combining a principal component analysis method, and the method has high diagnosis accuracy. In the prior art, a fault diagnosis model based on a high-dimensional nonlinear classifier is designed, fault diagnosis of a simulation hydraulic cylinder model established in AMESim software is completed, the problems of nonlinearity and small samples are solved, and the fault identification capability of the fault diagnosis model is improved.
The prior art has certain limitations, which are shown as follows:
1. research on the valve-controlled hydraulic cylinder system with independent control of the load port mainly focuses on three layers of structural design, controller design and system application of the system, but the system consists of a plurality of components, and each component can have a large influence on the overall performance of the system when in failure.
2. The fault diagnosis of the existing valve-controlled hydraulic cylinder system mainly aims at single components in the system, such as valves or hydraulic cylinders, ignores system-level signal difference caused by multi-sensor feedback and control strategies of the system, and lacks of research on system-level fault diagnosis.
3. The existing research is directed at active fault-tolerant control of a hydraulic valve with independent valve ports, and the control strategy design of the hydraulic valve with the independent valve ports is established under the condition of known faults, but the diagnosis and the judgment of the faults of the hydraulic valve are lacked.
Therefore, a new technical solution needs to be proposed.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a fault diagnosis method for a valve-controlled hydraulic cylinder system independently controlled by a load port.
According to the fault diagnosis method for the valve-controlled hydraulic cylinder system independently controlled by the load port, which is provided by the invention, the method comprises the following steps:
step S1: establishing a valve control hydraulic cylinder system;
step S2: fault injection is carried out to generate eight types of faults;
and step S3: acquiring signals to obtain nine types of signals and generate a sample;
and step S4: preprocessing a sample;
step S5: after the pretreatment is finished, dividing the generated sample into a training set, a verification set and a test set according to a proportion;
step S6: the training set and the verification set are used for training a fault diagnosis algorithm;
step S7: and judging the performance of the trained algorithm model after the test of the test set.
Preferably, the fault in step S2 includes four high-speed switching valves, two hydraulically-operated directional control valves, a hydraulic cylinder and a displacement sensor.
Preferably, the PWM driving voltage of the high-speed switching valve is provided by matched software and hardware.
Preferably, the failure of the hydraulically operated directional control valve is: oil particles and oil impact wear the valve element and leak and seal ring damage failures and spring failures.
Preferably, the displacement sensor is mounted on the valve body.
Preferably, the signals in step S3 are nine categories composed of the fault in step S2 and the system normal state, each category collects two main valve control cavity pressure signals and spool displacement signals, and collects a hydraulic cylinder control cavity pressure signal and a rod displacement signal, and samples 2S at a sampling frequency of 1000 Hz; the normal data and fault data each contained 900 sets of data, each set of data including 9 signatures, each signature including 2000 data points, the samples being generated.
Preferably, said step S4 preprocesses the sample by the following formula, wherein x m It is shown that the m-th feature,
as a result after pretreatment:
preferably, the ratio in step S5 is 6:2:1.
compared with the prior art, the invention has the following beneficial effects:
1. according to the invention, the element characteristics under long time span are excavated by a deep learning algorithm according to the sensor information of a plurality of components of the valve-controlled hydraulic cylinder system which is independently controlled towards the load port, and the specific element of the system which has a fault is identified, so that the fault diagnosis work of the valve-controlled hydraulic cylinder system which is independently controlled towards the load port is realized;
2. the invention constructs a valve-controlled hydraulic cylinder system with independently controlled load ports, and the sensor information of a plurality of components is collected to express the system characteristics; by designing a deep learning algorithm, in particular a deep learning algorithm of a one-dimensional large convolution kernel and a residual error network, multi-source signal fusion work is carried out, and feature extraction of the valve control hydraulic cylinder system under long time span is realized;
3. according to the method, normal data and fault data of the valve-controlled hydraulic cylinder system are distinguished aiming at the constructed valve-controlled hydraulic cylinder system; meanwhile, when the system fails, the specific element with the failure in the system is identified, so that the system is favorable for quickly carrying out maintenance work when the system fails;
4. according to the invention, the fault is positioned to a specific element in the system through a deep learning algorithm, so that the problem of completing system fault detection by virtue of manual experience is solved, the rapid diagnosis of the system fault is realized, the maintenance and replacement work of a fault part is completed by a method for identifying the specific fault element, and the maintenance cost of the system is reduced while the safe operation of the system is ensured.
Drawings
Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:
FIG. 1 is a schematic diagram of a load port independent control oriented valve-controlled hydraulic cylinder system of the present invention;
FIG. 2 is a control block diagram of the valve-controlled hydraulic cylinder system facing independent control of a load port according to the invention;
FIG. 3 is a flow chart of the system fault diagnosis of the present invention;
FIG. 4 is a diagram of a system fault diagnosis algorithm of the present invention;
FIG. 5 is a fault diagnosis confusion matrix diagram of the system of the present invention.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit of the invention. All falling within the scope of the invention.
Example 1:
according to the fault diagnosis method for the valve-controlled hydraulic cylinder system independently controlled by the load port, which is provided by the invention, the method comprises the following steps:
step S1: establishing a valve control hydraulic cylinder system;
step S2: fault injection is carried out to generate eight types of faults; the faults comprise four high-speed switching valves, two hydraulic reversing valves, a hydraulic cylinder and a displacement sensor; the PWM driving voltage of the high-speed switch valve is provided by matched software and hardware; the hydraulic change valve has the following faults: oil particles and oil impact on the abrasion of the valve core, leakage, damage of a sealing ring and failure of a spring; the displacement sensor is mounted on the valve body.
And step S3: acquiring signals to obtain nine types of signals and generate a sample; the signals are composed of faults in the step S2 and system normal states into nine categories, each category is used for collecting two main valve control cavity pressure signals and valve core displacement signals, collecting hydraulic cylinder control cavity pressure signals and rod displacement signals, and sampling is carried out for 2S at the sampling frequency of 1000 Hz; the normal data and fault data each contained 900 sets of data, each set of data including 9 signatures, each signature including 2000 data points, the samples being generated.
And step S4: preprocessing a sample; pretreating the sample by the following formula, wherein x m It is shown that the m-th feature,
for pretreating the rear knotAnd (4) fruit:
step S5: after the pretreatment is finished, dividing the generated sample into a training set, a verification set and a test set according to the proportion; the proportion is 6:2:1.
step S6: the training set and the verification set are used for training a fault diagnosis algorithm;
step S7: and judging the performance of the trained algorithm model after the test of the test set.
Example 2:
example 2 is a preferred example of example 1, and the present invention will be described in more detail.
Fig. 1 and fig. 2 show a schematic diagram and a control block diagram of a valve-controlled hydraulic cylinder system facing load port independent control according to the proposal, respectively. The system realizes independent control of two cavity pressures of the hydraulic cylinder by a digital hydraulic pilot programmable valve. The pilot stage of the digital hydraulic pilot programmable valve is composed of four same two-position three-way slide valve type high-speed switch valves, the main stage is composed of two same three-position three-way slide valve type hydraulic reversing valves, and two constant voltage sources are adopted to respectively supply oil to the main stage and the pilot stage. Besides LVDT sensor sensing main valve core displacement and hydraulic cylinder rod displacement, the system is also provided with pressure sensor sensing pressure of the main valve and the hydraulic cylinder control cavity. The control strategy adopts a two-stage PID feedback structure, and the load displacement pushed by the oil cylinder can track the reference displacement according to requirements when the system inputs the reference displacement. The first-stage PID1 is composed of controllers PID1-1 and PID1-2, and generates reference displacement for a left main valve spool and reference displacement for a right main valve spool by taking the displacement of an oil cylinder as a feedback signal. The second-stage PID2 consists of controllers PID2-1, PID2-2, PID2-3 and PID2-4, and respectively uses the displacement of the left valve core and the displacement of the right valve core as feedback signals to generate control signals for controlling the opening and closing characteristics of the four pilot valves.
The failure of the valve-controlled hydraulic cylinder system which is independently controlled facing the load port relates to 8 components: four pilot stage high-speed switch valves, two main stage hydraulic reversing valves, a hydraulic cylinder and a displacement sensor. The PWM driving voltage of the high-speed switch valve is provided by matched software and hardware, on one hand, the time difference of the response of the hardware end can cause the delay of the control signal time of the high-speed switch valve, and on the other hand, the frequency of the control signal can cause the inaccurate switching frequency of the high-speed switch valve due to the influence of the software and hardware precision. Meanwhile, the high-frequency opening and closing characteristics of the high-speed switch valve repeatedly compress the spring, so that the fatigue failure of the spring of the high-speed switch valve is easily caused. The main faults of the hydraulic reversing valve are abrasion of a valve core caused by oil particles and oil impact, leakage caused by abrasion of the valve core and damage of a sealing ring, and fatigue failure of a spring caused by the abrasion. The displacement sensor is installed on the valve body, and the valve body can produce high-frequency vibration because of the high-speed opening and closing characteristic of the pilot stage high-speed switch valve to lead to the displacement sensor probe of installing in the system to appear the vibration condition, consequently influence the accuracy of displacement sensor feedback displacement volume. The hydraulic cylinder pushes the load to move according to the requirement, and the main fault in the operation process is the hydraulic cylinder fault caused by the increase of leakage amount.
As shown in fig. 3, a fault diagnosis process of the load port independent control-oriented valve-controlled hydraulic cylinder system is provided, after the load port independent control-oriented valve-controlled hydraulic cylinder system is established, fault injection is performed to generate 8 types of faults including four high-speed switching valves, two hydraulic reversing valves, a hydraulic cylinder and a sensor, the 8 types of faults and the normal state of the system form 9 types, and the fault diagnosis work of the system is realized for the 9 types. And acquiring two main valve control cavity pressure signals and valve core displacement signals for each category, acquiring a hydraulic cylinder control cavity pressure signal and a rod displacement signal, and sampling for 2s at the sampling frequency of 1000 Hz. The normal data and fault data each contain 900 sets of data, each set of data including 9 signatures, each signature including 2000 data points. To avoid the effect of signals of different orders of magnitude on the model training, the data is preprocessed by the following formula, where x m It is shown that the m-th feature,
is the result after pretreatment. After the data preprocessing is finished, the generated sample isThe training set, the verification set and the test set are divided according to the proportion of 6. The training set and the verification set are used for training a fault diagnosis algorithm, and the performance is judged after the trained algorithm model is tested by the test set.
The proposal designs a fault diagnosis algorithm based on a one-dimensional large convolution kernel and a residual error network aiming at the fault diagnosis problem of a valve-controlled hydraulic cylinder system, and the structural diagram of the algorithm is shown in figure 4. Firstly, a long-time input sequence of a valve-controlled hydraulic cylinder system is operated through a one-dimensional large convolution kernel, a single large convolution kernel traverses the whole input time sequence by zero filling and moving a certain step length, and then the result of the one-dimensional large convolution kernel convolution operation is processed through the maximum pooling operation and then is input into a residual block. The algorithm designs 6 residual blocks in total, each residual block utilizes local information of a small convolution kernel sensing sequence, and the batch normalization layer represented by the formula (1) enables output and input to have distribution similarity so as to increase the training speed and stability of the network. Meanwhile, by taking ReLU of the formula (2) as an activation function, for each input variable x, a large value compared with 0 is output, and the gradient problem is solved while convergence is accelerated. Mu in formula (1) B And
respectively at time t for a given batch of samples
Is a given constant vector avoiding a denominator of 0, gamma and beta are the scaling and translation factors to be trained respectively,
is input into
And (5) outputting through a batch normalization layer. By introducing residual structuresThe algorithm can improve the accuracy rate by increasing the depth, and the problem of gradient disappearance caused by increasing the depth in the network is relieved. The output of 6 residual blocks generates a one-dimensional feature vector with fixed feature number through an average pooling layer, the feature vector obtains a feature vector with 9 feature number through a full connection layer, the vector obtains probability distribution through a softmax function shown in a formula (3), wherein y is i Represents the output of the ith sample after passing through the fully connected layer, y ij Represents the output y i The value of the jth variable in the table, and m represents the classification number of the classifier, namely 9. Thus y ij J corresponding to the maximum value in the data is the category corresponding to the ith sample.
relu(x)＝max(0,x)#(2)
The algorithm shown in fig. 4 is a multi-classification problem, and a cross entropy loss function shown in formula (4) is used for an evaluation index of the network during training. In the formula, N is the number of samples,
an indicator variable representing the ith sample. For a problem of the M classification,
for a vector containing M elements, the jth value of a sample is 1, which represents that the true class of the sample is jth, and the rest values are 0.
The prediction class probability value for the sample is also a vector of M elements, which is formed with
Similarly.
Through the verification of the fault diagnosis process of the valve-controlled hydraulic cylinder system facing the load port independent control in fig. 3 and the fault diagnosis algorithm corresponding to fig. 4, the accuracy of the test set can be 95.4%, and the corresponding confusion matrix is shown in fig. 5. Meanwhile, when the system breaks down, the specific element which breaks down in the system is identified, and the system is favorable for quickly developing maintenance work when the system breaks down.
1) A whole set of fault diagnosis process is provided for a valve-controlled hydraulic cylinder system which is independently controlled by a load port, and faults of the system are located to specific elements in the system and are to be protected.
2) The idea of one-dimensional large convolution kernel and residual error network is applied to fault diagnosis of the valve-controlled hydraulic cylinder system which is independently controlled for the load port, so that the fault diagnosis work is completed and protection is required.
Those skilled in the art will understand this embodiment as a more specific description of embodiment 1.
It is well within the knowledge of a person skilled in the art to implement the system and its various devices, modules, units provided by the present invention in a purely computer readable program code means that the same functionality can be implemented by logically programming method steps in the form of logic gates, switches, application specific integrated circuits, programmable logic controllers, embedded microcontrollers and the like. Therefore, the system and various devices, modules and units thereof provided by the invention can be regarded as a hardware component, and the devices, modules and units included in the system for realizing various functions can also be regarded as structures in the hardware component; means, modules, units for realizing various functions can also be regarded as structures in both software modules and hardware components for realizing the methods.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes or modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.
Claims (8)
1. A fault diagnosis method for a valve-controlled hydraulic cylinder system independently controlled by a load port is characterized by comprising the following steps:
step S1: establishing a valve control hydraulic cylinder system;
step S2: fault injection is carried out to generate eight types of faults;
and step S3: acquiring signals to obtain nine types of signals and generating a sample;
and step S4: preprocessing a sample;
step S5: after the pretreatment is finished, dividing the generated sample into a training set, a verification set and a test set according to a proportion;
step S6: the training set and the verification set are used for training a fault diagnosis algorithm;
step S7: and judging the performance of the trained algorithm model after the test of the test set.
2. The method for diagnosing the fault of the valve-controlled hydraulic cylinder system facing the load port independent control according to claim 1, wherein the fault in the step S2 comprises four high-speed switching valves, two hydraulic reversing valves, a hydraulic cylinder and a displacement sensor.
3. The method for diagnosing the fault of the valve-controlled hydraulic cylinder system facing the load port independent control according to claim 2, wherein the PWM driving voltage of the high-speed switch valve is provided by matched software and hardware.
4. The method for diagnosing the fault of the valve-controlled hydraulic cylinder system facing the load port independent control according to claim 2, wherein the fault of the hydraulic reversing valve is as follows: oil particles and oil impact wear the valve element and leak out with seal ring damage and failure of the spring.
5. The method of claim 2, wherein the displacement sensor is mounted on the valve body.
6. The method for diagnosing the fault of the valve-controlled hydraulic cylinder system facing to the load port independent control, according to claim 1, wherein the signals in the step S3 are composed of the fault in the step S2 and the normal state of the system into nine categories, each category is used for collecting two main valve control cavity pressure signals and two spool displacement signals, and collecting a hydraulic cylinder control cavity pressure signal and a rod displacement signal, and sampling is carried out for 2S at a sampling frequency of 1000 Hz; the normal data and fault data each contained 900 sets of data, each set of data contained 9 signatures, each signature consisting of 2000 data points, resulting in a sample.
7. The method for diagnosing the fault of the valve-controlled hydraulic cylinder system facing the independent control of the load port according to claim 1, wherein the step S4 is to preprocess the sample by the following formula, wherein x is m It is shown that the m-th feature,
as a result after pretreatment:
8. the method for diagnosing the fault of the valve-controlled hydraulic cylinder system facing the load port independent control according to claim 1, wherein the ratio in the step S5 is 6:2:1.
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