CN116068949B - Self-calibration method, self-calibration device and storage medium for main valve of full electric control system - Google Patents
Self-calibration method, self-calibration device and storage medium for main valve of full electric control system Download PDFInfo
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
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Abstract
The invention discloses a self-calibration method, a self-calibration device and a storage medium of a main valve of a full electric control system, wherein the self-calibration method comprises the following steps: acquiring key data of control parameters of different control main valves; storing the key data and the information of the corresponding control main valve into a storage element in the form of a data packet; the controller reads all data packets from the storage element; and after the controller receives the self-calibration instruction, the controller automatically calibrates different control main valves according to the read data packet. Therefore, the controller can directly call key data in the storage element to carry out self-calibration, so that the operation steps can be simplified, and the calibration efficiency can be improved; when the controller and the control main valve are assembled on the whole machine product, the controller and the control main valve can be matched at will, and the assembly efficiency, the assembly flexibility and the interchangeability can be greatly improved.
Description
Technical Field
The invention relates to the technical field of engineering machinery, in particular to a self-calibration method, a self-calibration device and a storage medium of a main valve of a full electric control system.
Background
The full electric control system is that the whole machine adopts the mode of an electric handle, an electric control main valve and an electric control pump, a control current is output to control a pilot control element in the electric control main valve after a controller of the whole machine receives a signal of the electric handle, after the pilot control element receives the control current, a pilot control pressure corresponding to the control current is output, the displacement of a valve core in the electric control main valve is controlled by the size of the pilot control pressure, the required control area is reached, and parameters such as the flow of the pump are controlled by the size of the control area. That is, the pressure output by the pilot control element determines the working accuracy of the subsequent electric control main valve and the electric control pump, and further influences the control performance and the action coordination performance of the engineering machinery product.
It should be noted that, a plurality of pilot control elements are disposed in one electrically controlled main valve, and output pressures of the plurality of pilot control elements need to be kept consistent to realize accurate control. If there is a difference between the pilot control elements, the control pressure actually output is deviated under the same control current, so that the control parameters of the hydraulic elements are inaccurate, and the consistency of the whole product cannot be ensured. Therefore, before the whole machine product is put into use, manufacturers can calibrate the whole electric control system so as to solve the problem of poor consistency of the performance of the whole machine.
At present, the following two calibration modes are mainly adopted: (1) After the whole machine products are assembled, each whole machine product is tested, and problems existing in each whole machine product are respectively adjusted on site. (2) After the controller is connected with the pilot control element, calibrating is carried out, a pressure sensor is arranged on the pilot control element to collect the actual output pressure of the pilot control element, whether the actual output pressure is within a deviation allowable range is analyzed, if the actual pressure value is out of the deviation range, a current increment is automatically added, and the relationship between the new output pressure and the deviation range is continuously judged until the actual output pressure value is within the deviation allowable range.
For the mode (1), one complete machine comprises a controller and a plurality of pilot control elements, after the complete machine is assembled, each complete machine needs to be tested one by one, the problem of each complete machine is recorded and solved one by one, when the number of complete machine products is huge (for example, tens of complete machine products exist), a great deal of manpower, time and detection instruments can be consumed, the problems of different complete machine products are not completely the same, a personalized solution is provided, and the calibration is needed again after the solution. Therefore, the (1) mode not only has complex and complicated calibration process and low calibration efficiency, but also needs to consume much manpower and time.
With regard to the (2) th mode, there are at least the following drawbacks:
1. the controller and the pilot control element are calibrated together, and then the controller and the pilot control element which are calibrated together are assembled on the same whole machine product, otherwise, calibration failure (namely invalid calibration) is caused, and the recalibration is needed.
2. When the controller or the pilot control element fails, after a new component is replaced, all steps are repeated from the beginning to recalibrate, so that the time is long, the interchangeability is poor, and the method is very inconvenient in practical use.
3. The actual output pressure is monitored in real time through the pressure sensor and fed back to the controller, and after compensation, detection and feedback are carried out again, so that the calibration steps are complicated, and the calibration efficiency is low.
In addition, the modes (1) and (2) only consider the influence of the pilot control element on the output consistency, and do not consider the parameters and performances of the main valve, and the problem of poor output consistency may be caused.
Disclosure of Invention
The present invention aims to solve at least one of the technical problems existing in the prior art.
The invention provides a self-calibration method, a self-calibration device and a storage medium for a main valve of a full-electric control system, which are used for self-calibration in a staged mode, so that the interchangeability of a controller and a pilot control element can be improved, the calibration efficiency can be improved, and the cost can be saved.
The technical scheme adopted for solving the technical problems is as follows: a self-calibration method of a main valve of a full electric control system comprises the following steps: s1: acquiring key data of control parameters of different control main valves; collecting characteristic curve data between the control parameters and the control current, and selecting a plurality of key points from the characteristic curve data as key data according to a point taking strategy; s2: storing the key data and the information of the corresponding control main valve into a storage element in the form of a data packet; s3: the controller reads all data packets from the storage element; s4: and after the controller receives the self-calibration instruction, the controller automatically calibrates different control main valves according to the read data packet.
Therefore, the controller can directly call key data in the storage element to perform self-calibration, and the pressure sensor does not need to be arranged to detect the actual output pressure of the pilot control element in real time to perform feedback, so that on one hand, the operation steps can be simplified, and the calibration efficiency is improved; on the other hand, when the controller and the pilot control element are assembled on the whole machine product, the controller and the pilot control element can be matched at will, and the assembly efficiency, the assembly flexibility and the interchangeability can be greatly improved.
Further, after calibration is completed, if the controller fails during the use of the full electronic control system, the controller is replaced, and steps S3-S4 are repeated.
Further, after the calibration is completed, in the use process of the full electronic control system,
if the control main valve fails, the failed control main valve is marked as A
Firstly, obtaining key data of control parameters of a new control main valve, marking the new control main valve as B,
information controlling the main valve B and corresponding critical data forming data packets C are stored in said memory element,
replacing the control main valve A with the control main valve B,
and the controller reads the data packet C to automatically calibrate the control main valve B.
Further, the control parameters of the control main valve include: the output pressure of the pilot control element, the displacement of the spool, and the control area of the control main valve.
Further, when the controller calibrates the control main valve, the controller selects at least one of the output pressure of the pilot control element, the displacement of the valve core and the control area of the control main valve for calibration.
Further, when the control parameter is the output pressure of the pilot control element, the setpoint strategy is:
Selecting a plurality of key points G1 from a control relation curve Y1 according to the control relation curve Y1 between the output pressure of the pilot control element and the control main valve,
obtaining a corresponding data value of the output pressure of the pilot control element according to the selected key point G1;
and obtaining corresponding data points from the characteristic curve data according to the corresponding data values.
The key points at least comprise: and the control area of the control main valve is provided with an opening point, a turning point and a maximum point.
Further, when the control parameter is the displacement of the valve core, the point taking strategy is as follows:
selecting a plurality of key points G2 from characteristic curve data between the displacement of the valve core and the control current;
the key point G2 at least includes: the valve core is provided with an opening point, a turning point and a maximum value point of displacement. Further, when the control parameter is a control area of the control main valve, the point taking strategy is as follows:
converting the relationship between the control area and the control current into the relationship between the pressure difference and the control current according to the relationship between the control area and the pressure difference;
selecting a plurality of key points G3 from a relation curve PJ between the pressure difference and the control current;
the key point G3 at least includes: the opening point, turning point, minimum point and intermediate point of the pressure difference.
Further, the control main valve comprises a valve core and a plurality of pilot control elements,
the information for controlling the main valve comprises the number of the main valve and the number of the pilot control element;
binding the serial number of the control main valve, the serial number of the pilot control element and the corresponding key data, storing the serial number and the serial number of the pilot control element in a data packet form into a storage element,
and after the controller reads all the data packets from the storage element, corresponding key data are selected according to the number information contained in the self-calibration instruction to automatically calibrate the control main valve.
Further, the storage element is: any one of a memory, a two-dimensional code, a cloud server or a radio frequency card.
Further, the automatic calibration of different control main valves according to the read data packet includes:
s41: the controller judges the validity of the read data packet, and the data packet judged to be valid is stored in a storage unit of the controller;
s42: the controller obtains a characteristic fitting curve F1 between control parameters of the control main valve and control current according to the effective key data;
s43: the controller stores the characteristic fitting curve F1 into a storage unit of the controller.
Further, after the controller obtains the characteristic fitting curve F1, the controller compares the characteristic fitting curve F1 with the standard curve in the storage unit,
the difference between the data points of the characteristic fitting curve F1 and the data points of the standard curve is calculated,
if the difference value is smaller than the replacement threshold value K, not processing;
if the difference value is greater than or equal to the replacement threshold value K, replacing the data point of the characteristic fitting curve F1 by the data point of the theoretical value to obtain a new characteristic fitting curve F2;
the controller stores the new characteristic fitting curve F2 in a storage unit.
Further, the method further comprises: and performing temperature compensation on the characteristic fitting curve F2.
Further, the temperature compensation process includes:
the compensation coefficients of different temperature sections are set,
and the controller selects a corresponding compensation coefficient according to the hydraulic oil temperature monitored by the system and compensates the characteristic fitting curve F2.
The invention also provides a self-calibration device of the full electronic control system, which adopts the self-calibration method, and comprises the following steps:
the selecting module is used for acquiring key data of control parameters of different control main valves;
A storage element for storing a data packet formed by the key data and information of a corresponding control main valve;
and the controller is used for reading all the data packets in the storage element and automatically calibrating different control main valves according to the read data packets.
The present invention also provides a computer readable storage medium having stored therein computer instructions for execution by a processor of the steps of the self-calibration method.
The invention has the advantages that,
the self-calibration method, the self-calibration device and the storage medium of the main valve of the full electric control system can lead the manufacturer of the main valve to store the key data of different main valves into the storage element in advance, and in the link of the manufacturer of the whole machine, the calibration process can be completed by only leading the data in the storage element into the controller, thereby saving the calibration time before the whole machine is off line, improving the calibration efficiency, simplifying the operation steps and being beneficial to improving the working efficiency of the production line. The controller and the control main valve can be matched at will, so that the control main valve and the controller are not limited to be assembled on the same whole machine product, the interchangeability and the assembly flexibility between parts are greatly improved, the assembly difficulty of a production line is reduced, and the assembly efficiency is improved. When the controller or the control main valve fails, only certain steps are needed to be repeated, the whole calibration process is not needed to be operated again, time is saved, and workload of workers is reduced.
Drawings
The invention will be further described with reference to the drawings and examples.
FIG. 1 is a flow chart of the self-calibration method of the present invention.
FIG. 2 is a schematic illustration of the self-calibration method of the present invention.
Fig. 3 is a schematic diagram of the characteristic curve of the pilot control element of the present invention.
Fig. 4 is a graph of the relationship between control area and output pressure of the pilot control element of the present invention.
FIG. 5 is a graph of control current versus differential pressure in accordance with the present invention.
Fig. 6 is a graph of control current versus spool displacement for the present invention.
FIG. 7 is a schematic view of the self-calibration device of the present invention.
In the figure: 1. selecting a module; 2. a memory element; 3. a controller; 4. controlling a main valve; 41. a valve core; 42. and a pilot control element.
Detailed Description
The invention will now be described in further detail with reference to the accompanying drawings. The drawings are simplified schematic representations which merely illustrate the basic structure of the invention and therefore show only the structures which are relevant to the invention.
In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the device or element being referred to must have a specific orientation, be configured and operated in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, features defining "first", "second" may include one or more such features, either explicitly or implicitly. In the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more.
In the description of the present invention, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
As shown in fig. 1 to 2, the self-calibration method of the main valve of the full electric control system of the invention comprises the following steps: s1: and acquiring key data of control parameters of different control main valves. S2: and storing the key data and the information of the corresponding control main valve into a storage element in the form of a data packet. S3: the controller reads all data packets from the memory element. S4: after the controller receives the self-calibration instruction, different control main valves are automatically calibrated according to the read data packet.
It should be noted that the self-calibration method of the present invention is performed in two stages, the first stage is steps S1-S2, where different control main valves are tested separately to obtain key data of each control main valve, and the key data and related information of the corresponding control main valve are assembled into a data packet and stored in an independent storage element. The second stage is steps S3-S4, when the controller and the control main valve are assembled on the whole machine, the relevant data packet in the storage element can be imported into the controller, and the controller automatically calibrates the control main valve on the whole machine according to the key data in the relevant data packet. Therefore, the controller can directly call key data in the storage element to carry out self-calibration, firstly, the operation steps can be simplified, and the calibration efficiency is improved; secondly, the controller and the control main valve are not bound and calibrated, and can be matched randomly when assembled on a whole product, so that the assembly efficiency and the assembly flexibility can be greatly improved; thirdly, after calibration, if the controller or the control main valve fails, only the failed element is replaced, and the failed element is recalibrated, so that the interchangeability of parts is greatly improved.
For example, after calibration is completed, if the controller fails during the use of the full electronic control system, the controller is replaced, and steps S3-S4 are repeated. That is, if the controller fails, the steps S1-S2 do not need to be repeated, and only the data packet in the storage element needs to be reintroduced into a new controller, and the new controller performs the calibration process by using the data packet. Compared with the prior art, in the recalibration step, only the second stage is needed, so that the recalibration step can be simplified, and the recalibration efficiency is improved.
For example, when the calibration is completed, during the use process of the full electronic control system, if the control main valve fails (the failed control main valve is denoted as a), key data of control parameters of a new control main valve is acquired (the new control main valve is denoted as B), information of the control main valve B and corresponding key data form a data packet C to be stored in a storage element, the control main valve a is replaced by the control main valve B, and the controller reads the data packet C to automatically calibrate the control main valve B. That is, if the control main valve fails, only the key data of the control parameter of the new control main valve needs to be acquired again and stored in the storage element, and the controller reads the new key data to calibrate the new control main valve. No additional calibration instrument is needed in the process, and the calibration result of other control main valves is not invalid.
It should be noted that, since the components may be aged, damaged, or malfunction after long-term use, the controller or the control main valve may need to be replaced. The existing calibration method can cause the failure of the original calibration result after the device is replaced, and the calibration needs to be completely re-calibrated, so that the working efficiency is low. In order to solve the problem, each control main valve has only corresponding key data, and after the fittings are replaced, only one control main valve can be recalibrated; if the controller is replaced, only the data packet needs to be reintroduced into the new controller. Therefore, the recalibration process can be greatly simplified, and the calibration efficiency is improved. The method is used for calibrating before the whole machine is offline, is beneficial to simplifying the calibration step, improves the calibration efficiency, and can also improve the interchangeability and collocation flexibility between the controller and the control main valve.
For example, control parameters for controlling the main valve include: the output pressure of the pilot control element, the displacement of the spool, and the control area of the control main valve. In a hydraulic system, the control area of a control main valve influences the working pressure and flow distribution of each actuating mechanism, thereby influencing the operability and action coordination of engineering machinery products. The controlled process of the control main valve is that the control current output by the controller determines the output pressure of the pilot control element, the output pressure of the pilot control element determines the displacement of the valve core, and the displacement of the valve core determines the control area. In the controlled process of the control main valve, the output pressure of the pilot control element, the displacement of the valve core and the control area all influence the final output precision of the control main valve. For example, there is a deviation between the output pressures of different pilot control elements, resulting in a difference between the output pressures of different pilot control elements when receiving the same control current, thereby affecting the output accuracy of the control main valve. Because of the differences of the processing sizes of the valve core and the valve body and the differences of the reset elastic values of the valve core, the displacement of the valve core is different when the valve core receives the same pilot output pressure. The difference of control areas can also be caused by the processing difference of the throttle groove of the valve core and the control edge of the valve body. That is, the displacement of the valve element is affected not only by the output pressure of the pilot control element, but also by the machining accuracy itself; the control area is affected not only by the output pressure of the pilot control element and the displacement of the valve element, but also by the machining accuracy itself.
Therefore, the self-calibration method of the invention at least selects any one of the output pressure of the pilot control element, the displacement of the valve core and the control area for calibration during calibration, so as to improve the final output precision of the control main valve and the consistency of the whole machine product. It can be understood that in practical application, the method can select any one of the output pressure of the pilot control element, the displacement of the valve core and the control area for calibration, or select any two of the three for calibration, or select the three for calibration. Any one of the output pressure of the pilot control element, the displacement of the valve core and the control area is calibrated, so that the output precision of the control main valve can be improved; any two or three control parameters are selected for calibration, and the calibration effect can be further improved on the basis of selecting one calibration, so that the output precision of the main control valve is further improved.
For example, the process of acquiring key data of control parameters of the control master valve includes: characteristic curve data between control parameters and control current are collected, and a plurality of key points are selected from the characteristic curve data to serve as key data according to a point taking strategy. The point-taking strategy may be somewhat different when different control parameters are selected for calibration. The self-calibration process is carried out in stages, the characteristic curve data of each control main valve is collected first, the collected data amount is large in the process, and in the practical application process, all the collected data are directly led into the controller, so that the self-calibration process in the second stage is complex and the calibration speed is low. In order to solve the problem, the invention provides a method for acquiring key data of a control main valve for calibration processing through a point-taking strategy so as to improve the processing efficiency of a controller and reduce the occupation of data on the memory of the controller.
For example, when the control parameter is the output pressure of the pilot control element, the setpoint strategy is: selecting a plurality of key points G1 from the control relation curve Y1 according to the control relation curve Y1 between the output pressure of the pilot control element and the control main valve, and obtaining corresponding data values of the output pressure of the pilot control element according to the selected key points G1; corresponding data points are obtained from the characteristic curve data based on the corresponding data values. The key points at least comprise: the control area of the control main valve is opened, turned and maximum value points.
For example, as shown in fig. 3, the characteristic curve data (i.e., control current-output pressure relation curve) between the output pressure of the pilot control element and the control current is the control current on the abscissa, and the output pressure on the ordinate, it can be seen from the figure that when the current value reaches a certain level, the pilot control element starts to output the pressure, and the level of the output pressure increases (changes linearly) with the increase of the control current, where the curve H represents the theoretical characteristic curve of the pilot control element, and the curve Q represents the actual output curve of the pilot control element, so that in practical application, the actual output pressure of the pilot control element may be larger or smaller than the theoretical value, and therefore, the consistency and the output accuracy of the whole product may be improved by calibrating the pilot control element before the whole product is put into use. For example, the actual output pressure of the pilot control element (i.e., characteristic curve data, for example, tens or hundreds of sets of characteristic curve data) under different current values may be collected through bench test, and then a plurality of data points are selected from the characteristic curve data as key data according to a point-taking strategy, and the number of the key data is, for example, 2, 3, 4, 5, etc., where it is required to be noted that the data amount of the key data is far smaller than the collected data amount. The purpose of this is to increase the processing efficiency of the controller. Assuming that 50 sets of data are collected by one pilot control element, and 20 pilot control elements are in a whole machine product, 50×20=1000 sets of data need to be imported into the controller, and if all the collected data are directly imported into the controller, more memory of the controller is occupied, and data processing efficiency and data reading efficiency are reduced. Therefore, the invention uses the point-taking strategy to select some data points as key data to be stored in the storage element, thereby greatly reducing the data quantity required to be read by the controller and being beneficial to improving the calibration efficiency of the controller.
The pilot control element is for example an electro proportional pressure reducing valve. Fig. 4 shows a control relation curve Y1 between the electrically controlled main valve and the pilot control element, the abscissa is the output pressure of the pilot control element, and the ordinate is the control area of the electrically controlled main valve, and it can be known from the figure that the output pressure and the control area are in piecewise linear relation, when a key point is selected, the opening point, the turning point and the maximum point of the control area can be selected, the output pressures (i.e. 0.65Mpa, 1.18Mpa and 2.05 Mpa) corresponding to the three key points are recorded, and then corresponding current values, i.e. control area→output pressure→control current, are obtained from the characteristic curve data of the pilot control element according to the three output pressure values. That is, the key data that is ultimately stored into the storage element is three sets of "control current-output pressure" data points.
For example, when the control parameter is displacement of the valve element, the point taking strategy is: selecting a plurality of key points G2 from characteristic curve data between the displacement of the valve core and the control current; the key point G2 at least includes: an opening point, a turning point and a maximum point of the displacement of the valve core. For example, as shown in fig. 6, the characteristic curve data between the displacement of the valve element and the control current increases, and the valve element displacement increases gradually as the control current increases. For example, a displacement sensor may be mounted on the valve spool to monitor the displacement value of the valve spool at different control currents to obtain characteristic curve data. As can be seen from the figure, the displacement of the valve element and the control current are in piecewise linear relation, so that when the key point is selected, the opening point, turning point and maximum point of the displacement of the valve element can be selected, for example, (630 ma,0 mm), (650 ma,1.5 mm), (1160 ma,10.2 mm).
For example, when the control parameter is the control area of the control master valve, the setpoint strategy is: converting the relationship between the control area and the control current into the relationship between the pressure difference and the control current according to the relationship between the control area and the pressure difference; from differential pressure and control current relationship curve P between J Selecting a plurality of key points G3; the key point G3 at least includes: an opening point, a turning point, a minimum point and an intermediate point of the pressure difference.
The relationship between the control area and the pressure difference is as follows:
wherein q represents flow, C d Represents the flow coefficient, a represents the control area, +.>
Indicating the oil density>
Representing the pressure differential. Because the relation between the control area and the control current cannot be measured through a bench test, the invention obtains the relation between the control area and the control current by changing the control current and recording the change of the pressure difference under the condition of fixed flow. When the flow is fixed, the control area and the pressure difference are changed along with the change of the control current, and the pressure difference is +.>
The control area can be obtained through measurement of a pressure sensor and converted according to the formula. For example, taking a boom control main valve as an example, the test procedure is: setting the fixed flow to be 100L/min, and feeding oil to the large cavity of the movable arm at the same time The control current is output to a pilot control element of a control main valve, the change range of the control current is 0 mA-1500 mA, and the output Pressure (PC) of a pump port and the Pressure (PA) of a large cavity of a movable arm are recorded, so that the control current is improved>
=pc-PA. After the test is completed, a curve of the pump port output Pressure (PC), the boom large chamber Pressure (PA) as a function of the control current can be obtained (as shown in fig. 5). As can be seen from the graph, as the control current increases, the differential pressure gradually decreases and eventually stabilizes (i.e., the control area gradually increases and eventually stabilizes). Therefore, when the key point is selected, the opening point, the turning point, the minimum point and the intermediate point of the pressure difference can be selected. The purpose of the intermediate value points is here to increase the accuracy of the subsequent calibration. For example, the intermediate value is obtained by: 2-3 data points are selected as intermediate value points between the opening point and the turning point at fixed control current intervals; and 2-3 data points are selected as intermediate value points between the turning point and the maximum value point by using a fixed control current difference value.
According to the invention, the proper key points are selected through the point taking strategy, so that on one hand, the data volume can be greatly reduced, and the calibration efficiency is improved; on the other hand, the accuracy of key point selection can be improved, the accuracy of subsequent calibration is improved, and the output consistency of the hydraulic system is improved.
For example, the control main valve includes a valve element and a plurality of pilot control elements, and the information for controlling the main valve includes the number of the control main valve and the number of the pilot control elements. After binding the serial number of the control main valve, the serial number of the pilot control element and the corresponding key data, storing the serial number and the corresponding key data in a storage element in the form of data packets, and after the controller reads all the data packets from the storage element, selecting the corresponding key data to automatically calibrate the control main valve according to the serial number information contained in the self-calibration instruction. It should be noted that in the steps S1-S2, the key data of the plurality of control main valves to be calibrated may be collected and stored in the storage element. In the calibration process, the controller selects a corresponding data packet according to the number of the control main valve, each control main valve has a corresponding number, for example, the number is 1 to M, the number of the pilot control element is for example, the number is M-N, M represents the number of the corresponding control main valve, for example, the number 1 of the control main valve corresponds to the number 1-1 to 1-20 of the pilot control element. Each data packet contains the serial number of the control main valve, the serial number of the leading control element and corresponding key data. When the controller and the control main valve are assembled on the whole machine, the control main valve and the pilot control element are attached with numbers (the staff can know the numbers), for example, a control main valve No. 1 is assembled on a certain whole machine product, the control main valve is associated with the pilot control elements No. 1 to No. 20, when the calibration is carried out, the staff can set the numbers (namely the calibration instructions) of the control main valve and the pilot control element which need to be calibrated through a man-machine interaction interface, and the controller selects key data of the corresponding numbers from the read data packet to carry out automatic calibration. For example, when a certain pilot control element (for example, the pilot control element No. 1) fails, key data of a new pilot control element is collected first, the new pilot control element can be marked as No. 21, the new number and the new key data are led into the controller in a new data packet form, and the controller can calibrate the pilot control element No. 21.
For example, the storage element is any one of a memory, a two-dimensional code, a cloud server, and a radio frequency card, but not limited thereto, and may be other components having a storage function. The memory can be, for example, a USB flash disk, and can be directly connected with the controller to import data; the two-dimensional code can be stuck on the shell of the electric control main valve, and key data are acquired through code scanning and are imported into the controller; the controller can also directly download key data from the cloud server; or a card reader is adopted to read key data in the radio frequency card to be imported into the controller. It should be noted that the process of obtaining and storing the key data may be performed by a manufacturer of the lead control element, and then the storage element and the parts are sent to the complete machine manufacturer together, and the self-calibration process is completed by the complete machine manufacturer, but the complete machine manufacturer only needs to import the data in the storage element into the controller, so that the calibration efficiency of the complete machine manufacturer before the complete machine product is taken off line can be significantly improved.
For example, the automatic calibration of different control main valves according to the read data packet includes: s41: the controller judges the validity of the read data packet, and the data packet judged to be valid is stored in a storage unit of the controller. S42: the controller obtains a characteristic fitting curve F1 between control parameters of the control main valve and control current according to the effective key data. S43: the controller stores the characteristic fitting curve F1 in its own memory unit.
It should be noted that, the validity judgment of the read data packet is mainly to prevent the occurrence of transmission errors or obviously erroneous data values in the data transmission process, and filter some invalid data to improve the calibration accuracy. After receiving the effective data of the storage element, the controller saves the effective data into a storage unit of the controller. For example, the controller includes a memory unit for storing the read data and a processing unit for performing an automatic calibration process. After the controller receives the effective key data, a corresponding characteristic fitting curve can be fitted through a piecewise linear interpolation method according to the key data (i.e. a plurality of key points). For example, let the coordinates of the key point G1 be (x 1 ，y 1 ）、（x 2 ，y 2 ) X represents the control current, y represents the output pressure, and is represented by the formula
The y value corresponding to any x between two points can be obtained, so that a control current-output pressure relation curve (namely a characteristic fitting curve) is obtained. The curve fitting process of the displacement and control area of the valve core is the same as the output pressure, and the description is omitted here. And storing the characteristic fitting curve F1 into a storage unit to finish automatic calibration. When in use, the controller can output control current to corresponding control parameters according to the characteristic fitting curve F1. And during the automatic calibration, the whole machine is forbidden to work.
In order to further improve the precision of the characteristic fitting curve F1, after the controller obtains the characteristic fitting curve F1, the controller compares the characteristic fitting curve F1 with a standard curve in a storage unit, calculates a difference value between a data point of the characteristic fitting curve F1 and a data point of the standard curve, and if the difference value is smaller than a replacement threshold K, does not process; if the difference value is greater than or equal to the replacement threshold value K, replacing the data point of the characteristic fitting curve F1 by the data point of the standard value to obtain a new characteristic fitting curve F1; the controller stores the new characteristic fitting curve F2 in the storage unit.
The standard curve is stored in advance in the memory unit of the controller. The comparison of the characteristic fitting curve F1 with the standard curve is to prevent the occurrence of data points in the characteristic fitting curve F1 that are clearly not fit to the actual situation. The standard curve of the pilot control element is, for example, a theoretical curve, and the standard curve of the displacement and control area of the spool is, for example, a test curve of a standard prototype. For example, a control main valve is selected as a standard prototype for testing (the testing process is the same as the testing process described above), and a standard curve is obtained. For example, taking the output pressure of the pilot control element as an example, when comparing, the difference between the actual output pressure and the standard output pressure at the same current value is calculated, for example, the replacement threshold K is set to 0.15MPa (i.e., 1.5 bar), if the difference between the output pressure of the characteristic fitting curve F1 and the output pressure of the standard curve at the same current point is equal to or greater than 0.15MPa, this data point in the characteristic fitting curve F1 is indicated to be problematic, and this data point (x, y) should be discarded, at which time the standard data point is replaced with the problematic data point, to form a new characteristic fitting curve F2. Therefore, some fitting points with obvious errors can be removed, and the precision of the characteristic fitting curve is further improved, so that the control precision of the whole product is improved, and the output consistency is improved.
The method further comprises the following steps: and (5) performing temperature compensation on the characteristic fitting curve F2. Because the output accuracy of the control main valve is affected when the hydraulic oil temperature is too low, temperature compensation is introduced in the method for further improving the output accuracy of the control main valve. The temperature compensation process comprises the following steps: and setting compensation coefficients of different temperature sections, and selecting corresponding compensation coefficients by the controller according to the hydraulic oil temperature monitored by the system to compensate the characteristic fitting curve F2. For example, when the hydraulic oil temperature is lower than 0 ℃, the compensation coefficient is set to a; setting a compensation coefficient as b when the temperature of the hydraulic oil is between 0 and 15 ℃; when the temperature of the hydraulic oil is 15-20 ℃, setting the compensation coefficient as c. For example, the compensation coefficient may be set as: a=10, b= 8,c =5. When the temperature of the hydraulic oil is detected to be in a corresponding temperature section, the control current value of the characteristic fitting curve is added with a compensation coefficient to carry out temperature compensation, so that the output pressure of the pilot control element is ensured to be consistent with a preset value.
After the controller finishes automatic calibration, when the whole machine product works, the controller outputs control current to the control main valve according to the calibrated characteristic fitting curve, and the pilot control element outputs corresponding pressure or the valve core moves corresponding displacement or reaches corresponding control area so as to ensure consistency between the output of the electric control main valve and the signal of the electric handle. The whole calibration link of the invention only needs to consume 20-30 seconds, while the method in the prior art needs to consume 3-15 minutes, thus the method can obviously save the calibration time and greatly improve the calibration efficiency.
As shown in FIG. 7, the invention also provides a self-calibration device of the main valve of the full electric control system, and the self-calibration method is adopted. The self-calibration device comprises: the selection module 1 is used for acquiring key data of control parameters of different control main valves 4; a memory element 2 for storing data packets formed by key data and information corresponding to the control master valve 4; and the controller 3 is used for reading all the data packets in the storage element 2 and automatically calibrating different control main valves 4 according to the read data packets. The control main valve 4 includes a valve element 41 and a plurality of pilot control elements 42.
The description of the relevant parts of the self-calibration device provided by the embodiment of the present invention is referred to the detailed description of the corresponding parts of the self-calibration method provided by the embodiment of the present invention, and will not be repeated here.
The invention also provides a computer readable storage medium having stored therein computer instructions for execution by a processor of the steps of the self-calibration method. Computer-readable storage media include, but are not limited to, random Access Memory (RAM), memory, read Only Memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disk, removable disk, and the like.
In summary, the self-calibration method, the self-calibration device and the storage medium of the main valve of the full electric control system adopt a staged calibration mode, and have at least the following advantages:
the manufacturer of the control main valve can store key data of different control main valves into the storage element in advance, and in the link of the whole machine manufacturer, the calibration process can be completed by only guiding the data in the storage element into the controller, so that the calibration time before the whole machine is off line can be saved, the calibration efficiency is improved, the operation steps are simplified, and the work efficiency of the production line is also improved.
The controller and the control main valve can be matched at will, so that the control main valve and the controller are not limited to be assembled on the same whole machine product, the interchangeability and the assembly flexibility between parts are greatly improved, the assembly difficulty of a production line is reduced, and the assembly efficiency is improved.
When the controller or the control main valve fails, only certain steps are needed to be repeated, the whole calibration process is not needed to be operated again, time is saved, and workload of workers is reduced.
The data package in the storage element corresponds to the unique control main valve, and when the controller is used for calibrating a certain control main valve, the controller can quickly find the corresponding data package to process, so that the data processing efficiency can be improved, and the accuracy of data calling can be ensured.
Key data are selected through a point-taking strategy and stored in the storage element, and on one hand, the accuracy of data selection can be improved; on the other hand, the data quantity which needs to be read by the controller can be reduced, and the data reading and processing speed can be improved.
In the calibration process, the characteristic fitting curve obtained by fitting is compared with the standard curve, so that some obviously abnormal data points can be eliminated, the accuracy of the characteristic fitting curve is further improved, and the control accuracy is further improved.
By introducing temperature compensation, the control accuracy can be further improved.
With the above-described preferred embodiments according to the present invention as an illustration, the above-described descriptions can be used by persons skilled in the relevant art to make various changes and modifications without departing from the scope of the technical idea of the present invention. The technical scope of the present invention is not limited to the description, but must be determined as the scope of the claims.
Claims (10)
1. The self-calibration method of the main valve of the full electric control system is characterized by comprising the following steps of:
s1: acquiring key data of control parameters of different control main valves;
characteristic curve data between the control parameters and the control current are collected,
Selecting a plurality of key points from the characteristic curve data as key data according to a point-taking strategy;
the control parameters of the control main valve comprise: the output pressure of the pilot control element, the displacement of the valve core and the control area of the control main valve;
when the control parameter is the output pressure of the pilot control element, the point taking strategy is as follows:
selecting a plurality of key points G1 from a control relation curve Y1 according to the control relation curve Y1 between the output pressure of the pilot control element and the control main valve,
obtaining a corresponding data value of the output pressure of the pilot control element according to the selected key point G1;
obtaining corresponding data points from the characteristic curve data according to the corresponding data values;
the key points at least comprise: the control main valve comprises an opening point, a turning point and a maximum value point of a control area;
when the control parameter is the displacement of the valve core, the point taking strategy is as follows:
selecting a plurality of key points G2 from characteristic curve data between the displacement of the valve core and the control current;
the key point G2 at least includes: the valve core is provided with an opening point, a turning point and a maximum value point of displacement;
when the control parameter is the control area of the control main valve, the point taking strategy is as follows:
Converting the relationship between the control area and the control current into the relationship between the pressure difference and the control current according to the relationship between the control area and the pressure difference;
selecting a plurality of key points G3 from a relation curve PJ between the pressure difference and the control current;
the key point G3 at least includes: the opening point, turning point, minimum point and intermediate point of the pressure difference;
s2: storing the key data and the information of the corresponding control main valve into a storage element in the form of a data packet; the information for controlling the main valve comprises the number of the main valve and the number of the pilot control element;
s3: the controller reads all data packets from the storage element;
s4: after the controller receives the self-calibration instruction, the controller automatically calibrates different control main valves according to the read data packet;
when the controller calibrates the control main valve, at least one of the output pressure of the pilot control element, the displacement of the valve core and the control area of the control main valve is selected for calibration;
the calibration process comprises the following steps:
s41: the controller judges the validity of the read data packet, and the data packet judged to be valid is stored in a storage unit of the controller;
S42: the controller obtains a characteristic fitting curve F1 between control parameters of the control main valve and control current according to the effective key data;
s43: the controller stores the characteristic fitting curve F1 into a storage unit of the controller.
2. A self-calibration method according to claim 1, wherein,
and when the calibration is finished, in the use process of the full electric control system, if the controller fails, replacing the controller, and repeating the steps S3-S4.
3. A self-calibration method according to claim 1, wherein,
when the calibration is completed, in the use process of the full electric control system,
if the control main valve fails, the failed control main valve is marked as A
Firstly, obtaining key data of control parameters of a new control main valve, marking the new control main valve as B,
information controlling the main valve B and corresponding critical data forming data packets C are stored in said memory element,
replacing the control main valve A with the control main valve B,
and the controller reads the data packet C to automatically calibrate the control main valve B.
4. A self-calibration method according to claim 1, wherein,
the control main valve comprises a valve core and a plurality of pilot control elements,
Binding the serial number of the control main valve, the serial number of the pilot control element and the corresponding key data, storing the serial number and the serial number of the pilot control element in a data packet form into a storage element,
and after the controller reads all the data packets from the storage element, corresponding key data are selected according to the number information contained in the self-calibration instruction to automatically calibrate the control main valve.
5. A self-calibration method according to claim 1, wherein,
the storage element is: any one of a memory, a two-dimensional code, a cloud server or a radio frequency card.
6. A self-calibration method according to claim 1, wherein,
after the controller obtains the characteristic fitting curve F1, the controller compares the characteristic fitting curve F1 with the standard curve in the storage unit,
the difference between the data points of the characteristic fitting curve F1 and the data points of the standard curve is calculated,
if the difference value is smaller than the replacement threshold value K, not processing;
if the difference value is greater than or equal to the replacement threshold value K, replacing the data points of the characteristic fitting curve F1 by the data points of the standard curve to obtain a new characteristic fitting curve F2;
the controller stores the new characteristic fitting curve F2 in a storage unit.
7. The self-calibration method of claim 6, wherein,
the method further comprises the steps of: and performing temperature compensation on the characteristic fitting curve F2.
8. The self-calibration method of claim 7, wherein,
the temperature compensation process comprises the following steps:
the compensation coefficients of different temperature sections are set,
and the controller selects a corresponding compensation coefficient according to the hydraulic oil temperature monitored by the system and compensates the characteristic fitting curve F2.
9. A self-calibration device for a main valve of an electronic control system, characterized in that it adopts a self-calibration method according to any one of claims 1 to 8, said self-calibration device comprising:
the selecting module is used for acquiring key data of control parameters of different control main valves;
a storage element for storing a data packet formed by the key data and information of a corresponding control main valve;
and the controller is used for reading all the data packets in the storage element and automatically calibrating different control main valves according to the read data packets.
10. A computer readable storage medium having stored therein computer instructions for execution by a processor of the steps of the self-calibration method according to any one of claims 1 to 8.
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| DE10131507C2 (en) * | 2001-07-02 | 2003-07-24 | Bosch Gmbh Robert | Method for operating an internal combustion engine, in particular a motor vehicle |
| EP1827933B1 (en) * | 2003-12-08 | 2008-10-08 | Continental Teves AG & Co. oHG | Method for calibrating analogue regulating, electrically controllable hydraulic valves |
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