CN202612240U - Intelligent hydraulic valve allowing clamping fault to be detected and repaired - Google Patents
Intelligent hydraulic valve allowing clamping fault to be detected and repaired Download PDFInfo
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- CN202612240U CN202612240U CN 201220268121 CN201220268121U CN202612240U CN 202612240 U CN202612240 U CN 202612240U CN 201220268121 CN201220268121 CN 201220268121 CN 201220268121 U CN201220268121 U CN 201220268121U CN 202612240 U CN202612240 U CN 202612240U
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Abstract
The utility model relates to an intelligent hydraulic valve allowing a clamping fault to be detected and repaired. The hydraulic valve comprises a proportional electromagnet, a valve core, a valve body with a valve cavity, an intelligent controller, a plurality of ultrasonic transducers and a valve core magnetizing device, wherein the valve body comprises a tailor-made valve wall; the intelligent controller is electrically connected with the ultrasonic transducers, the proportional electromagnet, the valve core magnetizing device and the tailor-made valve wall respectively; the ultrasonic transducers are fixedly arranged on the outer side of the valve body of the hydraulic valve; the axes of the ultrasonic transducers are vertically intersected with the central axis of the valve cavity in the valve body; and the tailor-made valve wall comprises upper, lower, left and right main valve walls, four magnetic isolating tapes and four groups of solenoid coils with magnetic conducting frames. Through the technical scheme, the clamping fault of the valve core of a sliding valve can be conveniently and accurately forecast and detected in real time, a clamping position is determined, the clamping fault caused by pollution and radial force imbalance can be conveniently repaired by using electromagnetic force, and the hydraulic valve is easy and convenient to operate and has a good using effect.
Description
Technical field
The utility model relates to a kind of hydrovalve, particularly a kind of intelligent hydraulic valve that detects and repair the chucking fault.
Background technique
Sliding valve core mechanism adopts maximum a kind of structural type in all kinds of hydrovalves.Guiding valve generally comprises spool and valve body, and valve body comprises valve wall and valve pocket.Through changing the position of spool in the valve pocket of valve body, guiding valve can be realized the change and the break-make of direction of flow.Guiding valve chucking fault is a common faults and one of failure mode the most in the hydraulic system, generally can be divided into hydraulic lock and machinery chucking two big classes.Unbalanced pressure causes because of machining causes how much proterties sum of errors of spool coaxiality error to produce radially in hydraulic lock; The machinery chucking is then deposited gradually in the guiding valve gap by the on-the-spot particulate pollutant of operation and causes.The chucking fault has the differentiation of slight and severe.
Guiding valve chucking fault is one of common faults and failure mode the most in the hydraulic system.Hydraulic system is as high-power actuator, in case appearance chucking fault, the lighter's thrashing, weight person goes back entail dangers to equipment even personal safety.Therefore, at first, find that in time the chucking fault is most important to the safe operation of hydraulic system; Secondly, more can fault be nipped in the bud to the forecast that tightens fault, significant to the reliability that improves whole system; The 3rd, if the chucking fault takes place, that lateral location that the judgement spool is clamped in the valve pocket is also very crucial for the chucking troubleshooting of faults.
Obtaining of existing guiding valve chucking information mainly is to realize through the detection to hydraulic system pressure, flow, displacement equivalent, belongs to the indirect detection method of diagnosing, can't directly obtain the spool working state.Special, the factor that influences parameters such as pressure, flow, displacement is a lot, and chucking is one of them, therefore tightens the accuracy that detects and remains to be weighed.
The scholar who also has proposes to utilize the variation that is superimposed upon the vibrating signal on the spool to detect chucking bite fault; This method can realize tightening the detection and the forecast of fault to a certain extent; But because it also is to change indirect detection spool mechanical motion state through electromagnetic field; Exist the decision influence factor many, judgment threshold is difficult to problems such as unified demarcation.
In addition, for chucking back valve core chucking position Detection, the then less report that is seen in.
In the existing technology, the method for fixing a breakdown mainly contains two kinds: the one, in processing and on-the-spot running, take measures, and reduce the probability that breaks down.Rationally offer balancing slit, strict processing and assembling quality etc. on fine filter, the spool such as in system, installing; Another kind method is exactly that online in real time fault diagnosis and fault are got rid of.
A kind of solenoid directional control valve that HERION company manufactures and designs except its work spool, also has " hammer " spool.During proper functioning, " hammer " spool is failure to actuate, and when spool can't playback because of chucking, " hammer " spool knocked the work spool under the spring force effect, make its return.The narrow limitation of this scheme is, owing to be to lean on that the compressed machinery spring obtains to knock energy when powering on, " hammer " spool is hammer action for once, and is unidirectional, can't guarantee the fault eliminating, also can't be applied to servo, proportional valve control system.
In view of this, the inventor combines to be engaged in hydrovalve area research work experience for many years, and the defective of above-mentioned technical field is studied for a long period of time, and this case produces thus.
The model utility content
The purpose of the utility model is to provide a kind of intelligent hydraulic valve that detects and repair the chucking fault simple in structure, with low cost; Can make things convenient for, accurate, real-time forecast, detect valve core of the spool valve chucking fault, judge the chucking position; And can utilize the electromagnetic force reparation easily by the chucking fault of polluting and the radial force imbalance causes; Easy and simple to handle, using effect is good.
To achieve these goals, the technological scheme of the utility model is following:
A kind of intelligent hydraulic valve that detects and repair the chucking fault comprises the valve body of proportion electro-magnet, spool and band valve pocket.Also comprise intelligent controller, a plurality of supersonic transducer and spool magnetizing assembly, valve body comprises special valve wall, and intelligent controller is electrically connected with supersonic transducer, proportion electro-magnet, spool magnetizing assembly and special valve wall respectively.
Said intelligent controller comprises CPU module, electromagnetic force chucking eliminating module, general proportional amplifier module, ultrasonic chucking failure prediction detection and location module, wireless communication module, power module of voltage regulation and magnetization control module; Ultrasonic chucking failure prediction detection and location module comprises high-speed a/d modular converter, echo signal filtering amplification module, ultrasound emission module and multichannel handover module.
Wherein, power module of voltage regulation is got rid of module, general proportional amplifier module, ultrasonic chucking failure prediction detection and location module, wireless communication module with CPU module, electromagnetic force chucking, the magnetization control module links to each other and required voltage is provided; CPU module and electromagnetic force chucking is got rid of module, ultrasonic chucking failure prediction detection and location module, wireless communication module, power module of voltage regulation, the magnetization control module links to each other and control the work of entire circuit; Wireless communication module links to each other with CPU module; General proportional amplifier module links to each other with CPU module and proportion electro-magnet; Four solenoids that electromagnetic force chucking is got rid of on module and CPU module and the four valve wall master walls link to each other; The magnetization control module links to each other with solenoid on CPU module and the spool magnetizing assembly; Ultrasonic chucking failure prediction detection and location module 23 links to each other with CPU module 20 and a plurality of ultrasonic transducer 50; But be specially link to each other with the high-speed a/d modular converter echo signal of processing collected of CPU module; The CPU module may command ultrasonic pulse that links to each other with the ultrasound emission module produces; CPU module and multichannel handover module link to each other to be used in and switch ultrasound emission, reception object between a plurality of supersonic transducers; The ultrasound emission module links to each other with the multichannel handover module; The high-speed a/d modular converter links to each other with echo signal filtering amplification module, and echo signal filtering amplification module links to each other with the multichannel handover module, and the multichannel handover module links to each other with a plurality of supersonic transducers.
Said supersonic transducer is fixedly installed in the outer side surface of hydraulic valve body, and the medial axis of the shaft axis of supersonic transducer and valve body internal valve cavity intersects vertically; Supersonic transducer and valve body outer side surface directly scribble acoustic coupling medium.
Said special valve wall comprises up and down four valve wall master walls, valve wall master wall is separated and is divided into four of four drift angles of valve wall at a distance from tapes and four groups of band magnetic conduction frameworks and be enclosed within four solenoids on the valve wall master wall respectively; Spool and valve wall master wall are processed by the magnet case alloy, are processed by magnet case alloy not at a distance from tape.
Said spool magnetizing assembly places between spool and the proportion electro-magnet, comprises the solenoid and the cylindrical shaft core of band magnetic conduction framework, and axle core and spool are processed one, and the axle core is by the magnet case metal alloy.
Further, said a plurality of supersonic transducers are the even number more than six, are divided into two rows, are parallel on adjacent two outer side surfaces that are installed in valve body of valve body internal valve cavity medial axis, and each supersonic transducer on each side is uniformly-spaced arranged.Thereby convenient, accurate, real-time forecast, detection valve core of the spool valve chucking fault, judgement chucking position, and cost is cheaper, and structure is simpler.
Further, said Frequency for Ultrasonic Energy Transducer is more than 10MHz.This design is to consider that spool and valve wall gap are less, thus the above-mentioned technique effect of more economical realization.
Further, the A/D converter in the said intelligent controller high speed A/D modular converter is selected the A/D chip of ADS5485 or equal performance for use, and said supersonic transducer is selected normal probe for use, and said acoustic coupling medium is a machine oil.Thereby the above-mentioned technique effect of more economical realization.
Further, said spool is processed by high magnetic conductance alloy 1J87, and said valve wall master's wall and cylindrical shaft core are processed by high magnetic conductance alloy 1J89, said at a distance from tape by YG8 not magnetic conduction import wolfram steel process.Thereby further improve the repairing effect of electromagnetic force in the present technique scheme, and using effect is better.
The working principle of employing present technique scheme detection chucking fault is (Fig. 5 is referring to the description of drawings part) as follows:
Ultrasound is that frequency is higher than 20 kilo hertzs mechanical wave, and this mechanical wave can be propagated with certain speed and direction in material, runs into the different heterogeneous interface of acoustic impedance (like the bottom surface of defective or measured object etc.) and will produce reflection.This reflex can be used to carry out ultrasonic flaw detection, and the most frequently used is the pulse echo defectoscopy.During flaw detection; The voltage that impulse oscillator sends is added in supersonic transducer (ultrasonic probe in other words; Be the detecting element of processing with piezoelectric constant or quartz wafer) on, the ultrasonic pulse that supersonic transducer sends gets into material through acoustic coupling medium (like machine oil or water etc.) and propagates therein, run into defective after; The partial reflection energy returns supersonic transducer along former approach, and supersonic transducer changes it into electrical pulse again.According to the position and the amplitude (making comparisons) of flaw echo electrical pulse, can measure the position and the approximate size of defective with the reflected wave amplitude of Artificial defect in the Reference block.
The utility model is used for reference the mechanism of above-mentioned ultrasonic flaw detection, utilizes ultrasound to realize forecast, detection and the location of spool chucking in the heterogeneous interface reflex.Hydrovalve as shown in Figure 5 is when proper functioning; The medial axis of valve pocket overlaps in spool 41 and the valve body 40; The electrical signal that the ultrasound emission module is sent is added on the supersonic transducer 50, and the ultrasonic pulse that produces then gets into the valve wall and propagates the gap location between valve wall and spool therein through acoustic coupling medium (machine oil); Because the hydraulic oil in the gap is different with the acoustic impedance of valve wall, ultrasound produces emission at gap location.The partial reflection energy returns supersonic transducer along former incident approach; Supersonic transducer changes it into electrical pulse again; CPU module is according to the position t1 and the amplitude v1 of the reflected wave electrical pulse of gathering; Carry out fuzzy judgment with reference position t and reference amplitude v, and then obtain being nominal situation this moment, do not have chucking failure judgment information; And work as hydrovalve because hydraulic lock or machinery chucking make spool depart from position, valve pocket medial axis.Gap smaller (the bite operating mode among Fig. 5) between this moment spool and the valve wall; CPU module still is t1 (boundary position of valve wall is constant) according to the position of the reflected wave electrical pulse of gathering; And amplitude becomes v2; V1 during with nominal situation compares significantly and reduces, and can forecast that thus the chucking fault has the trend of generation; When the chucking fault takes place; This moment, spool departed from the medial axis far away; And (the bite operating mode among Fig. 5) almost very close to each other between the valve wall, CPU module is according to the position or the t1 of the reflected wave electrical pulse of gathering, and amplitude has become v3; If the v3 value is made as the detection threshold that tightens fault, then can whether be lower than the generation that v3 judges the chucking fault through judging reflex amplitude.Otherwise; If the supersonic transducer among Fig. 5 is installed in opposite one side; Then in chucking operating mode transforming process, the value of v1 v2 v3 then is to increase progressively relation to hydrovalve at nominal situation, then can whether be higher than whether v3 judges has the chucking fault to the side generation through judging reflex amplitude.
As preferably, for more accurate forecast, detection and location chucking fault, on the axial cross section of spool, needing two supersonic transducers at least is that decidable tightens the position (having 8 kinds of possibility orientation at least) that takes place on this cross section; Because spool is axially having certain length, chucking might occur in any one axial position, and at least 3 transducers on the axis can be used for detecting chucking position in the axial direction.
Adopt the working principle of present technique scheme reparation machinery chucking fault following:
When electro-hydraulic proportional valve produces machinery chucking fault; With the approaching contamination particle of the gap size of valve body spool because of valve body and uneven big the contamination particle of formation that be detained of spool face; Be trapped between large particle than granule simultaneously; Constitute the dirty grain of dynamic growth cake, both actings in conjunction form common pollution chucking.Spool chucking fault is mainly two kinds of forms of expression, or spool mainly is stuck in some sides of valve pocket, or spool mainly is stuck in certain two side (as above these more serious bi-side of principle analysis generally are adjacent) of valve pocket.We can detect, judge through said apparatus to this.
When judging that spool mainly is stuck in the some of valve pocket or two sides, the axle core that is inserted in the solenoid is magnetized in the then solenoid of spool magnetizing assembly energising, makes the spool that links to each other with the axle core be magnetized to S or N magnetic pole.Simultaneously, four solenoids on the valve wall master wall are switched on simultaneously, and each coil current equates.The current direction of controlling in four solenoids makes valve wall master wall be geomagnetic into the magnetic pole identical with spool.At this moment spool becomes two blocks of identical magnet of polarity with valve wall master wall, produces electromagnetic repulsion force between them.The electromagnetic repulsion force that one or two side of pressing close to spool receives is bigger, and the electromagnetic repulsion force of all the other several side is less, and when repulsion during greater than the active force of machinery chucking, spool begins to the motion of the medial axis of valve pocket direction, and gripping orientation is eased.Consider that the relative both sides of spool all produce the situation of polluting chucking in various degree; Behind the energising of the solenoid on spool magnetizing assembly and four side valve wall master walls certain hour, make each solenoid outage certain hour simultaneously, so circulation is repeatedly; Spool is under the effect of electromagnetic force; Along the radially significantly vibration of valve pocket, make a big contamination particle and a dirty grain cake receive the mechanical vibration effect and fragmentation is decomposed into granule and is melted in the hydraulic oil, and with the fluid circulation by band from slide-valve gear; Thereby reach cleaning fluid and the purpose of removing the chucking fault, and finally make spool can rest on place, valve pocket medial axis.
Certain above-mentioned electromagnetic force also can be an electromagnetic attraction; It is constant promptly to start the spool magnetization; And only make the solenoid energising on the valve wall master wall of one or both sides on some or opposite, two sides at valve pocket chucking place, make this corresponding valve wall master wall be magnetized, and the current direction in the control solenoid; Make spool and valve wall master wall become opposite polarity two blocks of magnet, produce electromagnetic attraction between them.When suction during greater than the active force of machinery chucking, spool begins towards opposite side or diagonal motion, and gripping orientation is eased.Consider the relative both sides of spool or all produce the situation of polluting chucking in various degree all around; Behind the solenoid on the valve wall master wall of one or both sides energising certain hour, this solenoid outage, and make the same time of solenoid energising on the valve wall master wall of one or both sides, opposite subsequently (as preferably; Electrical current on latter's solenoid little than on the former solenoid; Thereby improve the effect of electromagnetic attraction de-chucking), so circulate repeatedly, spool is under the effect of electromagnetic force; Along the radially significantly vibration of valve pocket, its effect is the same.
Adopt the working principle of present technique scheme reparation hydraulic lock fault following:
The reason that electro-hydraulic proportional valve produces the hydraulic lock fault is to produce radially unbalanced pressure because of machining causes how much proterties sum of errors of spool coaxiality error, makes spool press to the valve body wall, finally produces hydraulic lock.Spool chucking fault is mainly two kinds of forms of expression, or spool mainly is stuck in some sides of valve pocket, or spool mainly is stuck in certain two side (as above these more serious bi-side of principle analysis generally are adjacent) of valve pocket.We can detect, judge through said apparatus to this.
When judging that spool mainly is stuck in the some of valve pocket or two sides, the axle core that is inserted in the solenoid is magnetized in the then solenoid of spool magnetizing assembly energising, makes the spool that links to each other with the axle core be magnetized to S or N magnetic pole.Simultaneously, four solenoids on the valve wall master wall are switched on simultaneously, and each coil current equates.The current direction of controlling in four solenoids makes valve wall master wall be geomagnetic into the magnetic pole identical with spool.At this moment spool becomes two blocks of identical magnet of polarity with valve wall master wall, produces electromagnetic repulsion force between them.The electromagnetic repulsion force that one or two side of pressing close to spool receives is bigger, and the electromagnetic repulsion force of all the other several side is less, and when repulsion during greater than the active force of machinery chucking, spool begins to the motion of the medial axis of valve pocket direction, and gripping orientation is eased.Behind the energising of the solenoid on spool magnetizing assembly and four side valve wall master walls certain hour, make each solenoid outage certain hour simultaneously, so circulation is repeatedly; Spool is under the effect of electromagnetic force; Radially significantly vibration along valve pocket makes radially that unbalanced pressure is able to alleviate or eliminate, thereby spool is suspended near the medial axis of valve pocket; Friction factor between valve interior surface and the spool significantly reduces; Avoiding spool to be crushed on the valve interior wall can't move, and reaches the purpose of removing hydraulic lock, and finally makes spool can rest on place, valve pocket medial axis.
Certain above-mentioned electromagnetic force also can be an electromagnetic attraction; It is constant promptly to start the spool magnetization; And only make the solenoid energising on the valve wall master wall of one or both sides on some or opposite, two sides at valve pocket chucking place, make this corresponding valve wall master wall be magnetized, and the current direction in the control solenoid; Make spool and valve wall master wall become opposite polarity two blocks of magnet, produce electromagnetic attraction between them.When suction during greater than the active force of hydraulic lock, spool begins towards opposite side or diagonal motion, and gripping orientation is eased.Behind the energising of the solenoid on the valve wall master wall of one or both sides certain hour; Let the outage of this solenoid, and make subsequently the same time of solenoid energising on the valve wall master wall of one or both sides, opposite (as preferably, little than on the former solenoid of the electrical current on latter's solenoid; Thereby improve the effect of electromagnetic attraction de-chucking); So circulate repeatedly, spool is under the effect of electromagnetic force, along the radially significantly vibration of valve pocket; Make radially that unbalanced pressure is able to alleviate or eliminate, thereby reach like above-mentioned technique effect.
When polluting the chucking fault and take place, spool generally can depart from position, valve pocket medial axis, and is in order to improve the effect of electromagnetic force de-chucking, smaller near the electrical current on the solenoid on the valve wall of that side of spool or those both sides.Four separated tapes are mainly used in the Magnetic field distribution when improving adverse, weaken the repulsion between same pole.
The utility model is compared with existing technology has following advantage and effect: 1, the principles with ultrasonic flaw detection tightens faut detection to hydrovalve; Simplicity of design is ingenious, can make things convenient for, accurate, real-time forecast, detect valve core of the spool valve chucking fault, judges the chucking position and get rid of; 2, above-mentioned detection is non-destructive inspection, need not to change the hydrovalve structure; 3, can realize tightening forecast, detection and the abort situation location of fault; 4, directly feed back the spool position information, than indirect detection better reliability; 5, the signal as the chucking faut detection is single, and accuracy is high, receives interference little; 6, utilize the bi-directional electromagnetic suction of electromagnet that spool is radially vibrated, thereby pulverize big contamination particle and dirty grain cake, the chucking fault decontaminates; 7, utilize the bi-directional electromagnetic suction of electromagnet to alleviate or eliminate radially unbalanced pressure, thereby reduce the friction factor between valve interior surface and the spool and spool is returned near the medial axis, get rid of the hydraulic lock fault; 8, the direction of chucking is radially, and the utility model is through radial electromagnetic force effect de-chucking fault, and its effect is better than the chucking solution through the axial vibration mode; 9, in the present technique scheme, the final equinoctial point that electromagnetic force can reach just is the nominal situation of Proportional valve, and promptly therefore the medial axis coincidence status of spool and valve pocket adopts the present technique scheme finally can make spool can rest on place, valve pocket medial axis; 10, the present technique scheme has failure prediction, detection and online from getting rid of function, and can to central control room the real-time status information of valve, the reliability and the working life of having improved hydrovalve be provided through wireless transport module; 11, adopt the present technique scheme, simple in structure, with low cost, easy and simple to handle, using effect is good.
In order further to explain the technological scheme of the utility model, the utility model is done further detailed description below in conjunction with accompanying drawing and embodiment.
Description of drawings
Fig. 1 is a common electrical liquid proportional valve arrangement schematic representation;
Fig. 2 is the structural representation of the utility model;
Fig. 3 is the sectional drawing of the utility model along vertical valve core direction of axis line;
Fig. 4 is a supersonic transducer mounting point schematic representation;
Fig. 5 is the utility model chucking faut detection working principle schematic representation;
Fig. 6 is the module frame chart of the utility model intelligent controller;
Fig. 7 is the CPU module of intelligent controller and the structured flowchart between ultrasonic chucking failure prediction detection and location module and the supersonic transducer;
Fig. 8 is the structural representation of the utility model spool magnetizing assembly.
Embodiment
Below in conjunction with the enforcement further detailed description of accompanying drawing to the utility model.
The structure of common electro-hydraulic proportional valve is as shown in Figure 1, comprises spool 1 ' and valve body, and valve body comprises valve pocket 2 ' and valve wall 3 '.As for miscellaneous part, generally also comprise proportional amplifier 5 ', proportion electro-magnet 4 '.Proportion electro-magnet 4 ' also can be single, replaces with Returnning spring at the other end.Proportion electro-magnet matches with spool, passing ratio solenoid actuated spool.The moving iron core of general proportion electro-magnet 4 ' heads on spool 1 '.Through changing the position of spool 1 ' in the valve pocket of valve body, Proportional valve can be realized the change and the break-make of direction of flow.Above-mentioned is existing technology, repeats no more here.
To shown in Figure 8, is the preferred embodiment of the utility model like Fig. 2.
A kind of intelligent hydraulic valve that detects and repair the chucking fault comprises the valve body 40 of proportion electro-magnet 30, spool 41 and band valve pocket 42.Above-mentioned is the state of the art, repeats no more here.
As shown in Figure 2; Also comprise intelligent controller 10, a plurality of supersonic transducer 50 and spool magnetizing assembly 60; Valve body comprises special valve wall 43, and intelligent controller 10 is electrically connected with supersonic transducer, proportion electro-magnet 30, spool magnetizing assembly 60 and special valve wall 43 respectively.
Like Fig. 6, shown in Figure 7, intelligent controller 10 comprises CPU module 20, electromagnetic force chucking eliminating module 21, general proportional amplifier module (adopting RT-5001 in the present embodiment) 22, ultrasonic chucking failure prediction detection and location module 23, wireless communication module 24, power module of voltage regulation 25 and magnetization control module 26; Ultrasonic chucking failure prediction detection and location module 23 comprises high-speed a/d modular converter 232, echo signal filtering amplification module 233, ultrasound emission module 234 and multichannel handover module 235.
Wherein, power module of voltage regulation 25 is got rid of module 21, general proportional amplifier module 22, ultrasonic chucking failure prediction detection and location module 23, wireless communication module 24 with CPU module 20, electromagnetic force chucking, magnetization control module 26 links to each other and required voltage is provided; CPU module 20 is got rid of module 21, ultrasonic chucking failure prediction detection and location module 23, wireless communication module 24, power module of voltage regulation 25, is magnetized the work that control module 26 links to each other and controls entire circuit with the electromagnetic force chucking; Wireless communication module 24 links to each other with CPU module 20; General proportional amplifier module 22 links to each other with CPU module 20 and proportion electro-magnet 30; Four solenoids that electromagnetic force chucking is got rid of on module 21 and CPU module 20 and the four valve wall master walls 43 link to each other; Magnetization control module 26 links to each other with solenoid 61 on CPU module 20 and the spool magnetizing assembly 60;
Ultrasonic chucking failure prediction detection and location module 23 links to each other with CPU module 20 and a plurality of ultrasonic transducer 50; But be specially link to each other with high-speed a/d modular converter 232 echo signal of processing collected of CPU module 20; The CPU module 20 may command ultrasonic pulse that links to each other with ultrasound emission module 234 produces; CPU module and multichannel handover module 235 link to each other to be used in and switch ultrasound emission, reception object between a plurality of supersonic transducers 50; Ultrasound emission module 234 links to each other with multichannel handover module 235; High-speed a/d modular converter 232 links to each other with echo signal filtering amplification module 233, and echo signal filtering amplification module 233 links to each other with multichannel handover module 235, and multichannel handover module 235 links to each other with a plurality of supersonic transducers 50;
Realize each module of above-mentioned functions, structures such as its concrete circuit, components and parts owing to belong to existing technology, just repeat no more here.Intelligent controller 10 adopts the aviation plug of 2 cores or 4 cores to be connected with supersonic transducer 50 respectively; Intelligent controller 10 links to each other through 7 cores or 12 core plugs with proportion electro-magnet 30.Four solenoids on intelligent controller 10 and the special valve wall 43 and the solenoid on the spool magnetizing assembly 60 are connected through 2 core aviation plugs.The moving iron core of proportion electro-magnet 30 heads on the axle core 62 of spool magnetizing assembly.
Consider that spool and valve wall gap are less, Frequency for Ultrasonic Energy Transducer is at least more than 10MHz.Supersonic transducer and valve body outer side surface directly scribble acoustic coupling medium, are machine oil in the present embodiment.This design is to consider that spool and valve wall gap are less on the one hand, thereby the above-mentioned technique effect of more economical realization is to consider with the better supersonic sounding effect of less cost realization on the other hand, and detection, judged result are more accurate.
Supersonic transducer is selected normal probe for use, and Couplant is a machine oil; A/D converter in the high-speed a/d modular converter is selected the A/D chip of ADS5485 or equal performance for use.
Special valve wall comprises up and down four valve wall master walls 431, valve wall master wall is separated and is divided into four of four drift angles of valve wall at a distance from tapes 432 and four groups of band magnetic conduction frameworks and be enclosed within four solenoids 433 on the valve wall master wall, the i.e. solenoids of belt coil respectively.Spool and valve wall master wall are processed by the magnet case alloy, are processed by magnet case alloy not at a distance from tape.
Like Fig. 2, shown in Figure 8, spool magnetizing assembly 60 places between spool 41 and the proportion electro-magnet 30.Spool magnetizing assembly 60 comprises the solenoid 61 (being the solenoid of belt coil) and the cylindrical shaft core 62 of band magnetic conduction framework, and axle core 62 is processed one with spool 41.The axle core is processed by the magnet case alloy.In the present embodiment, the structure of spool magnetizing assembly 60 is as shown in Figure 8, is made up of with the cylindrical shaft core 62 that high magnetic conductance alloy 1J89 processes the solenoid 61 of band magnetic conduction framework; Axle core 62 is processed one with spool 41, and the mode of processing one has a lot, and only otherwise influencing magnetized axle core 62 drives the magnetization of spools 41 homopolarities and get final product, in the present embodiment, both fuse, and the shaft axis coincidence promptly can be regarded as the axle core extension of spool.Thereby further improve the repairing effect of electromagnetic force in the present technique scheme, and using effect is better.
In the present embodiment, electro-hydraulic proportional valve is as shown in Figure 3 along the sectional drawing of vertical valve core direction of axis line.The 41st, spool is processed by high hardness, high magnetic conductance alloy 1J89; The 42nd, valve pocket; The 432nd, by YG8 not magnetic conduction import wolfram steel process at a distance from tape, totally four, on four drift angles of rectangular cross-section, its size is as shown in the figure respectively; The 431st, by the valve wall master wall that high hardness, high magnetic conductance alloy 1J89 process, totally four, formed valve body valve wall jointly at a distance from tape separation and four separated tapes; 433 is solenoids of four groups of band magnetic conduction frameworks, and promptly the solenoid of belt coil is enclosed within respectively on four valve wall master walls 431.Thereby further improve the repairing effect of electromagnetic attraction in the present technique scheme, realize preferable technique effect with lower cost.
Four separated tapes are mainly used in the Magnetic field distribution when improving adverse, weaken the repulsion between same pole.The soft magnetic material that axle core in the spool magnetizing assembly and spool adopt is respectively high magnetic conductance alloy 1J89 and high magnetic conductance alloy 1J87; Wherein the magnetic property of 1J87 is better than 1J89; The purpose of design is to improve solenoid magnetic field on every side, energising back respectively like this, improves the magnetization effect of spool.
The push rod that is noted that existing proportion electro-magnet is the two-part that separate with spool, and proportion electro-magnet energising rear push-rod promotes valve core movement in proportion.In the present technique scheme; In the spool magnetizing assembly, the axle core of spool and spool magnetizing assembly is processed one, and the magnetic conduction ability of spool section material is stronger; Purpose is the Magnetic field distribution when improving the energising of spool magnetizing assembly, adds the magnetization degree of forcing that section of spool material.The push rod of the proportion electro-magnet in the present technique scheme promotes axle core (and spool) motion of spool magnetizing assembly under nominal situation.
Embodiment 1: the failure prediction of machinery chucking, detection, location and eliminating (side chucking) certainly:
In this mode of execution, the wireless communication module 24 of intelligent controller receives from the given signal of central control room and sends signal to CPU module 20; CPU module 20 is delivered to general proportional amplifier module 22 with this signal; General proportional amplifier module 22 arrives proportion electro-magnet 30 according to this signal through processing of circuit output power control signal; This moment magnetizing assembly 60 solenoid 61 no electric circuits, the moving iron core pushing shaft core 62 of proportion electro-magnet 30 also drives spool 41 and moves by given control signal and make the hydrovalve proper functioning.
Regularly produce ultrasonic pulse encourages six ultrasonic transducers and detection of echoes signal to ultrasonic chucking failure prediction detection and location module 23 in turn; And this echo signal and benchmark calibration signal compared differentiation; When departing from the regime values scope, send failure prediction to CPU module 20.CPU module 20 driving wireless communication modules 24 send to central control room with this failure prediction and carry out fault pre-alarming.If ultrasonic chucking failure prediction detection and location module 23 detects echo signal and drops on the chucking number range; Except sending the trouble report to CPU module 20; Also will detect the occurrence positions of chucking fault simultaneously---confirm the chucking position of this plane normal direction through the echo values of three place's supersonic transducers on the more same plane, and this information is sent to CPU module 20.CPU module 20 is according to energising direction, electric current, time and the frequency of four solenoids 5,6,7,8 on the solenoid on this signal deciding spool magnetizing assembly 60 62 and the special valve wall 43, and this information delivered to spool magnetizing assembly 60 get rid of module 21 with the electromagnetic force chucking.Spool magnetizing assembly 60 moves in view of the above with electromagnetic force chucking eliminating module 21 corresponding solenoid energising enforcement chucking fault is got rid of.
Suppose that spool mainly is stuck in the A side of valve pocket (left side shown in Figure 3 promptly marks 431 and 432 sides, and solenoid 8 is arranged on it), then this side opposite side is B side (there is solenoid 6 on right side shown in Figure 3 on it).Then 61 energisings of the solenoid on the spool magnetizing assembly 60, the spool 41 that axle core 62 is magnetized to N magnetic pole and axle core 62 one is magnetized to the N magnetic pole equally.Four groups of (5,6,7,8) solenoid 433 energisings simultaneously; Make the four side valve wall master walls 431 that twined by solenoid 433 all be geomagnetic into the N magnetic pole; Spool 41 becomes two blocks of identical magnet of polarity with four side valve wall master walls 431, produces electromagnetic repulsion force between them.When repulsion during greater than the active force of machinery chucking, spool begins to the motion of valve pocket medial axis direction, and gripping orientation is eased.The AB both sides of considering spool all produce the situation of polluting chucking in various degree; Behind the solenoid 61 and the 433 energising certain hours of the solenoid on the four side valve wall master walls 431 of magnetizing assembly 60, make each solenoid outage certain hour simultaneously, so circulation is repeatedly; Spool 41 is under the effect of electromagnetic force; Radially (A is to B) along valve pocket 42 significantly vibrates, and makes a big contamination particle and a dirty grain cake receive the mechanical vibration effect and fragmentation is decomposed into granule and is melted in the hydraulic oil, and with the fluid circulation by band from slide-valve gear; Thereby reach cleaning fluid and the purpose of removing the chucking fault, and finally make spool can rest on place, valve pocket medial axis.Special; Supersonic transducer is pressed from spool magnetizing assembly 60 distances from the near to the remote with supersonic transducer called after 50a, 50b, 50c on the same plane; If detected chucking fault point is respectively when 50a, 50b, 50c position; Electrical current on the corresponding solenoid 5,6,7,8 is ia, ib, ic, and ia < ib < ic.
Certain above-mentioned electromagnetic force also can be an electromagnetic attraction; It is constant promptly to start spool 41 magnetization; And only make solenoid 433 energisings on the B side valves wall master wall 433, and make B side valve wall master wall 431 and spool 41 become opposite polarity two blocks of magnet, produce electromagnetic attraction between them.When suction during greater than the active force of machinery chucking, spool begins towards the motion of B side direction, and gripping orientation is eased.Consider that the relative both sides of spool all produce the situation of polluting chucking in various degree; Behind the solenoid on B side valve wall master wall energising certain hour, this solenoid outage, and make the same time of solenoid energising on the A side valve wall master wall subsequently (as preferably; Electrical current on the A side solenoid little than on the B side solenoid; Thereby improve the effect of electromagnetic attraction de-chucking), so circulate repeatedly, spool is under the effect of electromagnetic force; Along the radially significantly vibration of valve pocket, its effect is the same.
Embodiment 2: hydraulic lock failure prediction, detection, location and eliminating (side chucking) certainly
In this mode of execution, the wireless communication module 24 of intelligent controller receives from the given signal of central control room and sends signal to CPU module 20; CPU module 20 is delivered to general proportional amplifier module 22 with this signal; General proportional amplifier module 22 arrives proportion electro-magnet 30 according to this signal through processing of circuit output power control signal; This moment magnetizing assembly 60 solenoid 61 no electric circuits, the moving iron core pushing shaft core 62 of proportion electro-magnet 30 also drives spool 41 and moves by given control signal and make the hydrovalve proper functioning.
Regularly produce ultrasonic pulse encourages six ultrasonic transducers and detection of echoes signal to ultrasonic chucking failure prediction detection and location module 23 in turn; And this echo signal and benchmark calibration signal compared differentiation; When departing from the regime values scope, send failure prediction to CPU module 20.CPU module 20 driving wireless communication modules 24 send to central control room with this failure prediction and carry out fault pre-alarming.If ultrasonic chucking failure prediction detection and location module 23 detects echo signal and drops on the chucking number range; Except sending the trouble report to CPU module 20; Also will detect the occurrence positions of chucking fault simultaneously---confirm the chucking position of this plane normal direction through the echo values of three place's supersonic transducers on the more same plane, and this information is sent to CPU module 20.CPU module 20 is according to energising direction, electric current, time and the frequency of four solenoids 5,6,7,8 on the solenoid on this signal deciding spool magnetizing assembly 60 62 and the special valve wall 43, and this information delivered to spool magnetizing assembly 60 get rid of module 21 with the electromagnetic force chucking.Spool magnetizing assembly 60 moves in view of the above with electromagnetic force chucking eliminating module 21 corresponding solenoid energising enforcement chucking fault is got rid of.
Suppose that spool mainly is stuck in the A side of valve pocket (left side shown in Figure 3 promptly marks 431 and 432 sides, and solenoid 8 is arranged on it), then this side opposite side is B side (there is solenoid 6 on right side shown in Figure 3 on it).Then 61 energisings of the solenoid on the spool magnetizing assembly 60, the spool 41 that axle core 62 is magnetized to N magnetic pole and axle core 62 one is magnetized to the N magnetic pole equally.Four groups of (5,6,7,8) solenoid 433 energisings simultaneously; Make the four side valve wall master walls 431 that twined by solenoid 433 all be geomagnetic into the N magnetic pole; Spool 41 becomes two blocks of identical magnet of polarity with four side valve wall master walls 431, produces electromagnetic repulsion force between them.When repulsion during greater than the active force of hydraulic lock, spool begins to the motion of valve pocket medial axis direction, and gripping orientation is eased.Behind the solenoid 61 and the 433 energising certain hours of the solenoid on the four side valve wall master walls of magnetizing assembly 60, make each solenoid outage certain hour simultaneously, so circulation is repeatedly; Spool 41 is under the effect of electromagnetic force; Radially (A is to B) along valve pocket 42 significantly vibrates, and makes radially that unbalanced pressure is able to alleviate or eliminate, thereby spool is got back near the medial axis of valve pocket; Friction factor between valve interior surface and the spool significantly reduces; Avoiding spool to be crushed on the valve interior wall can't move, and reaches the purpose of removing hydraulic lock, and finally makes spool can rest on place, valve pocket medial axis.Special; Supersonic transducer is pressed from spool magnetizing assembly 60 distances from the near to the remote with supersonic transducer called after 50a, 50b, 50c on the same plane; If detected chucking fault point is respectively when 50a, 50b, 50c position; Electrical current on the corresponding solenoid 5,6,7,8 is ia, ib, ic, and ia < ib < ic.
Certain above-mentioned electromagnetic force also can be an electromagnetic attraction, and it is constant promptly to start spool 41 magnetization, and only makes 431 energisings of B side valve wall master wall and make spool 41 and B side valve wall master wall 431 become opposite polarity two blocks of magnet, produces electromagnetic attraction between them.When suction during greater than the active force of hydraulic lock, spool begins towards the motion of B side direction, and gripping orientation is eased.Behind the energising of the solenoid on B side valve wall master wall certain hour; The outage of this solenoid, and make subsequently the same time of solenoid energising on the A side valve wall master wall (as preferably, little than on the B side solenoid of the electrical current on the A side solenoid; Thereby improve the effect of electromagnetic attraction de-chucking); So circulate repeatedly, spool is under the effect of electromagnetic force, along the radially significantly vibration of valve pocket; Make radially that unbalanced pressure is able to alleviate or eliminate, thereby reach like above-mentioned technique effect.
As aforementioned, the direction of chucking is radially, and the utility model is through radial electromagnetic force effect de-chucking fault, and its effect is better than the chucking solution through the axial vibration mode; Simultaneously, adopt the present technique scheme, simple in structure, with low cost, easy and simple to handle, using effect is good.
Among above-mentioned two embodiments, each module and CPU module 20 tighten the working procedure of failure prediction, detection and location such as following in the ultrasonic chucking failure prediction detection and location module 23.
The working procedure of chucking failure prediction and detection is following:
With that side surface wiped clean that hydrovalve is installed supersonic transducer, spread machine oil, the equidistant average line placement of six supersonic transducers along the valve pocket medial axis of hydrovalve;
When using for the first time, earlier spool is adjusted to nominal situation (medial axis of spool and valve pocket overlaps); Supersonic transducer 50 is linked to each other with multichannel handover module 235, start CPU module 20 work; CPU module 20 at first follow procedure control multichannel handover module 235 is connected No. 1 supersonic transducer; Starting ultrasound emission module 234 then sends electrical signal and is added on No. 1 supersonic transducer; The ultrasonic pulse that No. 1 supersonic transducer is excited to produce gets into the valve wall through acoustic coupling medium (machine oil) and propagates therein; Gap location between valve wall and spool; Because the hydraulic oil in the gap is different with the acoustic impedance of valve wall, ultrasound produces emission at gap location.The partial reflection energy returns supersonic transducer No. 1 along former incident approach; No. 1 supersonic transducer changes it into electrical pulse again, and this electrical pulsing signal is input to high-speed a/d modular converter 232 after through echo signal filtering amplification module 233 and converts digital quantity into and send to CPU module 20.CPU module 20 is with the reflected wave electrical pulse record of gathering and preserve the reference signal sequence as this monitoring point.According to hydrovalve and ultrasound parameter, calculate the echo position in gap between spool valve wall, the reference signal amplitude according to the corresponding amplitude in this fetched reference signal sequence during as nominal situation.
Then hydrovalve is adjusted to the chucking operating mode and repeat above-mentioned steps, the reference signal amplitude of correspondence when obtaining tightening operating mode.
Repeat by above program for other 5 supersonic transducers, finally obtain the complete reference signal sequence of 6 monitoring points.
When the chucking fault takes place; Spool and a certain side valve wall contact, and then the gap between this side valve core and valve wall is close to and disappears, at this moment; When central processing unit (CPU) module 20 follow procedures carry out ultrasound detection to this monitoring point; The echo signal that is collected is compared with the reference signal amplitude of chucking operating mode after treatment, can forecast and detect the generation that tightens fault, its order of severity etc. through Fuzzy Processing.
The working procedure of chucking fault localization is following:
With that side surface wiped clean that hydrovalve is installed supersonic transducer, spread machine oil, the equidistant average line placement of six supersonic transducers along the valve pocket medial axis of hydrovalve;
When using for the first time, earlier spool is adjusted to nominal situation (medial axis of spool and valve pocket overlaps); Supersonic transducer 50 is linked to each other with multichannel handover module 235, start CPU module 20 work; CPU module 20 at first follow procedure control multichannel handover module 235 is connected No. 1 supersonic transducer; Starting ultrasound emission module 234 then sends electrical signal and is added on No. 1 supersonic transducer; The ultrasonic pulse that No. 1 supersonic transducer is excited to produce gets into the valve wall through acoustic coupling medium (machine oil) and propagates therein; Gap location between valve wall and spool; Because the hydraulic oil in the gap is different with the acoustic impedance of valve wall, ultrasound produces emission at gap location.The partial reflection energy returns supersonic transducer No. 1 along former incident approach; No. 1 supersonic transducer changes it into electrical pulse again, and this electrical pulsing signal is input to high-speed a/d modular converter 232 after through echo signal filtering amplification module 233 and converts digital quantity into and send to CPU module 20.CPU module 20 is with reflected wave electrical pulse (the being echo signal) record of gathering and preserve the reference signal sequence as this monitoring point.According to hydrovalve and ultrasound parameter, calculate the echo position in gap between spool valve wall, the reference signal amplitude according to the corresponding amplitude in this fetched reference signal sequence during as nominal situation.
Then hydrovalve is adjusted to the chucking operating mode and repeat above-mentioned steps, the reference signal amplitude of correspondence when obtaining tightening operating mode.Repeat by above program for other 5 supersonic transducers, finally obtain the complete reference signal sequence of 6 monitoring points.
When the chucking fault takes place; Spool and a certain side valve wall contact; Then the gap between this side valve core and valve wall is close to and disappears, at this moment, and when central processing unit (CPU) module 20 follow procedures carry out ultrasound detection to this monitoring point; The echo signal that is collected is compared with the reference signal amplitude of chucking operating mode after treatment, can judge that through Fuzzy Processing the chucking fault takes place.Press above program for all the other 5 and all can draw the judgement that whether tightens, the comprehensive chucking situation of these 6 points, the chucking position that can draw spool.
The working principle of above-mentioned location is following: when chucking took place, the part of spool and valve wall pressure were tight, almost do not have the space between the two; And leave the space between remaining part and the valve wall.When ultrasonic echo detected, the size in space can be through drawing the echo signal signature analysis like this.Can obtain the chucking information of this tangent plane along the bull ultrasonic probe of spool axial distribution installation.If more ultrasonic probe is installed along the distribution of spool circumferencial direction, just can obtain steric information about chucking, the position of spool chucking also can be by accurate location in three dimensional space.
The specific embodiment that the above is merely the utility model is not the restriction to this case design, and all equivalent variations of doing according to the design key of this case all fall into the protection domain of this case.
Claims (5)
1. one kind can be detected and repair the intelligent hydraulic valve that tightens fault; The valve body that comprises proportion electro-magnet, spool and band valve pocket; It is characterized in that: also comprise intelligent controller, a plurality of supersonic transducer and spool magnetizing assembly; Valve body comprises special valve wall, and intelligent controller is electrically connected with supersonic transducer, proportion electro-magnet, spool magnetizing assembly and special valve wall respectively;
Said intelligent controller comprises CPU module, electromagnetic force chucking eliminating module, general proportional amplifier module, ultrasonic chucking failure prediction detection and location module, wireless communication module, power module of voltage regulation and magnetization control module; Ultrasonic chucking failure prediction detection and location module comprises high-speed a/d modular converter, echo signal filtering amplification module, ultrasound emission module and multichannel handover module;
Wherein, power module of voltage regulation is got rid of module, general proportional amplifier module, ultrasonic chucking failure prediction detection and location module, wireless communication module with CPU module, electromagnetic force chucking, the magnetization control module links to each other and required voltage is provided; CPU module and electromagnetic force chucking is got rid of module, ultrasonic chucking failure prediction detection and location module, wireless communication module, power module of voltage regulation, the magnetization control module links to each other and control the work of entire circuit; Wireless communication module links to each other with CPU module; General proportional amplifier module links to each other with CPU module and proportion electro-magnet; Four solenoids that electromagnetic force chucking is got rid of on module and CPU module and the four valve wall master walls link to each other; The magnetization control module links to each other with solenoid on CPU module and the spool magnetizing assembly; Ultrasonic chucking failure prediction detection and location module 23 links to each other with CPU module 20 and a plurality of ultrasonic transducer 50; But be specially link to each other with the high-speed a/d modular converter echo signal of processing collected of CPU module; The CPU module may command ultrasonic pulse that links to each other with the ultrasound emission module produces; CPU module and multichannel handover module link to each other to be used in and switch ultrasound emission, reception object between a plurality of supersonic transducers; The ultrasound emission module links to each other with the multichannel handover module; The high-speed a/d modular converter links to each other with echo signal filtering amplification module, and echo signal filtering amplification module links to each other with the multichannel handover module, and the multichannel handover module links to each other with a plurality of supersonic transducers;
Said supersonic transducer is fixedly installed in the outer side surface of hydraulic valve body, and the medial axis of the shaft axis of supersonic transducer and valve body internal valve cavity intersects vertically; Supersonic transducer and valve body outer side surface directly scribble acoustic coupling medium;
Said special valve wall comprises up and down four valve wall master walls, valve wall master wall is separated and is divided into four of four drift angles of valve wall at a distance from tapes and four groups of band magnetic conduction frameworks and be enclosed within four solenoids on the valve wall master wall respectively; Spool and valve wall master wall are processed by the magnet case alloy, are processed by magnet case alloy not at a distance from tape;
Said spool magnetizing assembly places between spool and the proportion electro-magnet, comprises the solenoid and the cylindrical shaft core of band magnetic conduction framework, and axle core and spool are processed one, and the axle core is by the magnet case metal alloy.
2. a kind of intelligent hydraulic valve that detects and repair the chucking fault as claimed in claim 1; It is characterized in that: said a plurality of supersonic transducers are the even number more than six; Be divided into two rows, be parallel on adjacent two outer side surfaces that are installed in valve body of valve body internal valve cavity medial axis, each supersonic transducer on each side is uniformly-spaced arranged.
3. according to claim 1 or claim 2 a kind of detects and repairs the intelligent hydraulic valve of chucking fault, and it is characterized in that: said Frequency for Ultrasonic Energy Transducer is more than 10MHz.
4. a kind of intelligent hydraulic valve that detects and repair the chucking fault as claimed in claim 3; It is characterized in that: the A/D converter in the said intelligent controller high speed A/D modular converter is selected the A/D chip of ADS5485 or equal performance for use; Said supersonic transducer is selected normal probe for use, and said acoustic coupling medium is a machine oil.
5. a kind of intelligent hydraulic valve that detects and repair the chucking fault as claimed in claim 3; It is characterized in that: said spool is processed by high magnetic conductance alloy 1J87; Said valve wall master's wall and cylindrical shaft core are processed by high magnetic conductance alloy 1J89, said at a distance from tape by YG8 not magnetic conduction import wolfram steel process.
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| CN 201220268121 CN202612240U (en) | 2012-06-08 | 2012-06-08 | Intelligent hydraulic valve allowing clamping fault to be detected and repaired |
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| CN 201220268121 CN202612240U (en) | 2012-06-08 | 2012-06-08 | Intelligent hydraulic valve allowing clamping fault to be detected and repaired |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102734550A (en) * | 2012-06-08 | 2012-10-17 | 绍兴文理学院 | Intelligent hydraulic valve capable of detecting and repairing chucking fault |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102734550A (en) * | 2012-06-08 | 2012-10-17 | 绍兴文理学院 | Intelligent hydraulic valve capable of detecting and repairing chucking fault |
| CN102734550B (en) * | 2012-06-08 | 2014-04-16 | 绍兴文理学院 | Intelligent hydraulic valve capable of detecting and repairing chucking fault |
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