CN2819235Y - On-line quality state monitoring system of electromagnetic component - Google Patents
On-line quality state monitoring system of electromagnetic component Download PDFInfo
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- CN2819235Y CN2819235Y CN 200520050438 CN200520050438U CN2819235Y CN 2819235 Y CN2819235 Y CN 2819235Y CN 200520050438 CN200520050438 CN 200520050438 CN 200520050438 U CN200520050438 U CN 200520050438U CN 2819235 Y CN2819235 Y CN 2819235Y
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Abstract
The utility model relates to an on-line quality state monitoring system of an electromagnetic component, which comprises a testing machine for testing the electromagnetic element, wherein the central shaft line of a main shaft of the testing machine is provided with a fixed clamping apparatus, a contact head cramping apparatus, a sensor and a driving device. An upright post of the testing machine is provided with a step-by-step motor, a power supply controller, a checking control device and an upper machine electrically connected with the upright post of the testing machine. Because a combined solution of the on-line data acquisition and the upper machine monitoring is used, the problem that the traditional test detection device has low datamation degree and high dynamic test investment can be solved. The utility model has the characteristics of simple system structure, low cost, convenient operation, convenient maintenance, strong anti-interference ability, high detection precision, stable and reliable information extraction, can be widely suitable to an electromagnetic element, and can be especially suitable for performance tests of an electromagnet and an electromagnetic clutch of special type, the data acquisition of integrated technical index such as parameters, etc., automatic test, and the monitoring of on-line quality state processed and analyzed.
Description
Technical field
The utility model relates to electromagnetic component on-line condition monitoring system, particularly relates to the military electromagnet on the production line and the monitoring system of the online quality state of electromagnetic clutch.
Background technology
In the electromagnetic component, electromagnet particularly, it is converted to the part that mechanical energy is applied to device for switching to electromagnetic energy, as the electromagnetic system of relay, contactor, the magnetictrip of low-voltage circuit breaker etc.; Electromagnet also can become an electric appliances, for example tractive magnet, Brake Electromagnet, electromagnetic clutch, electromagnetic worktable etc. separately.That electromagnet has is simple in structure, volume is little, in light weight, starting suction is big, low price and have suction and advantage that the ratio of power input is bigger, so be widely used in all kinds of hydraulic systems, mining machinery and the heavy-duty machineries such as steel rolling, transportation.In some application scenario, high requirement has been proposed for the rapidity of its action, displacement, suction etc.As in high-voltage fence, when short trouble appears in circuit, rely on the rapid interrupting short circuit of extra high voltage circuit breaker; In the extra high voltage circuit breaker hydraulic actuating mechanism, the performance of solenoid electromagnet has a significant impact the rapidity of total system.Because electromagnet output is big, purposes is wide, thus design, make a kind of electromagnet that good working performance has higher economic target again that has, not only to promoting the development of the national economy but also development national defense construction all being played important effect.Equally, electromagnetic clutch is one of main element of robotization control in the electromagnetic component, be the driven by power parts that transmit rotating speed and moment of torsion, its performance comprise in turn-on time, trip time, the course of action in conjunction with merit, under certain operating frequency hour in conjunction with merit, Q-percentile life and coil stable temperature rise etc.; It has compact conformation, controls simply, is easy to realize advantages such as remote operation and automatic control.Initial application is based on lathe, and now spreaded all over textile machine, package packing machine, printing machinery, office machinery, woodworking machinery, fishery machinery, mining machinery and heavy-duty machineries such as steel rolling, transportation, thereby its reliability is subjected to people's common concern.To the exploration and the research of above-mentioned electromagnetic component, early than the eighties mid-term, country has made national standard and industry mark Huaihe River.Because the widespread use of electromagnetic component and the specific (special) requirements of some special industry, just the automatic test record of comprehensive technical indexes such as every performance test of polytype electromagnet and electromagnetic clutch and parameter, data acquisition and processing (DAP) analysis etc. are proposed higher quality as certain industrial system and detected requirement, particularly parameters such as the operating voltage of electromagnetic component, turn-on time, trip time, displacement, moment have been proposed higher quality testing requirement.
At present, in order to detect electromagnetic component, particularly detect the monitoring equipment of electromagnet and the online quality state of electromagnetic clutch, still not having ripe product both at home and abroad can be for selecting for use.Present similarly equipment, as: the off-line type spring testing machine, all there are many families to produce both at home and abroad, test item is value, displacement, rigidity etc. effectively, but the test of a collection of workpiece (spring) is finished in the multiple spot setting in turn automatically.Electromagnet and electromagnetic clutch have a wide range of applications in the system of all kinds of electric liquid combinations as a kind of controlling and driving mechanism commonly used.For example: as the switching mode electromagnet of one of reversal valve vitals, whether the characteristic that its operating characteristic and reversal valve mate mutually is appropriate, directly affects the performance of solenoid directional control valve and whole hydraulic system thereof.For the production of electromagnet design, stroke-pull characteristics are most important, be quality testing must try project." sensor+function record instrument " test mode that present domestic most electromagnet manufacturer is adopted at the trial is though can satisfy the test demand to a certain extent.But because self structure defective, this test mode exists the deficiency of two aspects: at first, function record instrument curve of output can't provide calibrated parameter coordinate scale division value, need the manual conversion, influenced the substantivity of curve statement, some are at the operation of curve, as the respective value of asking for specified point still needs manual carrying out; On the other hand, the narrower frequency range of function record instrument self has restricted its use in the dynamic property test, and traditional experiment platform such as need carry out dynamic test, must use light oscillator oscillograph instead, and this investment to testing table is totally unfavorable.In the promoting the use of of electromagnet and electromagnetic clutch, one of problem that the user is concerned about most is its serviceable life, so the life-span is an important technology index.Existing all do not have standard to the durability test of some special electromagnet and electromagnetic clutch, do not see the disclosure that test method is arranged yet.So, the focus that has become people to pay close attention to the monitoring of electromagnetic component online production quality state.
Summary of the invention
At above-mentioned situation, the purpose of this utility model is to provide electromagnetic component online quality state monitoring system, it has polytype electromagnetic component on the production line, and the data acquisition of comprehensive technical indexes such as every performance test of particularly military electromagnet and electromagnetic clutch and parameter, automatic test record and analyzing and processing are carried out the monitoring of quality state.
For achieving the above object, the online quality state monitoring system of a kind of electromagnetic component of the present utility model comprises: the test machine that is used to test electromagnetic component; Wherein, the alignment of shafts axis place of test machine is provided with stationary fixture, contact anchor clamps, sensor, gear train, and the test machine column is provided with stepper motor, detection control apparatus, and the host computer that is electrically connected with it.
Antijamming capability is strong, accuracy of detection is high in order to reach, information extraction is reliable and stable, and its further step is:
Detection control apparatus, it comprises communication interface, slave computer CPU, storer, complex programmable logic device (CPLD); Wherein, slave computer CPU is connected with storer, programmable logic device (CPLD) respectively through data address bus, and the per os line directly is connected with the inefficacy decision circuitry, connects described host computer through communication interface; And programmable logic device (CPLD) is connected with signal Processing amplifying circuit and sensor through A/D converter, and the closed control circuit of forming through photoelectric isolating circuit and power-supply controller of electric, step motor drive module and tachogenerator is connected.
The control circuit of power-supply controller of electric comprises: the DC power supply circuit of being made up of the isolating transformer T2 that is connected with AC power, rectifier bridge D25～D28 and capacitor C 38～C39 outputs to tested electromagnetic component and step motor drive module, and the wire loop of tested electromagnetic component and inefficacy decision circuitry, driving power pipe Q1～Q4, measuring resistance R48 parallel with one another are connected in series; The grid of Q1～Q4 is subjected to by the precision voltage source D29 that connects with R47, unity gain buffer IC13:D, I through resistance R 43～R46
2C bus four digital regulation resistance IC12:X9241, differential amplifier IC13:C and be parallel with the voltage stabilizing regulating circuit control that the comparer IC13:B of the little capacitor C 41 of feedback forms; Wherein, be used as the digital regulation resistance IC12 of the digital control adjusting of realization through I
2The C bus is connected with slave computer CPU, and the digital regulation resistance POTO of IC12 is as the current-limiting resistance of impact damper IC13:D output signal, and two-digit potentiometer POT1, POT2 are made as input " coarse adjustment " and the input " fine tuning " in the differential amplifier IC13:C circuit respectively in addition; Also be useful on the DC power supply circuit of forming by power transformer T1, rectifier bridge D21～D24, capacitor C 36～C37 and voltage transformation and Voltage stabilizing module that comprises of system.
The inefficacy decision circuitry comprises: output to the regional comparator circuit of being made up of operational amplifier IC14:C, IC14:D, gate circuit IC15:A, potentiometer W2～W3 and R54, C42, D30 through the operational amplifier IC14:B that is connected with dc output end measuring resistance R48 and be provided with adjustable potentiometer W1; Wherein, potentiometer W2 is provided with the higher limit of comparison domain, and potentiometer W3 is provided with the lower limit of comparison domain; The output of zone comparator circuit is connected with the reset input end of the rest-set flip-flop circuit of being made up of gate circuit IC15:C and IC15:D via the plastic filter circuit that gate circuit IC15:B, R55, C43, C44 form; Wherein, the set input end of rest-set flip-flop circuit is connected with CPU control output, output terminal judges that with the inefficacy of CPU input end is connected with the acousto-optic control warning circuit of being made up of gate circuit IC16:B, IC16:C, IC16:D and R56, R57, C45, D31, and output terminal is connected with the gate circuit IC16:A and the R58 that are used for the work indication.
The circuit of detection control apparatus comprises: pressure, displacement, vibration, voltage and current sensor, the signal Processing amplifying circuit of forming by dual operational amplifier OPA235, resistance, electric capacity and diode, the analog to digital conversion circuit of forming by six passage synchronous acquisition A/D conversion chip ADS7864, dual operational amplifier IC9 and electric capacity, the control circuit of forming by CPLD, CPU, storer, photoelectric isolating circuit, communication interface circuit and peripheral circuit thereof; Wherein, the pull pressure sensor circuit adopts resistance-strain chip pull pressure sensor to detect the pressure data F of electromagnetic component presence, the displacement transducer circuit adopts magnetosensitive near inductive di lacement tra ducer detection contact displacement data δ, voltage-current sensor all adopts the resistance sampling type sensor that declines, vibration transducer adopts piezoelectric acceleration transducer, and their output form adopts the output of three-wire system voltage; Thereafter signal Processing amplifying circuit adopts the differential type input amplification mode that suppresses common mode interference, the output of pull pressure sensor connects by dual operational amplifier IC1:OPA235, resistance R 1～R8, the signal Processing amplifying circuit that capacitor C 1～C4 and diode D1～D4 forms, the homophase of pull pressure sensor and reversed-phase output are connected to respectively by resistance capacitance R3 in this circuit, C2 and resistance capacitance R7, the low-pass filter circuit that C4 forms, be coupled to two in-phase input ends of dual operational amplifier IC1, these two in-phase input ends connect the resistance R 4 that is used to provide the direct current datum, R8, resistance R 1, R2 and resistance R 5, R6 is respectively applied for the enlargement factor of regulating dual operational amplifier, two output terminals of this dual operational amplifier also meet protection limiter diode D1～D4, are connected to the channel C HAO+ of A/D conversion chip IC6 then, CHAO-; The homophase of vibration transducer and reversed-phase output all adopt the high-pass filtering ac-coupled circuit of being made up of resistance capacitance R37, C18 and R40, C20, and the follow-up signal Processing amplifying circuit of vibration transducer and other sensors, its structure and function and pull pressure sensor circuit are roughly the same;
Wherein also comprise: the tachometer circuit of forming by the photoelectric isolating device IC10 that is connected with CPLD, tachogenerator, resistance R 41～R42; The numerical portion power circuit of forming by the filter inductance L1～L3 that is connected with voltage transformation and Voltage stabilizing module, filter capacitor C25～C27 and voltage stabilizing diode WD1; The simulation part independent power source circuit that filter inductance L4～L8, filter capacitor C28～C35, voltage stabilizing diode WD2～WD4, the integrated regulator IC11 that is connected by voltage transformation and Voltage stabilizing module forms.
Host computer comprises: upper PC, keyboard, display, printer and master menu are selected master routine control module down and can be for the runnable interface of operating.
The master routine control module comprises systemic-function, test item classification, testing result analysis and returns at least three sub-program controling modules.
The subroutine control module wherein comprises in the systemic-function subroutine control module: submenu 1 selected cell of master menu is printed, returned to demonstration, interpolation, modification, deletion, inquiry, chart; Comprise in the test item specification subroutine control module: the selection of measured workpiece model, operating voltage range detection, life tests, the detection of pressure pulling force, stroke selection, confining force detect, return submenu 2 selected cells of master menu; Comprise in the testing result analysis subroutine control module: submenu 3 selected cells of master menu are printed, returned to parameter setting, data acquisition, data processing, chart demonstration, data storage, chart.
Because the scheme that the utility model adopts on-line data acquisition to combine with ipc monitor has overcome the difficult problem that traditional experiment checkout equipment datamation degree is too low, the dynamic test investment is higher again; The utility model is compared with traditional test macro, has electromagnet suction characteristic is tested automatically, and the measured piece quality is carried out the function of assistant analysis, and work efficiency obviously improves.Aspect measuring accuracy, system carries out suitable compensation and revises the non-linear effects that reduces resistance-strain chip pressure transducer the later The data host computer of A/D analog to digital conversion, aspect file information management, system adopts the database storing administrative unit, has a series of functions such as interpolation, deletion, inquiry, modification, data output; And the utlity model has that system architecture is simple, cost is lower, convenient operating maintenance, antijamming capability is strong, accuracy of detection is high, information extraction is reliable and stable, can be to polytype electromagnetic component on the production line, the data acquisition of comprehensive technical indexes such as every performance test of particularly military electromagnet and electromagnetic clutch and parameter, test and Treatment Analysis are carried out the monitoring of online quality state automatically.Can be widely used in the monitoring of the online quality state of various electromagnetic components.
Below in conjunction with drawings and Examples the utility model is described in further detail.
Description of drawings
Fig. 1 is system architecture of the present utility model and detection architecture synoptic diagram.
Fig. 2 is a system of the present utility model detection control apparatus composition frame chart.
Fig. 3 is system power control circuit theory diagrams of the present utility model.
Fig. 4 is a thrashing decision circuitry schematic diagram of the present utility model.
Fig. 5 is that system of the present utility model detects the control circuit schematic diagram.
Fig. 6 is system of the present utility model host computer and master routine control module structured flowchart.
Fig. 7 is the runnable interface figure of Fig. 6.
Fig. 8 is a system of the present utility model typical coil current waveform figure.
Embodiment
Referring to accompanying drawing, it is the online quality state monitoring system of military electromagnet and electromagnetic clutch that present embodiment provides a kind of electromagnetic component.
System shown in Figure 1 comprises: the test machine support 1 that is positioned at test machine alignment of shafts axial location place, on this support 1, be provided with the anchor clamps 2 of the tested electromagnetic component that is installed successively, vibration transducer 3, tested electromagnetic component 4, the contact anchor clamps 5 of tested electromagnetic component, displacement sensing chip 6, displacement transducer 7, pull pressure sensor 8, gear train 9, control hand wheel 10, drive screw 11 and stepper motor 12, light electricity velocity sensor 13, detection control apparatus 14, on-scene communication bus 15, host computer 16 components and parts such as grade.Wherein anchor clamps 2 are installed in the bottom of support 1, are used for fixing tested electromagnetic component 4 housings, are benchmark with the central axis of drive screw 11, can 360 ° regulate level angle and perpendicular displacement; Contact anchor clamps 5, displacement sensing chip 6, displacement transducer 7, pull pressure sensor 8 and drive screw 11 all are fixed on the main shaft, can by gear train 9 and control hand wheel 10 it be moved up and down respectively; Vibration transducer 3 is directly installed on the housing of tested electromagnetic component 4 by the magnetic pedestal, the mechanical vibration that produce when being used to measure measured piece work; Displacement transducer 7 is fixed on the screw bracket of test machine column, can regulate the upper-lower position of its installation by screw rod, the displacement that contact moves up and down when being used to measure tested electromagnetic component work; Light electricity velocity sensor 13 is installed in the gear case of gear train 9 of test machine column, and the feedback speed signal when being used to stepper motor 12 work are provided is so that realize the closed-loop control of stepper motor; Pull pressure sensor 8 and contact anchor clamps 5, drive screw 11 are fixed on the middle and upper part at alignment of shafts axial location place, the electromagnetic force that produces when being used to measure measured piece work; Detection control apparatus 14 is installed on the column of test machine support 1, is electrically connected with host computer 16 by on-scene communication bus 15.
Open and operational system, provide the power supply of tested electromagnet or electromagnetic clutch 4, stepper motor 12, simultaneously and control the duty of measured piece 4, stepper motor 12 by detection control apparatus 14; Gear train 9 makes measured piece and sensor be in the dynamical state of operation under stepper motor 12 drives, communicate by letter the collection of the various detection data parameters that the system that finishes is required, signal Processing, fault diagnosis and various test function and monitoring by on-scene communication bus 15 and host computer 16.
In conjunction with the accompanying drawings, system is to the test monitoring principle and the course of work of each parameter:
Detection to the operating pressure or the pulling force of electromagnet, electromagnetic clutch.By tested electromagnetic component contact anchor clamps 5 and tested electromagnetic component anchor clamps 2 respectively with housing and two partial fixings of contact of tested electromagnet or electromagnetic clutch, moving of power supply that detection control apparatus 14 tested electromagnet of supply or electromagnetic clutch are required and control step motor, measure operating pressure or pulling force (recording) at each displacement point (recording) by pull pressure sensor by displacement transducer, measurement data sends host computer 16 to by on-scene communication bus 15, after host computer is judged measurement data, draw out " displacement-power " curve.
Measurement to connection voltage, off voltage and the operating voltage range of electromagnet or electromagnetic clutch.Tested electromagnet or electromagnetic clutch is fixing as stated above, detection control apparatus 14 is under the monitoring of host computer 16, regulate and measure the operating voltage of electromagnet or electromagnetic clutch, variation by pull pressure sensor 8 measurement moments, judge the state that switches on and off of tested electromagnet or electromagnetic clutch according to the situation of change of moment, thereby measure connection voltage, off voltage and the operating voltage range of electromagnet or electromagnetic clutch, and send host computer 16.
To the contact travel of electromagnet or electromagnetic clutch and the detection of speed.The housing of tested electromagnet or electromagnetic clutch is fixed by tested electromagnetic component anchor clamps 2, remove tested electromagnetic component contact anchor clamps 5 by control hand wheel 10, on the contact of tested electromagnet or electromagnetic clutch, fix a lighter displacement sensing chip 7 and regulate relative position with displacement transducer, measure the contact travel and the speed of electromagnet or electromagnetic clutch by displacement transducer 7 and detection control apparatus 14, and send host computer 16.
Mensuration to electromagnet or electromagnetic clutch serviceable life.The housing of tested electromagnet or electromagnetic clutch is fixing by measured piece anchor clamps 2, remove measured piece contact anchor clamps 5 by control hand wheel 10, on the contact of tested electromagnet or electromagnetic clutch, fix a lighter displacement sensing chip and regulate relative position with displacement transducer, by the failure detection circuit of detection control apparatus 14 inside it is measured and (to apply pulse current, write down its action frequency), measurement result is real-time transmitted to host computer 16, till tested electromagnet or electromagnetic clutch inefficacy.
Measurement to mechanical vibration.Tested electromagnet or electromagnetic clutch are fixed by the operating pressure of electromagnet, electromagnetic clutch or the method for pulling force detection, measurement result according to operating pressure or pulling force detection, select any moment between maximum moment～minimum moment, impose on tested electromagnet or electromagnetic clutch by stepper motor; Under this state, measure by vibration transducer 3 and 14 pairs of mechanical vibration of detection control apparatus, measurement data sends host computer 16 to by telecommunication cable 15, computing machine carries out signal Processing, fault diagnosis to measurement data, provides time domain, frequency curve and the fault diagnosis result of tested electromagnet or electromagnetic clutch mechanical vibration.
More than all measurements all under the monitoring of host computer 16, carry out, host computer 16 not only will be finished functions such as the parameter control, Measurement and Data Processing, fault diagnosis differentiation of various testing processes, and can also set up slip condition database at electromagnet, the electromagnetic clutch of various models, can carry out statistic of attribute and management to electromagnet, electromagnetic clutch.
Fig. 2 is the composition frame chart of the detection control apparatus of system.Mainly form by detection control apparatus and host computer 16; Detection control apparatus comprise test the speed, voltage, electric current, displacement, vibration, pull pressure sensor, power-supply controller of electric, the step motor drive module, failure detection circuit, signal Processing amplifying circuit, photoelectric isolating circuit, A/D converter, complex logic programming device CPLD, storer, CPU, communication interface; Host computer 16 comprises upper PC, keyboard, display, printer.Detection control apparatus is finished the desired various surveying works of system under the monitoring of host computer 16, measurement result sends host computer 16 to, carry out signal analysis and processing, fault diagnosis by 16 pairs of measurement data of host computer, provide the test result of tested electromagnet or electromagnetic clutch.Power-supply controller of electric among Fig. 2 is used for providing working power to tested electromagnet or electromagnetic clutch, stepper motor and whole detection control apparatus; Under the control of CPU, cooperate the closed-loop control that realizes stepper motor with the step motor drive module by tachogenerator; Failure detection circuit is used for tested electromagnet or electromagnetic clutch are carried out mensuration in serviceable life; Voltage, electric current, displacement, vibration, voltage, electric current, displacement, vibration, pulling force or pressure when pull pressure sensor realizes tested electromagnet or electromagnetic clutch work with signal Processing amplifying circuit, A/D converter, complex logic programming device CPLD are monitored in real time; Whole detection control apparatus is to finish various measurements and control under the control of following bit CPU, and storer is used to deposit the detection data, and communication interface is used for being connected with upper PC.
Fig. 3 is the utility model power controller circuit schematic diagram.For sensitivity, need a kind of high stability D.C. magnetic field with high-acruracy survey electromagnet or electromagnetic clutch.At present, adjustable current source all is to adopt the work of feedback stability formula principle, promptly detects the voltage of the standard resistor at two terminals of connect with load, and its value and the reference voltage that can hand adjustment scans are compared.Shown in accompanying drawing, the utility model adopts the special current stabilization circuit mode different with traditional current stabilization circuit, and it adopts the MOSFET power transistor of voltage-controlled form, and exciting circuit is simplified greatly.Fig. 3 is the basic circuit of current source, and (220v 50Hz) provides power supply by AC power by a stable isolating transformer T2.Rectifier bridge D25～D28 that the back has smoothing filter capacitor C 38, C39 is used for the output of T2 is converted to direct current, four RS220 type MOSFET power transistor Q1～Q4 are parallel with one another, formed basic current control circuit, and be connected in series with magnet coil and the mark Huaihe River resistance R 48 that is connected across dc output end.In addition, do not produce vibration, the resistance of 100 Ω (R43～R46) connect with the grid of mosfet transistor in order to guarantee MOSFET with good high frequency response.R48 (0.47 Ω) is an accurate power resistor that is contained in the golden shell, as the measuring resistance of failure detection.The voltage drop at R48 two ends (it and current of electromagnet proportional) compares with the reference voltage of control section, and the control element mosfet transistor that can change electromagnet current is received in its output, and the voltage drop at R48 two ends is remained unchanged.IC13:B is a TL034 type operational amplifier, as comparer, in order to prevent various vibrations, is connected to a small capacitor C41 (0.1nF) in backfeed loop.Highly stable reference voltage is provided by precision voltage source D29 through unity gain buffer IC13:D and differential amplifier IC13:C.In order to obtain required load current value when electromagnet or electromagnetic clutch detect, and this electric current can be by the pick-up unit regulating and controlling, and the utility model adopts I
2C bus four digital regulation resistance IC12:X9241 realize, the digital regulation resistance POTO of IC12 is as the current-limiting resistance of impact damper IC13:D output signal, and two other digital regulation resistance POT1, the POT2 of IC12 is as input " coarse adjustment ", " fine tuning " of differential amplifier IC13:C.Rectifier bridge D21～D24 that power transformer T1 among Fig. 3 and back have smoothing filter capacitor C 36, C37 is used for the output of T1 is converted to direct current, offers the working power of pick-up unit other parts.
Fig. 4 is that the control circuit schematic diagram is judged in the utility model inefficacy.The life-span of electromagnet and electromagnetic clutch (being the adhesive number of times) is one of important techniques index; At present, many electromagnet and electromagnetic clutch producer also all continue to use relay control adhesive number of times, count with mechanical counter; Because the life-span of relay itself is limited, mechanical counter often also can be stuck in long-term the use, therefore whenever doing a durability test all needs repeatedly to change relay, can make manufacturer feel headache, and this durability test in the type approval test is one of the content that regularly must check.To be coil around disconnected, coil short, turn-to-turn short circuit and mechanical part stuck etc. for the electromagnet failure mode, and the life-span of electromagnetic clutch is meant at the number of times that guarantees that the moment that electromagnetic clutch transmitted is constant substantially, can be connected under the situation that combination and trip time are up to specification, depend mainly on the degree of wear of friction disc, and the user mode of abrasion condition and complete machine is relevant.The utility model adopts inefficacy shown in Figure 4 to judge control circuit according to the test standard of electromagnet and electromagnetic clutch, and electromagnet and electromagnetic clutch are carried out life test.
Technical requirement regulation according to the electromagnet life test, it per hour is 3000 times, the clock frequency that promptly is equivalent to 0.8Hz, improve the testing time that test frequency can shorten the life-span, but China does not still have concrete standard at present, consider this factor, the utility model on-site detecting device adopts the software control clock frequency of slave computer CPU, is designed to on-the-spot frequency adjustable; Adjustable extent 2000 times/hour to 9000 times/hour.The electromagnet failure mode is that coil blows, coil short, turn-to-turn short circuit and mechanical part are stuck etc., be reflected on the electrical quantity and increase when being current ratio operate as normal on the sample resistance (R48 among Fig. 3) or reduce, after sampling, get magnitude of voltage relatively, realize cutting off or not cutting off the power supply of driving power by the IC12 digital regulation resistance in the CPU control chart 3 at last; Make signal alarm with light emitting diode simultaneously, promote the Yang Sheng device as audible alarm with trigger-type warning integrated circuit; In case report to the police, only can work in replacing or after repairing electromagnet, CPU inside counting device also will stop the counting of this electromagnet, and its principle is seen shown in Figure 4.Shown in accompanying drawing, the inefficacy sampled signal is input to the in-phase input end of operational amplifier IC14:B, forms the in-phase amplifier that enlargement factor is adjustable through IC14:B and potentiometer W1; Arrive by operational amplifier IC14:C, IC14:D gate circuit IC15:A, the regional comparer that potentiometer W2, W3 and R54, C42, D30 form; Potentiometer W2 is used to be provided with the higher limit of comparison domain, and potentiometer W3 is used to be provided with the lower limit of comparison domain.For example, when potentiometer W2 be output as 3V, when W3 is output as 1V, if
Inefficacy sampled signal＜3V after 1V＜amplification
Then gate circuit IC15:A is output as low level, and IC15:A all exports high level under other situation.That is to say, when electromagnet or electromagnetic clutch were working properly, its working current should fluctuate in certain scope, the sampled signal that promptly lost efficacy after amplifying also in certain voltage range, this scope is set by potentiometer W2, W3, and gate circuit IC15:A is output as low level.Behind electromagnet or electromagnetic clutch operational failure, its working current is according to the failure mode difference, increases when occurring than operate as normal or reduces, thereby make gate circuit IC15:A be output as high level.This signal is behind the plastic filter circuit that gate circuit IC15:B and R55, C43, C44 form, and when becoming operate as normal, IC15:B is output as high level; After the inefficacy, IC15:B is output as low level.Gate circuit IC15:C and IC15:D form a basic rest-set flip-flop, put 1 input end S by bit CPU control down, put the inefficacy sampled signal that 0 input end R connects IC15:B output.During the beginning durability test, by negative pulse of bit CPU output is to putting 1 input end down, relay indicating light is bright, and the sound and light alarm control circuit is not worked; When the inefficacy sampled signal was imported, alarm lamp was bright, and relay indicating light does not work, and formed the output of audible alarm control circuit by gate circuit IC16:B, IC16:C, IC16:D and R56, R57, C45, D31 and triggered control signal.
Fig. 5 is that the utility model detects the control section circuit theory diagrams.As shown in the figure, analog quantitys such as mechanical vibration when this circuit is used to detect voltage and current, contact displacement, pulling force or pressure, the work of tested electromagnet or electromagnetic clutch are measured the stepper motor rotating speed and by the step motor drive module it are realized closed-loop control.The contrast accompanying drawing further describes below.
Electromagnet and electromagnetic clutch are a kind of electromagnetic attractions that produces in the electromagnetic system that relies on, and make armature do mechanical motion, thereby make the electric device of its external work done.Therefore, armature F=f (δ) that concerns between suffered electromagnetic attraction F and its stroke δ in motion process just becomes the essential characteristic that characterizes its main performance inevitably.The pull characteristics of test electromagnet are exactly test F-δ relation curve in steady-state process.Past, producer adopted the traditional-handwork method to detect, very difficult assurance is accomplished magnet check safe against all possibilities, for avoiding detecting the drawback of bringing manually, urgent problem provides and a kind ofly can be used for production run electromagnet suction characteristic testing apparatus fully, the corresponding raising of its quality inspection means energy of this equipment requirements, the characteristics of this equipment be utilize that computer program is controlled, data acquisition and signal Processing, realization is tested and assistant analysis automatically to electromagnet suction characteristic, draws its correct testing result and provides reasonably quality discrimination.Pull pressure sensor circuit among Fig. 5 adopts the resistance-strain type pull pressure sensor, three-wire system is adopted in the output connection of sensor, the signal Processing amplifying circuit adopts differential type input mode, can effectively suppress common mode interference, form by dual operational amplifier IC1:OPA235, resistance R 1～R8, capacitor C 1～C4, diode D1～D4.R3 and C2 and R7 and C4 form two low-pass filters respectively; be used to leach the undesired signal of in-phase end and end of oppisite phase on the sensor line; R1=R5, R2=R6 are used to be provided with the enlargement factor of two operational amplifiers; R4, R8 are used for providing datum to operational amplifier; C1, C3 are two integrating capacitors; be used to increase the stability of operational amplifier, D1, D2 and D3, D4 are used for the output violent change to in-phase end and end of oppisite phase amplifier, with the A/D converter of protection back.Displacement transducer adopts magnetosensitive near inductive di lacement tra ducer, and three-wire system is still adopted in its output connection, and the structure of signal Processing amplifying circuit and function and pull pressure sensor are similar.
When we carry out electromagnet or the characteristic test of electromagnetic clutch pressure, tested electromagnet or electromagnetic clutch are fixed on the fixed end of work top, on the pull pressure sensor as the moved end above the armature stud of electromagnet or electromagnetic clutch withstands, connect certain operating voltage at this moment for the magnetizing coil of electromagnet or electromagnetic clutch, the armature pressure acts on the pressure transducer, step motor drive Novikov gear worm reducer, make pull pressure sensor on the direction of motion of armature, make linear uniform motion, the displacement of dwang drive simultaneously sensing chip moves, obtain needed test data by tension-compression sensor and displacement transducer output like this, through measuring amplifying circuit, A/D analog to digital conversion to the next single-chip microcomputer forms electromagnet or electromagnetic clutch suffered electromagnetic attraction F and the data acquisition between its stroke δ in galvanization.In order to guarantee certain measuring accuracy, stepper motor adopts close-loop control mode, makes its rotating speed steady, and starting moment is bigger.Pull pressure sensor adopts resistance-strain chip pull pressure sensor, and maximum dynamometry value is 100N, has temperature and floats little, highly sensitive, response speed reaches good linearty soon, measure amplifying circuit and adopt high cmrr, high input impedance, highly sensitive integrated operational amplifier.The sensor of measuring stroke adopts magnetosensitive near inductive di lacement tra ducer, has very high measuring accuracy.Upper PC and the next single-chip microcomputer are the cores of total system, by controller realize to worktable starting, stop and restoring supervisor and control.
Whether the pressure characteristic test of electromagnet or electromagnetic clutch is qualified, except Direct observation in test process, also need to obtain some parameters, as maximum suction, initial suction and total travel etc. by pressure, the run-length data that collects in the test carried out analytical calculation.Analyze in conjunction with measured F-δ relation curve, differentiate specified pressure and predetermined stroke that whether pressure and stroke reach defined.For example: with the suction, the initial suction of run-length data analytical calculation electromagnet, maximum suction and the total travel that collect, establish suction sampled signal f (n), n=0 wherein, 1,2,3 ... ..N, sample shift spacing L.Tested electromagnet armature head is adjusted at reference position, connects 85% load voltage value, the suction that produce this moment is initial suction; In f (n), get f (0), initial suction fn=f (0).In F-δ relation curve, there is a maximal value in F, and this maximal value is exactly maximum suction; In f (n), search f (n
MAX) 〉=f (n), n=0 wherein, 1,2,3 ... the some n of ..N
MAX, obtain maximum suction f
MAX=f (n
MAX).The computing method of total travel are the displacement of electromagnet title from reference position to maximum suction, total travel δ
K=L * n
MAXK
Underproof reason to occur mainly be the ratings that suction and stroke do not reach them to electromagnet suction characteristic in test process; Industry regulation is regulated tested electromagnet to rated travel and 85% load voltage value, requires the suction of electromagnet all to be not less than the rated attraction force of defined.If electromagnet rated attraction force Fo, electromagnet rated travel Po searches f (n in f (n)
1)＞Fo, f (n
1-1)＜the some n of Fo
10＜n wherein
1＜N, n=0,1,2,3 ... ..N.In the pull characteristics of electromagnet, require F-δ relation curve smoothly to rise, so need meet the following conditions.
f(n
1+n)-f(n
1+n-1)＞0 n＝0，1，2，ΛΛ(N-n
1)
To the calculating of electromagnet stroke is to be not less than effective displacement under the rated attraction force condition of defined at the suction that can guarantee electromagnet.Requiring stroke to satisfy more than or equal to rated travel, so need meet the following conditions, then is specification product.
δ
1＝(n
MAX-n
1)×L＞Po
Three-wire system is still adopted in the output connection of voltage-current sensor among Fig. 5, the structure of its signal Processing amplifying circuit and function and pull pressure sensor similar.Close on (branch) operating coil loop at electromagnet or electromagnetic clutch and to add voltage sensor, close the voltage of (branch) operating coil, monitoring operating voltage by measurement.When passing through electric current in the coil, in electromagnet or electromagnetic clutch, produce magnetic flux, iron core is subjected to the electromagnetic force effect, makes contact close (branch) operation.Analyze course of action and coil current waveform as can be known, in the current waveform of coil, comprising important information, reflected electromagnet or the electromagnetic clutch working condition in operating process.Typical coil current waveform as shown in Figure 8, motion can be divided into following five stages to this waveform according to iron core.
1. Phase I, t=t
0～t
1'.Coil is at t
0Constantly begin energising, to t
1' moment setting in motion unshakable in one's determination.Characteristics in this stage are that electric current rises, and iron core is not motion also.
2. Phase, t=t
1'～t
2In this stage, iron core overcomes resistance setting in motions such as gravity, spring force under the electromagnetic force effect.
3. Phase I, t=t
2～t
3In this stage, iron core is stop motion again.
4. Phase IV, t=t
3～t
4This stage is the continuity of Phase I, and electric current reaches approximate stable state.
5. stage V, t=t
4～t
5The failure of current stage.
Analyze current waveform as can be known, electric current has two peak points and a valley point.With t
0Be the zero point of order time, characteristic parameter has t
1, t
2, t
3, t
4, t
5, I
1, I
2, I
3The factor that causes the coil current variation is a lot, as the mechanical action situation of voltage, iron core idle motion, frictional resistance, clamping stagnation and operating mechanism.The variation of coil current has reflected the variation of iron core motion state and other machine performance.The situation of comprehensive above several stages from analytical line loop current waveform, can detect the operating mechanism various states, thereby can predict the omen of accident.Measuring system of the present utility model is measured the current/voltage of coil, can calculate iron core start-up time, run duration, coil electrify time according to current waveform.
Electromagnet or electromagnetic clutch are when work, and the noise measurement of magnetic system should have a quantitatively regulation.Adopt Denmark B﹠amp in the world; Factory noise identified and measures by the accurate integration type sound meter of K company for environment.Therefore ground unrest must carry out in special anechoic room when detecting electromagnet or electromagnetic clutch vibration noise less than noise source 20dB around it required, and was not suitable for the on-the-spot online detection of Workshop Production.The utility model adopts method for testing vibration, can solve the vibration noise problem of the ferromagnetic or electromagnetic clutch of workshop in situ quantitation test electromagnetism, for design, the development and production process of improving electromagnet or electromagnetic clutch and improve the quality of products significant.Vibration transducer adopts piezoelectric acceleration transducer among Fig. 5, three-wire system is still adopted in its output connection, the structure of follow-up signal Processing amplifying circuit and function and pull pressure sensor similar, just, realize by resistance capacitance R37, C18 and R40, C20 to the homophase of sensor and the AC coupling mode of reversed-phase output employing high-pass filtering.Electromagnet or electromagnetic clutch are in closing (branch) process, because operating mechanism, interlinked mechanism, first-class motion, the bump of movable contact, on electromagnet or electromagnetic clutch shell, produce a series of impact shock response signal, the waveform reflection electromagnet of these vibration signals or the motion process of the internal mechanism of electromagnetic clutch in closing (branch) process.According to this point, select for use external vibration signal in the operating process as the characteristic signal that detects electromagnet or electromagnetic clutch internal state, the utilization signal processing technology, the state that can from vibration signal waveforms, detect electromagnet or electromagnetic clutch mechanism kinematic and relevant time parameter etc.Vibration signal carries out signal Processing after sampling, specific algorithm is as follows: 1. ask signal overall average energy; 2. signal square adds low-pass filtering, its envelope; 3. check the peak value in the envelope, statistics vibration event number; 4. ask Time To Event and signal intensity.By top algorithm computation, get Time To Event and signal intensity.According to the sequencing that incident takes place, can determine the machine performance of electromagnet or electromagnetic clutch.When electromagnet or electromagnetic clutch close (branch) operation, gather vibration signal after treatment as the basis of diagnosing, the advantage of this method is that the size of sensor is little, reliable operation, sensitivity is good, and is anti-interference good, the electromagnet that is particularly suitable for acting frequently or the on-line monitoring of electromagnetic clutch, do not need to dismantle the machine performance that electromagnet or electromagnetic clutch can detect its mechanism, judging has the non-fault tendency to occur.
Fig. 6 is the utility model host computer structured flowchart, and Fig. 7 is the runnable interface figure of the utility model host computer.Shown in accompanying drawing, the operation monitoring of host computer and analyzing and processing main program module adopt the function modoularization structure, comprising: the memory module that is used for the device file management; The testing result analysis module that is used for measurement data and analyzes, judge and deal with; The output module that is used for result's monitoring, test item classification, testing result analysis, measurement parameter setting, output chart and print plot; For improving the operability degree, be provided with menu Chinese character unit and Chinese operation indicating unit in the display module; Its display interface as shown in Figure 7.Native system is mainly finished tasks such as system management, measurement range selection, data acquisition and processing, graphic presentation, printing, table output, data storage, data base administration.Wherein, the master routine control module comprises systemic-function, test item classification, testing result analysis and returns at least three sub-program controling modules.Comprise in the systemic-function subroutine control module: submenu 1 selected cell of master menu is printed, returned to demonstration, interpolation, modification, deletion, inquiry, chart; Comprise in the test item specification subroutine control module: the selection of measured workpiece model, operating voltage range detection, life tests, the detection of pressure pulling force, stroke selection, confining force detect, return submenu 2 selected cells of master menu; Comprise in the testing result analysis subroutine control module: submenu 3 selected cells of master menu are printed, returned to parameter setting, data acquisition, data processing, chart demonstration, data storage, chart.
Below only be preferred embodiment of the present utility model, according to above-mentioned design of the present utility model, those skilled in the art also can make various modifications and conversion to this.For example, the selection of program language, and the structural change at design cycle and main interface or the like.Yet similar this conversion and modification all belong to scope of the present utility model.
Claims (8)
1, the online quality state monitoring system of a kind of electromagnetic component, this system mainly comprises a test machine, be provided with anchor clamps (2) on the described test machine support (1) successively, vibration transducer (3), tested electromagnetic component (4), contact anchor clamps (5), displacement sensing chip (6), displacement transducer (7), pull pressure sensor (8), gear train (9), control hand wheel (10), drive screw (11), stepper motor (12), light electricity velocity sensor (13), detection control apparatus (14) and on-scene communication bus (15) and host computer (16) is characterized in that described anchor clamps (2) are installed in the bottom of described test machine alignment of shafts axis place's support (1) and the housing of the described tested electromagnetic component (4) that is fixedly clamped; Described contact anchor clamps (5), displacement sensing chip (6), pull pressure sensor (8), gear train (9), control hand wheel (10) and drive screw (11) are fixed on the described test machine alignment of shafts axis place main shaft; Described vibration transducer (3) is directly installed on described tested electromagnetic component (4) housing through the magnetic pedestal; Described displacement transducer (7) is fixed on the described test machine column screw bracket; Described light electricity velocity sensor (13) is installed in the gear case of described gear train (9); Described stepper motor (12), detection control apparatus (14) are installed on the described test machine column, and they all are electrically connected with described host computer (16) through described on-scene communication bus (15).
2, the online quality state monitoring system of electromagnetic component according to claim 1 is characterized in that described detection control apparatus (14) comprises communication interface, slave computer CPU, storer, programmable logic device (CPLD); Wherein, slave computer CPU is connected with storer, programmable logic device (CPLD) respectively through data address bus, and the per os line directly is connected with the inefficacy decision circuitry, and connect described host computer through communication interface; Described programmable logic device (CPLD) is connected with signal Processing amplifying circuit and sensor through A/D converter, and also the closed control circuit of forming through photoelectric isolating circuit and power-supply controller of electric, step motor drive module and tachogenerator is connected.
3, the online quality state monitoring system of electromagnetic component according to claim 2, the control circuit that it is characterized in that described power-supply controller of electric comprises: by the DC power supply circuit that outputs to tested electromagnetic component (4) and step motor drive module that the isolating transformer T2 that is connected with AC power, rectifier bridge D25～D28 and capacitor C 38～C39 form, the wire loop of described tested electromagnetic component (4) is connected in series with inefficacy decision circuitry, driving power pipe Q1～Q4, measuring resistance R48; And the grid of driving power pipe Q1～Q4 is subjected to by the precision voltage source D29 that connects with R47, impact damper IC13:D, I through resistance R 43～R46
2The voltage stabilizing regulating circuit control that the comparer IC13:B of C bus four digital regulation resistance IC12:X9241, differential amplifier IC13:C and C41 forms, wherein, digital regulation resistance IC12 is through I
2The C bus is connected with slave computer CPU; Also comprise the DC power supply circuit of forming by power transformer T1, rectifier bridge D21～D24, capacitor C 36～C37 and voltage transformation and Voltage stabilizing module.
4, the online quality state monitoring system of electromagnetic component according to claim 3 is characterized in that described inefficacy decision circuitry comprises: output to the regional comparator circuit of being made up of operational amplifier IC14:C, IC14:D, gate circuit IC15:A, potentiometer W2～W3 and R54, C42, D30 through the operational amplifier IC14:B that is connected with dc output end measuring resistance R48 and be provided with adjustable potentiometer W1; The output of this regional comparator circuit is connected with the reset input end of the rest-set flip-flop circuit of being made up of gate circuit IC15:C and IC15:D via the plastic filter circuit that gate circuit IC15:B, R55, C43, C44 form; Wherein, the set input end of rest-set flip-flop circuit is connected with CPU control output, output terminal judges that with the inefficacy of CPU input end is connected with the acousto-optic control warning circuit of being made up of gate circuit IC16:B, IC16:C, IC16:D and R56, R57, C45, D31, and output terminal AND circuit IC16:A and R58 connect.
5, the online quality state monitoring system of electromagnetic component according to claim 1 and 2, the circuit that it is characterized in that described detection control apparatus (14) comprises: pressure, displacement, vibration, the voltage and current sensor, by dual operational amplifier 0PA235, resistance, the signal Processing amplifying circuit that electric capacity and diode are formed, by six passage synchronous acquisition A/D conversion chip ADS7864, the analog to digital conversion circuit that dual operational amplifier IC9 and electric capacity are formed is by CPLD, CPU, storer, photoelectric isolating circuit, the control circuit that communication interface circuit and peripheral circuit thereof are formed; Thereafter in the signal Processing amplifying circuit, the output of pull pressure sensor connects by dual operational amplifier IC1:0PA235, resistance R 1～R8, the signal Processing amplifying circuit that capacitor C 1～C4 and diode D1～D4 forms, the homophase of pull pressure sensor and reversed-phase output are connected to respectively by resistance capacitance R3 in this circuit, C2 and resistance capacitance R7, the low-pass filter circuit that C4 forms, be coupled to two in-phase input ends of dual operational amplifier IC1, these two in-phase input ends connect resistance R 4, R8, two output terminals of dual operational amplifier also meet diode D1～D4, are connected to the channel C HAO+ of A/D conversion chip IC6 then, CHAO-; The high-pass filtering ac-coupled circuit that the homophase of vibration transducer and reversed-phase output are made up of resistance capacitance R37, C18 and R40, C20; And, the tachometer circuit of forming by the photoelectric isolating device IC1O that is connected with CPLD, tachogenerator, resistance R 41～R42; The numerical portion power circuit of forming by the filter inductance L1～L3 that is connected with voltage transformation and Voltage stabilizing module, filter capacitor C25～C27 and voltage stabilizing diode WD1; The simulation part independent power source circuit that filter inductance L4～L8, filter capacitor C28～C35, voltage stabilizing diode WD2～WD4, the integrated regulator IC11 that is connected by voltage transformation and Voltage stabilizing module forms.
6, the online quality state monitoring system of electromagnetic component according to claim 1 is characterized in that described host computer (16) comprising: upper PC, keyboard, display, printer and master menu are selected master routine control module down and can be for the runnable interface of operating.
7, the online quality state monitoring system of electromagnetic component according to claim 6 is characterized in that described master routine control module comprises systemic-function, test item classification, testing result analysis and returns at least three sub-program controling modules.
8, the online quality state monitoring system of electromagnetic component according to claim 7, it is characterized in that described subroutine control module, wherein comprise in the systemic-function subroutine control module: submenu 1 selected cell of master menu is printed, returned to demonstration, interpolation, modification, deletion, inquiry, chart; Comprise in the test item specification subroutine control module: the selection of measured workpiece model, operating voltage range detection, life tests, the detection of pressure pulling force, stroke selection, confining force detect, return submenu 2 selected cells of master menu; Comprise in the testing result analysis subroutine control module: submenu 3 selected cells of master menu are printed, returned to parameter setting, data acquisition, data processing, chart demonstration, data storage, chart.
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|---|---|---|---|
| CN 200520050438 CN2819235Y (en) | 2005-03-09 | 2005-03-09 | On-line quality state monitoring system of electromagnetic component |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 200520050438 CN2819235Y (en) | 2005-03-09 | 2005-03-09 | On-line quality state monitoring system of electromagnetic component |
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| CN 200520050438 Expired - Fee Related CN2819235Y (en) | 2005-03-09 | 2005-03-09 | On-line quality state monitoring system of electromagnetic component |
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