Pressure switch fatigue test system and method based on data analysis

Abstract

The invention discloses a pressure switch fatigue test system and method based on data analysis, and relates to the field of switch pressure test. The method comprises the following steps: S1, constructing an instantaneous pressure regulation factor based on a preset target pressure value and a current pressure deviation, and superposing external disturbance compensation to generate a real-time pressure signal; s2, based on the real-time pressure signal, an analog current signal is generated through nonlinear coupling, the dynamic proportion of the pressure to the current change rate is synchronously adjusted, and the corrected current change rate is output; s3, comparing the real-time pressure signal with a preset pressure threshold value, judging the on-off state of the switch, and performing cumulative statistics on the on-off times of the switch; s4, based on the real-time pressure and current signals, fatigue damage is dynamically evaluated through a stress-strain feedback model, and the switch fatigue degree is calculated in an accumulated mode to generate an accumulated fatigue damage strength index. Through fusion of dynamic regulation and control, current synchronization and a damage integration mechanism, working conditions are accurately simulated, nonlinear damage is quantified, and test authenticity and life reliability are improved.

Description

Technical Field

[0001] The present invention relates to the field of switch pressure testing, and in particular to a pressure switch fatigue testing system and method based on data analysis. Background Art

[0002] As a critical fluid control and pressure safety protection component, pressure switches are widely used in numerous fields, including industrial automation, energy, aerospace, and automotive. Their reliability is directly related to production safety and system stability. During the design, production, and verification of pressure switches, simulating repeated start-stop operations under actual operating conditions is crucial to assess the switch's mechanical life, contact life, and overall reliability.

[0003] Traditional testing methods primarily use periodic pressure loading to drive a switch to repeatedly operate and record the number of opening and closing cycles. However, existing technologies have significant limitations: Pressure control rigidity: Testing typically relies on a preset, fixed pressure waveform, which cannot be dynamically adjusted based on real-time feedback and has weak anti-interference capabilities. This causes the actual pressure curve to deviate from the set value, making it difficult to accurately simulate complex working conditions.

[0004] Pressure-current simulation distortion: Existing methods often use fixed ratios or simple linear relationships to simulate the current signals associated with switching. This lacks a realistic simulation of the nonlinear acceleration of current caused by pressure changes, and cannot dynamically synchronize the rates of change of pressure and current.

[0005] Fatigue assessment is crude: The core evaluation metric relies solely on the cumulative number of actuations, completely ignoring the actual differences in damage to the device caused by the load size and rate of change of each actuation. Operation under high-voltage fluctuations and under low-voltage fluctuations cause completely different cumulative damage to the switch, but existing technology cannot quantify this difference.

[0006] Insufficient data utilization: The multi-dimensional data in the testing process often lacks unified integration and collaborative display, which is not conducive to a comprehensive analysis of the performance evolution and failure modes of the switch.

[0007] In summary, the traditional pressure switch fatigue testing method has obvious shortcomings in terms of pressure dynamic simulation accuracy, accompanying current signal authenticity, detailed fatigue damage assessment, and multi-dimensional data analysis, which limits the validity and reliability of the test results and urgently needs to be improved. Summary of the Invention

[0008] Based on the above-mentioned shortcomings of the prior art, the purpose of the present invention is to provide a pressure switch fatigue testing system and method based on data analysis to solve the above-mentioned technical problems.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a pressure switch fatigue testing method based on data analysis, comprising: S1: Based on the preset target pressure value, the instantaneous pressure adjustment factor is constructed in combination with the current pressure deviation, and external disturbance compensation is superimposed to generate a real-time pressure signal; S2: Based on the real-time pressure signal, the analog current signal is obtained through a nonlinear coupling relationship, the dynamic proportional relationship between the pressure change rate and the current change rate is synchronously adjusted, and the corrected current change rate is output; S3: Determine the switch open / close status by comparing the real-time pressure signal with the preset pressure threshold, and accumulate and count the number of switch openings and closings; S4: Based on the real-time pressure signal and simulated current signal, the fatigue damage of the switch is dynamically evaluated through the stress-strain feedback model, and the fatigue degree of the switch is cumulatively calculated to generate a cumulative fatigue damage intensity index.

[0010] The present invention is further configured such that S1 includes: Based on the preset target pressure value, the deviation between the preset target pressure value and the real-time pressure monitoring value is calculated, and the instantaneous pressure adjustment factor is constructed in combination with the maximum pressure of the system; On the basis of constructing the instantaneous pressure adjustment factor, the preset pressure target is compensated through the preset external disturbance compensation mechanism to generate a real-time pressure signal.

[0011] The present invention is further configured such that S2 includes: Based on the real-time pressure signal, an analog current signal is generated through a composite coupling mechanism; The composite coupling mechanism includes: a basic linear response term, a nonlinear speed-up correction term, and a periodic disturbance term; Based on the fixed proportional relationship between the real-time pressure signal and the current output, it constitutes the basic linear response term of current generation; By applying a nonlinear response index to the pressure ratio of the real-time pressure signal to the maximum pressure of the system, the flow pulse coefficient is constructed through adjustment of the coupling coefficient. The nonlinear acceleration effect of the super-proportional growth of current caused by slight pressure changes in the high-pressure area is quantified according to the flow pulse coefficient, and a nonlinear growth rate correction term is constructed.

[0012] The present invention is further configured to dynamically adjust the current disturbance coefficient according to the system operating state, environmental factors and the influence of external disturbance sources; Based on the spectrum analysis of the current signal through Fourier transform, the dominant oscillation frequency is extracted from the current fluctuation and normalized into a frequency factor; The periodic disturbance term is constructed by combining the current disturbance coefficient and the frequency factor.

[0013] The present invention is further configured to apply exponential nonlinear mapping based on the normalized deviation between the real-time pressure signal and the target pressure value, superimpose the weighted results of the normalized deviation between the analog electrical signal and the target current value through independent exponential mapping, and regulate the weights of the two contributions by a preset sensitivity adjustment factor to dynamically generate a synchronous control coefficient.

[0014] The present invention is further configured to obtain a target current change rate instruction based on the pressure change rate combined with the synchronous control coefficient; Based on the target current change rate instruction, the current signal is driven to change at a specified rate to achieve synchronization of the current and pressure signal trajectories.

[0015] The present invention is further configured such that S3 includes: Continuously monitor the dynamic numerical relationship between the real-time pressure signal and the preset trigger threshold, and generate a status flag through scalar comparison operation; Based on the discrete time series of the state flag quantity, the transition event of the real-time pressure signal exceeding the trigger threshold is set as the switch-on signal. The full-time domain turn-on events are counted in a non-cumulative manner, and the cumulative frequency of the output switch action cycle is the number of switch turns.

[0016] The present invention is further configured as follows: S4: By dynamically calculating the combined effect of pressure and current at each moment, real-time fatigue damage feedback is obtained and a stress-strain feedback model is constructed; Based on the real-time pressure signal sequence and current signal sequence, an exponential nonlinear amplification effect is performed after maximum range normalization, the dynamic nonlinear response output of the coupled stress-strain feedback model is output, and continuous integration operation is performed on the time dimension to generate a cumulative fatigue damage strength index.

[0017] The present invention is further configured such that the method further comprises a feedback module: Integrate all test data to construct a test data set, which includes: preset pressure, preset time, real-time pressure sequence, real-time current sequence, switch opening and closing times, and cumulative fatigue damage strength index sequence; The test data set is transmitted to the display device to show the change process of the switch fatigue test data over time.

[0018] The present invention also provides a pressure switch fatigue testing system based on data analysis, the system comprising: Pressure regulation module: Based on the preset target pressure value, it builds an instantaneous pressure regulation factor in combination with the current pressure deviation, superimposes external disturbance compensation, and generates a real-time pressure signal; Current control module: Based on the real-time pressure signal, the analog current signal is obtained through nonlinear coupling, the dynamic proportional relationship between the pressure change rate and the current change rate is synchronously adjusted, and the corrected current change rate is output; Switch opening and closing determination module: determines the switch opening and closing status by comparing the real-time pressure signal with the preset pressure threshold, and accumulates and counts the number of switch opening and closing times; Fatigue calculation module: Based on real-time pressure signals and simulated current signals, the fatigue damage of the switch is dynamically evaluated through a stress-strain feedback model, and the fatigue degree of the switch is cumulatively calculated to generate a cumulative fatigue damage intensity index.

[0019] The present invention provides a pressure switch fatigue testing system and method based on data analysis. The method comprises the following steps: S1: taking a preset target pressure value as a reference, combining the current pressure deviation to construct an instantaneous pressure adjustment factor, superimposing external disturbance compensation, and generating a real-time pressure signal; S2: based on the real-time pressure signal, obtaining an analog current signal through a nonlinear coupling relationship, synchronously adjusting the dynamic proportional relationship between the pressure change rate and the current change rate, and outputting the corrected current change rate; S3: determining the switch on / off state through a comparison result between the real-time pressure signal and a preset pressure threshold, and accumulating and counting the number of switch on / off times; and S4: based on the real-time pressure signal and the analog current signal, dynamically evaluating the fatigue damage of the switch through a stress-strain feedback model, and accumulating the fatigue degree of the switch to generate a cumulative fatigue damage intensity index. The beneficial effects produced include: By constructing an instantaneous pressure adjustment factor and superimposing external disturbance compensation, the system responds to pressure deviations and external uncertainty in real time, dynamically generating a real-time pressure signal that better matches the target pressure curve. This overcomes the drawbacks of traditional preset static waveforms, enabling the actual pressure applied to the switch to more accurately track complex operating conditions, significantly improving the authenticity and control robustness of the test environment.

[0020] A composite coupling mechanism accurately simulates the nonlinear acceleration of current under pressure changes, avoiding the distortion inherent in simple proportional relationships. A periodic perturbation term, known as a synchronous control coefficient, dynamically adjusts the rate of change of current to precisely match the rate of change of pressure. This ensures that the simulated current signal not only reflects the pressure level but also simulates the electrical dynamics associated with pressure changes in real time, significantly enhancing the realism of electrical load simulation.

[0021] Breaking through the limitations of crude evaluation based solely on the number of actuations, a stress-strain feedback model was established to dynamically quantify the instantaneous micro-damage to the switch's internal structure caused by the combined effects of real-time pressure and simulated current. By applying an exponential nonlinear amplification effect to the normalized pressure and current signals and integrating the dynamic nonlinear response output of the coupled model over time, a cumulative fatigue damage intensity index was generated. This index, which incorporates key factors such as load intensity, rate, frequency, and their nonlinear effects, more scientifically reflects the actual cumulative damage to the switch under complex dynamic loads, significantly improving the accuracy and reliability of life predictions.

[0022] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without inventive efforts. In the drawings: Figure 1 This is a flow chart showing a method for fatigue testing a pressure switch based on data analysis according to an exemplary embodiment of the present invention; Figure 2 The figure is a structural diagram of a pressure switch fatigue testing system based on data analysis, showing an exemplary embodiment of the present invention. DETAILED DESCRIPTION

[0024] The following describes the embodiments of the present invention with reference to the accompanying drawings and preferred embodiments. Those skilled in the art will readily appreciate the other advantages and benefits of the present invention from the disclosure herein. The present invention may also be implemented or applied through various other specific embodiments, and the various details in this specification may be modified or altered based on different viewpoints and applications without departing from the spirit of the present invention. It should be understood that the preferred embodiments are intended only to illustrate the present invention and are not intended to limit the scope of protection of the present invention.

[0025] It should be noted that the illustrations provided in the following embodiments are merely schematic illustrations of the basic concept of the present invention. Therefore, the illustrations only show components related to the present invention and are not drawn according to the number, shape, and size of components in actual implementation. In actual implementation, the type, quantity, and proportion of each component may be changed arbitrarily, and the component layout may also be more complex.

[0026] In the following description, numerous details are discussed to provide a more thorough explanation of the embodiments of the present invention. However, it will be apparent to those skilled in the art that the embodiments of the present invention may be practiced without these specific details. In other embodiments, well-known structures and devices are shown in block diagram form rather than in detail to avoid obscuring the embodiments of the present invention.

[0027] Example 1

[0028] A fatigue testing method for pressure switches based on data analysis, such as Figure 1 Shown, including: S1: Based on the preset target pressure value, the instantaneous pressure adjustment factor is constructed in combination with the current pressure deviation, and external disturbance compensation is superimposed to generate a real-time pressure signal; S2: Based on the real-time pressure signal, the analog current signal is obtained through a nonlinear coupling relationship, the dynamic proportional relationship between the pressure change rate and the current change rate is synchronously adjusted, and the corrected current change rate is output; S3: Determine the switch open / close status by comparing the real-time pressure signal with the preset pressure threshold, and accumulate and count the number of switch openings and closings; S4: Based on the real-time pressure signal and simulated current signal, the fatigue damage of the switch is dynamically evaluated through the stress-strain feedback model, and the fatigue degree of the switch is cumulatively calculated to generate a cumulative fatigue damage intensity index.

[0029] The present invention is further configured such that S1 includes: Based on the preset target pressure value, the deviation between the preset target pressure value and the real-time pressure monitoring value is calculated, and the instantaneous pressure adjustment factor is constructed in combination with the maximum pressure of the system; Based on the construction of the instantaneous pressure adjustment factor, the preset pressure target is compensated through the preset external disturbance compensation mechanism to generate a real-time pressure signal. Specifically, the instantaneous adjustment factor is used to accurately adjust the dynamic changes of pressure to ensure that the pressure changes meet the predetermined dynamic response requirements. It is corrected according to the pressure deviation to meet the system's requirements for accuracy and stability. The specific calculation formula is: ,in, is the instantaneous pressure adjustment factor; is the actual pressure collected, which can also be understood as the pressure value at the previous moment; The preset target pressure value is the pressure that the switch needs to withstand during the fatigue test, set by the tester at the beginning of the test; The sensitivity of the adjustment factor is used to control the degree of influence of pressure regulation and determines the response speed and strength during the pressure regulation process. The higher the sensitivity, the faster the pressure change adjustment, but it may cause system instability. When the sensitivity is low, the pressure regulation will be smoother, but the response may be slower. The value range is between 0.1 and 1.0, and the specific value should be adjusted according to the actual system needs. The maximum set pressure value is used to normalize the pressure value to ensure that the pressure changes within the set range and does not exceed the maximum value. It helps to balance the response to environmental fluctuations during the pressure regulation process. The specific value is determined according to the maximum safety value of the system design; It is a nonlinear index of pressure change, which is used to control the nonlinear characteristics of pressure regulation. When the pressure changes greatly, the response growth rate of the adjustment factor is different from the linear relationship. Nonlinear regulation helps to optimize the system response and avoid system oscillations caused by over-regulation. The value range is between 0.5 and 2.0. The specific value is selected according to the pressure change law in actual application. The real-time pressure signal can be directly used to control the opening and closing state of the pressure switch and the implementation of the fatigue test process to ensure high precision and high stability of pressure changes during the test. Simply put, this process is used to prevent the real-time pressure from being too far away from the set pressure. The instantaneous adjustment factor is used to regulate based on the preset pressure to keep the pressure change amplitude within a stable range and avoid sudden increases or decreases. The specific calculation formula is: ,in, It is a real-time pressure signal; It is the pressure disturbance factor, which reflects the impact of external environmental changes on pressure. It is used to simulate the dynamic compensation of the preset target pressure in different external environments. The value range is between -1 and 1. Negative values ​​represent pressure decreases, and positive values ​​represent pressure increases. The specific value is determined according to the external environment of the actual reference scenario.

[0030] The present invention is further configured such that S2 includes: Based on the real-time pressure signal, an analog current signal is generated through a composite coupling mechanism; The composite coupling mechanism includes: a basic linear response term, a nonlinear speed-up correction term, and a periodic disturbance term; Based on the fixed proportional relationship between the real-time pressure signal and the current output, it constitutes the basic linear response term of current generation; By applying a nonlinear response index to the pressure ratio between the real-time pressure signal and the system's maximum pressure, the flow pulse coefficient is constructed through adjustment of the coupling coefficient. The nonlinear acceleration effect of the current exceeding the proportional growth caused by slight pressure changes in the high-pressure area is quantified based on the flow pulse coefficient, and a nonlinear growth correction term is constructed. Specifically, to simulate the complex nonlinear relationship between pressure and current, a composite coupling mechanism is adopted. This not only considers the direct impact of pressure on current, but also introduces dynamic adjustment based on the current threshold offset. The simulation current signal calculation logic is as follows: ,in, is an analog current signal, indicating ; It is the linear coefficient between current and pressure, reflecting the influence of voltage on current. Its value range is between 0.1 and 1. The higher the influence intensity, the larger the value. is the flow pulse coefficient; is the flow disturbance coefficient, which is used to control the amplitude of the periodic disturbance; is the frequency factor, which is used to simulate the change of periodic disturbance; is the basic linear response term; is the nonlinear growth rate correction term; The main purpose of the basic linear response term is to provide a basic linear response framework for current generation by simulating the fixed proportional relationship between real-time pressure changes and current. and real-time pressure signals The nonlinear acceleration correction term is used to take into account the nonlinear acceleration effect of the current response under high pressure. That is, under high pressure, the rate of current change will be higher than the rate predicted by the linear relationship, which reflects that a small change in pressure may cause an over-proportional increase in current. Based on the constructed pulsation coefficient The basic linear response term is used to make nonlinear corrections to the basic simulated current. It represents the dynamic coupling strength of the current nonlinear response under pressure pulsation conditions. It is a dimensionless scalar. The real-time pressure signal is normalized by pressure scale. Mapped as relative pressure ratio ; Introducing nonlinear response index , quantify the speed-up characteristics of the current offset in the high-voltage region; combined with the coupling strength constant , generate the pulse coefficient response intensity value, the specific calculation formula is: ,in, is the flow pulse coefficient; is the coupling strength constant, which is used to control the intensity of the influence of pressure on current and determine the response amplitude of pressure change to current. Its value range is between 0.1 and 2. If the value is large, the influence of pressure on current is strong, and if the value is small, the influence is weak. It is a nonlinear index used to control the growth rate of the effect of pressure on current offset. It determines the nonlinear degree of the effect of pressure change on current. The value range is between 0.5 and 2. When the value is greater than 1, the growth rate of the effect of pressure change on current is accelerated. When the value is less than 1, the growth rate is slow. When it is at 1, it is the standard value. The specific value is set according to the nonlinear characteristics in the actual test.

[0031] The present invention is further configured to dynamically adjust the current disturbance coefficient according to the system operating state, environmental factors and the influence of external disturbance sources; Based on the spectrum analysis of the current signal through Fourier transform, the dominant oscillation frequency is extracted from the current fluctuation and normalized into a frequency factor; Combining the current disturbance coefficient and the frequency factor, a periodic disturbance term is constructed. Specifically, the periodic disturbance term It is used to simulate the periodic fluctuations in the current signal caused by external disturbance sources. By analyzing the spectrum characteristics of the current signal, it can identify and capture the main periodic disturbance frequency and simulate the environmental noise with an independent sine wave to enhance the signal authenticity. The periodic disturbance term is composed of the current disturbance coefficient and frequency factor Constructed; current disturbance coefficient It is used to control the amplitude of periodic disturbances and is dynamically calibrated by the standard deviation of the system noise level and the intensity of environmental interference through real-time spectrum analysis. The value range is between 0 and 0.1. It is an existing technology and will not be described in detail here. It is used to simulate the changes of periodic disturbances, which are caused by circuit oscillations or mechanical oscillations. The main frequency is extracted by Fourier transform spectrum analysis of the real-time current signal, and then normalized and mapped to the typical interference frequency band. It is an existing technology and will not be described in detail here.

[0032] The present invention further employs an exponential nonlinear mapping based on the normalized deviation between the real-time pressure signal and the target pressure value, superimposing the weighted results of the independent exponential mappings of the normalized deviation between the analog electrical signal and the target current value, and dynamically generating a synchronization control coefficient by regulating the weights of the two contributions using a preset sensitivity adjustment factor. Specifically, to optimize the synchronization between current and pressure, a dynamic adjustment formula based on the difference between current and pressure is designed. The synchronization coefficient is adjusted according to the difference between the current pressure and current to minimize the synchronization error; the synchronization control coefficient calculation formula is: ,in, is the synchronous control coefficient; It is the adjustment factor of the synchronization coefficient, which controls the sensitivity of current and pressure synchronization and adjusts the response degree of synchronization error. The larger the value, the higher the synchronization, but it may cause over-regulation of the system. The value range is between 0.1 and 2, and it is set according to the error requirements in the test. This is the adjustment factor for flow synchronization, which controls the degree of influence of current on synchronization error. A larger value results in better synchronization, but it may cause over-regulation of the system. The value range is between 0.1 and 2, and is set according to the error requirements in the test. is the nonlinear index of pressure synchronization, which controls the speed of the influence of pressure on synchronization error. Its value range is between 0.5 and 2. The larger the value, the faster the speed. It is the nonlinear index of current synchronization, which controls the speed of the influence of current on synchronization error. Its value range is between 0.5 and 2. The larger the value, the faster the speed. is the set target current; It is the preset maximum current value to prevent the switch from overloading due to excessive current.

[0033] The present invention is further configured to obtain a target current change rate instruction based on the pressure change rate combined with the synchronous control coefficient; Based on the target current change rate instruction, the current signal is driven to change at a specified rate to achieve synchronization of the current and pressure signal trajectories. Specifically, in order to ensure the synchronization of pressure and current changes, a synchronization control coefficient is introduced. , used to dynamically adjust the time synchronization error between pressure and current. Through the synchronization control coefficient, the real-time synchronization of current and pressure is achieved, so that the two remain consistent during the change process; the current change rate calculation formula is: ,in, The current change rate indicates the rate at which the current changes with time, that is, the instantaneous rate of change of the current, which is the first-order derivative of the current with respect to time; The voltage change rate indicates the rate at which the voltage changes with time, that is, the instantaneous rate of change of the voltage, which is the first-order derivative of the voltage with respect to time; It is used to dynamically adjust the synchronous control according to the difference between the current change rate and the pressure change rate to ensure the temporal consistency of current and pressure.

[0034] The present invention is further configured such that S3 includes: Continuously monitor the dynamic numerical relationship between the real-time pressure signal and the preset trigger threshold, and generate a status flag through scalar comparison operation; Based on the discrete time series of the state flag quantity, the transition event of the real-time pressure signal exceeding the trigger threshold is set as the switch-on signal. The full-time domain open events are counted in a non-cumulative manner, and the output switch action cycle frequency accumulation is the number of switch-on times. Specifically, according to the set pressure threshold, the switch open and close state is determined, and the number of switch open and close times is counted. The switch state is determined according to the real-time pressure signal, and the number of switch triggers is counted during the entire test process. The switch state determination logic: ,in, The switch is on or off, and its value is 0 or 1. The pressure is greater than the set threshold , the switch is in the on state , otherwise, the switch is closed , according to the switch state sequence, all states with state 1 are counted as the number of switch triggers; The preset pressure threshold is used to determine the switch triggering standard. The set value should be reasonably selected according to the equipment requirements and the system's operating pressure range. Every moment within Switch status Sum up to get the total number of opening and closing times; the statistical calculation logic of the switch opening and closing times: ,in, The number of times the switch is opened and closed indicates the total number of times the switch is switched within the preset test time; The total test duration is the total duration of the switch test preset by the tester before the test begins. Indicates that the state of the switch changes from "off" to "on". Indicates that the switch changes from "on" to "off". By counting these state changes, the total number of opening and closing times can be obtained. .

[0035] The present invention is further configured as follows: S4: By dynamically calculating the combined effect of pressure and current at each moment, real-time fatigue damage feedback is obtained and a stress-strain feedback model is constructed; Based on the real-time pressure signal sequence and current signal sequence, after normalization to the maximum range, an exponential nonlinear amplification effect is performed, the dynamic nonlinear response output of the coupled stress-strain feedback model is output, and continuous integration operation is performed on the time dimension to generate a cumulative fatigue damage intensity index. Specifically, the stress-strain feedback model dynamically calculates the combined effect of pressure and current at each moment to obtain real-time fatigue damage feedback; the calculation logic of the stress-strain feedback model is: ,in, It is a stress-strain feedback model; It is a stress factor used to control the contribution of pressure to fatigue damage. By adjusting the parameters, the model accuracy can be optimized according to the actual operation of the equipment. The value range is between 0 and 1, and the specific value is determined according to the actual application scenario. The current stress influence factor indicates the degree of influence of current on fatigue damage and reflects the contribution of current to fatigue damage. By adjusting the parameter, the model accuracy can be optimized according to the actual operation of the equipment. The value range is between 0 and 1, and the specific value is determined according to the actual application scenario. The current moment of the switch fatigue test The actual current; The current moment of the switch fatigue test The actual pressure. In order to accurately evaluate the fatigue of the pressure switch, the fatigue damage intensity index is introduced. The fatigue damage intensity index is obtained by real-time calculation of the combined load of pressure and current, and cumulative evaluation based on the stress-strain feedback model. The fatigue damage intensity index calculation logic is as follows: ,in, is the cumulative fatigue damage strength index, which means at time The fatigue degree at that time is calculated by accumulating the load effects of pressure and current. As time goes by, fatigue damage will increase, indicating that the degree of damage to the equipment is gradually increasing. The index of the impact of pressure on fatigue damage reflects the sensitivity of pressure changes to fatigue damage. The value range is between 0 and 2. A higher value means a greater impact of pressure on fatigue damage. The specific value is determined according to the actual application scenario. It is the influence index of current on fatigue damage, which characterizes the contribution of current to fatigue damage. The value range is between 0 and 2. The higher the value, the greater the influence of current on fatigue damage. The specific value is determined according to the actual application scenario.

[0036] The present invention is further configured such that the method further comprises a feedback module: Integrate all test data to construct a test data set, which includes: preset pressure, preset time, real-time pressure sequence, real-time current sequence, switch opening and closing times, and cumulative fatigue damage strength index sequence; The test data set is transmitted to a display device, showing how the switch fatigue test data changes over time. Specifically, by real-time monitoring and recording of key data during the test, the test data set is integrated and constructed, and displayed to the tester via an intelligent display device. This provides real-time fatigue damage status, switch opening and closing times, and pressure and current change trends. Based on the real-time feedback of the test results, the tester can conduct a comprehensive analysis of the pressure switch performance based on the displayed results, adjust the experimental settings, diagnose problems, and provide switch optimization recommendations.

[0037] Example 2

[0038] See also Figure 2 , the exemplary data analysis-based pressure switch fatigue testing system includes: Pressure regulation module: Based on the preset target pressure value, it builds an instantaneous pressure regulation factor in combination with the current pressure deviation, superimposes external disturbance compensation, and generates a real-time pressure signal; Current control module: Based on the real-time pressure signal, the analog current signal is obtained through nonlinear coupling, the dynamic proportional relationship between the pressure change rate and the current change rate is synchronously adjusted, and the corrected current change rate is output; Switch opening and closing determination module: determines the switch opening and closing status by comparing the real-time pressure signal with the preset pressure threshold, and accumulates and counts the number of switch opening and closing times; Fatigue calculation module: Based on real-time pressure signals and simulated current signals, the fatigue damage of the switch is dynamically evaluated through a stress-strain feedback model, and the fatigue degree of the switch is cumulatively calculated to generate a cumulative fatigue damage intensity index.

[0039] It should be noted that the data analysis-based pressure switch fatigue testing system provided in the above embodiment and the data analysis-based pressure switch fatigue testing method provided in the above embodiment are based on the same concept. The specific manner in which each module and unit performs operations has been described in detail in the method embodiment and will not be repeated here. In actual applications, the data analysis-based pressure switch fatigue testing system provided in the above embodiment can allocate the above functions to different functional modules as needed, that is, divide the internal structure of the system into different functional modules to complete all or part of the functions described above, and this is not limited here.

[0040] The above embodiments can be implemented in whole or in part by software, hardware, firmware or any other combination. When implemented using software, the above embodiments can be implemented in whole or in part in the form of a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer program are loaded or executed on a computer, the process or function described in the embodiment of the present application is generated in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another computer-readable storage medium. For example, the computer instructions can be transmitted from one website, computer, server or data center to another website, computer, server or data center via a wired (e.g., infrared, wireless, microwave, etc.) method. The computer-readable storage medium can be any available medium that can be accessed by a computer or a data storage device such as a server or data center that contains one or more available media sets. The available medium can be a magnetic medium (e.g., a floppy disk, a hard disk, a tape), an optical medium (e.g., a DVD), or a semiconductor medium. The semiconductor medium can be a solid-state drive.

[0041] It should be understood that the term "and / or" as used herein simply describes a relationship between associated objects, indicating that three possible relationships exist. For example, "A and / or B" can represent: A alone, A and B together, or B alone. A and B can be singular or plural. Furthermore, the character " / " as used herein generally indicates an "or" relationship between the associated objects, but it may also indicate an "and / or" relationship. For specific understanding, please refer to the context.

[0042] In this application, "at least one" means one or more, and "plurality" means two or more. "At least one of the following" or similar expressions refers to any combination of these items, including any combination of single or plural items. For example, at least one of a, b, or c can mean: a, b, c, ab, ac, bc, or abc, where a, b, and c can be single or plural.

[0043] It should be understood that in the various embodiments of the present application, the size of the serial numbers of the above-mentioned processes does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.

[0044] Those skilled in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0045] Those skilled in the art will clearly understand that, for the convenience and brevity of description, the specific working processes of the systems, devices and units described above can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0046] In the several embodiments provided in this application, it should be understood that the disclosed system can be implemented in other ways. For example, the device embodiments described above are merely schematic. For example, the division of the units is merely a logical function division. In actual implementation, there may be other division methods, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of devices or units, which can be electrical, mechanical or other forms.

[0047] The units described as separate components may or may not be physically separate, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed across multiple network units. Some or all of these units may be selected to achieve the purpose of this embodiment according to actual needs.

[0048] In addition, each functional unit in each embodiment of the present application may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit.

[0049] If the functions are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present application, or the part that contributes to the prior art, or the part of the technical solution, can be embodied in the form of a software product. The computer software product is stored in a storage medium and includes several instructions for enabling a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the method described in each embodiment of the present application. The aforementioned storage medium includes various media that can store program codes, such as a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk.

[0050] The above description is merely a specific embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this application should be included in the scope of protection of this application. Therefore, the scope of protection of this application should be based on the scope of protection of the claims.

Claims

1. A pressure switch fatigue testing method based on data analysis, characterized in that: include: S1: Based on the preset target pressure value, the instantaneous pressure adjustment factor is constructed in combination with the current pressure deviation, and external disturbance compensation is superimposed to generate a real-time pressure signal; S2: Based on the real-time pressure signal, the analog current signal is obtained through a nonlinear coupling relationship, the dynamic proportional relationship between the pressure change rate and the current change rate is synchronously adjusted, and the corrected current change rate is output; S3: Determine the switch open / close status by comparing the real-time pressure signal with the preset pressure threshold, and accumulate and count the number of switch openings and closings; S4: Based on the real-time pressure signal and simulated current signal, the fatigue damage of the switch is dynamically evaluated through the stress-strain feedback model, and the fatigue degree of the switch is cumulatively calculated to generate a cumulative fatigue damage intensity index.

2. A pressure switch fatigue testing method based on data analysis according to claim 1, characterized in that: Said S1 comprises: Based on the preset target pressure value, the deviation between the preset target pressure value and the real-time pressure monitoring value is calculated, and the instantaneous pressure adjustment factor is constructed in combination with the maximum pressure of the system; On the basis of constructing the instantaneous pressure adjustment factor, the preset pressure target is compensated through the preset external disturbance compensation mechanism to generate a real-time pressure signal.

3. The method for fatigue testing a pressure switch based on data analysis according to claim 1, characterized in that: The S2 includes: Based on the real-time pressure signal, an analog current signal is generated through a composite coupling mechanism; The composite coupling mechanism includes: a basic linear response term, a nonlinear speed-up correction term, and a periodic disturbance term; Based on the fixed proportional relationship between the real-time pressure signal and the current output, it constitutes the basic linear response term of current generation; By applying a nonlinear response index to the pressure ratio of the real-time pressure signal to the maximum pressure of the system, the flow pulse coefficient is constructed through adjustment of the coupling coefficient. The nonlinear acceleration effect of the super-proportional growth of current caused by slight pressure changes in the high-pressure area is quantified according to the flow pulse coefficient, and a nonlinear growth rate correction term is constructed.

4. The method for fatigue testing a pressure switch based on data analysis according to claim 3, characterized in that: The current disturbance coefficient is obtained by dynamic adjustment according to the system operating status, environmental factors and the influence of external disturbance sources; Based on the spectrum analysis of the current signal through Fourier transform, the dominant oscillation frequency is extracted from the current fluctuation and normalized into a frequency factor; The periodic disturbance term is constructed by combining the current disturbance coefficient and the frequency factor.

5. The method for fatigue testing a pressure switch based on data analysis according to claim 4, characterized in that: An exponential nonlinear mapping is applied based on the normalized deviation between the real-time pressure signal and the target pressure value, and the weighted results of the normalized deviation between the analog electrical signal and the target current value obtained through independent exponential mapping are superimposed. The weights of the two contributions are regulated by the preset sensitivity adjustment factor to dynamically generate a synchronous control coefficient.

6. The method for fatigue testing a pressure switch based on data analysis according to claim 5, characterized in that: The target current change rate instruction is obtained based on the pressure change rate and combined with the synchronous control coefficient; Based on the target current change rate instruction, the current signal is driven to change at a specified rate to achieve synchronization of the current and pressure signal trajectories.

7. The method for fatigue testing a pressure switch based on data analysis according to claim 1, characterized in that: The S3 includes: Continuously monitor the dynamic numerical relationship between the real-time pressure signal and the preset trigger threshold, and generate a status flag through scalar comparison operation; Based on the discrete time series of the state flag quantity, the transition event of the real-time pressure signal exceeding the trigger threshold is set as the switch-on signal. The full-time domain turn-on events are counted in a non-cumulative manner, and the cumulative frequency of the output switch action cycle is the number of switch turns.

8. The method for fatigue testing a pressure switch based on data analysis according to claim 1, characterized in that: The S4: By dynamically calculating the combined effect of pressure and current at each moment, real-time fatigue damage feedback is obtained and a stress-strain feedback model is constructed; Based on the real-time pressure signal sequence and current signal sequence, an exponential nonlinear amplification effect is performed after maximum range normalization, the dynamic nonlinear response output of the coupled stress-strain feedback model is output, and continuous integration operation is performed on the time dimension to generate a cumulative fatigue damage strength index.

9. The method for fatigue testing a pressure switch based on data analysis according to claim 1, characterized in that: The method further comprises a feedback module: Integrate all test data to construct a test data set, which includes: preset pressure, preset time, real-time pressure sequence, real-time current sequence, switch opening and closing times, and cumulative fatigue damage strength index sequence; The test data set is transmitted to the display device to show the change process of the switch fatigue test data over time.

10. A pressure switch fatigue testing system based on data analysis, used to implement the pressure switch fatigue testing method based on data analysis according to any one of claims 1 to 9, characterized in that: include: Pressure regulation module: Based on the preset target pressure value, it builds an instantaneous pressure regulation factor in combination with the current pressure deviation, superimposes external disturbance compensation, and generates a real-time pressure signal; Current control module: Based on the real-time pressure signal, the analog current signal is obtained through nonlinear coupling, the dynamic proportional relationship between the pressure change rate and the current change rate is synchronously adjusted, and the corrected current change rate is output; Switch opening and closing determination module: determines the switch opening and closing status by comparing the real-time pressure signal with the preset pressure threshold, and accumulates and counts the number of switch opening and closing times; Fatigue calculation module: Based on real-time pressure signals and simulated current signals, the fatigue damage of the switch is dynamically evaluated through a stress-strain feedback model, and the fatigue degree of the switch is cumulatively calculated to generate a cumulative fatigue damage intensity index.

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