Diagnostic method for hydraulic system

Abstract

The present application discloses a diagnostic method for a hydraulic system, which relates to the field of oil and gas exploitation. The diagnostic method includes: detecting the oil temperature at the high-temperature port of the thermostat and the oil temperature in the hydraulic oil circuit, and judging the fault state of the thermostat according to the oil temperature at the high-temperature port and the oil temperature in the hydraulic oil circuit; detecting the first pressure difference between the inlet and the outlet of the return oil filter; judging the fault state of the return oil filter according to the first pressure difference and the oil temperature in the hydraulic oil circuit; detecting the second pressure difference between the inlet and the outlet of the suction oil filter; judging the fault state of the suction oil filter according to the second pressure difference and the oil temperature in the hydraulic oil. The present application can solve the problem that the hydraulic system cannot be monitored online and cannot be maintained in time.

Description

Technical Field

[0001] This application belongs to the technical field of oil and gas production, and particularly relates to a diagnostic method for a hydraulic system. Background Art

[0002] Casing equipment is used for the development of oil and gas reservoirs. Currently, the hydraulic systems of some casing equipment cannot monitor the operation of the hydraulic system online. When a fault occurs, professional hydraulic engineers usually need to perform steps such as fault analysis, data testing, and solution verification to judge the fault, and then equipment maintenance can be carried out for the fault. However, there are usually no professional hydraulic engineers and hydraulic system detection equipment in the operation scenario. Therefore, it is impossible to make a timely and effective fault judgment.

[0003] During the operation of the casing equipment, the hydraulic system may face damage to hydraulic components. If the hydraulic system can be monitored online in real time, timely maintenance can be obtained when the fault just appears, thereby avoiding economic losses caused by damage to hydraulic components and interruption of casing operations.

[0004] Therefore, it is particularly important to monitor the hydraulic system of the casing equipment online. Summary of the Invention

[0005] The purpose of the embodiments of this application is to provide a diagnostic method for a hydraulic system, which can solve the problem that the hydraulic system cannot be monitored online and cannot be maintained in a timely manner.

[0006] To solve the above technical problems, this application is implemented as follows:

[0007] The embodiments of this application provide a diagnostic method for a hydraulic system, and the diagnostic method includes:

[0008] Detect the oil temperature at the high-temperature port of the thermostat and the oil temperature in the hydraulic oil circuit in the hydraulic system;

[0009] Judge the fault state of the thermostat according to the oil temperature at the high-temperature port and the oil temperature in the hydraulic oil circuit;

[0010] Detect the first pressure difference between the inlet and the outlet of the return oil filter in the hydraulic system;

[0011] Judge the fault state of the return oil filter according to the first pressure difference and the oil temperature in the hydraulic oil circuit;

[0012] Detect the second pressure difference between the inlet and the outlet of the suction oil filter in the hydraulic system;

[0013] Judge the fault state of the suction oil filter according to the second pressure difference and the oil temperature in the hydraulic oil circuit.

[0014] The embodiments of the present application can detect the oil temperature at the high-temperature port of the thermostat and the oil temperature in the hydraulic oil circuit, and judge the fault state of the thermostat according to the oil temperature at the high-temperature port and the oil temperature in the hydraulic oil circuit, so as to realize the fault troubleshooting of the thermostat. Furthermore, the thermostat can be replaced in time when a fault occurs, preventing the fault of the thermostat from having an adverse impact on the operation of the hydraulic system. By detecting the pressure difference between the inlet and outlet of the return oil filter and combining it with the oil temperature in the hydraulic oil circuit, the fault state of the return oil filter is judged to realize the fault troubleshooting of the return oil filter; by detecting the pressure difference between the inlet and outlet of the suction oil filter and combining it with the oil temperature in the hydraulic oil circuit, the fault state of the suction oil filter is judged to realize the fault troubleshooting of the suction oil filter. Based on the above settings, the embodiments of the present application can diagnose the faults of some hydraulic components in the hydraulic system, so as to repair and replace them in time when a fault occurs in the hydraulic components, thereby ensuring the normal operation of the hydraulic system and avoiding economic losses caused by the damage of hydraulic components or the interruption of the cementing operation. Description of the Drawings

[0015] Figure 1 It is a flow chart for diagnosing the faults of the return oil filter, suction oil filter and thermostat disclosed in the embodiments of the present application;

[0016] Figure 2 It is a flow chart for detecting the fuel tank liquid level disclosed in the embodiments of the present application;

[0017] Figure 3 It is a flow chart for detecting the volumetric efficiency and diagnosing the faults of the hydraulic pump disclosed in the embodiments of the present application;

[0018] Figure 4 It is a flow chart for detecting the volumetric efficiency and diagnosing the faults of the motor disclosed in the embodiments of the present application;

[0019] Figure 5 It is a flow chart for diagnosing the self-rotation fault of the centrifugal pump and detecting the rotation speed of the centrifugal pump drive motor disclosed in the embodiments of the present application;

[0020] Figure 6 It is a flow chart for controlling the flow rate of the centrifugal pump disclosed in the embodiments of the present application;

[0021] Figure 7 It is a flow chart for diagnosing the misoperation fault of the butterfly valve of the centrifugal pump disclosed in the embodiments of the present application;

[0022] Figure 8 It is a flow chart for diagnosing the automatic flow regulation, jamming and shaft seal damage faults of the mixing motor disclosed in the embodiments of the present application;

[0023] Figure 9 It is a flow chart for diagnosing the faults of the ash discharging cylinder and the electromagnetic directional valve disclosed in the embodiments of the present application. Detailed Embodiments

[0024] The following will clearly and completely describe the technical solutions in the embodiments of the present application in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without making creative efforts belong to the scope of protection of the present application.

[0025] The terms "first", "second", etc. in the specification and claims of the present application are used to distinguish similar objects, rather than to describe a specific order or sequence. It should be understood that such data can be interchanged under appropriate circumstances so that the embodiments of the present application can be implemented in an order other than those illustrated or described herein, and the objects distinguished by "first", "second", etc. are generally of the same category, and do not limit the number of objects. For example, the first object can be one or multiple. In addition, "and / or" in the specification and claims means at least one of the connected objects, and the character " / " generally indicates an "or" relationship between the associated objects before and after.

[0026] The following will specifically illustrate the embodiments of the present application in conjunction with the accompanying drawings through specific embodiments and their application scenarios.

[0027] Reference Figures 1 to 9 , the embodiments of the present application disclose a diagnostic method for a hydraulic system. This diagnostic method can perform fault diagnosis on the hydraulic system of a cementing device to ensure the normal operation of the hydraulic system, thereby ensuring the normal cementing operation of the cementing device. In the embodiments of the present application, the hydraulic system may include the following various hydraulic components. The specific structures and working principles of each hydraulic component and its hydraulic system can all refer to the prior art and will not be elaborated in detail here.

[0028] The disclosed diagnostic method includes the steps of performing fault diagnosis on a thermostat, specifically as follows:

[0029] Detect the oil temperature at the high-temperature port of the thermostat in the hydraulic system and the oil temperature in the hydraulic oil circuit, and judge the fault state of the thermostat based on the oil temperature at the high-temperature port and the oil temperature in the hydraulic oil circuit.

[0030] One of the methods is: detect the oil temperature at the high-temperature port of the thermostat in the hydraulic system. When the oil temperature at the high-temperature port of the thermostat is lower than the first preset temperature, it is determined that the thermostat has a fault and a first prompt operation message is output. The first prompt operation message is to replace the thermostat.

[0031] Specifically, a temperature sensor can be set at the high-temperature port of the thermostat. Through the temperature sensor, the temperature at the high-temperature port of the thermostat can be detected in real time, so as to obtain the working condition of the thermostat. When the temperature at the high-temperature port of the thermostat detected by the temperature sensor is always lower than the opening temperature (i.e., the first preset temperature) during continuous operation, it indicates that the valve core of the thermostat is stuck, that is, the thermostat fails. At this time, the thermostat needs to be replaced. Based on the above process, the fault diagnosis of the thermostat is realized to avoid the adverse impact on the hydraulic system due to untimely fault diagnosis of the thermostat. Optionally, the first preset temperature can be 50 °C. Of course, it can also be other degrees.

[0032] Another way is: detect the oil temperature in the hydraulic oil circuit. When the oil temperature in the hydraulic oil circuit reaches or is higher than the second preset temperature, it is determined that the thermostat fails, and the first prompt operation information is output. The first prompt operation information is to replace the thermostat.

[0033] Specifically, a temperature sensor can be set in the hydraulic oil circuit or the oil tank in the hydraulic system. Through the temperature sensor, the temperature of the hydraulic oil can be detected in real time, so as to obtain the working condition of the thermostat according to the oil temperature. When the oil temperature detected by the temperature sensor is high and reaches or exceeds the second preset temperature, it indicates that the thermostat fails. At this time, the thermostat needs to be replaced. Based on the above process, the fault diagnosis of the thermostat is also realized. Optionally, the second preset temperature can be 80 °C. Of course, it can also be other degrees.

[0034] In the embodiment of the present application, at least one of the temperature at the high-temperature port of the thermostat and the temperature of the hydraulic oil is detected by a temperature sensor for logical judgment, so as to realize the troubleshooting of the thermostat failure, thereby avoiding the problem that the oil temperature of the hydraulic system is too high due to the long-term damage of the thermostat.

[0035] In the embodiment of the present application, the diagnostic method includes the step of fault diagnosis of the return oil filter, which is specifically as follows:

[0036] Detect the first pressure difference between the inlet and the outlet of the return oil filter in the hydraulic system, and judge the fault state of the return oil filter according to the first pressure difference and the oil temperature in the hydraulic oil circuit.

[0037] When the first pressure difference reaches the first preset pressure difference, and the oil temperature in the hydraulic oil circuit reaches or is higher than the third preset temperature and lower than the second preset temperature, it is determined that the return oil filter fails, and the second prompt operation information is output. The second prompt operation information is to replace the return oil filter element. Wherein, the third preset temperature is lower than the second preset temperature.

[0038] Specifically, a pollutant blockage transmitter (or differential pressure sensor) can be installed on the return oil filter, and the first differential pressure between the inlet and outlet of the return oil filter is detected in real time through the pollutant blockage transmitter. When the first differential pressure reaches the first preset differential pressure, the pollutant blockage transmitter sends a signal to the control element. At the same time, the temperature of the hydraulic oil in the hydraulic oil circuit (or oil tank) is measured through a temperature sensor, and the detected temperature of the hydraulic oil is compared with the second preset temperature. When the temperature of the hydraulic oil is lower than the second preset temperature, it indicates that the hydraulic oil is within a reasonable temperature range. At this time, the temperature data of the hydraulic oil can be saved. Further, continue to check whether the temperature of the hydraulic oil is higher than the third preset temperature. Optionally, the first preset differential pressure can be 0.7 bar. Of course, it can also be other values.

[0039] Based on the above settings, when the pollutant blockage transmitter sends a signal and the temperature of the hydraulic oil is between the third preset temperature and the second preset temperature, the control element determines that the return oil filter is blocked and displays a prompt message indicating that the filter element of the return oil filter needs to be replaced. In this way, by combining the pollutant blockage transmitter (or differential pressure sensor) with the temperature sensor to confirm whether the return oil filter is blocked, the fault diagnosis of the return oil filter is realized to ensure the normal operation of the return oil filter.

[0040] In the embodiment of the present application, the diagnosis method includes the steps of fault diagnosis of the suction oil filter, which are specifically as follows:

[0041] Detect the second differential pressure between the inlet and outlet of the suction oil filter in the hydraulic system, and judge the fault state of the suction oil filter according to the second differential pressure and the oil temperature in the hydraulic oil circuit.

[0042] When the second differential pressure reaches the second preset differential pressure and the oil temperature in the hydraulic oil circuit reaches or is higher than the fourth preset temperature, it is determined that the suction oil filter has a fault, and a third prompt operation message is output, and the third prompt operation message is to replace the suction oil filter element.

[0043] Specifically, a filter element pollution transmitter (or differential pressure sensor) can be installed on the suction oil filter, and the second differential pressure between the inlet and outlet of the suction oil filter is detected in real time through the filter element pollution transmitter. When the second differential pressure reaches the second preset differential pressure, the filter element pollution transmitter sends a signal to the control element. At the same time, the temperature of the hydraulic oil in the hydraulic oil circuit (or oil tank) is measured through a temperature sensor, and the detected oil temperature of the hydraulic oil is compared with the fourth preset temperature. When the temperature of the hydraulic oil reaches or is higher than the fourth preset temperature, it indicates that the suction oil filter has a fault. Optionally, the second differential pressure can be 0.7 bar. Of course, it can also be other differential pressure values. In addition, the fourth preset temperature can be 5°C. Of course, it can also be other degrees.

[0044] Based on the above settings, when the filter element contamination transmitter sends a signal and the temperature of the hydraulic oil reaches or is higher than the fourth preset temperature, it is determined by the control element that the suction filter is blocked, and a prompt message indicating that the filter element of the suction filter needs to be replaced is controlled to be displayed. In this way, by combining the filter element contamination transmitter (or differential pressure sensor) with the temperature sensor to confirm whether the suction filter is blocked, the fault diagnosis of the suction filter is realized to ensure the normal operation of the suction filter.

[0045] In addition, when the oil temperature of the hydraulic oil in the hydraulic oil circuit is lower than the fourth preset temperature, it indicates that the oil temperature is too low. At this time, the viscosity of the oil product is increased, resulting in relatively large differential pressures of the return filter and the suction filter respectively, affecting the normal operation of the filter. In this way, the hydraulic oil in the hydraulic oil circuit can be controlled to be heated. Specifically, the hydraulic oil in the fuel tank can be heated to raise the oil temperature and reduce the viscosity of the oil product, thereby ensuring the normal use of the return filter and the suction filter.

[0046] In the embodiment of the present application, the oil temperature at the high-temperature port of the thermostat and the oil temperature in the hydraulic oil circuit can be detected, and the fault state of the thermostat can be judged according to the oil temperature at the high-temperature port and the oil temperature in the hydraulic oil circuit, so as to realize the fault troubleshooting of the thermostat. Furthermore, when the thermostat fails, the thermostat can be replaced in time to prevent the failure of the thermostat from having an adverse impact on the operation of the hydraulic system. By detecting the differential pressure at the inlet and outlet of the return filter and combining the oil temperature in the hydraulic oil circuit, the fault state of the return filter is judged to realize the fault troubleshooting of the return filter; by detecting the differential pressure at the inlet and outlet of the suction filter and combining the oil temperature in the hydraulic oil circuit, the fault state of the suction filter is judged to realize the fault troubleshooting of the suction filter. Based on the above settings, the embodiment of the present application can perform fault diagnosis on some hydraulic components in the hydraulic system, so as to repair and replace them in time when the hydraulic components fail, thereby ensuring the normal operation of the hydraulic system and avoiding economic losses caused by the damage of hydraulic components or the interruption of cementing operations.

[0047] In the embodiment of the present application, the diagnostic method includes the step of diagnosing whether the hydraulic oil in the fuel tank is sufficient, specifically as follows:

[0048] Detect the liquid level in the fuel tank of the hydraulic system, compare the detected liquid level with the preset minimum set liquid level. When the detected liquid level is lower than the preset minimum set liquid level, it is determined that the hydraulic oil in the fuel tank is insufficient, and a fourth prompt operation message is output. Among them, the fourth prompt operation message is to add hydraulic oil and check whether there is a leakage point in the system.

[0049] It can be understood that the liquid level sensor is installed in the fuel tank. Through program detection, it is compared with the preset minimum liquid level of the fuel tank in real time. When the liquid level is lower than the preset minimum liquid level, the control element will issue a control instruction to control the alarm device to send out an alarm signal, and control the prompt information for prompting to add hydraulic oil and check whether there is a leakage point in the hydraulic system, so as to facilitate troubleshooting.

[0050] Based on the above settings, the liquid level data detected by the liquid level sensor is compared with the preset minimum liquid level of the system, and an alarm message is sent out in time when the hydraulic oil is insufficient, so that it can effectively avoid the hydraulic oil pump from sucking air and generating cavitation due to too low liquid level, and the leakage point can be found in time, so as to take corresponding measures to prevent leakage.

[0051] In the embodiment of the present application, the diagnosis method includes the step of diagnosing whether the working efficiency of the hydraulic pump is normal, specifically as follows:

[0052] Obtain the rotational speed of the hydraulic pump, the rated displacement of the hydraulic pump, and the actual flow rate of the hydraulic oil in the hydraulic pump in the hydraulic system. According to the rotational speed of the hydraulic pump, the rated displacement of the hydraulic pump, and the actual flow rate of the hydraulic oil in the hydraulic pump, calculate the volumetric efficiency of the hydraulic pump, and compare the calculated volumetric efficiency with the preset volumetric efficiency of the hydraulic pump. When the calculated volumetric efficiency is less than the preset volumetric efficiency, it is determined that the working efficiency of the hydraulic pump is abnormal, and the fifth prompt operation information is output, and the fifth prompt operation information is that the efficiency of the hydraulic pump is low and the hydraulic pump needs to be replaced; on the contrary, when the calculated volumetric efficiency is greater than or equal to the preset volumetric efficiency, it is determined that the working efficiency of the hydraulic pump is normal, and the data is saved.

[0053] It can be understood that the rotational speed of the hydraulic pump can be calculated according to the rotational speed of the engine, the power take-off speed ratio, and the transmission speed ratio in the hydraulic system. Specifically, n 泵转速 =n 发动机 ×i 取力器速比 ×i 分动箱速比 .

[0054] Furthermore, when the rated displacement of the hydraulic pump is known, the volumetric efficiency of the hydraulic pump can be obtained by combining the actual flow rate of the hydraulic pump. Specifically:

[0055]

[0056] In addition, the preset volumetric efficiency can be 60%. When the calculated volumetric efficiency is less than 60%, it indicates that the working efficiency of the hydraulic pump is relatively low. At this time, the control displays the prompt information that the hydraulic pump needs to be replaced; when the calculated volumetric efficiency is greater than or equal to 60%, it indicates that the working efficiency of the hydraulic pump is normal. At this time, the data can be saved for subsequent retrieval and use at any time.

[0057] In the embodiments of the present application, the actual flow rate of the hydraulic pump can be obtained in the following two ways, specifically:

[0058] 1) Detect the flow rate of the hydraulic oil at the outlet of the hydraulic pump. Specifically, the overflow valve can be directly assembled at the outlet of the hydraulic pump. In this case, the flowmeter can be directly installed at the oil outlet of the hydraulic pump, so as to directly detect the flow rate at the outlet of the hydraulic pump through the flowmeter.

[0059] 2) Detect the flow rate of the hydraulic oil at the oil drain port of the overflow valve in the hydraulic system, the flow rate of the hydraulic oil at the remote control port of the overflow valve, and the flow rate of the hydraulic oil at the oil inlet port of the hydraulic motor in the hydraulic system. According to the sum of the flow rates of the hydraulic oil at the oil drain port, the remote control port, and the oil inlet port, the actual flow rate of the hydraulic oil in the hydraulic pump can be obtained.

[0060] In the above method, the overflow valve is led out by a pipeline and fixed on the equipment. At this time, three flowmeters are required, and the three flowmeters are respectively installed at the oil drain port of the overflow valve, the remote control port of the overflow valve, and the oil inlet port of the hydraulic motor. Thus, the flow rates at the three places can be detected respectively through the three flowmeters, and the flow rates detected at the three places are added together to obtain the actual flow rate of the hydraulic pump.

[0061] Based on the above settings, the reading of the displacement of the hydraulic pump by the flowmeter realizes the real-time detection of the volumetric efficiency of the hydraulic pump. When the hydraulic pump reaches the lowest volumetric efficiency, a prompt to replace the hydraulic pump is given, and the efficiency of the hydraulic pump can be read at any time to avoid finding that the equipment power is insufficient during operation failures, which affects normal operation.

[0062] In the embodiments of the present application, the diagnostic method includes the step of diagnosing whether the working efficiency of the hydraulic motor is normal. Optionally, the hydraulic motor can be a circulating motor, an injection motor, a stirring motor, etc. The specific diagnostic steps are as follows:

[0063] Obtain the rotational speed of the hydraulic motor in the hydraulic system, the rated displacement of the hydraulic motor, and the actual flow rate of the hydraulic oil in the hydraulic motor. According to the rotational speed of the hydraulic motor, the rated displacement of the hydraulic motor, and the actual flow rate of the hydraulic oil in the hydraulic motor, calculate the volumetric efficiency of the hydraulic motor. Specifically:

[0064]

[0065] Compare the calculated volumetric efficiency with the preset volumetric efficiency of the hydraulic motor. When the calculated volumetric efficiency is less than the preset volumetric efficiency, it is determined that the working efficiency of the hydraulic motor is low, and a prompt message to replace the hydraulic motor is controlled to be displayed (that is, the fifth prompt operation message is output); when the calculated volumetric efficiency is greater than or equal to the preset volumetric efficiency, it is determined that the working efficiency of the hydraulic motor is normal, and the data is saved.

[0066] Among them, the preset volumetric efficiency can be 60%. When the calculated volumetric efficiency is less than 60%, it indicates that the volumetric efficiency of the hydraulic motor is low and the hydraulic motor needs to be replaced. When the calculated volumetric efficiency is greater than or equal to 60%, it indicates that the volumetric efficiency is normal. At this time, the data can be saved for subsequent retrieval and use at any time.

[0067] In addition, a flow sensor can be installed at the oil inlet of the hydraulic motor, and a speed sensor can be installed on the hydraulic motor. The selected displacement of the hydraulic motor is input into the computer system (i.e., the control system), and the actual volumetric efficiency of the hydraulic motor is calculated through the hydraulic motor efficiency formula. In this way, when the actual volumetric efficiency of the hydraulic motor is low, the system will prompt that the volumetric efficiency of the hydraulic motor is low and a new hydraulic motor needs to be replaced. At the same time, the system saves the efficiency data when the hydraulic motor is working properly for subsequent retrieval of the data at any time.

[0068] Based on the above settings, a flowmeter is used to read the actual displacement of the hydraulic motor, diagnose whether the working efficiency of the hydraulic motor is normal, prompt to replace the hydraulic motor when the hydraulic motor reaches the lowest volumetric efficiency, and the volumetric efficiency of the hydraulic motor can be read at any time to avoid finding that the power of the equipment is insufficient only when there is an operation failure, which affects the operation.

[0069] In the embodiment of the present application, the diagnosis method includes steps of diagnosing the failure of the centrifugal pump to rotate on its own and detecting the rotational speed of the centrifugal pump drive motor, specifically as follows:

[0070] Detect the pressure value at the remote control port of the overflow valve in the hydraulic system. When the pressure value at the remote control port is less than the preset pressure value and greater than or equal to the pressure at the back pressure valve of the centrifugal pump drive motor in the hydraulic system, output the first display information, the sixth prompt operation information, and the seventh prompt operation information. Among them, the first display information is the information that the centrifugal pump drive motor drives the centrifugal pump to rotate on its own. The sixth prompt operation information is the prompt operation to turn off the engine and heat the hydraulic oil tank if there is no water in the centrifugal pump. The seventh prompt operation is the prompt operation information to only heat the hydraulic oil tank if there is water in the centrifugal pump.

[0071] Specifically, a pressure sensor can be installed at the remote control port of the overflow valve to detect the pressure value at the remote control port. Optionally, the preset pressure value can be 2 Mpa. Of course, it can also be other pressure values. When the detected pressure value at the remote control port is lower than 2 Mpa and higher than the pressure at the back pressure valve of the centrifugal pump drive motor, the system alarms and displays that the centrifugal pump drive motor drives the centrifugal pump to rotate on its own, and two prompt operations pop up. If there is no medium such as water in the centrifugal pump, the engine should be stopped and the hydraulic oil tank should be heated to avoid the sealing wear and failure caused by the rotation of the centrifugal pump without lubricating medium. If there is medium such as water in the centrifugal pump, the hydraulic oil tank should be heated to avoid the problem that the centrifugal pump is damaged by the high temperature of the liquid caused by the long-term self-rotation of the centrifugal pump when the equipment is not operating.

[0072] When the pressure value at the remote control port is lower than the preset pressure value and lower than the pressure of the back pressure valve of the centrifugal pump drive motor in the hydraulic oil circuit, a second display message is output, and the second display message is to display that the rotation speed of the centrifugal pump drive motor is zero.

[0073] In addition, the detection of the rotation speed of the centrifugal pump drive motor can be obtained not only by installing a flow meter at the oil inlet of the centrifugal pump drive motor, but also by analyzing the pressure value of the remote control port of the overflow valve. Specifically:

[0074] Detect the pressure value at the remote control port of the overflow valve in the hydraulic system. When the pressure value at the remote control port is greater than or equal to the preset pressure value and less than the maximum set pressure of the overflow valve in the hydraulic system, calculate the rotation speed of the centrifugal pump drive motor according to the rotation speed of the centrifugal pump, the input displacement of the centrifugal pump, and the input displacement of the centrifugal pump drive motor. And the data can be saved for easy retrieval and viewing according to the operation requirements at any time.

[0075] The embodiment of the present application can use a pressure sensor to detect the pressure value at the remote control port of the overflow valve to monitor the operation of the centrifugal pump, send an alarm for the occurrence of a fault situation, and provide an operation prompt to avoid the occurrence of damage to the centrifugal pump due to self-rotation; at the same time, perform logical analysis and calculation according to the detected pressure value, and even without installing a flow meter, the rotation speed of the centrifugal pump drive motor can be obtained, and the storage and retrieval of data can be realized.

[0076] The diagnostic method in the embodiment of the present application includes the step of controlling the output flow of the centrifugal pump, specifically as follows:

[0077] Detect the pressure at the outlet of the centrifugal pump in the hydraulic system, and obtain the real-time flow of the centrifugal pump according to the pressure at the outlet of the centrifugal pump, the flow-pressure curve of the centrifugal pump, and the rotation speed of the centrifugal pump drive motor, and adjust the real-time flow to make the real-time flow equal to the preset flow.

[0078] It should be noted here that the output flow of the centrifugal pump is not only related to the rotation speed of the centrifugal pump drive motor, but also related to the size of the outlet pressure. Controlling the output flow of the centrifugal pump plays an important role in the mixing effect of the cement slurry.

[0079] Based on the above settings, a pressure sensor can be installed at the outlet of the centrifugal pump, and the flow-pressure curve data of the centrifugal pump can be input into the computer system. Combining the rotation speed data of the centrifugal pump drive motor, the real-time flow data of the centrifugal pump can be obtained. And the operator can adjust the opening degree of the outlet valve of the centrifugal pump according to the operation needs during the operation to control the output flow of the centrifugal pump.

[0080] In the embodiments of the present application, by using a pressure sensor and combining with the flow-pressure curve database of the centrifugal pump and the rotational speed of the driving motor of the centrifugal pump, the output flow of the centrifugal pump can be detected in real time, so that the operator can make operation adjustments according to actual requirements.

[0081] In the embodiments of the present application, the diagnostic method includes the steps of diagnosing the misoperation fault of the butterfly valve of the centrifugal pump, specifically as follows:

[0082] Detect the temperature at the outlet of the centrifugal pump in the hydraulic system. When the difference between the temperature at the outlet of the centrifugal pump and the ambient temperature is greater than a preset difference, control to check the states of the butterfly valve at the inlet and the butterfly valve at the outlet of the centrifugal pump respectively, and keep the butterfly valves all in the open state.

[0083] It should be noted here that when the butterfly valve at the inlet or outlet of the centrifugal pump is misclosed, it will cause the centrifugal pump to be overheated or even burst. Thus, a temperature sensor can be installed at the outlet of the centrifugal pump to detect the temperature there in real time. When the temperature at the outlet of the centrifugal pump is higher than the ambient temperature by a preset difference, such as 10 °C, etc., the system will prompt to check the opening and closing states of the butterfly valve at the inlet and the butterfly valve at the outlet of the centrifugal pump respectively, and keep each butterfly valve in the open state to prevent overheating or bursting in the centrifugal pump.

[0084] Based on the above settings, by using the temperature sensor, the temperature at the outlet of the centrifugal pump can be detected in real time. When the temperature is abnormal, the system can prompt to check the state of the butterfly valve in time to avoid the occurrence of overheating and bursting of the centrifugal pump caused by the misoperation of the butterfly valve.

[0085] In the embodiments of the present application, the diagnostic method includes the steps of diagnosing the flow self-regulation of the stirring motor, the jamming of the stirring motor, and the damage of the shaft seal, specifically as follows:

[0086] Detect the pressure at the oil inlet of the stirring motor in the hydraulic system. When the pressure at the oil inlet of the stirring motor is lower than the preset pressure, control to increase the flow rate of the proportional speed control valve in the hydraulic system to increase the pressure at the oil inlet of the stirring motor and achieve the rotational adjustment of the flow rate in the stirring motor.

[0087] Specifically, a pressure sensor can be installed at the oil inlet of the stirring motor. By comparing with the data accumulated in on-site operations, this database includes the operating pressures of the stirring motor under different mud densities and ambient temperatures. If the value obtained by the pressure sensor is lower than the database pressure value, the system will automatically increase the flow rate of the proportional speed control valve until the pressure value is between the pressures in the database, achieving the automatic adjustment of the flow rate of the stirring motor, and the data can be saved in real time for easy retrieval or review.

[0088] In addition, the flow rate and pressure at the oil inlet of the stirring motor in the hydraulic system are detected. When the flow rate at the oil inlet of the stirring motor is lower than the preset flow rate and the pressure is higher than the preset pressure, it is determined that the stirring motor is stuck, and the eighth prompt operation information is output. The eighth prompt operation information is: control the display to adjust the electro-hydraulic proportional speed control valve of the stirring motor to zero, and restore the electro-hydraulic proportional control valve after the fault is eliminated; and when the stirring motor is stuck and the volumetric efficiency of the stirring motor is lower than the preset efficiency, it is determined that the shaft seal of the stirring motor is damaged, and the ninth prompt operation information is output. The ninth prompt operation information is the prompt information for controlling the display to replace the shaft seal.

[0089] Specifically, a flow sensor can be installed at the oil inlet of the stirring motor. When the flow rate at the oil inlet of the stirring motor is lower than the flow rate adjusted by the system through the proportional speed control valve and the value obtained by the pressure sensor is higher than the database pressure value, the system prompts that the stirring motor is stuck and displays the operation option of "adjust the electro-hydraulic proportional speed control valve of the stirring motor to zero, and restore the electro-hydraulic proportional speed control valve after the fault is eliminated"; when the efficiency of the stirring motor is lower than 60% and the stirring motor is stuck at the same time, the system prompts that the shaft seal of the stirring motor is damaged and the prompt information for replacing the shaft seal is required.

[0090] Based on the above settings, by installing a pressure sensor and a flow sensor at the oil inlet of the stirring motor and combining the above motor efficiency detection method, the automatic adjustment of the flow rate of the stirring motor and the troubleshooting of the stuck and shaft seal damage of the stirring motor can be realized to ensure the normal operation of the hydraulic system.

[0091] In the embodiment of the present application, the diagnosis method includes the steps of diagnosing the faults of the ash discharging oil cylinder and the ash discharging solenoid valve, specifically as follows:

[0092] The pressure at the oil inlet and the oil outlet of the ash discharging oil cylinder in the hydraulic system and the opening of the ash discharging valve are detected. When the opening of the ash discharging valve does not change with the adjustment of the electromagnetic reversing valve controlling the ash discharging oil cylinder and pressure values are detected at both the oil inlet and the oil outlet of the ash discharging oil cylinder, it is determined that the ash discharging oil cylinder is stuck, and the tenth prompt operation information is output. The tenth prompt operation information is the prompt information for controlling the display to replace the ash discharging oil cylinder; when the opening of the ash discharging valve does not change with the adjustment of the electromagnetic reversing valve controlling the ash discharging oil cylinder and a pressure value is detected at one of the oil inlet and the oil outlet of the ash discharging oil cylinder and no pressure value is detected at the other, it is determined that the electromagnetic reversing valve is stuck, and the eleventh prompt operation information is output. The eleventh prompt operation information is the prompt information for controlling the display to replace the electromagnetic reversing valve.

[0093] Specifically, a position sensor for detecting the opening degree of the ash discharging valve can be installed on the ash discharging oil cylinder, and pressure sensors can be installed at the oil inlet and outlet of the ash discharging oil cylinder. When the opening degree of the ash discharging valve does not change with the adjustment of the electromagnetic reversing valve, and pressure sensors at both oil ports of the ash discharging oil cylinder can detect pressure values, the system prompts that the ash discharging oil cylinder is stuck and needs to be replaced; when the opening degree of the ash discharging valve does not change with the adjustment of the electromagnetic reversing valve, and one of the pressure sensors at the oil inlet and outlet of the ash discharging oil cylinder has no pressure value, the system prompts that the spool of the electromagnetic reversing valve is stuck and needs to be replaced.

[0094] Based on the above settings, by using the position sensor and pressure sensor for detecting the opening degree of the ash discharging valve, the diagnosis of faults of the ash discharging oil cylinder and the electromagnetic reversing valve can be realized, so as to timely replace the faulty parts and ensure the normal progress of the mud mixing operation.

[0095] In summary, the embodiments of the present application can perform fault diagnosis and analysis on multiple hydraulic components in the hydraulic system, so as to timely detect when the hydraulic components fail, thereby effectively avoiding the situation that the hydraulic system affects normal operation for a long time after the hydraulic components are damaged, and even causing economic losses.

[0096] The embodiments of the present application have been described above with reference to the accompanying drawings. However, the present application is not limited to the above specific embodiments. The above specific embodiments are merely illustrative and not restrictive. Under the inspiration of the present application, those of ordinary skill in the art can also make many forms without departing from the purpose of the present application and the scope protected by the claims, and all of them belong to the protection scope of the present application.

Claims

1. A diagnostic method for a hydraulic system, characterized in that, The described diagnostic method includes: Detecting the pressures at the oil inlet and outlet of the ash discharging cylinder in the hydraulic system, and the opening degree of the ash discharging valve; When the opening degree of the ash discharging valve does not change with the adjustment of the electromagnetic reversing valve controlling the ash discharging cylinder, and pressure values are detected at both the oil inlet and outlet of the ash discharging cylinder, it is determined that the ash discharging cylinder is stuck, and the tenth prompt operation information is output, where the tenth prompt operation information is the prompt information for controlling the display to replace the ash discharging cylinder; When the opening degree of the ash discharging valve does not change with the adjustment of the electromagnetic reversing valve controlling the ash discharging cylinder, and a pressure value is detected at one of the oil inlet and outlet of the ash discharging cylinder, and no pressure value is detected at the other, it is determined that the electromagnetic reversing valve is stuck, and the eleventh prompt operation information is output, where the eleventh prompt operation information is the prompt information for controlling the display to replace the electromagnetic reversing valve; Detecting the pressure value at the remote control port of the relief valve in the hydraulic system; When the pressure value is less than the preset pressure value and greater than or equal to the pressure at the back pressure valve of the centrifugal pump drive motor in the hydraulic system, the first display information, the sixth prompt operation information, and the seventh prompt operation information are output. The first display information is the information that the centrifugal pump drive motor drives the centrifugal pump to rotate on its own. The sixth prompt operation information is the prompt operation of closing the engine and heating the hydraulic oil tank if there is no water in the centrifugal pump. The seventh prompt operation information is the prompt operation information of only heating the hydraulic oil tank if there is water in the centrifugal pump; When the pressure value is less than the preset pressure value and less than the pressure at the back pressure valve of the centrifugal pump drive motor in the hydraulic system, the second display information is output, where the second display information is to display that the rotational speed of the centrifugal pump drive motor is zero.

2. The diagnostic method according to claim 1, wherein The described diagnostic method includes: Detecting the oil temperature at the high-temperature port of the thermostat and the oil temperature in the hydraulic oil circuit in the hydraulic system; Judging the fault state of the thermostat according to the oil temperature at the high-temperature port and the oil temperature in the hydraulic oil circuit; Detecting the first pressure difference between the inlet and outlet of the return oil filter in the hydraulic system; Judging the fault state of the return oil filter according to the first pressure difference and the oil temperature in the hydraulic oil circuit; Detecting the second pressure difference between the inlet and outlet of the suction oil filter in the hydraulic system; Judging the fault state of the suction oil filter according to the second pressure difference and the oil temperature in the hydraulic oil circuit.

3. The diagnostic method according to claim 2, characterized in that, The judging the fault state of the thermostat according to the oil temperature at the high-temperature port and the oil temperature in the hydraulic oil circuit includes: when the oil temperature at the high-temperature port is lower than the first preset temperature, or the oil temperature in the hydraulic oil circuit reaches or is higher than the second preset temperature, it is determined that the thermostat fails, and the first prompt operation information is output, where the first prompt operation information is to replace the thermostat; And / or, judging the fault state of the return oil filter according to the first pressure difference and the oil temperature in the hydraulic oil circuit, includes: when the first pressure difference reaches a first preset pressure difference, and the oil temperature in the hydraulic oil circuit reaches or is higher than a third preset temperature and lower than a second preset temperature, it is determined that the return oil filter has a fault, and a second prompt operation message is output, and the second prompt operation message is to replace the return oil filter element; And / or, judging the fault state of the suction oil filter according to the second pressure difference and the oil temperature in the hydraulic oil circuit, includes: when the second pressure difference reaches a second preset pressure difference, and the oil temperature in the hydraulic oil circuit reaches or is higher than a fourth preset temperature, it is determined that the suction oil filter has a fault, and a third prompt operation message is output, and the third prompt operation message is to replace the suction oil filter element; And / or, when the oil temperature in the hydraulic oil circuit is lower than the fourth preset temperature, control to heat the hydraulic oil in the hydraulic oil circuit to increase the oil temperature.

4. The diagnostic method according to claim 1, characterized in that, The diagnosis method includes: Detect the liquid level in the fuel tank of the hydraulic system, compare the detected liquid level with a preset minimum set liquid level, and when the detected liquid level is lower than the preset minimum set liquid level, it is determined that the hydraulic oil in the fuel tank is insufficient, and a fourth prompt operation message is output, and the fourth prompt operation message is to add hydraulic oil and check whether there is a leakage point in the system.

5. The diagnostic method according to claim 1, characterized in that, The diagnosis method includes: Obtain the rotational speed of the hydraulic pump or hydraulic motor in the hydraulic system, the rated displacement of the hydraulic pump or the hydraulic motor, and the actual flow rate of the hydraulic oil in the hydraulic pump or the hydraulic motor, and calculate the volumetric efficiency of the hydraulic pump or the hydraulic motor respectively according to the rotational speed, rated displacement and actual flow rate of the hydraulic pump or the hydraulic motor; When the volumetric efficiency is less than the preset volumetric efficiency of the hydraulic pump or the hydraulic motor respectively, it is determined that the working efficiency of the hydraulic pump or the hydraulic motor is abnormal, and a fifth prompt operation message is output, and the fifth prompt operation message is that the hydraulic pump efficiency is low and the hydraulic pump needs to be replaced.

6. The diagnostic method according to claim 5, wherein Obtaining the actual flow rate of the hydraulic oil in the hydraulic pump includes: Detect the flow rate of the hydraulic oil at the outlet of the hydraulic pump; Or, detect the flow rate of the hydraulic oil at the oil drain port of the relief valve in the hydraulic system, the flow rate of the hydraulic oil at the remote control port of the relief valve, and the flow rate of the hydraulic oil at the inlet port of the hydraulic motor in the hydraulic system, and obtain the actual flow rate of the hydraulic oil in the hydraulic pump according to the sum of the flow rate of the hydraulic oil at the oil drain port, the flow rate of the hydraulic oil at the remote control port and the flow rate of the hydraulic oil at the inlet port.

7. The diagnostic method according to claim 1, wherein The diagnosis method includes: When the pressure value at the remote control port of the relief valve in the hydraulic system is greater than or equal to the preset pressure value and less than the highest set pressure of the relief valve in the hydraulic system, calculate the rotational speed of the centrifugal pump drive motor according to the rotational speed of the centrifugal pump, the input displacement of the centrifugal pump and the input displacement of the centrifugal pump drive motor, and save the data.

8. The diagnostic method according to claim 1, characterized in that, The diagnosis method includes: Detect the pressure at the outlet of the centrifugal pump in the hydraulic system; Obtain the real-time flow rate of the centrifugal pump based on the pressure at the outlet of the centrifugal pump, the flow-pressure curve of the centrifugal pump, and the rotational speed of the centrifugal pump drive motor; Adjust the real-time flow rate to make it equal to the preset flow rate.

9. The diagnostic method according to claim 1, wherein The diagnostic method includes: Detect the temperature at the outlet of the centrifugal pump in the hydraulic system; When the difference between the temperature at the outlet of the centrifugal pump and the ambient temperature is greater than the preset difference, control to check the states of the butterfly valve at the inlet and the butterfly valve at the outlet of the centrifugal pump, and make both butterfly valves in the open state.

10. The diagnostic method according to claim 1, wherein The diagnostic method includes: Detect the pressure at the oil inlet of the stirring motor in the hydraulic system. When the pressure at the oil inlet of the stirring motor is lower than the preset pressure, control to increase the flow rate of the proportional speed control valve in the hydraulic system to increase the pressure at the oil inlet of the stirring motor, realize the automatic adjustment of the flow rate in the stirring motor, and save the data; Alternatively, detect the flow rate and pressure at the oil inlet of the stirring motor in the hydraulic system. When the flow rate at the oil inlet of the stirring motor is lower than the preset flow rate and the pressure is higher than the preset pressure, determine that the stirring motor is stuck, and output the eighth prompt operation information, where the eighth prompt operation information is to control the display to adjust the electro-hydraulic proportional speed control valve of the stirring motor to zero, and restore the electro-hydraulic proportional control valve after the fault is removed; When the stirring motor is stuck and the volumetric efficiency of the stirring motor is lower than the preset efficiency, determine that the shaft seal of the stirring motor is damaged, and output the ninth prompt operation information, where the ninth prompt operation information is to control the display to show the prompt information that the shaft seal needs to be replaced.

Images