Press machine lubricating oil flow detection system and method thereof

Abstract

The application discloses a kind of press lubricating oil flow detection system and method in the technical field of press lubricating control, including flow sensor, flow sensor is arranged on pipeline, flow sensor is connected with signal isolation module, signal isolation module is connected with A / D converter, A / D converter is connected with PLC controller, PLC controller is connected with touch screen;Flow sensor is used to sample and process lubricating oil flow data, and the stability of signal long-distance transmission is guaranteed by isolating and protecting the collected signal;The analog signal is converted into specific flow value and displayed in the touch screen, for intuitive, real-time lubricating flow monitoring and alarm, to effectively monitor the lubricating system of press for a long time, avoid equipment damage caused by lubricating system failure.

Description

TECHNICAL FIELD

[0001] The present application relates to a lubricating oil flow detection system and method in the technical field of press lubrication control. BACKGROUND

[0002] Lubricating oil is an important cooling lubricating medium for large presses, and is of great significance to the safe operation of the equipment. Monitoring of the cooling medium is also of equal importance, and the flow detection device plays such a role. The selection, installation and commissioning of the flow detection device are important links that affect flow monitoring.

[0003] The normal operation of the lubricating oil system is extremely important for ensuring the safe operation of the equipment. If the lubricating system suddenly stops, even for a short time, it is easy to cause mechanical failure of the equipment, which may result in a serious accident. The traditional press lubrication control system mainly has the following problems: the traditional press lubrication detection control system generally only detects the passage of lubricating oil in the lubricating pipeline, and can only determine whether there is lubricating oil passing through, but cannot measure the specific value of the lubricating flow. The traditional press lubrication detection control system cannot effectively support complex data operations, resulting in that the lubricating flow data cannot be completely stable and accurate. SUMMARY

[0004] The purpose of the present application is to provide a press lubricating oil flow detection system and method for effectively and long-term monitoring of the lubricating system of the press, avoiding damage to the equipment due to failure of the lubricating system.

[0005] To achieve the above-mentioned purpose, the present application provides a press lubricating oil flow detection system, comprising a flow sensor, the flow sensor being arranged on a pipeline, the flow sensor being connected with a signal isolation module, the signal isolation module being connected with an A / D converter, the A / D converter being connected with a PLC controller, and the PLC controller being connected with a touch screen.

[0006] Compared with the prior art, the present application has the beneficial effects that the flow sensor is used to sample and process the lubricating oil flow data, the collected signals are isolated and protected, the stability of long-distance signal transmission is ensured, the analog signal is converted into a specific flow value and displayed in the touch screen, the lubricating flow is monitored and alarmed directly and in real time, the lubricating system of the press is effectively and long-term monitored, and damage to the equipment due to failure of the lubricating system is avoided.

[0007] As a further improvement of the present application, the pipeline is horizontally placed, and the flow sensor is installed from the side of the pipeline.

[0008] In this way, when the pipeline is horizontally placed and the pipeline is filled with fluid, the monitoring data may be unstable and the measurement may be inaccurate. The side installation can avoid the above problems and ensure the measurement accuracy.

[0009] As a further improvement of the present application, the pipeline is vertically placed, and the tip of the flow sensor is fixedly installed from the side of the vertical pipeline, wherein the flow direction of the vertical pipeline is from bottom to top.

[0010] In this way, the lubricating oil in the pipeline is transported from bottom to top, so that the lubricating oil in the pipeline is definitely full, and the flow can be accurately measured. If the flow direction of the lubricating oil is from top to bottom, the pipeline cannot be full, which leads to inaccurate measurement.

[0011] As a further improvement of the present application, the flow sensor is installed on the pipeline at a position at least five times the inner diameter length of the straight section of the pipeline.

[0012] In this way, the stability of the monitoring can be improved, and the inaccurate measurement caused by being too close to the bend can be avoided.

[0013] As a further improvement of the present application, eight flow sensors are arranged on the pipeline of the press, and are respectively arranged on the main pipe, the left crankshaft supporting pipe, the left mandrel pipe, the left clutch pipe, the right clutch pipe, the right mandrel pipe, the right crankshaft supporting pipe and the balance cylinder pipe.

[0014] In this way, the flow sensors are arranged on the pipelines of the components requiring lubricating oil in the press, so that the flow of the lubricating oil entering the components can be accurately measured, and the related processing can be performed according to the data, thereby ensuring the normal operation of the press.

[0015] In order to achieve the above-mentioned purpose, the present application also provides a press lubricating oil flow detection method, comprising the following steps,

[0016] Step 1: collecting the lubricating oil flow data in the pipeline by the flow sensor and outputting an analog signal;

[0017] Step 2: isolating and protecting the analog signal in step 1 by a signal isolation module;

[0018] Step 3: receiving the analog signal output by the signal isolation module and processing and converting it into a digital signal by an A / D converter;

[0019] Step 4: receiving the digital signal output by the A / D converter and processing it by a PLC;

[0020] Step 5: displaying the data processed by the PLC in real time by a touch screen.

[0021] Compared with the prior art, the present application has the beneficial effects that the flow sensor is used to sample and process the lubricating oil flow data, the analog signal isolation module is used to isolate and protect the collected signal, the stability and transmission rate of the signal long-distance transmission are ensured, the fast, uninterrupted and stable analog signal collection is realized, the analog signal is converted into specific lubricating flow numerical value through the A / D converter and PLC processing and displayed in the touch screen, the intuitive and real-time lubricating flow monitoring and alarm are carried out, the purpose of effectively and long-term monitoring the lubricating system of the press is achieved, and the equipment damage caused by the lubricating system failure is avoided.

[0022] As a further improvement of the present application, in step 3, the A / D converter converts the signal through the following formula: (E-F) / (G-F)=(H-I) / (J-I), wherein E is the analog signal value, F is the minimum value output by the flow sensor, G is the maximum value output by the flow sensor, H is the digital signal value, I is the minimum value output by the A / D converter, and J is the maximum value output by the A / D converter; the digital signal value H of the lubricating oil flow output by the A / D converter can be obtained through the above formula, H=[(E-F)*(J-I) / (G-F)]+I.

[0023] In this way, the data conversion between different specifications of flow sensors and different specifications of A / D converters can be applied, so as to obtain the digital signal value of the lubricating oil flow, which has wide application range, good universality and accurate analog signal conversion.

[0024] As a further improvement of the present application, in step 4, the PLC processes the digital signal, converts the digital signal value output by the A / D converter with the data inside the PLC, so as to convert the data read by the PLC into the actual lubricating oil flow value, and compares the actual lubricating oil flow value with the set flow value range, and an alarm signal is output when the output flow is too low or too high.

[0025] In this way, the value measured by the sensor can be accurately judged, so as to accurately control the lubricating oil flow in the pipeline.

[0026] As a further improvement of the present application, the conversion formula of the actual lubricating oil flow value is as follows: (H-K) / (L-K)=(Q-I) / (J-I), wherein H is the digital signal value, K is the minimum value of the PLC conversion value, L is the maximum value of the PLC conversion value, Q is the actual lubricating oil flow value, I is the minimum value output by the A / D converter, and J is the maximum value output by the A / D converter; the actual lubricating oil flow value Q output by the PLC can be obtained through the above formula, Q=[(H-K)*(J-I) / (L-K)]+I.

[0027] This method can be used for data conversion between PLCs of different specifications and A / D converters of different specifications, so as to obtain the actual flow value of lubricating oil. It has a wide range of applications, good versatility, and accurate conversion results. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the hardware structure of the present invention.

[0029] Figure 2 This is a schematic diagram of the vertical pipe installation position of the sensor of the present invention.

[0030] Figure 3 This is a schematic diagram of the horizontal pipe installation position of the sensor of the present invention.

[0031] Figure 4 This is a schematic diagram of the mounting location of the sensor of the present invention on a press.

[0032] Figure 5 This is a flowchart of the present invention.

[0033] Among them, 1 is the flow sensor, 2 is the pipe, 3 is the main pipe, 4 is the left crankshaft support pipe, 5 is the left spindle pipe, 6 is the left clutch pipe, 7 is the right clutch pipe, 8 is the right spindle pipe, 9 is the right crankshaft support pipe, 10 is the balance cylinder pipe, and 11 is the electrical control box. Detailed Implementation

[0034] The present invention will be further described below with reference to the accompanying drawings:

[0035] like Figures 1-4 The system shown includes a flow sensor 1, which is mounted on a pipe 2. The flow sensor 1 is connected to a signal isolation module, which is connected to an A / D converter. The A / D converter is connected to a PLC controller, and the PLC controller is connected to a touch screen. The pipe 2 is placed horizontally, and the flow sensor 1 is installed from the side of the pipe 2. The pipe 2 is also placed vertically, and the tip of the flow sensor 1 is fixed from the side of the vertical pipe 2. The flow direction of the vertical pipe 2 is from bottom to top. The flow sensor 1 is installed at a position on the vertical or front-back straight section of the pipe 2 that is at least five times the length of the inner diameter.

[0036] Eight flow sensors 1 are installed on the press pipe 2, located at the main pipe 3, left crankshaft support pipe 4, left spindle pipe 5, left clutch pipe 6, right clutch pipe 7, right spindle pipe 8, right crankshaft support pipe 9, and balance cylinder pipe 10.

[0037] like Figure 4 The method for detecting the flow rate of lubricating oil in a press, as shown, includes the following steps:

[0038] Step 1, the flow sensor 14 collects the lubricating oil flow data in the pipeline 2 and outputs an analog signal.

[0039] Step 2, the analog signal in step 1 is isolated and protected by a signal isolation module.

[0040] Step 3, the A / D converter receives the analog signal output by the signal isolation module and processes it into a digital signal; the A / D converter converts the signal by the following formula,

[0041] (E-F) / (G-F)=(H-I) / (J-I)

[0042] Wherein, E: analog signal value, F: minimum value output by the flow sensor 14, G: maximum value output by the flow sensor 14, H: digital signal value, I: minimum value output by the A / D converter, J: maximum value output by the A / D converter;

[0043] The above formula can be obtained A / D converter output lubricating oil flow digital signal value H,

[0044] H=[(E-F)*(J-I) / (G-F)]+I

[0045] Step 4, the PLC receives the digital signal sent by the A / D converter and processes it;

[0046] The PLC processes the digital signal, converts the digital signal value output by the A / D converter and the data inside the PLC, and converts the data read by the PLC into the actual lubricating oil flow value, and compares it with the set flow value range. When the output flow is too low or too high, an alarm signal will be sent.

[0047] The actual lubricating oil flow value conversion formula is as follows,

[0048] (H-K) / (L-K)=(Q-I) / (J-I)

[0049] Wherein, H: digital signal value, K: minimum value of PLC conversion value, L: maximum value of PLC conversion value, Q: actual lubricating oil flow value, I: minimum value output by the A / D converter, J: maximum value output by the A / D converter;

[0050] The above formula can be obtained PLC output actual lubricating oil flow value Q,

[0051] Q=[(H-K)*(J-I) / (L-K)]+I.

[0052] Step 5, the touch screen displays the data processed by the PLC in real time.

[0053] The output range of the flow sensor 1 is 4-20mA, the output range of the A / D converter is 0-100mm2 / s, and the conversion range of the PLC is 0-4000, which are taken as examples for specific description.

[0054] When the flow sensor 1 is installed, it is ensured that the sensor does not bear any pressure and that the installation position is free of lubricating oil leakage. The sensor is directly clamped on the outer periphery of the pipeline 2 through the clamp sleeve provided by itself. The transmitter on the sensor sends ultrasonic waves in the same direction and opposite direction to the direction of the lubricating oil flow in the pipeline 2. The faster the flow rate, the shorter the time of arrival in the same direction, and the longer the time of arrival in the opposite direction. By measuring the difference between the opposite and the same, the influence of environmental changes can be offset, and stable measurement of the flow rate can be achieved.

[0055] First, the flow sensor 1 collects and processes the flow rate of the lubricating oil flowing through the pipeline 2 according to the pressure machine, and sends a 4-20mA analog signal E.

[0056] Then, the signal isolation module isolates and protects the 4-20mA analog signal E sent by the flow sensor 1, so that the analog signal E is not disturbed during transmission, and the accuracy of the data is improved.

[0057] The A / D converter receives the 4-20mA analog signal E sent by the flow sensor 1 after isolation protection, and converts it into a digital signal H, where E: analog signal value, F: 4mA, G: 20mA, H: digital signal value, I: 0mm 2 / s, J: 100mm2 / s,

[0058] H = [(E-4)*(100-0) / (20-4)]+0 = 6.25*(E-4)

[0059] The PLC processes the digital signal value H and converts it into the actual flow rate value Q of the lubricating oil, where H: digital signal value, K: 0, L: 4000, Q: actual flow rate value of the lubricating oil, I: 0mm 2 / s, J: 100mm2 / s.

[0060] Q = [(H-0)*(100-0) / (4000-0)]+0 = H / 40 = [6.25*(E-4)] / 40

[0061] In this way, the actual flow rate value of the lubricating oil collected by the flow sensor 1 in the pipeline 2 can be finally obtained by the PLC, and this result can be finally displayed on the touch screen.

[0062] Meanwhile, the flow value is compared with upper and lower limit values of the set normal working flow value in the PLC, if greater than the upper limit value or less than the lower limit value, an alarm signal is sent by the PLC and displayed on the touch screen, and the running equipment is immediately stopped, effectively reducing maintenance cost, failure cost and precision influence.

[0063] The analog signal isolation module, the A / D converter, the PLC and the touch screen are arranged in the electric control box 1113, the lubricating oil flow data is sampled and processed by the flow sensor 1, the collected signal is isolated and protected by the analog signal isolation module, the stability and transmission rate of long-distance signal transmission are ensured, fast, uninterrupted and stable analog signal acquisition is realized, the analog signal is converted into specific lubricating flow numerical value by the A / D converter and the PLC, and the specific lubricating flow numerical value is displayed in the touch screen, intuitive and real-time lubricating flow monitoring and alarm are carried out, the purpose of effectively and long-term monitoring the lubricating system of the press machine is achieved, and equipment damage caused by lubricating system failure is avoided.

[0064] The present application is not limited to the above-mentioned embodiments, on the basis of the technical solutions of the present disclosure, the skilled in the art can make some substitutions and modifications to some technical features according to the disclosed technical content without creative labor, and these substitutions and modifications are all within the protection scope of the present application.

Claims

1. A press lubricating oil flow detection system, characterized in that: This includes a flow sensor, which is installed on the pipeline. The flow sensor is connected to a signal isolation module, which is connected to an A / D converter. The A / D converter is connected to a PLC controller, and the PLC controller is connected to a touch screen. The pipe is placed horizontally, and the flow sensor is installed from the side of the pipe. The pipe is placed vertically, and the tip of the flow sensor is fixed from the side of the vertical pipe, where the flow direction of the vertical pipe is from bottom to top; The flow sensor is installed at a position at least five times the inner diameter of the straight section above, below, or before and after the pipe. Eight flow sensors are installed on the press pipeline, located in the main pipe, left crankshaft support pipe, left spindle pipe, left clutch pipe, right clutch pipe, right spindle pipe, right crankshaft support pipe, and balance cylinder pipe.

2. A method for detecting the flow rate of lubricating oil in a press, characterized in that: Using the press lubricating oil flow detection system as described in claim 1, Includes the following steps, Step 1: Collect lubricating oil flow data in the pipeline using a flow sensor and output an analog signal; Step 2: Isolate and protect the analog signal from Step 1 using a signal isolation module; Step 3: The A / D converter receives the analog signal output from the signal isolation module and processes it to convert it into a digital signal; Step 4: The PLC receives and processes the digital signal from the A / D converter. Step 5: The touchscreen displays the data processed by the PLC in real time. In step 3, the A / D converter performs signal conversion using the following formula: (EF) / (GF) = (HI) / (JI) Where E: analog signal value, F: minimum output value of the flow sensor, G: maximum output value of the flow sensor, H: digital signal value, I: minimum output value of the A / D converter, and J: maximum output value of the A / D converter; The digital signal value H of the lubricating oil flow rate output by the A / D converter can be obtained from the above formula. H = [(EF) * (JI) / (GF)] + I; In step 4, the PLC processes the digital signal, converting the digital signal value output by the A / D converter with the data inside the PLC. This converts the data read by the PLC into the actual flow rate of the lubricating oil. By comparing it with the set flow rate range, an alarm signal will be issued if the output flow rate is too low or too high. In step 4, the actual lubricating oil flow rate is converted using the following formula: (HK) / (LK) = (QI) / (JI) Where H: digital signal value, K: minimum value of PLC conversion, L: maximum value of PLC conversion, Q: actual lubricating oil flow rate, I: minimum value of A / D converter output, J: maximum value of A / D converter output; The actual lubricating oil flow rate Q output by the PLC can be obtained from the above formula. Q = [(HK)*(JI) / (LK)] + I.

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