A real-time prediction method and storage medium for fatigue damage failure of plunger pump motor

Abstract

This invention discloses a real-time prediction method and storage medium for fatigue damage failures in plunger pump motors. Using bench testing, a curve is obtained showing the relationship between the pressure load and fatigue damage frequency of the plunger pump motor. By collecting the hydraulic system's pressure load signals during actual operation, the fatigue damage rate of the plunger pump motor is calculated in real time, predicting the degree of fatigue damage. If the total fatigue damage rate exceeds a set fatigue damage threshold, the plunger pump motor is deemed to have experienced a damage failure.

Description

Technical Field

[0001] The invention relates to a real-time prediction method for fatigue damage failure of a plunger pump motor and a storage medium, belonging to the technical field of engineering machinery hydraulics. Background Art

[0002] Construction machinery is a crucial application area for plunger pumps and motors. Due to the harsh operating conditions, the loads on these equipment are characterized by high pressure, high shock, and high randomness. These loads expose the motors to complex alternating stresses, which are the primary cause of their failure. Fatigue damage to the motor structure under these alternating loads can lead to leakage in the hydraulic system, increasing downtime for users and repair costs for the manufacturer, potentially leading to safety incidents. Currently, excavators are equipped with various sensors to monitor the equipment's operating status and various operating parameters, such as speed, torque, pressure, current, and temperature. The hydraulic system of construction machinery incorporates basic status monitoring capabilities. This system utilizes a pressure sensor at the main pump outlet to collect real-time data on the system's random pressure shock loads. Using a real-time pressure load data processing method, key pressure load data is extracted during operation. A fatigue damage algorithm is then used to calculate this data in real time to determine the degree of fatigue damage, enabling fatigue damage prediction for the plunger pump and motor. By synchronously sending data on key failure times and pressure load peaks and valleys of the plunger pump motor to the cloud server, maintenance personnel can develop strategies for parts repair intervals. Based on this information, they can formulate detailed parts demand and production plans, improving spare parts inventory turnover. Furthermore, the cloud server processes and stores pressure load data to obtain hydraulic cycle impact load data throughout the entire lifecycle. This data analyzes the structural strength and flow field characteristics of the plunger pump motor, and assesses its reliability based on cumulative damage theory.

[0003] The failure of the piston pump motor of construction machinery often occurs within the system. In addition, the inspection conditions at the construction machinery work site are poor, so it is difficult to detect directly, and fault analysis and judgment are difficult.

[0004] At present, the methods used to solve this problem at home and abroad are mainly:

[0005] 1. Domestic companies often use offline diagnostic methods. While the engineering machinery is working, they use commercial data acquisition systems to collect hydraulic system pressure and load data on site. The collected data is then processed and equivalent reliability test methods are developed to evaluate the life of hydraulic components.

[0006] 2. Foreign companies such as Caterpillar and Komatsu employ online diagnostic methods. For maintenance and diagnostic purposes, they utilize sensors installed on or in the entire machine to measure operating conditions such as engine speed, oil pressure, water temperature, boost pressure, oil contamination, motor current, hydraulic pressure, and system voltage. While operating, storage devices are used to compile a database. Technicians accumulate field failure data or analyze experimental data to develop a component failure data trend model. This model is used to assess overall machine performance and help diagnose the machine's current operating status. During maintenance and disassembly, maintenance personnel accumulate component damage data to better understand the causes of machine performance degradation, wear, or failure. Similarly, service personnel evaluate stored machine status data to predict significant performance loss, wear, and catastrophic failures, allowing maintenance to be scheduled during periods when productivity is least impacted, thus avoiding catastrophic failures.

[0007] The current on-site data collection method used in China involves processing the collected data and evaluating the life of hydraulic components through equivalent reliability tests. This only allows for reliability assessment of hydraulic components and cannot predict the time point when fatigue damage will occur. This method, which involves adding fault data analysis equipment and sensors to the entire machine, requires high sensor sensitivity and requires sensors to be installed at points prone to fatigue damage. Sensor damage and loss can lead to expensive monitoring costs. Furthermore, during normal machine operation, various on-site factors may affect the state of the hydraulic system, resulting in significant issues with the accuracy of hydraulic system state assessment and fault prediction. This approach cannot fully meet the actual work needs of mobile equipment, such as construction machinery. Summary of the Invention

[0008] The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide a real-time prediction method and storage medium for fatigue damage failure of a plunger pump motor.

[0009] To achieve the above objectives, the present invention provides a real-time prediction method for fatigue damage failure of a plunger pump motor, comprising:

[0010] Step 1: Periodically input pressure load signal S to the first group of pump pressure shock test benches j Until the pump casing fatigue damage occurs, the input pressure load signal S when the pump casing fatigue damage occurs is obtained. j Number of times data N j ;

[0011] Periodically input pressure load signal S to the second group of pump pressure shock test bench k Until the pump casing fatigue damage occurs, the input pressure load signal S when the pump casing fatigue damage occurs is obtained. k Number of times data N k ;

[0012] Step 2, based on S j 、S k 、N j and N k , find the unknown quantity of the function;

[0013] Using the unknown quantity of the function, the pressure shock load-fatigue damage frequency curve of the plunger pump motor is constructed;

[0014] Step 3: Obtain a pressure load signal set S of the entire engineering machinery equipment;

[0015] If the pressure load signal set S meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode and the process proceeds to step 4; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode and the process ends.

[0016] Step 4: Use the pressure shock load-fatigue damage frequency curve corresponding to the plunger pump motor to calculate the loss rate η of fatigue damage to the pump housing caused by each pressure load shock i ;

[0017] The loss rate η of fatigue damage to the pump casing caused by each pressure load impact is used i , calculate the fatigue damage degree η of the pump casing k .

[0018] Prior to step 2, based on S j 、S k 、N j and N k , find the unknown quantity of the function, and implement it through the following steps:

[0019] Use the following formula to calculate the unknown function quantities D and C:

[0020] N j *(S j ) D =C,

[0021] N k *(S k ) D =C,

[0022]

[0023] Where D is the slope coefficient of the pressure shock load-fatigue damage frequency curve of the plunger pump motor.

[0024] Prioritize using the unknown function to construct the pressure shock load-fatigue damage frequency curve of the plunger pump motor by the following steps:

[0025] Functional expression of the pressure shock load-fatigue damage frequency curve of the plunger pump motor:

[0026] N e ·(S e ) D =C, where S e It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N e Set value for the fatigue life of the pump casing at rated working pressure.

[0027] Preferably, in step 3, if the pressure load signal set S meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, the pressure load signal set S is recorded, and step 4 is entered, which is achieved by the following steps:

[0028] If the pressure load signal S i to S i+n Are greater than or equal to 1.34S0, S i+n and S i ∈S, n is a positive integer, S0 is the initial pressure shock load signal when the plunger pump motor starts, then it is determined that the engineering machinery equipment has entered the working mode, and the pressure shock load signal S is recorded. i , go to step 4;

[0029] If S i All less than 1.05S0, S i+n ∈S, it is determined that the entire engineering machinery equipment has exited the working mode and ended the operation.

[0030] Preferably, in step 4, the loss rate η of fatigue damage to the pump housing caused by each pressure load impact is calculated using the pressure impact load-fatigue damage frequency curve of the plunger pump motor. i , achieved by the following steps:

[0031] Calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi :

[0032]

[0033] S ai =|S i+1 -S i |,

[0034]

[0035] Where S i+1 is the collected pressure load signal of the i+1th engineering machinery equipment, S i+1 ∈S,S i is the collected pressure load signal of the i-th engineering machinery equipment, δ b is the ultimate strength of the material;

[0036] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei :

[0037]

[0038] Where N eqi is the number of impact cycles counted under the condition of the i-th equivalent pressure load amplitude; S e It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N ei is the number of impact cycles that produce fatigue damage under the i-th equivalent pressure load amplitude condition converted to the rated working pressure.

[0039] Preferably, in step 4, the loss rate η of fatigue damage to the pump housing caused by each pressure load impact is calculated using the pressure impact load-fatigue damage frequency curve of the plunger pump motor. i , achieved by the following steps:

[0040] Substitute the rated working pressure of the current plunger pump motor in the hydraulic system of the whole machine into the corresponding pressure shock load-fatigue damage frequency curve of the plunger pump motor to calculate the fatigue life setting value N under the rated working pressure. e ;

[0041] Based on the known N ei and N e , calculate the loss rate η of the pump casing fatigue damage caused by each pressure load impact i :

[0042]

[0043] Where N ei is the number of impact cycles that produce fatigue damage under the i-th equivalent pressure load amplitude condition converted to the rated working pressure;

[0044] Step 4: Use the loss rate η of fatigue damage to the pump casing caused by each pressure load impact i , calculate the fatigue damage degree η of the pump casing k , achieved by the following steps:

[0045] Calculation of pump casing fatigue damage η k :

[0046]

[0047] Preferably, in step 11, a third pressure load signal is periodically input to the third group of pump pressure shock test benches until plunger fatigue damage occurs, and data on the number of times the third pressure load signal is input when plunger fatigue damage occurs is obtained;

[0048] Periodically inputting a fourth pressure load signal to the fourth group of pump pressure shock test benches until plunger fatigue damage occurs, and obtaining data on the number of times the fourth pressure load signal is input when plunger fatigue damage occurs;

[0049] Step 12, obtaining an unknown quantity of the second function based on the third pressure load signal, the fourth pressure load signal, the number of times the third pressure load signal is input when fatigue damage occurs to the plunger, and the number of times the fourth pressure load signal is input when fatigue damage occurs to the plunger;

[0050] Using the unknown quantity of the second function, a pressure shock load-plunger fatigue damage frequency curve is constructed;

[0051] Step 13: Obtain a pressure load signal set A of the entire engineering machinery equipment;

[0052] If the pressure load signal set A meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode and the process proceeds to step 14; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode and the process ends.

[0053] Step 14: Using the pressure impact load-plunger fatigue damage frequency curve, calculate the loss rate η of the plunger fatigue damage caused by each pressure load impact i ;

[0054] The loss rate η of plunger fatigue damage caused by each pressure load impact is used i , calculate the plunger fatigue damage degree η z .

[0055] Preferably, in step 21, a fifth pressure load signal is periodically input to the fifth group of pump pressure shock test benches until fatigue damage of the transmission shaft occurs, and data on the number of times the fifth pressure load signal is input when fatigue damage of the transmission shaft occurs is obtained;

[0056] periodically inputting a sixth pressure load signal to the sixth group of pump pressure shock test benches until fatigue damage of the transmission shaft occurs, and obtaining data on the number of times the sixth pressure load signal is input when fatigue damage of the transmission shaft occurs;

[0057] Step 22, obtaining an unknown quantity of the third function based on the fifth pressure load signal, the sixth pressure load signal, the number of times the fifth pressure load signal is input when fatigue damage to the transmission shaft occurs, and the number of times the sixth pressure load signal is input when fatigue damage to the transmission shaft occurs;

[0058] Using the unknown quantity of the third function, the pressure impact load-drive shaft fatigue damage frequency curve is constructed;

[0059] Step 23: Obtain a pressure load signal set B of the entire engineering machinery equipment;

[0060] If the pressure load signal set B meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, and the process proceeds to step 24; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode, and the operation ends;

[0061] Step 24, using the pressure impact load-transmission shaft fatigue damage frequency curve, calculate the loss rate of transmission shaft fatigue damage caused by each pressure load impact;

[0062] The fatigue damage degree η of the transmission shaft is calculated using the loss rate of the transmission shaft fatigue damage caused by each pressure load impact. C Preferably, in step 31, periodically inputting a seventh pressure load signal to the seventh group of pump pressure shock test benches until bearing fatigue damage occurs, and obtaining data on the number of times the seventh pressure load signal is input when bearing fatigue damage occurs;

[0063] periodically inputting an eighth pressure load signal to the eighth group of pump pressure shock test benches until bearing fatigue damage occurs, and obtaining data on the number of times the eighth pressure load signal is input when bearing fatigue damage occurs;

[0064] Step 32, obtaining an unknown quantity of the fourth function based on the seventh pressure load signal, the eighth pressure load signal, the number of times the seventh pressure load signal is input when bearing fatigue damage occurs, and the number of times the eighth pressure load signal is input when bearing fatigue damage occurs;

[0065] Using the unknown quantity of the fourth function, the pressure impact load-bearing fatigue damage frequency curve is constructed;

[0066] Step 33: Obtain a pressure load signal set E of the entire engineering machinery equipment;

[0067] If the pressure load signal set E meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, and the process proceeds to step 34; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode, and the operation ends;

[0068] Step 34, using the pressure impact load-bearing fatigue damage frequency curve, calculate the loss rate of bearing fatigue damage caused by each pressure load impact;

[0069] The bearing fatigue damage degree η is calculated using the loss rate of bearing fatigue damage caused by each pressure load impact g .

[0070] Preferably, in step 41, a ninth pressure load signal is periodically input to the ninth group of pump pressure shock test benches until fatigue damage of the oil distribution plate occurs, and data on the number of times the ninth pressure load signal is input when fatigue damage of the oil distribution plate occurs is obtained;

[0071] Periodically inputting a tenth pressure load signal to the tenth group of pump pressure shock test benches until fatigue damage to the oil distribution plate occurs, and obtaining data on the number of times the tenth pressure load signal is input when fatigue damage to the oil distribution plate occurs;

[0072] Step 42 , obtaining an unknown quantity of the fifth function based on the ninth pressure load signal, the tenth pressure load signal, the number of times the ninth pressure load signal is input when fatigue damage to the oil distribution plate occurs, and the number of times the tenth pressure load signal is input when fatigue damage to the oil distribution plate occurs;

[0073] Using the unknown quantity of the fifth function, the pressure shock load-oil distribution plate fatigue damage frequency curve is constructed;

[0074] Step 43: Obtain a pressure load signal set F of the entire engineering machinery equipment;

[0075] If the pressure load signal set F meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, and the process proceeds to step 44; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode, and the operation ends;

[0076] Step 44, using the pressure impact load-oil distribution plate fatigue damage frequency curve, calculate the loss rate of the oil distribution plate fatigue damage caused by each pressure load impact;

[0077] The fatigue damage degree η of the oil distribution plate is calculated by using the loss rate of fatigue damage of the oil distribution plate caused by each pressure load impact. p Preferably, in step 51, the eleventh pressure load signal is periodically input to the eleventh group of pump pressure shock test benches until fatigue damage occurs to the end caps at both ends of the plunger, and data on the number of times the eleventh pressure load signal is input when fatigue damage occurs to the end caps at both ends of the plunger is obtained;

[0078] Periodically inputting a twelfth pressure load signal to the twelfth group of pump pressure shock test benches until fatigue damage occurs to the end covers at both ends of the plunger, and obtaining data on the number of times the twelfth pressure load signal is input when fatigue damage occurs to the end covers at both ends of the plunger;

[0079] Step 52, obtaining the unknown quantity of the sixth function based on the eleventh pressure load signal, the twelfth pressure load signal, the number of times the eleventh pressure load signal is input when fatigue damage occurs to the end caps at both ends of the plunger, and the number of times the twelfth pressure load signal is input when fatigue damage occurs to the end caps at both ends of the plunger;

[0080] Using the unknown quantity of the sixth function, a pressure shock load-fatigue damage frequency curve of the end caps at both ends of the plunger is constructed;

[0081] Step 53: Obtain a pressure load signal set G of the entire engineering machinery equipment;

[0082] If the pressure load signal set G meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, and the process proceeds to step 54; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode, and the operation ends;

[0083] Step 54, using the pressure impact load-fatigue damage frequency curve of the end caps at both ends of the plunger, calculate the loss rate of fatigue damage of the end caps at both ends of the plunger caused by each pressure load impact;

[0084] The fatigue damage degree η of the end caps at both ends of the plunger is calculated by using the loss rate of fatigue damage of the end caps at both ends of the plunger caused by each pressure load impact. d .

[0085] Prior to this, the total fatigue damage rate η is calculated:

[0086] η=min(η z ,η k ,η c ,η g ,η p ,η d ), where η z is the fatigue damage degree of the plunger; η k is the fatigue damage degree of the pump casing; η c is the fatigue damage degree of the transmission shaft; η g is the bearing fatigue damage degree; η p is the fatigue damage degree of the oil distribution plate; η d is the fatigue damage degree of the end covers at both ends of the plunger.

[0087] Preferably, if η=min(η z ,η k ,η c ,η g ,η p ,η d ) is greater than the set fatigue damage threshold, it is determined that the plunger pump motor has a damage fault.

[0088] An electronic device comprises a memory, a processor and a computer program stored in the memory and executable on the processor, wherein the processor implements the steps of any one of the above methods when executing the program.

[0089] A computer-readable storage medium stores a computer program, which, when executed by a processor, implements the steps of any of the above methods.

[0090] The beneficial effects achieved by the present invention are:

[0091] The present invention proposes a real-time prediction method and storage medium for fatigue damage failure of a plunger pump motor. A mathematical model of the relationship between the pressure load and fatigue damage frequency (SN) of the plunger pump motor is obtained by bench testing. By real-time acquisition of the hydraulic system pressure load parameters during the actual operation of the entire machine, the pressure load peak and valley value data are extracted. The mathematical model of the pressure load-fatigue damage frequency relationship is used to calculate the fatigue damage rate of the plunger pump motor in real time, and predict the fatigue damage degree of the plunger pump motor.

[0092] By synchronously transmitting data on key failure points and pressure load peaks and valleys of the plunger pump motor to a cloud server, this method helps maintenance personnel develop component repair interval strategies. Based on this information, they can formulate detailed component demand and production plans, improving spare parts inventory turnover. Furthermore, the cloud server processes and stores pressure load data to obtain hydraulic cycle impact load data throughout the entire lifecycle. It also analyzes the structural strength and flow field characteristics of the plunger pump motor, assessing its reliability based on cumulative damage theory.

[0093] The present invention calculates the pressure load signal of the entire construction machinery in real time to obtain the fatigue damage degree of the plunger pump motor. When the set threshold is reached, the controller can send a warning to the entire machine display, reminding maintenance personnel to replace the plunger pump motor in advance, thereby reducing user downtime losses and repair service costs and possible safety accidents.

[0094] The present invention can obtain a complete life cycle of the plunger pump motor through data accumulation, providing data support for designers to complete the structural strength analysis and flow field characteristic analysis of the plunger pump motor, further evaluate the reliability of the plunger pump motor, and support maintenance personnel in establishing a parts maintenance interval strategy. At the same time, based on this information, a detailed parts demand plan and production plan can be formulated to improve the parts inventory turnover rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0095] Figure 1 It is a principle block diagram of the present invention;

[0096] Figure 2 This is the curve of pressure shock load-fatigue damage frequency of plunger pump motor;

[0097] Figure 3 This is a schematic diagram of the main pump status detection of the whole machine;

[0098] Figure 4 is a flow chart of the present invention;

[0099] Figure 5 is the periodic input pressure load signal S j Schematic diagram of;

[0100] Figure 6is the periodic input pressure load signal S k Schematic diagram of . DETAILED DESCRIPTION

[0101] The following examples are only used to more clearly illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention.

[0102] Example 1

[0103] A real-time prediction method for fatigue damage failure of a plunger pump motor comprises:

[0104] Step 1: Periodically input pressure load signal S to the first group of pump pressure shock test benches j Until the pump casing fatigue damage occurs, the input pressure load signal S when the pump casing fatigue damage occurs is obtained. j Number of times data N j ;

[0105] Periodically input pressure load signal S to the second group of pump pressure shock test bench k Until the pump casing fatigue damage occurs, the input pressure load signal S when the pump casing fatigue damage occurs is obtained. k Number of times data N k ;

[0106] Step 2, based on S j 、S k 、N j and N k , find the unknown quantity of the function;

[0107] Using the unknown quantity of the function, the pressure shock load-fatigue damage frequency curve of the plunger pump motor is constructed;

[0108] Step 3: Obtain a pressure load signal set S of the entire engineering machinery equipment;

[0109] If the pressure load signal set S meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode and the process proceeds to step 4; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode and the process ends.

[0110] Step 4: Use the pressure shock load-fatigue damage frequency curve corresponding to the plunger pump motor to calculate the loss rate η of fatigue damage to the pump housing caused by each pressure load shock i ;

[0111] The loss rate η of fatigue damage to the pump casing caused by each pressure load impact is used i , calculate the fatigue damage degree η of the pump casing k .

[0112] Prior to step 2, based on S j 、Sk 、N j and N k , find the unknown quantity of the function, and implement it through the following steps:

[0113] Use the following formula to calculate the unknown function quantities D and C:

[0114] N j *(S j ) D =C,

[0115] N k *(S k ) D =C,

[0116]

[0117] Where D is the slope coefficient of the pressure shock load-fatigue damage frequency curve of the plunger pump motor.

[0118] Prioritize using the unknown function to construct the pressure shock load-fatigue damage frequency curve of the plunger pump motor by the following steps:

[0119] Functional expression of the pressure shock load-fatigue damage frequency curve of the plunger pump motor:

[0120] N e ·(S e ) D =C, where S e It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N e Set value for the fatigue life of the pump casing at rated working pressure.

[0121] Preferably, in step 3, if the pressure load signal set S meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, the pressure load signal set S is recorded, and step 4 is entered, which is achieved by the following steps:

[0122] If the pressure load signal S i to S i+n Are greater than or equal to 1.34S0, S i+n and S i ∈S, n is a positive integer, S0 is the initial pressure shock load signal when the plunger pump motor starts, then it is determined that the engineering machinery equipment has entered the working mode, and the pressure shock load signal S is recorded. i , go to step 4;

[0123] If S i All less than 1.05S0, S i+n ∈S, it is determined that the entire engineering machinery equipment has exited the working mode and ended the operation.

[0124] Preferably, in step 4, the loss rate η of fatigue damage to the pump housing caused by each pressure load impact is calculated using the pressure impact load-fatigue damage frequency curve of the plunger pump motor. i , achieved by the following steps:

[0125] Calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi :

[0126]

[0127] S ai =|S i+1 -S i |,

[0128]

[0129] Where S i+1 is the collected pressure load signal of the i+1th engineering machinery equipment, S i+1 ∈S,S i is the collected pressure load signal of the i-th engineering machinery equipment, δ b is the ultimate strength of the material;

[0130] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei :

[0131]

[0132] Where N eqi is the number of impact cycles counted under the condition of the i-th equivalent pressure load amplitude; S e It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N ei is the number of impact cycles that produce fatigue damage under the i-th equivalent pressure load amplitude condition converted to the rated working pressure.

[0133] Preferably, in step 4, the loss rate η of fatigue damage to the pump housing caused by each pressure load impact is calculated using the pressure impact load-fatigue damage frequency curve of the plunger pump motor. i , achieved by the following steps:

[0134] Substitute the rated working pressure of the current plunger pump motor in the hydraulic system of the whole machine into the corresponding pressure shock load-fatigue damage frequency curve of the plunger pump motor to calculate the fatigue life setting value N under the rated working pressure. e ;

[0135] Based on the known N ei and N e, calculate the loss rate η of the pump casing fatigue damage caused by each pressure load impact i :

[0136]

[0137] Where N ei is the number of impact cycles that produce fatigue damage under the i-th equivalent pressure load amplitude condition converted to the rated working pressure;

[0138] Step 4: Use the loss rate η of fatigue damage to the pump casing caused by each pressure load impact i , calculate the fatigue damage degree η of the pump casing k , achieved by the following steps:

[0139] Calculation of pump casing fatigue damage η k :

[0140]

[0141] Preferably, in step 11, a third pressure load signal is periodically input to the third group of pump pressure shock test benches until plunger fatigue damage occurs, and data on the number of times the third pressure load signal is input when plunger fatigue damage occurs is obtained;

[0142] Periodically inputting a fourth pressure load signal to the fourth group of pump pressure shock test benches until plunger fatigue damage occurs, and obtaining data on the number of times the fourth pressure load signal is input when plunger fatigue damage occurs;

[0143] Step 12, obtaining an unknown quantity of the second function based on the third pressure load signal, the fourth pressure load signal, the number of times the third pressure load signal is input when fatigue damage occurs to the plunger, and the number of times the fourth pressure load signal is input when fatigue damage occurs to the plunger;

[0144] Among them, the unknown quantities D2 and C2 of the second function are calculated using the following formula:

[0145] N j2 *(S j2 ) D2 =C2,

[0146] N k2 *(S k2 ) D2 =C2,

[0147]

[0148] Where S j2 is the third pressure load signal, S k2 is the fourth pressure load signal, N j2N is the number of times the third pressure load signal is input when plunger fatigue damage occurs. k2 is the number of times the fourth pressure load signal is input when plunger fatigue damage occurs, D2 is the slope coefficient of the pressure impact load-plunger fatigue damage frequency curve, and C2 is a constant.

[0149] Using the unknown quantity of the second function, a pressure shock load-plunger fatigue damage frequency curve is constructed;

[0150] Specifically, the functional expression of the pressure impact load-plunger fatigue damage frequency curve is:

[0151] N e2 ·(S e2 ) D2 =C2, where S e2 It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N e2 Set value for plunger fatigue life at rated working pressure.

[0152] Step 13: Obtain a pressure load signal set A of the entire engineering machinery equipment;

[0153] If the pressure load signal set A meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode and the process proceeds to step 14; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode and the process ends.

[0154] Specifically, if all pressure load signals S i2 to S i2+n Are greater than or equal to 1.34S0, S i2 ∈A, S0 is the initial pressure shock load signal when the plunger pump motor starts, then it is determined that the engineering machinery equipment has entered the working mode, and the pressure shock load signal S is recorded. i2 , go to step 14, otherwise it is determined that the entire engineering machinery equipment has exited the working mode and the operation ends.

[0155] Step 14: Using the pressure impact load-plunger fatigue damage frequency curve, calculate the loss rate η of the plunger fatigue damage caused by each pressure load impact i ;

[0156] The loss rate η of plunger fatigue damage caused by each pressure load impact is used i2 , calculate the plunger fatigue damage degree η z .

[0157] Specifically, calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi2 :

[0158]

[0159] Sai2 =|S i2+1 -S i2 |,

[0160]

[0161] Where S i2+1 is the collected pressure load signal of the i2+1th engineering machinery equipment, S i2+1 ∈S,S i2 is the collected pressure load signal of the i2th engineering machinery equipment, δ b2 is the ultimate strength of the material;

[0162] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei2 :

[0163]

[0164] Where N eqi2 is the number of impact cycles counted under the condition of the i2th equivalent pressure load amplitude; S e2 It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N ei2 It is the number of impact cycles that produce fatigue damage under the i2th equivalent pressure load amplitude condition converted to the rated working pressure.

[0165] Substitute the rated working pressure of the current plunger pump motor in the hydraulic system of the whole machine into the pressure shock load-plunger fatigue damage frequency curve to calculate the plunger fatigue life setting value N under the rated working pressure. e2 ;

[0166] Based on the known N ei2 and N e2 , calculate the loss rate η of plunger fatigue damage caused by each pressure load impact i2 :

[0167]

[0168] Where N ei2 is the number of impact cycles that produce plunger fatigue damage under the i2th equivalent pressure load amplitude condition converted to the rated working pressure;

[0169] Calculation of plunger fatigue damage η z :

[0170]

[0171] Preferably, in step 21, a fifth pressure load signal is periodically input to the fifth group of pump pressure shock test benches until fatigue damage of the transmission shaft occurs, and data on the number of times the fifth pressure load signal is input when fatigue damage of the transmission shaft occurs is obtained;

[0172] periodically inputting a sixth pressure load signal to the sixth group of pump pressure shock test benches until fatigue damage of the transmission shaft occurs, and obtaining data on the number of times the sixth pressure load signal is input when fatigue damage of the transmission shaft occurs;

[0173] Step 22, obtaining an unknown quantity of the third function based on the fifth pressure load signal, the sixth pressure load signal, the number of times the fifth pressure load signal is input when fatigue damage to the transmission shaft occurs, and the number of times the sixth pressure load signal is input when fatigue damage to the transmission shaft occurs;

[0174] Specifically, the third function unknowns D3 and C3 are calculated using the following formula:

[0175]

[0176] N k3 *(S k3 ) D3 =C3,

[0177]

[0178] Where S j3 is the fifth pressure load signal, S k3 is the sixth pressure load signal, N j3 N is the number of times the fifth pressure load signal is input when plunger fatigue damage occurs. k3 is the number of times the sixth pressure load signal is input when fatigue damage occurs to the plunger, D3 is the slope coefficient of the pressure impact load-transmission shaft fatigue damage frequency curve, and C3 is a constant.

[0179] Using the unknown quantity of the third function, the pressure impact load-drive shaft fatigue damage frequency curve is constructed;

[0180] Specifically, the functional expression of the pressure impact load-transmission shaft fatigue damage frequency curve is:

[0181] N e3 ·(S e3 ) D3 =C3, where S e3 It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N e3 Set value for the fatigue life of the transmission shaft at rated working pressure.

[0182] Step 23: Obtain a pressure load signal set B of the entire engineering machinery equipment;

[0183] If the pressure load signal set B meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, and the process proceeds to step 24; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode, and the operation ends;

[0184] Specifically, if all pressure load signals S i3 to S i3+n Are greater than or equal to 1.34S0, S i3 ∈B, S0 is the initial pressure shock load signal when the plunger pump motor starts, then it is determined that the entire engineering machinery equipment has entered the working mode, and the pressure shock load signal S is recorded. i3 , go to step 24, otherwise it is determined that the entire engineering machinery equipment has exited the working mode and the operation ends.

[0185] Step 24, using the pressure impact load-transmission shaft fatigue damage frequency curve, calculate the loss rate of transmission shaft fatigue damage caused by each pressure load impact;

[0186] Specifically, calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi3 :

[0187]

[0188] S ai3 =|S i3+1 -S i3 |,

[0189]

[0190] Where S i3+1 is the collected pressure load signal of the i3+1th engineering machinery equipment, S i3+1 ∈S,S i3 is the collected pressure load signal of the i3th engineering machinery equipment, δ b3 is the ultimate strength of the material;

[0191] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei3 :

[0192]

[0193] Where N eqi3 is the number of impact cycles counted under the i3th equivalent pressure load amplitude condition; S e3 It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N ei3 It is the number of impact cycles that produce fatigue damage under the i3th equivalent pressure load amplitude condition converted to the rated working pressure.

[0194] The fatigue damage degree η of the transmission shaft is calculated using the loss rate of the transmission shaft fatigue damage caused by each pressure load impact. C .

[0195] Specifically, calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi3 :

[0196]

[0197] S ai3 =|S i3+1 -S i3 |,

[0198]

[0199] Where S i3+1 is the collected pressure load signal of the i3+1th engineering machinery equipment, S i3+1 ∈S,S i3 is the collected pressure load signal of the i3th engineering machinery equipment, δ b 3 is the ultimate strength of the material;

[0200] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei3 :

[0201]

[0202] Where N eqi3 is the number of impact cycles counted under the i3th equivalent pressure load amplitude condition; S e3 It is the rated working pressure of the transmission shaft pump motor in the hydraulic system of the whole machine; N ei3 It is the number of impact cycles that produce fatigue damage of the transmission shaft under the i3th equivalent pressure load amplitude condition converted to the rated working pressure.

[0203] Substitute the rated working pressure of the current transmission shaft pump motor in the hydraulic system of the whole machine into the pressure shock load-transmission shaft fatigue damage frequency curve to calculate the transmission shaft fatigue life setting value N under the rated working pressure. e3 ;

[0204] Based on the known N ei3 and N e3 , calculate the loss rate η of the transmission shaft fatigue damage caused by each pressure load impact i3 :

[0205]

[0206] Where N ei3is the number of impact cycles that produce fatigue damage to the transmission shaft under the i3th equivalent pressure load amplitude condition converted to the rated working pressure;

[0207] Calculation of drive shaft fatigue damage η C :

[0208]

[0209] Preferably, in step 31, a seventh pressure load signal is periodically input to the seventh group of pump pressure shock test benches until bearing fatigue damage occurs, and data on the number of times the seventh pressure load signal is input when bearing fatigue damage occurs is obtained;

[0210] periodically inputting an eighth pressure load signal to the eighth group of pump pressure shock test benches until bearing fatigue damage occurs, and obtaining data on the number of times the eighth pressure load signal is input when bearing fatigue damage occurs;

[0211] Step 32, obtaining an unknown quantity of the fourth function based on the seventh pressure load signal, the eighth pressure load signal, the number of times the seventh pressure load signal is input when bearing fatigue damage occurs, and the number of times the eighth pressure load signal is input when bearing fatigue damage occurs;

[0212] The unknown quantities D4 and C4 of the fourth function are calculated using the following formula:

[0213]

[0214] N k4 *(S k4 ) D4 =C4,

[0215]

[0216] Where S j4 is the seventh pressure load signal, S k4 is the eighth pressure load signal, N j4 N is the number of times the seventh pressure load signal is input when plunger fatigue damage occurs. k4 is the number of times the eighth pressure load signal is input when plunger fatigue damage occurs, D4 is the slope coefficient of the pressure impact load-bearing fatigue damage frequency curve, and C4 is a constant.

[0217] Using the unknown quantity of the fourth function, the pressure impact load-bearing fatigue damage frequency curve is constructed;

[0218] Specifically, the functional expression of the pressure impact load-bearing fatigue damage frequency curve is:

[0219] N e4 ·(S e4 ) D4=C4,

[0220] Where S e4 It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N e4 Set the value for bearing fatigue life at rated working pressure.

[0221] Step 33: Obtain a pressure load signal set E of the entire engineering machinery equipment;

[0222] If the pressure load signal set E meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, and the process proceeds to step 34; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode, and the operation ends;

[0223] Specifically, if all pressure load signals S i4 to S i4+n Are greater than or equal to 1.34S0, S i4 ∈E, S0 is the initial pressure shock load signal when the plunger pump motor starts, then it is determined that the engineering machinery equipment has entered the working mode, and the pressure shock load signal S is recorded. i4 , go to step 34; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode and the operation ends.

[0224] Step 34, using the pressure impact load-bearing fatigue damage frequency curve, calculate the loss rate of bearing fatigue damage caused by each pressure load impact;

[0225] Specifically, calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi4 :

[0226]

[0227] S ai4 =|S i4+1 -S i4 |,

[0228]

[0229] Where S i4+1 is the collected pressure load signal of the i4+1th engineering machinery equipment, S i4+1 ∈S,S i4 is the collected pressure load signal of the i4th engineering machinery equipment, δ b 4 is the ultimate strength of the material;

[0230] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei4 :

[0231]

[0232] Where N eqi4 is the number of impact cycles counted under the i4th equivalent pressure load amplitude condition; S e4 It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N ei4 It is the number of impact cycles that produce bearing fatigue damage under the i4th equivalent pressure load amplitude condition converted to the rated working pressure.

[0233] The bearing fatigue damage degree η is calculated using the loss rate of bearing fatigue damage caused by each pressure load impact g .

[0234] Specifically, calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi4 :

[0235]

[0236] S ai4 =|S i4+1 -S i4 |,

[0237]

[0238] Where S i4+1 is the collected pressure load signal of the i4+1th engineering machinery equipment, S i4+1 ∈S,S i4 is the collected pressure load signal of the i4th engineering machinery equipment, δ b 4 is the ultimate strength of the material;

[0239] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei4 :

[0240]

[0241] Where N eqi4 is the number of impact cycles counted under the i4th equivalent pressure load amplitude condition; S e4 is the rated working pressure of the bearing pump motor in the hydraulic system of the whole machine; N ei4 It is the number of impact cycles that produce bearing fatigue damage under the i4th equivalent pressure load amplitude condition converted to the rated working pressure.

[0242] Substitute the rated working pressure of the current bearing pump motor in the hydraulic system of the whole machine into the pressure shock load-bearing fatigue damage frequency curve to calculate the bearing fatigue life setting value N under the rated working pressure. e4 ;

[0243] Based on the known N ei4and N e4 , calculate the loss rate η of bearing fatigue damage caused by each pressure load impact i4 :

[0244]

[0245] Where N ei4 is the number of impact cycles that produce bearing fatigue damage under the i4th equivalent pressure load amplitude condition converted to the rated working pressure;

[0246] Calculation of bearing fatigue damage η g :

[0247]

[0248] Preferably, in step 41, a ninth pressure load signal is periodically input to the ninth group of pump pressure shock test benches until fatigue damage of the oil distribution plate occurs, and data on the number of times the ninth pressure load signal is input when fatigue damage of the oil distribution plate occurs is obtained;

[0249] Periodically inputting a tenth pressure load signal to the tenth group of pump pressure shock test benches until fatigue damage to the oil distribution plate occurs, and obtaining data on the number of times the tenth pressure load signal is input when fatigue damage to the oil distribution plate occurs;

[0250] Step 42 , obtaining an unknown quantity of the fifth function based on the ninth pressure load signal, the tenth pressure load signal, the number of times the ninth pressure load signal is input when fatigue damage to the oil distribution plate occurs, and the number of times the tenth pressure load signal is input when fatigue damage to the oil distribution plate occurs;

[0251] The unknown quantities D5 and C5 of the fifth function are calculated using the following formula:

[0252] N j5 *(S j5 ) D5 =C5,

[0253] N k5 *(S k5 ) D5 =C5,

[0254]

[0255] Where S j5 is the ninth pressure load signal, S k5 is the tenth pressure load signal, N j5 N is the number of times the ninth pressure load signal is input when the plunger fatigue damage occurs. k5 is the number of times the tenth pressure load signal is input when plunger fatigue damage occurs, D5 is the slope coefficient of the pressure impact load-oil distribution plate fatigue damage frequency curve, and C5 is a constant.

[0256] Using the unknown quantity of the fifth function, the pressure shock load-oil distribution plate fatigue damage frequency curve is constructed;

[0257] Specifically, the function expression of the pressure impact load-oil distribution plate fatigue damage frequency curve is:

[0258] N e5 ·(S e5 ) D5 =C5,

[0259] Where S e5 It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N e5 Set value for the fatigue life of the oil distribution plate at rated working pressure.

[0260] Step 43: Obtain a pressure load signal set F of the entire engineering machinery equipment;

[0261] If the pressure load signal set F meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, and the process proceeds to step 44; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode, and the operation ends;

[0262] Specifically, if all pressure load signals S i5 to S i5+n Are greater than or equal to 1.34S0, S i5 ∈F, S0 is the initial pressure shock load signal when the plunger pump motor starts, then it is determined that the engineering machinery equipment has entered the working mode, and the pressure shock load signal S is recorded. i5 , go to step 44; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode and the operation ends.

[0263] Step 44, using the pressure impact load-oil distribution plate fatigue damage frequency curve, calculate the loss rate of the oil distribution plate fatigue damage caused by each pressure load impact;

[0264] Specifically, calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi5 :

[0265]

[0266] S ai5 =|S i5+1 -S i5 |,

[0267]

[0268] Where S i5+1 is the collected pressure load signal of the i5+1th engineering machinery equipment, S i5+1 ∈S,Si5 is the collected pressure load signal of the i5th engineering machinery equipment, δ b 5 is the ultimate strength of the material;

[0269] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei5 :

[0270]

[0271] Where N eqi5 is the number of impact cycles counted under the i5th equivalent pressure load amplitude condition; S e5 It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N ei5 It is the number of impact cycles that produce fatigue damage under the i5th equivalent pressure load amplitude condition converted to the rated working pressure.

[0272] The fatigue damage degree η of the oil distribution plate is calculated by using the loss rate of fatigue damage of the oil distribution plate caused by each pressure load impact. p .

[0273] Specifically, calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi5 :

[0274]

[0275] S ai5 =|S i5+1 -S i5 |,

[0276]

[0277] Where S i5+1 is the collected pressure load signal of the i5+1th engineering machinery equipment, S i5+1 ∈S,S i5 is the collected pressure load signal of the i5th engineering machinery equipment, δ b 5 is the ultimate strength of the material;

[0278] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei5 :

[0279]

[0280] Where N eqi5 is the number of impact cycles counted under the i5th equivalent pressure load amplitude condition; S e5 It is the rated working pressure of the oil distribution plate pump motor in the hydraulic system of the whole machine; N ei5It is the number of impact cycles that produces fatigue damage to the oil distribution plate under the i5th equivalent pressure load amplitude condition converted to the rated working pressure.

[0281] Substitute the rated working pressure of the current oil distribution plate pump motor in the hydraulic system of the whole machine into the pressure shock load-oil distribution plate fatigue damage frequency curve to calculate the fatigue life setting value N of the oil distribution plate under the rated working pressure. e5 ;

[0282] Based on the known N ei5 and N e5 , calculate the loss rate η of fatigue damage to the oil distribution plate caused by each pressure load impact i5 :

[0283]

[0284] Where N ei5 is the number of impact cycles that produce fatigue damage to the oil distribution plate under the i5th equivalent pressure load amplitude condition converted to the rated working pressure;

[0285] Calculation of fatigue damage degree η of oil distribution plate p :

[0286]

[0287] Preferably, in step 51, the eleventh pressure load signal is periodically input to the eleventh group of pump pressure shock test benches until fatigue damage occurs to the end caps at both ends of the plunger, and data on the number of times the eleventh pressure load signal is input when fatigue damage occurs to the end caps at both ends of the plunger is obtained;

[0288] Periodically inputting a twelfth pressure load signal to the twelfth group of pump pressure shock test benches until fatigue damage occurs to the end covers at both ends of the plunger, and obtaining data on the number of times the twelfth pressure load signal is input when fatigue damage occurs to the end covers at both ends of the plunger;

[0289] Step 52, obtaining the unknown quantity of the sixth function based on the eleventh pressure load signal, the twelfth pressure load signal, the number of times the eleventh pressure load signal is input when fatigue damage occurs to the end caps at both ends of the plunger, and the number of times the twelfth pressure load signal is input when fatigue damage occurs to the end caps at both ends of the plunger;

[0290] The unknown quantities D6 and C6 of the sixth function are calculated using the following formula:

[0291] N j6 *(S j6 ) D6 =C6,

[0292] N k6 *(S k6 ) D6 =C6,

[0293]

[0294] Where S j6 is the eleventh pressure load signal, S k6 is the twelfth pressure load signal, N j6 N is the number of times the eleventh pressure load signal is input when plunger fatigue damage occurs. k6 = is the number of times the twelfth pressure load signal is input when plunger fatigue damage occurs, D6 is the slope coefficient of the pressure shock load-plunger end cap fatigue damage frequency curve, and C6 is a constant. Using the unknown quantity of the sixth function, construct the pressure shock load-plunger end cap fatigue damage frequency curve;

[0295] Specifically, the function expression of the pressure impact load-fatigue damage frequency curve of the end caps at both ends of the plunger is:

[0296] N e6 ·(S e6 ) D6 =C6,

[0297] Where S e6 It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N e6 It is the set value for the fatigue life of the end covers at both ends of the plunger under the rated working pressure.

[0298] Step 53: Obtain a pressure load signal set G of the entire engineering machinery equipment;

[0299] If the pressure load signal set G meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, and the process proceeds to step 54; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode, and the operation ends;

[0300] Specifically, if all pressure load signals S i6 to S i6+n Are greater than or equal to 1.34S0, S i6 ∈G, S0 is the initial pressure shock load signal when the plunger pump motor starts, then it is determined that the engineering machinery equipment has entered the working mode, and the pressure shock load signal S is recorded. i6 , go to step 54; otherwise, it is determined that the entire engineering machinery equipment has exited the working mode and the operation ends.

[0301] Step 54, using the pressure impact load-fatigue damage frequency curve of the end caps at both ends of the plunger, calculate the loss rate of fatigue damage of the end caps at both ends of the plunger caused by each pressure load impact;

[0302] Specifically, calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi6 :

[0303]

[0304] S ai6 =|S i6+1 -S i6 |,

[0305]

[0306] Where S i6+1 is the collected pressure load signal of the i6+1th engineering machinery equipment, S i6+1 ∈S,S i6 is the collected pressure load signal of the i6th engineering machinery equipment, δ b 6 is the ultimate strength of the material;

[0307] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei6 :

[0308]

[0309] Where N eqi6 is the number of impact cycles counted under the i6th equivalent pressure load amplitude condition; S e6 It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; N ei6 It is the number of impact cycles that produce fatigue damage under the i6th equivalent pressure load amplitude condition converted to the rated working pressure.

[0310] The fatigue damage degree η of the end caps at both ends of the plunger is calculated by using the loss rate of fatigue damage of the end caps at both ends of the plunger caused by each pressure load impact. d .

[0311] Specifically, calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi6 :

[0312]

[0313] S ai6 =|S i6+1 -S i6 |,

[0314]

[0315] Where S i6+1 is the collected pressure load signal of the i6+1th engineering machinery equipment, S i6+1 ∈S,S i6 is the collected pressure load signal of the i6th engineering machinery equipment, δ b6 is the ultimate strength of the material;

[0316] Convert each pressure load impact to the fatigue damage frequency N of the rated pressure load condition ei6 :

[0317]

[0318] Where N eqi6 is the number of impact cycles counted under the i6th equivalent pressure load amplitude condition; S e6 The rated working pressure of the end covers of the plunger and the pump motor in the hydraulic system of the whole machine; N ei6 It is the number of impact cycles that produces fatigue damage to the end covers of the plunger at both ends under the i6th equivalent pressure load amplitude condition converted to the rated working pressure.

[0319] Substitute the rated working pressure of the current plunger end cap pump motor in the whole machine hydraulic system into the pressure shock load-plunger end cap fatigue damage frequency curve to calculate the fatigue life setting value N of the plunger end cap under the rated working pressure. e6 ;

[0320] Based on the known N ei6 and N e6 , calculate the loss rate η of fatigue damage to the end caps at both ends of the plunger caused by each pressure load impact i6 :

[0321]

[0322] Where N ei6 is the number of impact cycles that produces fatigue damage to the end caps at both ends of the plunger under the i6th equivalent pressure load amplitude condition converted to the rated working pressure;

[0323] Calculate the fatigue damage degree η of the end caps at both ends of the plunger p :

[0324]

[0325] Prior to this, the total fatigue damage rate η is calculated:

[0326] η=min(η z ,η k ,η c ,η g ,η p ,η d ),

[0327] Where η z is the fatigue damage degree of the plunger; η k is the fatigue damage degree of the pump casing; η c is the fatigue damage degree of the transmission shaft; η gis the bearing fatigue damage degree; η p is the fatigue damage degree of the oil distribution plate; η d is the fatigue damage degree of the end covers at both ends of the plunger.

[0328] Preferably, if η=min(η z ,η k ,η c ,η g ,η p ,η d ) is greater than the set fatigue damage threshold, it is determined that the plunger pump motor has a damage fault.

[0329] An electronic device comprises a memory, a processor and a computer program stored in the memory and executable on the processor, wherein the processor implements the steps of any one of the above methods when executing the program.

[0330] A computer-readable storage medium stores a computer program, which, when executed by a processor, implements the steps of any of the above methods.

[0331] There are many models of plungers, pump housings, drive shafts, bearings, oil distribution plates and end covers at both ends of the plunger that can be used in the prior art. Those skilled in the art can select appropriate models according to actual needs, and this embodiment will not give examples one by one.

[0332] Example 2

[0333] Taking fatigue damage failure prediction for the main pump casing of construction machinery as an example, the present invention requires first obtaining a pressure shock load-fatigue damage frequency curve to calculate the pump casing damage caused by the main pump pressure load. A mathematical model for pump casing reliability assessment was developed for use in pump casing reliability assessment of construction machinery main pumps. To obtain a fitting equation for the pressure shock load-fatigue damage frequency curve corresponding to the main pump casing, pump reliability bench testing was performed to determine the relationship between different pressure load levels and the number of shocks required to cause pump casing fatigue damage.

[0334] Step 1: To obtain the curve function expression:

[0335]

[0336] Solution 1)

[0337] By conducting pressure shock loading tests on two pumps from the same batch under different pressure load conditions, the number of fatigue damage occurrences on the pump casing was recorded. Based on these two sets of different main pump pressure load bench test data, the unknown quantity of the function was derived using the formula.

[0338]

[0339]

[0340] According to the bench test data, N j 、S j 、N k and S k , substituting the known values ​​into the equation can obtain D and C.

[0341] If the sample size is sufficient, a pressure shock loading test can be performed on 8 pumps from the same batch under different pressure load conditions, and the number of pump housing fatigue damage data is recorded. The best fitting equation is obtained using the least squares method. The load is generally divided into 8 steps, including equal interval method and non-equal interval method. This scheme is explained and described using the non-equal interval method as an example. The test bench impact pressure is selected as S i Take S e The ratio coefficients are 1, 0.95, 0.85, 0.725, 0.575, 0.425, 0.275, and 0.125. The load S of different pressure levels can be obtained through bench fatigue tests. i Corresponding number of impact cycles N when fatigue failure occurs i , as shown in Table 1 below.

[0342] Table 1 Pressure load data statistics

[0343] Pressure amplitude / bar <![CDATA[1×S e ]]> <![CDATA[0.95×S e ]]> <![CDATA[0.85×S e ]]> <![CDATA[0.725×S e ]]> <![CDATA[0.575×S e ]]> <![CDATA[0.425×S e ]]> <![CDATA[0.275×S e ]]> <![CDATA[0.125×S e ]]> Number of cycles / times <![CDATA[N e =N1]]> <![CDATA[N2]]> <![CDATA[N3]]> <![CDATA[N4]]> <![CDATA[N5]]> <![CDATA[N6]]> <![CDATA[N7]]> <![CDATA[N8]]>

[0344] Through 8 sets of bench pressure load reliability tests, the number of impacts required for fatigue damage of the corresponding pump casing under different pressure levels was obtained, and the unknown quantity of the function was derived using the formula.

[0345] According to the actual cyclic impact load data table, Si and Ni can be obtained.

[0346] D and C can also be obtained by substituting the known values ​​into the equation through the least square method. At this point, both coefficients in the equation are obtained. The pressure impact load-fatigue damage frequency curve is obtained, such as Figure 2 shown.

[0347] The equivalent calculation of the number of non-rated working pressure load impacts can be calculated by the number of rated working pressure load impacts:

[0348]

[0349] It is deduced that:

[0350]

[0351] Step 2: Extract the main pump pressure load-pump casing fatigue damage frequency data from the pressure load data. The pressure shock load-fatigue damage frequency curve can be used for main pump reliability assessment and pump casing fatigue damage failure prediction.

[0352] The data source is the pressure sensor signal of the main pump of the hydraulic system of the engineering machinery, such as Figure 3 As shown, in order to facilitate the power matching between the hydraulic system and the engine, a pressure sensor is installed at the outlet of the main pump to measure the pressure load signal P in real time. 泵1 、P 泵2 ,The pressure load signal is input through the input port of the main controller, and the pressure impact load data generated during the operation of the whole machine is input into the data extraction module of the controller for data preprocessing, such as Figure 4 shown.

[0353] 1) In the pressure load data extraction module, during the operation of the equipment, the collected main pump pressure load data is transmitted to the controller. When the whole machine is in the idle working state, the data collected by main pump 1 and main pump 2 are M0 and N0. When the data collected by main pump 1 and main pump 2 meet M i ≥1.34M0 and N i ≥1.34N0, the whole machine is judged to enter the working mode, and each sensor signal collects data and starts recording. When the data collected by main pump 1 and main pump 2 meet M i ≤1.05M0 and N i If ≤1.05N0, the whole machine is judged to exit the working mode, and each sensor signal stops recording after collecting data. The variables set for the i-th data point are M i and N i .

[0354] 2) Pressure load data extraction module, which extracts the peak value of the collected main pump pressure load data and stores it as pressure load data P i If (M i-1 -M i )×(M i -M i+1 )<0,P i =M i Otherwise, M i Remove the value and judge again, (M i-1 -M i+1 )×(M i+1 -M i+2 )<0,P i =M i+1 . This process repeats until the last data point.

[0355] Step 3: Fatigue damage calculation module, real-time S i The data were calculated to obtain the fatigue damage percentage.

[0356] The measured pressure load mean and amplitude are corrected to the equivalent stress amplitude using formula (1):

[0357]

[0358] Where: S ai =|P i+1 -P i |;

[0359] Each pressure load impact is converted to the fatigue damage frequency of the rated pressure load condition through formula (5):

[0360]

[0361] Where: N eqi To count the number of impact cycles under the condition of the i-th equivalent pressure load amplitude, the real-time collection load impact cycle only includes the cycle from trough to peak or from peak to trough, which is only half of the complete impact cycle and is taken as 0.5; S e Rated working pressure of the main pump in the hydraulic system of the whole machine; N ei is the number of impact cycles that produce fatigue damage under the i-th equivalent pressure load amplitude condition converted to the rated working pressure, which is the fatigue life design value; D is the constant obtained in the bench test;

[0362] The fatigue damage loss rate of the pump casing caused by each pressure load impact is η i :

[0363]

[0364] Fatigue damage rate η caused by pressure load impact on the main pump housing k :

[0365]

[0366] Step 4: Calculate the fatigue damage rate of each piston pump motor component in real time, predicting the fatigue damage level of each component, including the plunger, pump housing, drive shaft, bearings, oil distribution plate, and end caps. Based on reliability testing or the designer's lifespan of each piston pump motor component under rated operating conditions, select the lowest lifespan as the damage rate threshold η. When this threshold is reached, the controller sends a warning to the system display.

[0367] η=min(η z ,η k ,η c ,η g ,η p ,η d ) (11)

[0368] Where η z is the fatigue damage degree of the plunger; η kis the fatigue damage degree of the plunger; η c is the fatigue damage degree of the plunger; η g is the fatigue damage degree of the plunger; η p is the fatigue damage degree of the plunger; η d is the fatigue damage degree of the plunger.

[0369] Step 5: Connect the data recorded in step 2 above to the cloud server through an external storage unit or through the network. The data collected in step 2 can be accumulated to obtain a complete life cycle of the plunger pump motor, such as Figure 5 Based on the cumulative damage theory, the structural strength and flow field characteristics of the plunger pump motor are analyzed to further assess its reliability. The fatigue damage rate data calculated in Step 3 can help maintenance personnel develop a strategy for component maintenance intervals. Based on this information, they can develop a detailed component demand and production plan, improving spare parts inventory turnover.

[0370] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the steps in the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0371] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0372] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0373] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A real-time prediction method for fatigue damage failure of a plunger pump motor, characterized in that: include: Step 1: Periodically input pressure load signal S to the first group of pump pressure shock test benches j Until the pump casing fatigue damage occurs, the input pressure load signal S when the pump casing fatigue damage occurs is obtained. j Number of times data N j ; Periodically input pressure load signal S to the second group of pump pressure shock test bench k Until the pump casing fatigue damage occurs, the input pressure load signal S when the pump casing fatigue damage occurs is obtained. k Number of times data N k ; Step 2, based on S j 、S k 、N j and N k , find the unknown quantity of the function; Using the unknown quantity of the function, the pressure shock load-fatigue damage frequency curve of the plunger pump motor is constructed; Step 3: Obtain a pressure load signal set S of the entire engineering machinery equipment; If the pressure load signal set S meets the set conditions, it is determined that the entire engineering machinery equipment enters the working mode and the process goes to step 4; Otherwise, the entire construction machinery equipment is determined to have exited the working mode and the operation is terminated; Step 4: Use the pressure shock load-fatigue damage frequency curve corresponding to the plunger pump motor to calculate the loss rate of fatigue damage to the pump housing caused by each pressure load shock. ; The loss rate of fatigue damage to the pump casing caused by each pressure load impact is used , calculate the fatigue damage degree η of the pump casing k ; Step 2, based on S j 、S k 、N j and N k , find the unknown quantity of the function, and implement it through the following steps: Use the following formula to calculate the unknown function quantities D and C: ， ， ， Where D is the slope coefficient of the pressure shock load-fatigue damage frequency curve of the plunger pump motor; Using the unknown quantity of the function, the pressure shock load-fatigue damage frequency curve corresponding to the plunger pump motor is constructed through the following steps: Functional expression of the pressure shock load-fatigue damage frequency curve of the plunger pump motor: ， Where, It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; Set value for the fatigue life of the pump casing at rated working pressure.

2. A real-time prediction method for fatigue damage failure of a plunger pump motor according to claim 1, characterized in that: Step 3: If the pressure load signal set S meets the set conditions, it is determined that the entire engineering machinery equipment has entered the working mode, the pressure load signal set S is recorded, and the process proceeds to step 4, which is achieved by the following steps: If the pressure load signal S i to S i+n Are greater than or equal to 1.34S0, S i+n and S i ∈S, n is a positive integer, S0 is the initial pressure shock load signal when the plunger pump motor starts, then it is determined that the engineering machinery equipment has entered the working mode, and the pressure shock load signal S is recorded. i , go to step 4; If S i All less than 1.05S0, S i+n ∈S, it is determined that the entire engineering machinery equipment has exited the working mode and ended the operation.

3. A real-time prediction method for fatigue damage failure of a plunger pump motor according to claim 2, characterized in that: Step 4: Use the pressure shock load-fatigue damage frequency curve corresponding to the plunger pump motor to calculate the loss rate of fatigue damage to the pump housing caused by each pressure load shock. , achieved by the following steps: Calculate the equivalent stress amplitude S of the entire engineering machinery equipment eqi : ， ， ， Where, is the collected pressure load signal of the i+1th engineering machinery equipment, ∈S, is the collected pressure load signal of the i-th engineering machinery equipment, is the ultimate strength of the material; Convert each pressure load impact to the fatigue damage frequency of the rated pressure load condition : ， Where, is the number of impact cycles counted under the condition of the i-th equivalent pressure load amplitude; S e It is the rated working pressure of the plunger pump motor in the hydraulic system of the whole machine; is the number of impact cycles that produce fatigue damage under the i-th equivalent pressure load amplitude condition converted to the rated working pressure.

4. A real-time prediction method for fatigue damage failure of a plunger pump motor according to claim 3, characterized in that: Step 4: Use the pressure shock load-fatigue damage frequency curve corresponding to the plunger pump motor to calculate the loss rate of fatigue damage to the pump housing caused by each pressure load shock. , achieved by the following steps: Substitute the rated working pressure of the current plunger pump motor in the hydraulic system of the whole machine into the corresponding pressure shock load-fatigue damage frequency curve of the plunger pump motor to calculate the fatigue life setting value N under the rated working pressure. e ; Based on known and N e , calculate the loss rate of fatigue damage to the pump casing caused by each pressure load impact : ， Where, is the number of impact cycles that produce fatigue damage under the i-th equivalent pressure load amplitude condition converted to the rated working pressure; Step 4: Use the loss rate of fatigue damage to the pump casing caused by each pressure load impact , calculate the fatigue damage degree η of the pump casing k , achieved by the following steps: Calculation of pump casing fatigue damage η k : 。 5. The method for real-time prediction of fatigue damage failure of a plunger pump motor according to claim 1, characterized in that: Step 11: periodically input a third pressure load signal to the third group of pump pressure shock test benches until plunger fatigue damage occurs, and obtain data on the number of times the third pressure load signal is input when plunger fatigue damage occurs; Periodically inputting a fourth pressure load signal to the fourth group of pump pressure shock test benches until plunger fatigue damage occurs, and obtaining data on the number of times the fourth pressure load signal is input when plunger fatigue damage occurs; Step 12, obtaining an unknown quantity of the second function based on the third pressure load signal, the fourth pressure load signal, the number of times the third pressure load signal is input when fatigue damage occurs to the plunger, and the number of times the fourth pressure load signal is input when fatigue damage occurs to the plunger; Using the unknown quantity of the second function, a pressure shock load-plunger fatigue damage frequency curve is constructed; Step 13: Obtain a pressure load signal set A of the entire engineering machinery equipment; If the pressure load signal set A meets the set conditions, it is determined that the entire engineering machinery equipment enters the working mode, and the process goes to step 14; Otherwise, the entire construction machinery equipment is determined to have exited the working mode and the operation is terminated; Step 14: Calculate the loss rate of plunger fatigue damage caused by each pressure load impact using the pressure impact load-plunger fatigue damage frequency curve. ; The loss rate of plunger fatigue damage caused by each pressure load impact is used , calculate the plunger fatigue damage degree η z .

6. A real-time prediction method for fatigue damage failure of a plunger pump motor according to claim 5, characterized in that: Step 21, periodically inputting a fifth pressure load signal to the fifth group of pump pressure shock test benches until fatigue damage of the transmission shaft occurs, and obtaining data on the number of times the fifth pressure load signal is input when fatigue damage of the transmission shaft occurs; periodically inputting a sixth pressure load signal to the sixth group of pump pressure shock test benches until fatigue damage of the transmission shaft occurs, and obtaining data on the number of times the sixth pressure load signal is input when fatigue damage of the transmission shaft occurs; Step 22, obtaining an unknown quantity of the third function based on the fifth pressure load signal, the sixth pressure load signal, the number of times the fifth pressure load signal is input when fatigue damage to the transmission shaft occurs, and the number of times the sixth pressure load signal is input when fatigue damage to the transmission shaft occurs; Using the unknown quantity of the third function, the pressure impact load-drive shaft fatigue damage frequency curve is constructed; Step 23: Obtain a pressure load signal set B of the entire engineering machinery equipment; If the pressure load signal set B meets the set conditions, it is determined that the entire engineering machinery equipment enters the working mode, and the process goes to step 24; Otherwise, the entire construction machinery equipment is determined to have exited the working mode and the operation is terminated; Step 24, using the pressure impact load-transmission shaft fatigue damage frequency curve, calculate the loss rate of transmission shaft fatigue damage caused by each pressure load impact; The fatigue damage degree η of the transmission shaft is calculated using the loss rate of the transmission shaft fatigue damage caused by each pressure load impact. C .

7. A real-time prediction method for fatigue damage failure of a plunger pump motor according to claim 6, characterized in that: Step 31, periodically inputting a seventh pressure load signal to the seventh group of pump pressure shock test benches until bearing fatigue damage occurs, and obtaining data on the number of times the seventh pressure load signal is input when bearing fatigue damage occurs; periodically inputting an eighth pressure load signal to the eighth group of pump pressure shock test benches until bearing fatigue damage occurs, and obtaining data on the number of times the eighth pressure load signal is input when bearing fatigue damage occurs; Step 32, obtaining an unknown quantity of the fourth function based on the seventh pressure load signal, the eighth pressure load signal, the number of times the seventh pressure load signal is input when bearing fatigue damage occurs, and the number of times the eighth pressure load signal is input when bearing fatigue damage occurs; Using the unknown quantity of the fourth function, the pressure impact load-bearing fatigue damage frequency curve is constructed; Step 33: Obtain a pressure load signal set E of the entire engineering machinery equipment; If the pressure load signal set E meets the set conditions, it is determined that the entire engineering machinery equipment enters the working mode, and the process goes to step 34; Otherwise, the entire construction machinery equipment is determined to have exited the working mode and the operation is terminated; Step 34, using the pressure impact load-bearing fatigue damage frequency curve, calculate the loss rate of bearing fatigue damage caused by each pressure load impact; The bearing fatigue damage degree η is calculated using the loss rate of bearing fatigue damage caused by each pressure load impact g .

8. A real-time prediction method for fatigue damage failure of a plunger pump motor according to claim 7, characterized in that: Step 41, periodically inputting a ninth pressure load signal to the ninth group of pump pressure shock test benches until fatigue damage to the oil distribution plate occurs, and obtaining data on the number of times the ninth pressure load signal is input when fatigue damage to the oil distribution plate occurs; Periodically inputting a tenth pressure load signal to the tenth group of pump pressure shock test benches until fatigue damage to the oil distribution plate occurs, and obtaining data on the number of times the tenth pressure load signal is input when fatigue damage to the oil distribution plate occurs; Step 42 , obtaining an unknown quantity of the fifth function based on the ninth pressure load signal, the tenth pressure load signal, the number of times the ninth pressure load signal is input when fatigue damage to the oil distribution plate occurs, and the number of times the tenth pressure load signal is input when fatigue damage to the oil distribution plate occurs; Using the unknown quantity of the fifth function, the pressure shock load-oil distribution plate fatigue damage frequency curve is constructed; Step 43: Obtain a pressure load signal set F of the entire engineering machinery equipment; If the pressure load signal set F meets the set conditions, it is determined that the entire engineering machinery equipment enters the working mode, and the process goes to step 44; Otherwise, the entire construction machinery equipment is determined to have exited the working mode and the operation is terminated; Step 44, using the pressure impact load-oil distribution plate fatigue damage frequency curve, calculate the loss rate of the oil distribution plate fatigue damage caused by each pressure load impact; The fatigue damage degree η of the oil distribution plate is calculated by using the loss rate of fatigue damage of the oil distribution plate caused by each pressure load impact. p .

9. A real-time prediction method for fatigue damage failure of a plunger pump motor according to claim 8, characterized in that: Step 51, periodically inputting an eleventh pressure load signal to the eleventh group of pump pressure shock test benches until fatigue damage occurs to the end caps at both ends of the plunger, and obtaining data on the number of times the eleventh pressure load signal is input when fatigue damage occurs to the end caps at both ends of the plunger; Periodically inputting a twelfth pressure load signal to the twelfth group of pump pressure shock test benches until fatigue damage occurs to the end covers at both ends of the plunger, and obtaining data on the number of times the twelfth pressure load signal is input when fatigue damage occurs to the end covers at both ends of the plunger; Step 52, obtaining the unknown quantity of the sixth function based on the eleventh pressure load signal, the twelfth pressure load signal, the number of times the eleventh pressure load signal is input when fatigue damage occurs to the end caps at both ends of the plunger, and the number of times the twelfth pressure load signal is input when fatigue damage occurs to the end caps at both ends of the plunger; Using the unknown quantity of the sixth function, a pressure shock load-fatigue damage frequency curve of the end caps at both ends of the plunger is constructed; Step 53: Obtain a pressure load signal set G of the entire engineering machinery equipment; If the pressure load signal set G meets the set conditions, it is determined that the entire engineering machinery equipment enters the working mode, and the process goes to step 54; Otherwise, the entire construction machinery equipment is determined to have exited the working mode and the operation is terminated; Step 54, using the pressure impact load-fatigue damage frequency curve of the end caps at both ends of the plunger, calculate the loss rate of fatigue damage of the end caps at both ends of the plunger caused by each pressure load impact; The fatigue damage degree η of the end caps at both ends of the plunger is calculated by using the loss rate of fatigue damage of the end caps at both ends of the plunger caused by each pressure load impact. d .

10. A real-time prediction method for fatigue damage failure of a plunger pump motor according to claim 9, characterized in that: The total fatigue damage rate η is calculated as: ， Where, is the fatigue damage degree of the plunger; is the fatigue damage degree of the pump casing; is the fatigue damage degree of the transmission shaft; is the bearing fatigue damage degree; is the fatigue damage degree of the oil distribution plate; is the fatigue damage degree of the end covers at both ends of the plunger.

11. A real-time prediction method for fatigue damage failure of a plunger pump motor according to claim 10, characterized in that: like If the fatigue damage threshold is greater than the set value, it is determined that the plunger pump motor has a damage fault.

12. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein: When the processor executes the program, the steps of the method according to any one of claims 1 to 11 are implemented.

13. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method according to any one of claims 1 to 11 are implemented.

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