A commutator self-diagnostic system and method

Abstract

The application discloses a commutator self-diagnosis system and method, and the system comprises a displacement sensor, a shaft coupling, a position switch, a position switch baffle, a switch base, a digital quantity acquisition board card, a counter acquisition board card, an upper computer and a power supply. The application can realize automatic monitoring of a commutator commutation action process, can clearly acquire the commutator commutation action process, and plays a monitoring role. The application can also realize curve recording and analysis of the commutator commutation action, and realizes intelligent self-diagnosis of the commutator.

Description

Technical Field

[0001] This invention relates to the field of commutator diagnostic technology for water flow devices, and specifically to a commutator self-diagnostic system and method. Background Technology

[0002] A water flow meter calibration device is the main equipment for verifying and calibrating flow meters. The commutator is one of the core components of this device, its function being to change the direction of water flow. The flow into the bypass pipe or the weighing container is entirely controlled by the commutator. During flow meter calibration, the water flows from the bypass pipe into the weighing container. When the commutator starts, a timer / frequency counter simultaneously starts to record the output signal of the flow meter under test. After a period of time in the weighing container, the water flows back through the commutator to the bypass pipe and finally back to the storage tank. When the commutator starts, the timer / frequency counter simultaneously stops recording the output signal of the flow meter under test. The mass obtained by the weighing system is compared with the mass calculated from the number of output pulses of the flow meter under test, ultimately yielding the error value of the flow meter under test. The working principle of the commutator is as follows: Figure 1 As shown.

[0003] The commutator is crucial for ensuring synchronization between the standard and the flow meter being measured. To guarantee measurement accuracy (sufficient synchronization), the commutator needs to be calibrated. However, during normal use, because the commutator is a moving component, it is susceptible to changes in cylinder or motor performance, damping variations, vibration affecting the position of the synchronization trigger switch, etc., which can alter the synchronization accuracy, introducing errors or increasing uncertainty, thus rendering the commutator calibration results invalid. Given the frequent use of the commutator, the likelihood of these problems is high and they are often difficult to detect during use, potentially causing it to operate in a faulty state for extended periods. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention aims to provide a commutator self-diagnosis system and method.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A commutator self-diagnostic system includes a displacement sensor, a coupling, a position switch, a position switch baffle, a switch base, a digital acquisition board, a counter acquisition board, a host computer, and a power supply.

[0007] The displacement sensor is connected to the distributor of the commutator. When the commutator reverses direction, the distributor can drive the displacement sensor to move together, thereby generating a series of pulse signals from the displacement sensor.

[0008] The position switch baffle is connected to the distributor of the commutator and can move synchronously with the distributor and displacement sensor under the drive of the distributor; the position switch is installed on the switch base and is used to detect the position of the position switch baffle.

[0009] The counter acquisition board is used to acquire signals from the displacement sensor;

[0010] The digital acquisition board is used to acquire signals from the position switch.

[0011] The host computer is used to extract the signals acquired by the counter acquisition board and the digital acquisition board, and to analyze and characterize the commutation speed curve of the commutator.

[0012] The power supply is used to power the displacement sensor and the position switch.

[0013] Furthermore, the position switch includes limit switch one, limit switch two, intermediate position switch, switching-in start marker switch, and switching-in end marker switch. The intermediate position switch, switching-in start marker switch, and switching-in end marker switch are all connected to a digital signal acquisition board for the board to acquire their signals. When the commutator finishes its switching-out action, the position switch baffle reaches the position of limit switch one, at which point the liquid flowing out of the nozzle enters the bypass pipeline. When the commutator performs a switching-in action, the position switch baffle passes sequentially through the switching-in start marker switch, intermediate position switch, and switching-in end marker switch, and finally reaches the position of limit switch two. At this point, the switching-in action ends, and the liquid flowing out of the nozzle enters the standard. When the position switch baffle corresponds to the position of the intermediate position switch, the nozzle corresponds exactly to the middle position of the distributor.

[0014] The present invention also provides a method for operating the above-mentioned commutator self-diagnosis system, the specific process of which is as follows:

[0015] Before the commutator starts its switching action, the position switch baffle is in the position of limit switch one, and liquid flows into the bypass pipeline. When the commutator receives the switching command, the distributor starts to operate, driving the position switch baffle to move to the starting switching point. At this point, the position switch baffle reaches the position of the switching start marker switch. The host computer collects the signal of the level change of the switching start marker switch through the digital acquisition board. At this time, the host computer starts to collect the number of pulse signals output by the displacement sensor and the frequency of each pulse through the counter acquisition board. After the distributor has run for several pulses, it starts to trigger the flow totalizer to work.

[0016] When the distributor runs to the synchronous trigger point, the position switch baffle reaches the middle position switch. At this time, the commutator sends a synchronization signal, and the liquid flows into the bypass pipeline and the standard at the same time.

[0017] When the water distributor reaches the end reversing point, the position switch baffle reaches the position of the reversing end marker switch. The host computer acquires the signal of the level change of the reversing start marker switch through the digital acquisition board. At this time, the host computer stops acquiring the pulse signal output by the displacement sensor, the water distributor stops operating, and finally the position switch baffle stops at the position of limit switch two, and the liquid flows into the standard. The host computer analyzes the pulse signal and frequency output by the displacement sensor, and combines the signal change time of the reversing start marker switch and the reversing end marker switch to obtain the speed change curve of the reversing process.

[0018] When the commutator receives the command to switch out, the water distributor starts to operate. When the position switch baffle moves to the end of the commutation point, the host computer collects the signal of the change in the level of the end of the commutation mark switch through the digital acquisition board. At this time, the host computer starts to collect the number of pulse signals output by the displacement sensor and the frequency of each pulse through the counter acquisition board. When the water distributor runs to the start working point of the flow totalizer, the flow totalizer stops working.

[0019] When the distributor runs to the synchronous trigger point, the position switch baffle reaches the middle position switch. At this time, the commutator sends a synchronization signal, and the liquid flows into the bypass pipeline and the standard at the same time.

[0020] When the water distributor reaches the starting reversing point, the host computer acquires the signal of the change in the level of the starting switch through the digital acquisition board. At this time, the host computer stops acquiring the pulse signal output by the displacement sensor, the water distributor stops operating, and the final position switch baffle stops at the position of limit switch one. The host computer analyzes the pulse signal and frequency output by the displacement sensor, and combines the signal change time of the starting switch and the ending switch to obtain the speed change curve of the commutator switching process.

[0021] Furthermore, the host computer performs digital feature extraction on the images of the speed change curves during the commutation input and output processes under normal operating conditions of the commutator, using them as reference curves for the commutation input and output processes. Subsequently, when the commutator is working, the same digital feature extraction is performed on the acquired speed change curves during the commutation input and output processes, and the digital features are compared and analyzed with the corresponding reference curves to determine whether the commutator is in normal operating condition.

[0022] The beneficial effects of this invention are as follows:

[0023] 1. This invention can realize the automatic monitoring of the commutator commutation process, and can clearly obtain the commutator commutation action, thus playing a monitoring role.

[0024] 2. Using this invention, the curve recording and analysis of the commutator's commutation action can be realized, enabling intelligent self-diagnosis of the commutator.

[0025] Specifically, the present invention can read the pulse signal generated by the displacement sensor to know and record the speed change curve of the commutator's commutation action. Through experiments, the standard commutation curve of the commutator can be obtained. After digital extraction of the image (curve), the commutation action curve of each commutation can be compared with the standard commutation curve, thereby judging the commutator's commutation state to ensure the basic consistency of each commutator commutation action. Attached Figure Description

[0026] Figure 1 A schematic diagram illustrating the working principle of an existing commutator;

[0027] Figure 2 This is a schematic diagram of the installation of the commutator self-diagnosis system in Embodiment 1 of the present invention;

[0028] Figure 3 This is a schematic diagram of the electrical connections of the commutator self-diagnosis system in Embodiment 1 of the present invention;

[0029] Figure 4 This is a flowchart illustrating the overall commutator switching process in Embodiment 2 of the present invention.

[0030] Figure 5 A schematic diagram of the commutator input ( / output) action monitoring curve;

[0031] Figure 6 This is a schematic diagram of the typical commutator speed curve characteristics;

[0032] Figure 7 This is a schematic diagram illustrating the labeling and extraction of curve feature values. Detailed Implementation

[0033] The present invention will be further described below with reference to the accompanying drawings. It should be noted that this embodiment is based on the present technical solution and provides detailed implementation methods and specific operation processes, but the protection scope of the present invention is not limited to this embodiment.

[0034] Example 1

[0035] This embodiment provides a commutator self-diagnostic system, which is a modification of a general commutator to achieve the purpose of monitoring the commutation process of the commutator. Figure 2 As shown, the commutator generally includes a nozzle 100, a sealing cover 101, and a water distributor 102. The movement (rotation or linear movement) of the water distributor 102 changes whether the liquid sprayed from the nozzle enters the bypass pipeline or the scale. This embodiment uses a rotating water distributor as an example for explanation.

[0036] like Figure 2-3As shown, the commutator self-diagnostic system includes a displacement sensor 1, a coupling 2, a position switch, a position switch baffle 4, a switch base 9, a digital acquisition board 5, a counter acquisition board 6, a host computer 7, and a power supply.

[0037] The displacement sensor 1 can be an encoder (suitable for rotary motion) or a grating ruler (suitable for linear motion), and is connected to the distributor of the commutator (in this embodiment, it is connected to the shaft of the distributor via a coupling 2). When the commutator reverses direction, the distributor can drive the displacement sensor to move together, thereby generating a series of pulse signals. By calculating the frequency of each pulse signal, and based on the relationship between frequency and speed, the speed-time curve of the commutator reversing can be obtained, thus achieving the purpose of detecting and recording the commutator reversing action.

[0038] The position switch baffle 4 is connected to the distributor of the commutator and can move synchronously with the distributor and displacement sensor 1 under the drive of the distributor. The position switch is mounted on the switch base and is used to detect the position of the position switch baffle 4. In this embodiment, the position switch baffle 4 is connected to the distributor and displacement sensor together via a coupling.

[0039] In this embodiment, as Figure 2 As shown, the position switches include limit switch 1 31, limit switch 2 32, intermediate position switch 35, switching-in start marker switch 33, and switching-in end marker switch 34. The intermediate position switch 35, switching-in start marker switch 33, and switching-in end marker switch 34 are all connected to a digital signal acquisition board for signal acquisition. When the commutator finishes its switching-out action, the position switch baffle 4 reaches the position of limit switch 1 31, at which point the liquid flowing from the nozzle enters the bypass pipeline. When the commutator performs a switching-in action, the position switch baffle 4 passes sequentially through switching-in start marker switch 33, intermediate position switch 35, and switching-in end marker switch 34, finally reaching the position of limit switch 2 32. At this point, the switching-in action ends, and the liquid flowing from the nozzle enters the standard. When the position switch baffle 4 corresponds to the position of intermediate position switch 35, the nozzle corresponds precisely to the middle position of the distributor. The arrangement of these position switches allows for recording the switching-in and switching-out time points of the distributor. When the position switch baffle passes to the position of the position switch, the position switch can generate a corresponding signal to mark the different positions or times of the position switch baffle, so as to better analyze the speed-time or speed-position curve of the commutator commutation. Figure 2 The position switches are arranged along the movement arc of the position switch baffle.

[0040] In this embodiment, the position switch is a photoelectric switch. Alternatively, a contact switch, electromagnetic switch, laser sensor, etc., can also be used.

[0041] In this embodiment, the switch base is not shown in the figure. Preferably, a movable switch base can be used to facilitate the position adjustment of the position switch.

[0042] The counter acquisition board is used to acquire signals from the displacement sensor. When the commutator reverses direction, the distributor drives the displacement sensor to move, and the displacement sensor outputs a series of pulse signals. The counter acquisition board can record the commutator reversing action.

[0043] The digital acquisition board is used to acquire signals from the position switches. During commutation, the distributor drives the position switch baffle to move. When the baffle passes the position switch, the position switch generates a signal. The digital acquisition board can record the moment the baffle passes the position switch, providing some assistance in depicting the speed-time curve of the commutator commutation.

[0044] The host computer is used to extract signals acquired by the counter acquisition board and the digital signal acquisition board, and to analyze and characterize the commutation speed-time curve of the commutator. The host computer can be an industrial control computer.

[0045] The power supply is used to power the displacement sensor and the position switch.

[0046] Example 2

[0047] This embodiment provides a working method for the commutator self-diagnosis system described in Embodiment 1, the specific process of which is as follows:

[0048] like Figure 4 As shown in (a), before the commutator starts its switching action, the position switch baffle is in the position of limit switch one, and liquid flows into the bypass pipeline. When the commutator receives the switching command, the distributor starts to operate, driving the position switch baffle to move to the starting switching point. At this point, the position switch baffle reaches the position of the switching start marker switch, as shown in (a). Figure 4 As shown in (b); the host computer acquires the signal of the level change of the switching start mark switch through the digital acquisition board. At this time, the host computer starts to acquire the number of pulse signals output by the displacement sensor and the frequency of each pulse through the counter acquisition board; after the water distributor runs for a number of pulses, it starts to trigger the flow totalizer to work.

[0049] When the water distributor reaches the synchronous trigger point, the position switch baffle reaches the middle position switch, such as... Figure 4 As shown in (c), at this time the commutator sends a synchronization signal, and the liquid flows into the bypass line and the standard at the same time.

[0050] When the water distributor reaches the end reversing point, the position switch baffle reaches the position of the end reversing marker switch, such as... Figure 4As shown in (d), the host computer acquires the signal of the change in the level of the switching start marker switch through the digital acquisition board. At this time, the host computer stops acquiring the pulse signal output by the displacement sensor, the water distributor stops operating, and the final position switch baffle stops at the position of limit switch two. Liquid flows into the standard, as shown in (d). Figure 4 As shown in (e), the host computer analyzes the pulse signal and frequency output by the displacement sensor, and combines the signal change time of the commutation start mark switch and the commutation end mark switch to obtain the speed change curve of the commutator commutation process.

[0051] like Figure 4 The reverse process is shown in the diagram. When the commutator receives the command to switch out, the distributor starts to operate. When the position switch baffle moves to the end switching point, the host computer collects the signal of the change in the switching end mark switch level through the digital acquisition board. At this time, the host computer starts to collect the number of pulse signals output by the displacement sensor and the frequency of each pulse through the counter acquisition board. When the distributor runs to the start working point of the flow totalizer, the flow totalizer stops working.

[0052] When the distributor runs to the synchronous trigger point, the position switch baffle reaches the middle position switch. At this time, the commutator sends a synchronization signal, and the liquid flows into the bypass pipeline and the standard at the same time.

[0053] When the distributor reaches the initial commutation point, the host computer acquires the signal of the change in the starting switch level via the digital acquisition board. At this point, the host computer stops acquiring the pulse signal output by the displacement sensor, the distributor stops operating, and the final position switch baffle stops at the position of limit switch one. By analyzing the pulse signal and frequency output by the displacement sensor, and combining the signal change times of the starting and ending switches, the host computer obtains the speed change curve of the commutator's commutation process.

[0054] Furthermore, in this embodiment, the host computer performs digital feature extraction on the images of the speed change curves of the commutation-in process and the speed change curves of the commutator under normal operating conditions, and uses them as reference curves for the commutation-in and commutation-out processes. Subsequently, when the commutator is working, the same digital feature extraction is performed on the speed change curves of the commutation-in process and the speed change curves of the commutator's commutation-out process, and the digital features are compared and analyzed with the corresponding reference curves to determine whether the commutator is in normal operating condition.

[0055] Figure 5 This is a schematic diagram of the commutator input ( / output) action monitoring curve. Figure 6 This is a schematic diagram of the speed curve characteristics of a typical commutator. According to the working characteristics of a general commutator, in a commutation action (commutation in or commutation out), its action curve is roughly trapezoidal in shape, divided into an acceleration segment, a steady segment, and a deceleration segment. Figure 7This diagram illustrates the labeling and extraction of curve feature values. It combines curve features with preset position switches as combined labels to mark curve characteristics for comparative analysis. Specifically:

[0056] ① The number of pulses between the first peak (the first point where acceleration is zero, starting from the initial switch marker) and the initial marker point;

[0057] ② The number of pulses between the starting marker point and the synchronization trigger point;

[0058] ③ The number of pulses between the synchronous trigger point and the end trigger point;

[0059] ④ The number of pulses between the last peak of the curve between the start and end markers (the highest peak near the third position switch during the switching process) and the end marker;

[0060] ⑤ The number of pulses between the starting and ending marker points;

[0061] ⑥ Width of the rectangular platform (between the first and last peaks);

[0062] ⑦ The slope of the curve (the speed increase segment) between the starting marker point and the first peak;

[0063] ⑧ The slope of the rectangular platform (from the first peak to the highest peak);

[0064] ⑨ The slope of the curve (speed decrease segment) between the last peak (the highest peak near the third position switch) and the end marker point;

[0065] However, these are not limited to the above-mentioned characteristic values. For example, the slope of the acceleration phase, the slope of the deceleration phase, and the vibration frequency of the steady phase. The changes and amplitudes of these characteristic values ​​may correspond to different fault types.

[0066] For those skilled in the art, various corresponding changes and modifications can be made based on the above technical solutions and concepts, and all such changes and modifications should be included within the protection scope of the claims of this invention.

Claims

1. A commutator self-diagnosis method, characterized in that, A commutator self-diagnostic system is applied, comprising a displacement sensor, a coupling, a position switch, a position switch baffle, a switch base, a digital acquisition board, a counter acquisition board, a host computer, and a power supply. The displacement sensor is connected to the commutator's distributor. The position switch baffle is connected to the commutator's distributor and can move synchronously with the distributor and displacement sensor under the drive of the commutator's distributor. The position switch includes a first limit switch, a second limit switch, an intermediate position switch, a commutation start marker switch, and a commutation end marker switch. The specific process of the method is as follows: Before the commutator starts its switching action, the position switch baffle is in the position of limit switch one, and liquid flows into the bypass pipeline. When the commutator receives the switching command, the distributor starts to operate, driving the position switch baffle to move to the starting switching point. At this point, the position switch baffle reaches the position of the switching start marker switch. The host computer collects the signal of the level change of the switching start marker switch through the digital acquisition board. At this time, the host computer starts to collect the number of pulse signals output by the displacement sensor and the frequency of each pulse through the counter acquisition board. After the distributor has run for several pulses, it starts to trigger the flow totalizer to work. When the distributor runs to the synchronous trigger point, the position switch baffle reaches the middle position switch. At this time, the commutator sends a synchronization signal, and the liquid flows into the bypass pipeline and the standard at the same time. When the water distributor reaches the end reversing point, the position switch baffle reaches the position of the reversing end marker switch. The host computer acquires the signal of the level change of the reversing start marker switch through the digital acquisition board. At this time, the host computer stops acquiring the pulse signal output by the displacement sensor, the water distributor stops operating, and finally the position switch baffle stops at the position of limit switch two, and the liquid flows into the standard. The host computer analyzes the pulse signal and frequency output by the displacement sensor, and combines the signal change time of the reversing start marker switch and the reversing end marker switch to obtain the speed change curve of the reversing process. When the commutator receives the command to switch out, the water distributor starts to operate. When the position switch baffle moves to the end of the commutation point, the host computer collects the signal of the change in the level of the end of the commutation mark switch through the digital acquisition board. At this time, the host computer starts to collect the number of pulse signals output by the displacement sensor and the frequency of each pulse through the counter acquisition board. When the distributor reaches the starting point of the flow totalizer, the flow totalizer stops working; When the distributor runs to the synchronous trigger point, the position switch baffle reaches the middle position switch. At this time, the commutator sends a synchronization signal, and the liquid flows into the bypass pipeline and the standard at the same time. When the water distributor reaches the starting reversing point, the host computer acquires the signal of the change in the level of the starting switch through the digital acquisition board. At this time, the host computer stops acquiring the pulse signal output by the displacement sensor, the water distributor stops operating, and the final position switch baffle stops at the position of limit switch one. The host computer analyzes the pulse signal and frequency output by the displacement sensor, and combines the signal change time of the starting switch and the ending switch to obtain the speed change curve of the commutator switching process.

2. The method according to claim 1, characterized in that, The host computer performs digital feature extraction on the images of the speed change curves during the commutation input and output processes under normal operating conditions of the commutator, using them as reference curves for the commutation input and output processes. Subsequently, when the commutator is working, the same digital feature extraction is performed on the acquired speed change curves during the commutation input and output processes, and the digital features are compared and analyzed with the corresponding reference curves to determine whether the commutator is in normal operating condition.

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