Hydraulic power unit health state integrated perception system and data acquisition method

Abstract

This invention relates to the field of hydraulic system monitoring technology, and discloses an integrated sensing system and data acquisition method for the health status of a hydraulic power unit. The integrated sensing system includes: a fluid channel; a first and a second inlet detachably and sealably disposed at both ends of the fluid channel; an interface assembly disposed on the fluid channel; a sensor assembly detachably and sealably mounted on the interface assembly for collecting fluid characteristic data; and an extended signal acquisition device disposed on the fluid channel for collecting fluid characteristic data. This integrated sensing system integrates multiple acquisition devices, enabling parallel acquisition of multiple data from the hydraulic system, while reducing the space occupied by equipment with equivalent functionality, and solving the problem that existing condition monitoring systems cannot simultaneously meet the detection needs of both small and large hydraulic equipment.

Description

Technical Field

[0001] This invention relates to the field of hydraulic system monitoring technology, specifically to an integrated sensing system and data acquisition method for the health status of a hydraulic power unit. Background Technology

[0002] With the rapid development of my country's infrastructure industry, the failure rate of hydraulic systems used in construction machinery, which involve high intensity, is increasing. In recent years, fault diagnosis and health monitoring systems based on condition monitoring have begun to be applied in the field of hydraulic equipment. Faults in hydraulic systems are scattered across various components. Existing monitoring systems' signal acquisition devices struggle to perform parallel data acquisition from multiple components in existing hydraulic equipment under high-pressure environments. Furthermore, limitations in the types of data collected during monitoring prevent accurate assessment of the equipment's real-time status. While acquiring diverse data types is valuable for large hydraulic equipment, smaller hydraulic equipment tends to reduce the types of data collected, focusing only on conventional data types due to cost considerations. Existing acquisition devices cannot simultaneously meet both requirements. Furthermore, due to space constraints in existing hydraulic equipment, the integration level and size of existing monitoring system acquisition devices are insufficient for practical applications. Therefore, developing a highly integrated, compact hydraulic system signal acquisition device with a complete range of acquired signal types and customizable acquisition methods has become particularly urgent. Summary of the Invention

[0003] The purpose of this invention is to provide an integrated sensing system and data acquisition method for the health status of a hydraulic power unit, which enables the monitoring and performance evaluation of the hydraulic system through rapid connection of hydraulic pipelines, thereby reducing enterprise operating costs, realizing intelligent operation and maintenance of hydraulic equipment, and improving the working efficiency of hydraulic equipment.

[0004] To achieve the above objectives, a first aspect of the present invention provides an integrated sensing system for the health status of a hydraulic power unit, comprising: a fluid channel, a first inlet and a second inlet detachably and sealably disposed at both ends of the fluid channel, an interface assembly disposed on the fluid channel, a sensor assembly detachably and sealably mounted on the interface assembly for collecting fluid characteristic data, and an extended signal acquisition device disposed on the fluid channel for collecting fluid characteristic data.

[0005] Furthermore, the integrated health status sensing system for the hydraulic power unit also includes a signal and power bundle interface;

[0006] Preferably, the signal and power bundle interface is disposed on the outer wall of the fluid channel.

[0007] Furthermore, the interface component includes a first interface for mounting a vibration-temperature integrated sensor, a second interface for mounting a pressure sensor, and a third interface for mounting a flow sensor.

[0008] The sensor assembly includes a vibration-temperature integrated sensor that can be installed at the first interface, a pressure sensor that can be installed at the second interface, and a flow sensor that can be installed at the third interface.

[0009] Preferably, the first interface, the second interface, and the third interface are arranged alternately from right to left.

[0010] Furthermore, the fluid channel includes a first signal acquisition channel and a second signal acquisition channel that are interconnected; wherein the cross-sectional area of ​​the second signal acquisition channel is smaller than the cross-sectional area of ​​the first signal acquisition channel; the extended signal acquisition device includes an extended channel connected in parallel with the second signal acquisition channel, a fourth interface disposed on the wall of the extended channel, a particle size detection sensor detachably connected to the fourth interface, and a moisture detection sensor disposed on the second signal acquisition channel for acquiring liquid medium-related data within the second signal acquisition channel.

[0011] Furthermore, the wall of the second signal acquisition channel is axially spaced with an inlet and an outlet that communicate with the expansion channel; a channel switch for opening and closing the inlet is provided at the inlet.

[0012] Preferably, the liquid inlet and the liquid outlet are located near the beginning and end of the second signal acquisition channel, respectively.

[0013] Furthermore, the channel switch includes a bolt threaded to one end of the expansion channel; the inlet is located within the area where the bolt extends into the expansion channel and covers the wall of the expansion channel.

[0014] Furthermore, both the first inlet and the second inlet are threaded at their ends; the first inlet and the second inlet are threadedly connected to the fluid channel.

[0015] Furthermore, sealing rings are provided at the connections between the first inlet and the second inlet and the fluid channel.

[0016] Furthermore, the integrated vibration and temperature sensor, the pressure sensor, and the flow sensor all include a sensor head, a sensor middle section, and a sensor tail section;

[0017] The sensor head extends into the first signal acquisition channel;

[0018] A thread is provided on the outer circumferential wall of the middle part of the sensor; the integrated vibration and temperature sensor, the pressure sensor and the flow sensor are all threadedly connected to the fluid channel through this thread;

[0019] The sensor tail is located outside the first signal acquisition channel and is provided with a quick interface for the acquisition harness;

[0020] Preferably, an annular flange is also provided on the circumferential outer wall of the middle part of the sensor.

[0021] The above technical solution enables parallel acquisition of multiple data points from the hydraulic system, accurately determining the real-time status of the equipment. Based on the detachable connections between various sensors and interfaces, the types and number of sensors under test can be freely selected, allowing for the acquisition of various data categories required for status monitoring and performance evaluation. This simultaneously meets the practical application needs of both small and large hydraulic equipment. It reduces enterprise operating costs, enables intelligent operation and maintenance of hydraulic equipment, and improves the working efficiency of hydraulic equipment.

[0022] A second aspect of the present invention provides a method for acquiring health status data of a hydraulic power unit, comprising:

[0023] Connect the first inlet and the second inlet to the hydraulic system and adjust the orientation of the expansion channel downwards;

[0024] Hydraulic oil is introduced from the first inlet to the second inlet;

[0025] The sensor assembly collects corresponding characteristic data of the hydraulic oil in the fluid channel.

[0026] The opening of the inlet is adjusted by the channel switch, allowing hydraulic oil to flow into the extended channel. The sensor collects the corresponding characteristic data of the hydraulic oil in the extended channel.

[0027] Preferably, the sum of the cross-sectional areas of the extended channel and the second signal acquisition channel is set to be slightly greater than or equal to the cross-sectional area of ​​the first signal acquisition channel.

[0028] Furthermore, depending on the required data type, the corresponding interface can be selectively opened or closed, or the corresponding sensor can be replaced to obtain the required data type.

[0029] Preferably, when it is necessary to acquire a flow signal, the flow sensor is installed at the third interface.

[0030] More preferably, the vibration signal, temperature signal, pressure signal, and flow signal of the hydraulic oil are acquired in the first signal acquisition channel; and the moisture signal and particle size signal of the hydraulic oil are acquired in the extended channel.

[0031] This method for collecting health status data of hydraulic power units can enable status monitoring and performance evaluation of hydraulic systems, reduce enterprise operating costs, realize intelligent operation and maintenance of hydraulic equipment, and improve the working efficiency of hydraulic equipment.

[0032] Other features and advantages of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of one embodiment of the hydraulic power unit health status integrated sensing system of the present invention;

[0034] Figure 2 yes Figure 1 A sectional view;

[0035] Figure 3 This is a structural diagram of one implementation of the extended channel.

[0036] Figure 4 This is an exploded view of the hydraulic power unit health status integrated sensing system of the present invention.

[0037] Explanation of reference numerals in the attached figures

[0038] 10 Fluid channel; 20 First inlet; 30 Second inlet; 41 Integrated temperature and vibration sensor; 42 Pressure sensor; 43 Flow sensor; 41a First interface; 41b Second interface; 41c Third interface; 11 First signal acquisition channel; 12 Second signal acquisition channel; 51 Expansion channel; 52 Moisture detection sensor; 53 Particle size detection sensor; 54 Liquid inlet; 55 Liquid outlet; 56 Channel switch; 60 Power supply interface. Detailed Implementation

[0039] The following provides a detailed description of specific embodiments of the present invention. It should be understood that the specific embodiments described herein are for illustrative and explanatory purposes only and are not intended to limit the scope of the invention.

[0040] In this invention, unless otherwise stated, directional terms such as "upper" and "lower" generally refer to the orientation in the assembled and used state. "Inner" and "outer" refer to the inner and outer sides relative to the outline of each component itself.

[0041] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of the invention described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0042] The first aspect of this invention provides an integrated sensing system for the health status of a hydraulic power unit. For example... Figures 1-4 As shown, the integrated health status sensing system of the hydraulic power unit includes: a fluid channel 10, a first inlet 20, a second inlet 30, a sensor assembly, and an extended signal acquisition device 50.

[0043] The fluid channel 10 has a first inlet 20 and a second inlet 30 at each end. Both the first inlet 20 and the second inlet 30 include pipes and threads at both ends of the pipes. The first inlet 20 and the second inlet 30 are detachably and sealingly connected to the fluid channel 10 via threads. Furthermore, a sealing ring is provided at the connection point for a more secure seal to prevent hydraulic oil leakage.

[0044] An interface component is disposed on and communicates with the fluid channel 10. A sensor component is detachably connected to and can be hermetically mounted on the fluid channel 10 via the interface component, for collecting data on the hydraulic oil within the fluid channel. An extended signal acquisition device 50 is also disposed on the fluid channel 10 for collecting relevant data signals of the hydraulic oil.

[0045] The signal and power bundle interface 60 integrates the data cables of the sensor assembly and the extended signal acquisition device 50 into one unit and connects to it. The data cables are connected to the signal and power bundle interface 60 through pinholes, enabling quick connection and improving work efficiency. Specifically, the signal and power bundle interface 60 can be installed on the outer wall of the fluid channel 10.

[0046] The interface assembly includes multiple interfaces for mounting sensors. In one optional embodiment, it includes a first interface 41a for mounting a vibration-temperature integrated sensor 41, a second interface 41b for mounting a pressure sensor 42, and a third interface 41c for mounting a flow sensor 43. The sensor assembly includes a vibration-temperature integrated sensor 41 that can be mounted at the first interface 41a, a pressure sensor 42 that can be mounted at the second interface 41b, and a flow sensor 43 that can be mounted at the third interface 41c. The first interface 41a, the second interface 41b, and the third interface 41c are arranged sequentially from right to left.

[0047] It needs to be explained that the working principle of the flow sensor 43 is as follows: the sensor head extends into the first signal acquisition channel 11 and senses the hydraulic oil flow by detecting the rotation speed of the blades set at the sensor head.

[0048] Based on the principle of flow measurement by the flow sensor 43, its volume extending into the first signal acquisition channel 11 is larger than that of other sensors. Therefore, in practical use, the flow sensor 43 needs to be installed downstream of the first signal acquisition channel 11, i.e., at the third interface 41c, while the pressure sensor and the integrated vibration and temperature sensor 41 are installed upstream of the flow sensor 43. This can improve the accuracy of the signals acquired by the pressure sensor 42 and the integrated vibration and temperature sensor 41.

[0049] It should be noted that other types of sensors can also be installed at the interface to collect other data about the hydraulic oil. However, the threads on the sensor must match the threads at the interface. Additionally, if it is not necessary to collect a certain type of data signal, such as flow rate, the flow sensor 43 can be removed, and the interface can be closed using a sealing device. The sealing device can be a bolt or a sealing ring.

[0050] The fluid channel 10 includes a first signal acquisition channel 11 and a second signal acquisition channel 12 that are interconnected. The cross-sectional area of ​​the second signal acquisition channel 12 is smaller than that of the first signal acquisition channel 11. The extended signal acquisition device 50 includes an extended channel 51 connected in parallel with the second signal acquisition channel 12, a fourth interface 57 disposed on the wall of the extended channel 51, a particle size detection sensor 53 detachably connected to the fourth interface 57, and a moisture detection sensor 52 disposed on the second signal acquisition channel 12 for acquiring hydraulic oil-related data signals within the second signal acquisition channel 12.

[0051] It should be noted that, in a preferred embodiment of the present invention, both the sensor and the interface can be sealed and detachably connected via a sealing ring and threads. For details on how to achieve this sealing and detachable connection, please refer to the threaded and sealing ring method described above.

[0052] In the above description, the purpose of setting the cross-sectional area of ​​the second signal acquisition channel 12 to be slightly smaller than that of the first signal acquisition channel 11 is to maintain a certain pressure within the second signal acquisition channel 12, allowing a small amount of hydraulic oil to flow into the expansion channel 51. This allows for the acquisition of moisture and particle size signals within the expansion channel 51, improving the accuracy of data acquisition. To prevent excessive pressure within the expansion channel 51, the sum of the cross-sectional areas of the expansion channel 51 and the second signal acquisition channel 12 is set to be slightly greater than or equal to the cross-sectional area of ​​the first signal acquisition channel 11.

[0053] In a preferred embodiment, the inlet is located on the second signal acquisition channel 12 and near the connection between the first signal acquisition channel 11 and the second signal acquisition channel 12. When hydraulic oil enters the second signal acquisition channel 12 from the first signal acquisition channel 11, the hydraulic oil carrying space changes instantaneously (from large to small). At this time, the space of the second signal acquisition channel 12 is insufficient to hold the hydraulic oil. Therefore, some hydraulic oil will flow to the expansion channel 51.

[0054] The second signal acquisition channel 12 has an inlet 54 and an outlet 55 axially spaced on its wall, communicating with the expansion channel 51. A channel switch 56 for opening and closing the inlet 54 is provided at the inlet 54. The inlet 54 and outlet 55 are located near the beginning and end of the second signal acquisition channel 12, respectively. It should be noted that since the second signal acquisition channel 12 and the expansion channel 51 are connected, the inlet 54 and outlet 55 are actually shared by both. It can be understood that the inlet 54 and outlet 55 are located both on the second signal acquisition channel 12 and the expansion channel 51. Therefore, naturally, the inlet 54 and outlet 55 are also located near the beginning and end of the expansion channel 51.

[0055] In one optional embodiment, the channel switch 56 includes a bolt threaded to one end of the expansion channel 51, and correspondingly, the inner wall of that end of the expansion channel 51 is provided with threads adapted to the bolt. The inlet 54 is located within the area where the bolt extends into the expansion channel 51 and covers the wall of the expansion channel 51. That is, when the bolt is screwed into the expansion channel 51, the bolt can completely cover the inlet 54, preventing hydraulic oil from entering the expansion channel 51. Of course, the length of the bolt screwed into the expansion channel 51 is adjustable, so the opening of the inlet 54 can be adjusted to control the amount of hydraulic oil entering the expansion channel 51. In addition, such an expansion channel structure reduces the processing difficulty of the expansion channel.

[0056] The integrated temperature and vibration sensor 41, pressure sensor 42, and flow sensor 43 all include a sensor head, a sensor middle section, and a sensor tail section. The sensor head extends into the first signal acquisition channel 11. A thread is provided on the circumferential outer wall of the sensor middle section, enabling a detachable connection with the first signal acquisition channel. A sealing ring is added for further sealing to prevent hydraulic oil leakage. Additionally, an annular flange is provided on the circumferential outer wall of the sensor middle section. This annular flange serves two purposes: limiting the sensor from extending further into the first signal acquisition channel 11 and providing pre-tightening and sealing. The sensor tail section, located outside the first signal acquisition channel 11, has a quick-connect interface for the acquisition cable harness, facilitating signal cable connection.

[0057] This integrated health status sensing system for hydraulic power units integrates multiple data acquisition devices, enabling parallel acquisition of multiple data from the hydraulic system. It also reduces the space occupied by equipment with equivalent functions and solves the problem that existing condition monitoring systems cannot simultaneously meet the detection needs of both small and large hydraulic equipment.

[0058] Based on the detachable connections between sensors and interfaces, the types of sensors, the number of sensors under test, and the categories of data required for condition monitoring and performance evaluation can be freely selected. This provides more data support for condition monitoring, fault diagnosis, and health monitoring of hydraulic systems.

[0059] Based on the detachable connection between each sensor and each interface, the first inlet 20 and the second inlet 30 are detachably connected to the fluid channel 10, thus realizing the modularity of the entire device.

[0060] By connecting the data cable to the signal and power bundle interface 60 via a pinhole, rapid assembly and connection of the device can be achieved.

[0061] Therefore, this integrated health status sensing system for hydraulic power units improves the efficiency of status monitoring, fault diagnosis, and health monitoring, reduces enterprise operating costs, realizes intelligent operation and maintenance of hydraulic equipment, and enhances the working efficiency of hydraulic equipment.

[0062] A second aspect of the present invention provides a method for acquiring health status data of a hydraulic power unit, comprising:

[0063] Connect the first inlet 20 and the second inlet 30 to the hydraulic system and adjust the orientation of the expansion channel 51 downwards. Collect corresponding characteristic data of the hydraulic oil in the fluid channel 10 using a sensor assembly. Adjust the opening of the inlet 54 via the channel switch 56 to allow hydraulic oil to flow into the expansion channel 51, and the sensor collects corresponding characteristic data of the hydraulic oil.

[0064] The purpose of adjusting the orientation of the expansion channel 51 to face downwards is that, since the particle density in hydraulic oil is greater than that in hydraulic oil, the particles will sink in the hydraulic oil; therefore, adjusting the orientation of the expansion channel 51 to face downwards facilitates the entry of particles into the expansion channel 51, thereby improving the accuracy of data acquisition.

[0065] In practical use, depending on the required data category, the corresponding interface can be selectively opened or closed, or the corresponding sensor can be replaced to obtain the required data type.

[0066] When a flow signal is required, the flow sensor is installed at the third interface 41c. The reason for placing the flow sensor at the third interface 41c has been explained previously and will not be repeated here.

[0067] In one optional embodiment, vibration signals, temperature signals, pressure signals and flow signals of hydraulic oil are collected in the first signal acquisition channel 11, and moisture signals and particle size signals of hydraulic oil are collected in the extended channel 51.

[0068] Based on the acquisition of the above signals, condition monitoring and performance evaluation of hydraulic equipment can be performed.

[0069] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

[0070] It should also be noted that the various specific technical features described in the above embodiments can be combined in any suitable manner without contradiction. To avoid unnecessary repetition, the present invention will not describe the various possible combinations separately.

[0071] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed by the present invention.

Claims

1. A hydraulic power unit health integrated perception system, comprising: include: The fluid channel (10), a first inlet (20) and a second inlet (30) detachably and sealably disposed at both ends of the fluid channel (10), an interface assembly disposed on the fluid channel (10), a sensor assembly for collecting fluid characteristic data detachably and sealably mounted at the interface assembly, and an extended signal acquisition device (50) for collecting fluid characteristic data disposed on the fluid channel (10). The interface assembly includes a first interface (41a) for mounting a vibration-temperature integrated sensor (41), a second interface (41b) for mounting a pressure sensor (42), and a third interface (41c) for mounting a flow sensor (43). The sensor assembly includes a vibration-temperature integrated sensor (41) that can be installed at the first interface (41a), a pressure sensor (42) that can be installed at the second interface (41b), and a flow sensor (43) that can be installed at the third interface (41c). The first interface (41a), the second interface (41b), and the third interface (41c) are arranged alternately from right to left; The fluid channel (10) includes a first signal acquisition channel (11) and a second signal acquisition channel (12) that are interconnected; wherein the cross-sectional area of ​​the second signal acquisition channel (12) is smaller than the cross-sectional area of ​​the first signal acquisition channel (11); the extended signal acquisition device (50) includes an extended channel (51) connected in parallel with the second signal acquisition channel (12), a fourth interface (57) disposed on the wall of the extended channel (51), a particle size detection sensor (53) detachably connected to the fourth interface (57), and a moisture detection sensor (52) disposed on the second signal acquisition channel (12) for acquiring liquid medium related data in the second signal acquisition channel (12).

2. The hydraulic power unit health integrated perception system of claim 1, wherein, The integrated sensing system for the health status of the hydraulic power unit also includes a signal and power bundle interface (60). The signal and power bundle interface (60) is located on the outer wall of the fluid channel (10).

3. The integrated health status sensing system for hydraulic power units according to claim 1, characterized in that, The second signal acquisition channel (12) is provided with an inlet (54) and an outlet (55) that are axially spaced and communicate with the expansion channel (51); a channel switch (56) for opening and closing the inlet (54) is provided at the inlet (54). The inlet (54) and outlet (55) are located at the beginning and end of the second signal acquisition channel (12), respectively.

4. The integrated health status sensing system for hydraulic power units according to claim 3, characterized in that, The channel switch (56) includes a bolt threaded to one end of the expansion channel (51); the inlet (54) is located within the area where the bolt extends into the expansion channel (51) and covers the wall of the expansion channel (51).

5. The integrated health status sensing system for hydraulic power units according to claim 1, characterized in that, The ends of the first inlet (20) and the second inlet (30) are both provided with threads; the first inlet (20) and the second inlet (30) are threadedly connected to the fluid channel (10); Sealing rings are provided at the connection points of the first inlet (20) and the second inlet (30) with the fluid channel (10).

6. The integrated health status sensing system for a hydraulic power unit according to claim 1, characterized in that, The integrated vibration and temperature sensor (41), the pressure sensor (42), and the flow sensor (43) all include a sensor head, a sensor middle, and a sensor tail. The sensor head extends into the first signal acquisition channel (11); A thread is provided on the outer circumferential wall of the middle part of the sensor; the integrated vibration and temperature sensor (41), the pressure sensor (42) and the flow sensor (43) are all threadedly connected to the fluid channel (10) through the thread; The sensor tail is located outside the first signal acquisition channel (11) and is provided with a quick interface for the acquisition harness; The sensor also has an annular flange on its central circumferential outer wall.

7. A method for acquiring health status data of a hydraulic power unit in the integrated sensing system for health status of a hydraulic power unit as described in claim 3, characterized in that, The method for collecting health status data of the hydraulic power unit includes: Connect the first inlet (20) and the second inlet (30) to the hydraulic system and adjust the orientation of the expansion channel (51) downwards; Hydraulic oil is introduced from the first inlet (20) towards the second inlet (30); The sensor assembly collects corresponding characteristic data of the hydraulic oil in the fluid channel (10); The opening of the inlet (54) is adjusted by the channel switch (56) so that hydraulic oil flows into the extended channel (51) and the sensor collects the corresponding characteristic data of the hydraulic oil. The sum of the cross-sectional areas of the extended channel (51) and the second signal acquisition channel (12) is set to be slightly greater than or equal to the cross-sectional area of ​​the first signal acquisition channel (11).

8. The method for acquiring health status data of a hydraulic power unit according to claim 7, characterized in that, Depending on the required data type, selectively open or close the corresponding interface, or replace the corresponding sensor to obtain the required data type; When it is necessary to acquire a flow signal, the flow sensor is installed at the third interface (41c).

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