Integrated detection device and method for sensors and hydraulic valve groups for tunneling machines

Abstract

This invention discloses an integrated detection device and method for sensors and hydraulic valve groups used in tunneling machines. The device includes a water system, a pneumatic system, a hydraulic system, an earth pressure monitoring system, a power supply system, a controller, and a host computer. The water system includes a water flow detection pipeline, a screw pump, a frequency converter, and an installation interface for a liquid flow meter. The pneumatic system includes an air flow detection pipeline, an air compressor, an intelligent air regulating valve, and an installation interface for a gas flow meter. The hydraulic system includes a hydraulic detection pipeline and a hydraulic pump; the hydraulic detection pipeline can form a circuit with the cylinders on the tunneling machine. The earth pressure monitoring system includes earth pressure detection fixtures, pressure gauges, and an installation interface for an earth pressure sensor. The power supply system includes a power supply and a power conversion module. This device can precisely adjust, monitor, and display data in real time. It can accurately detect and evaluate various sensor components, hydraulic control valve groups, and stroke sensors built into the cylinders. It can accurately detect switch signal sensors, and the range setting is convenient.

Description

Technical Field

[0001] This invention relates to tunneling machine testing, specifically to an integrated testing device and method for tunneling machine sensors and hydraulic valve groups. Background Technology

[0002] After a tunneling machine completes a project, it needs to be maintained and repaired. During the maintenance process, its sensors and valve groups need to be tested. The conventional testing method is to perform system debugging and testing after the tunneling machine is mounted and powered on. However, the existing testing system has the following problems: 1) Low detection accuracy, and it cannot achieve accurate detection and evaluation on some high-precision sensors; 2) Inconvenient sensor range setting; 3) It cannot provide its own power unit and needs to rely on the tunneling machine to provide power; 4) Limited detection function, it can only detect valve groups, temperature and pressure sensors, and cannot detect switch signal sensors (such as displacement sensors with start / stop output). Summary of the Invention

[0003] The purpose of this invention is to provide an integrated detection device and method for sensors and hydraulic valve groups used in tunneling machines. This device can accurately adjust, monitor and display in real time, accurately detect and evaluate various sensor components, hydraulic control valve groups and stroke sensors built into the cylinders, accurately detect switch signal sensors, and has convenient range setting.

[0004] The technical solution adopted in this invention is:

[0005] An integrated detection device for sensors and valve assemblies in a tunneling machine includes a water system, a pneumatic system, a hydraulic system, an earth pressure monitoring system, a power supply system, a controller, and a host computer. The water system includes a water flow detection pipeline, a screw pump for supplying water to the water flow detection pipeline, and a frequency converter for controlling the screw pump; the water flow detection pipeline has an installation interface for a liquid flow meter. The pneumatic system includes an air flow detection pipeline, an air compressor for supplying air to the air flow detection pipeline, and an intelligent air regulating valve installed on the air flow detection pipeline; the air flow detection pipeline has an installation interface for a gas flow meter. The hydraulic system includes a hydraulic detection pipeline and a hydraulic pump that supplies pressurized oil to the hydraulic detection pipeline; the hydraulic detection pipeline is compatible with the hydraulic cylinders on the tunneling machine. The circuit is formed by connecting the hydraulic cylinder to the hydraulic detection circuit. The electro-hydraulic proportional valve on the tunneling machine is located at the pressure end, and the pressure sensor and pressure gauge are located at the return oil end. The earth pressure system includes an earth pressure detection fixture that can simulate earth pressure and a pressure gauge installed on the earth pressure detection fixture. The earth pressure detection fixture is equipped with an installation interface for the earth pressure sensor. The power system includes a power supply and a power conversion module. The power supply is used to provide power to the entire device, and the power conversion module is used to convert the power of the connected switch signal sensors, tilt sensors, and temperature sensors. The controller is used to receive data from each sensor and upload it to the host computer. It controls each actuator according to the instructions of the host computer. The host computer is used to realize human-machine interaction and data setting, analysis, and storage.

[0006] Preferably, the earth pressure testing fixture is driven by an air compressor.

[0007] Preferably, the control signals sent by the controller to the electro-hydraulic proportional valve and the air intelligent regulating valve are first amplified by a signal amplifier board.

[0008] Preferably, the controller is a PLC controller.

[0009] Preferably, the switching signal sensor includes a liquid level switch sensor, a temperature switch sensor, and a proximity switch sensor.

[0010] An integrated detection method for sensors and hydraulic valve groups in a tunneling machine, based on the aforementioned integrated detection device for sensors and hydraulic valve groups used in tunneling machines;

[0011] When testing liquid flow rate: Install the liquid flow rate meter on the water flow detection pipeline. Send instructions to the controller via the host computer. The controller adjusts the speed of the screw pump through the frequency converter to regulate the water flow rate. The liquid flow rate meter transmits the detected flow rate to the controller in real time and displays it on the host computer. The host computer compares the set flow rate data with the flow rate data uploaded by the liquid flow rate meter and judges whether the liquid flow rate meter is qualified and accurate based on the deviation rate.

[0012] When testing gas flow rate: Install the gas flow rate meter on the gas flow detection pipeline, turn on the air compressor, and send a command to the controller through the host computer. The controller adjusts the air flow rate by adjusting the opening of the intelligent air regulating valve. The gas flow rate meter transmits the detected flow rate to the controller in real time and displays it on the host computer. The host computer compares the set flow rate data with the flow rate data uploaded by the gas flow rate meter, and judges whether the gas flow rate meter is qualified and accurate based on the deviation rate.

[0013] When testing pressure sensors, hydraulic control valve groups, and cylinder-embedded stroke sensors: connect the cylinder and its accessories to the hydraulic testing circuit, start the hydraulic pump, and send a command to the controller via the host computer. The controller adjusts the cylinder circuit pressure by regulating the electro-hydraulic proportional valve. The pressure sensor transmits the detected circuit pressure to the controller in real time and displays it on the host computer. The host computer compares the data from the pressure gauge on the cylinder circuit with the circuit pressure data uploaded by the pressure sensor, and determines whether the pressure sensor is qualified and accurate based on the deviation rate. It also determines whether the hydraulic control valve group is working properly based on whether there is a change in the circuit pressure. After the cylinder extends to its full position, the stroke sensor transmits the detected stroke to the controller in real time and displays it on the host computer. The host computer compares the cylinder extension length measured on-site with the stroke detected by the stroke sensor, and determines whether the stroke sensor is qualified and accurate based on the deviation rate.

[0014] When testing the earth pressure sensor: install the earth pressure sensor on the earth pressure testing fixture, turn on the air compressor and adjust the output pressure. The pressure detected by the earth pressure sensor is transmitted to the controller in real time and displayed on the host computer. The host computer compares the data of the pressure gauge on the earth pressure testing fixture with the pressure data uploaded by the earth pressure sensor, and judges whether the earth pressure sensor is qualified and accurate based on the deviation rate.

[0015] When testing a digital signal sensor: The digital signal sensor is powered by a power conversion module and connected to the controller to form a loop. The controller determines whether the digital signal sensor is working properly by detecting whether there is a signal feedback in the loop.

[0016] When testing the tilt sensor: The tilt sensor to be tested and the standard tilt sensor are powered by the power conversion module and connected to the controller to form a loop, so that the two will produce tilt angle changes together. The tilt angles detected by the two are transmitted to the controller in real time and displayed on the host computer. The host computer compares the two values ​​and judges whether the tilt sensor to be tested is qualified and accurate based on the deviation rate.

[0017] When testing the temperature sensor: The temperature sensor is powered by the power conversion module and connected to the controller to form a circuit. The temperature sensor and the thermometer are placed in the same heating environment. The temperature detected by the temperature sensor is transmitted to the controller in real time and displayed on the host computer. The host computer compares the data from the thermometer with the pressure data uploaded by the temperature sensor, and judges whether the temperature sensor is qualified and accurate based on the deviation rate.

[0018] Preferably, the heating environment is a container equipped with a heating mechanism.

[0019] Preferably, the host computer automatically generates a test report based on the test results, and the test report can be downloaded and printed.

[0020] The beneficial effects of this invention are:

[0021] This device integrates several detection systems, adopts human-machine interaction, and can accurately adjust, monitor and display in real time. It can not only accurately detect and evaluate various sensors to three decimal places, but also detect the stroke sensors built into hydraulic control valve groups and cylinders. It has wide applicability and can also accurately detect switch signal sensors (such as displacement sensors with start / stop output). For the same type of sensor signal input, only the sensor range needs to be input to accurately detect the actual value of the sensor, solving the problem of inconvenient range setting. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the detection principle of the integrated detection device for sensors and hydraulic valve groups used in tunneling machines in an embodiment of the present invention. Detailed Implementation

[0023] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0024] like Figure 1As shown, an integrated detection device for sensors and valve groups in a tunneling machine includes a water system, a pneumatic system, a hydraulic system, an earth pressure system, a power system, a controller, and a host computer. The water system includes a water flow detection pipeline, a screw pump for supplying water to the water flow detection pipeline, and a frequency converter for controlling the screw pump. A liquid flow meter mounting interface is provided on the water flow detection pipeline. The pneumatic system includes an air flow detection pipeline, an air compressor for supplying air to the air flow detection pipeline, and an intelligent air regulating valve installed on the air flow detection pipeline. A gas flow meter mounting interface is provided on the air flow detection pipeline. The hydraulic system includes a hydraulic detection pipeline and a hydraulic pump that supplies pressurized oil to the hydraulic detection pipeline. The hydraulic detection pipeline can communicate with the oil supply on the tunneling machine. The cylinder forms a circuit. After the oil cylinder is connected to the hydraulic detection circuit, the electro-hydraulic proportional valve on the tunneling machine is located at the pressure end, and the pressure sensor and pressure gauge are located at the return oil end. The earth pressure system includes an earth pressure detection fixture that can simulate earth pressure and a pressure gauge installed on the earth pressure detection fixture. The earth pressure detection fixture is equipped with an installation interface for the earth pressure sensor. The power system includes a power supply and a power conversion module. The power supply is used to provide power to the entire device, and the power conversion module is used to convert the power of the connected switch signal sensors, tilt sensors, and temperature sensors. The controller is used to receive data from each sensor and upload it to the host computer. It controls each actuator according to the instructions of the host computer. The host computer is used to realize human-machine interaction and data setting, analysis, and storage.

[0025] Earth pressure testing equipment should be selected from existing earth pressure sensor testing equipment, such as... Figure 1 As shown, preferably, the earth pressure testing fixture is driven by an air compressor, so that the air system and the earth pressure system can share a single power source.

[0026] like Figure 1 As shown, preferably, the control signals sent by the controller to the electro-hydraulic proportional valve and the air intelligent regulating valve are first amplified by a signal amplifier board, so that the low-power control signal can be converted into a higher-power output control signal.

[0027] The preferred controller is a PLC controller, which has mature technology, high reliability, strong anti-interference ability, complete functions, wide applicability, convenient maintenance, easy modification, small size, light weight and low energy consumption.

[0028] like Figure 1 As shown, the switching signal sensors include a liquid level switch sensor, a temperature switch sensor, and a proximity switch sensor.

[0029] During the maintenance of the tunneling machine, the sensors and hydraulic valve groups in the machine are tested using the aforementioned testing device. The testing method is as follows:

[0030] When testing liquid flow rate: Remove the liquid flow rate meter from the tunneling machine and install it on the water flow detection pipeline. Send instructions to the controller via the host computer. The controller adjusts the speed of the screw pump through the frequency converter to regulate the water flow rate. The liquid flow rate meter transmits the detected flow rate to the controller in real time and displays it on the host computer. The host computer compares the set flow rate data with the flow rate data uploaded by the liquid flow rate meter and judges whether the liquid flow rate meter is qualified and accurate based on the deviation rate (the deviation rate is qualified if it is within a certain threshold, and accurate if it is within a smaller threshold. The specific threshold parameters are set according to actual needs).

[0031] When testing gas flow rate: Remove the gas flow rate meter from the tunneling machine and install it on the gas flow detection pipeline. Turn on the air compressor and send a command to the controller via the host computer. The controller adjusts the airflow by adjusting the opening of the intelligent air regulating valve. The gas flow rate meter transmits the detected flow rate to the controller in real time and displays it on the host computer. The host computer compares the set flow rate data with the flow rate data uploaded by the gas flow rate meter and judges whether the gas flow rate meter is qualified and accurate based on the deviation rate (the deviation rate is qualified if it is within a certain threshold, and accurate if it is within a smaller threshold. The specific threshold parameters are set according to actual needs).

[0032] When testing the pressure sensor, hydraulic control valve group, and the stroke sensor built into the cylinder: Disconnect the cylinder from the original connection with the tunneling machine, connect the cylinder and its accessories to the hydraulic testing circuit, start the hydraulic pump, and send a command to the controller via the host computer. The controller adjusts the cylinder circuit pressure by adjusting the electro-hydraulic proportional valve. The pressure sensor transmits the detected circuit pressure to the controller in real time and displays it on the host computer. The host computer compares the data of the pressure gauge on the cylinder circuit with the circuit pressure data uploaded by the pressure sensor, and judges whether the pressure sensor is qualified and accurate based on the deviation rate (a deviation rate within a certain threshold is considered qualified, and within a smaller threshold is considered accurate; the specific threshold parameters are set according to actual needs). The host computer judges whether the hydraulic control valve group is working properly based on whether there is a change in the circuit pressure. After the cylinder extends to the position, the stroke sensor transmits the detected stroke to the controller in real time and displays it on the host computer. The host computer compares the cylinder extension length measured on site with the stroke detected by the stroke sensor, and judges whether the stroke sensor is qualified and accurate based on the deviation rate (a deviation rate within a certain threshold is considered qualified, and within a smaller threshold is considered accurate; the specific threshold parameters are set according to actual needs).

[0033] When testing the earth pressure sensor: Remove the earth pressure sensor from the tunneling machine, install the earth pressure sensor on the earth pressure testing fixture, turn on the air compressor and adjust the output pressure. The pressure detected by the earth pressure sensor is transmitted to the controller in real time and displayed on the host computer. The host computer compares the data of the pressure gauge on the earth pressure testing fixture with the pressure data uploaded by the earth pressure sensor, and judges whether the earth pressure sensor is qualified and accurate based on the deviation rate (the deviation rate is qualified if it is within a certain threshold, and accurate if it is within a smaller threshold. The specific threshold parameters are set according to actual needs).

[0034] When testing the switch signal sensor: Remove the switch signal sensor from the tunneling machine, power the switch signal sensor with the power conversion module and connect it to the controller to form a loop. The controller determines whether the switch signal sensor is working properly by detecting whether there is a signal feedback in the loop.

[0035] When testing the tilt sensor: Remove the tilt sensor to be tested from the tunneling machine. Power the tilt sensor to be tested and the standard tilt sensor to be tested and connect them to the controller to form a loop, so that the two sensors can produce tilt angle changes together. The tilt angle detected by the two sensors is transmitted to the controller in real time and displayed on the host computer. The host computer compares the two values ​​and judges whether the tilt sensor to be tested is qualified and accurate based on the deviation rate (the deviation rate is qualified if it is within a certain threshold, and accurate if it is within a smaller threshold. The specific threshold parameters are set according to actual needs).

[0036] When testing the temperature sensor: Remove the temperature sensor from the tunneling machine, power the temperature sensor with the power conversion module and connect it to the controller to form a circuit. Place the temperature sensor and thermometer in the same heating environment (generally, a container with a heating mechanism can be used, such as a measuring cup with a heater). The temperature detected by the temperature sensor is transmitted to the controller in real time and displayed on the host computer. The host computer compares the data from the thermometer with the pressure data uploaded by the temperature sensor, and judges whether the temperature sensor is qualified and accurate based on the deviation rate (the deviation rate is qualified if it is within a certain threshold, and accurate if it is within a smaller threshold. The specific threshold parameters are set according to actual needs).

[0037] After the test is completed, the host computer automatically generates a test report based on the test results, and the test report can be downloaded and printed.

[0038] This device integrates several detection systems, adopts human-machine interaction, and can accurately adjust, monitor and display in real time. It can not only accurately detect and evaluate various sensors to three decimal places, but also detect the stroke sensors built into hydraulic control valve groups and cylinders. It has wide applicability and can also accurately detect switch signal sensors (such as displacement sensors with start / stop output). For the same type of sensor signal input, only the sensor range needs to be input to accurately detect the actual value of the sensor, solving the problem of inconvenient range setting.

[0039] It should be understood that those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. An integrated detection method for sensors and hydraulic valve groups in a tunneling machine, characterized in that: An integrated detection device for sensors and valve groups in a tunneling machine includes a water system, a pneumatic system, a hydraulic system, an earth pressure monitoring system, a power supply system, a controller, and a host computer. The water system includes a water flow detection pipeline, a screw pump for supplying water to the water flow detection pipeline, and a frequency converter for controlling the screw pump. A liquid flow meter mounting interface is provided on the water flow detection pipeline. The pneumatic system includes an air flow detection pipeline, an air compressor for supplying air to the air flow detection pipeline, and an intelligent air regulating valve installed on the air flow detection pipeline. A gas flow meter mounting interface is provided on the air flow detection pipeline. The hydraulic system includes a hydraulic detection pipeline and a hydraulic pump that provides pressurized oil to the hydraulic detection pipeline. The hydraulic detection pipeline can connect to the tunneling machine... The hydraulic cylinder forms a circuit. After the hydraulic cylinder is connected to the hydraulic detection circuit, the electro-hydraulic proportional valve on the tunneling machine is located at the pressure end, and the pressure sensor and pressure gauge are located at the return oil end. The earth pressure system includes an earth pressure detection fixture that can simulate earth pressure, a pressure gauge installed on the earth pressure detection fixture, and an installation interface for the earth pressure sensor on the earth pressure detection fixture. The power system includes a power supply and a power conversion module. The power supply is used to provide power to the entire device, and the power conversion module is used to convert the power of the connected switch signal sensors, tilt sensors, and temperature sensors. The controller is used to receive data from each sensor and upload it to the host computer, and control each actuator according to the instructions of the host computer. The host computer is used to realize human-machine interaction and data setting, analysis, and storage. When testing liquid flow rate: Install the liquid flow rate meter on the water flow detection pipeline. Send instructions to the controller via the host computer. The controller adjusts the speed of the screw pump through the frequency converter to regulate the water flow rate. The liquid flow rate meter transmits the detected flow rate to the controller in real time and displays it on the host computer. The host computer compares the set flow rate data with the flow rate data uploaded by the liquid flow rate meter and judges whether the liquid flow rate meter is qualified and accurate based on the deviation rate. When testing gas flow rate: Install the gas flow rate meter on the gas flow detection pipeline, turn on the air compressor, and send a command to the controller through the host computer. The controller adjusts the air flow rate by adjusting the opening of the intelligent air regulating valve. The gas flow rate meter transmits the detected flow rate to the controller in real time and displays it on the host computer. The host computer compares the set flow rate data with the flow rate data uploaded by the gas flow rate meter, and judges whether the gas flow rate meter is qualified and accurate based on the deviation rate. When testing pressure sensors, hydraulic control valve groups, and cylinder-embedded stroke sensors: connect the cylinder and its accessories to the hydraulic testing circuit, start the hydraulic pump, and send a command to the controller via the host computer. The controller adjusts the cylinder circuit pressure by regulating the electro-hydraulic proportional valve. The pressure sensor transmits the detected circuit pressure to the controller in real time and displays it on the host computer. The host computer compares the data from the pressure gauge on the cylinder circuit with the circuit pressure data uploaded by the pressure sensor, and determines whether the pressure sensor is qualified and accurate based on the deviation rate. It also determines whether the hydraulic control valve group is working properly based on whether there is a change in the circuit pressure. After the cylinder extends to its full position, the stroke sensor transmits the detected stroke to the controller in real time and displays it on the host computer. The host computer compares the cylinder extension length measured on-site with the stroke detected by the stroke sensor, and determines whether the stroke sensor is qualified and accurate based on the deviation rate. When testing the earth pressure sensor: install the earth pressure sensor on the earth pressure testing fixture, turn on the air compressor and adjust the output pressure. The pressure detected by the earth pressure sensor is transmitted to the controller in real time and displayed on the host computer. The host computer compares the data of the pressure gauge on the earth pressure testing fixture with the pressure data uploaded by the earth pressure sensor, and judges whether the earth pressure sensor is qualified and accurate based on the deviation rate. When testing a digital signal sensor: The digital signal sensor is powered by a power conversion module and connected to the controller to form a loop. The controller determines whether the digital signal sensor is working properly by detecting whether there is a signal feedback in the loop. When testing the tilt sensor: The tilt sensor to be tested and the standard tilt sensor are powered by the power conversion module and connected to the controller to form a loop, so that the two will produce tilt angle changes together. The tilt angles detected by the two are transmitted to the controller in real time and displayed on the host computer. The host computer compares the two values ​​and judges whether the tilt sensor to be tested is qualified and accurate based on the deviation rate. When testing the temperature sensor: The temperature sensor is powered by the power conversion module and connected to the controller to form a circuit. The temperature sensor and the thermometer are placed in the same heating environment. The temperature detected by the temperature sensor is transmitted to the controller in real time and displayed on the host computer. The host computer compares the data from the thermometer with the pressure data uploaded by the temperature sensor, and judges whether the temperature sensor is qualified and accurate based on the deviation rate.

2. The integrated detection method for sensors and hydraulic valve groups in a tunneling machine as described in claim 1, characterized in that: The heating environment is a container equipped with a heating mechanism.

3. The integrated detection method for sensors and hydraulic valve groups in a tunneling machine as described in claim 1, characterized in that: The host computer automatically generates test reports based on the test results, and the test reports can be downloaded and printed.

4. The integrated detection method for sensors and hydraulic valve groups in a tunneling machine as described in claim 1, characterized in that: The earth pressure testing equipment is driven by an air compressor.

5. The integrated detection method for sensors and hydraulic valve groups in a tunneling machine as described in claim 1, characterized in that: The control signals sent by the controller to the electro-hydraulic proportional valve and the air intelligent regulating valve are first amplified by the signal amplifier board.

6. The integrated detection method for sensors and hydraulic valve groups in a tunneling machine as described in claim 1, characterized in that: The controller is a PLC controller.

7. The integrated detection method for sensors and hydraulic valve groups in a tunneling machine as described in claim 1, characterized in that: Switching signal sensors include level switch sensors, temperature switch sensors, and proximity switch sensors.

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