A system for testing and evaluating the performance of an internal curve hydraulic motor

Abstract

This application discloses a system for testing and evaluating the installation performance of an internal curve hydraulic motor, comprising a hydraulic system for motor installation testing and a motor performance data analysis system. The hydraulic system includes a first motor-pump assembly capable of bidirectional hydraulic oil output, a first pressure sensor, a reducer, a speed sensor, a temperature sensor, a second flow meter, a second pressure sensor, a vibration sensor, an oil measuring instrument, a torque sensor, a filter, a third flow meter, a hydraulic oil tank, an oil direction control valve assembly, and a controller. The motor performance data analysis system includes a data monitoring module, a data analysis module, and a database correction module. This application analyzes the performance of the hydraulic motor and predicts faults based on real-time monitoring data, avoiding damage to the system during installation testing, improving construction efficiency and the accuracy of fault warnings, and is of great significance for the installation application and experimental development of hydraulic components.

Description

Technical Field

[0001] This application relates to the field of hydraulic component installation and testing technology, and in particular to an installation performance testing and evaluation system for an internal curve hydraulic motor. Background Technology

[0002] The auger conveyor system of a tunnel boring machine (TBM) primarily removes the soil cut by the cutterhead from the shield. As the core actuator of this system, the hydraulic motor's failure can directly cause the TBM to shut down and cease tunneling. In some special geological conditions, the auger conveyor motor operates in harsh environments and is subjected to alternating impact loads, which can damage the motor. To avoid equipment downtime due to motor failure, motor installation testing is essential to verify its operating conditions and environmental adaptability. Therefore, newly developed motors must undergo installation and application testing before mass production.

[0003] Currently, there are few performance testing and evaluation schemes for screw conveyor system motors. On the one hand, the data collection of various aspects of the shield machine motor is incomplete. The measured data is generally used to troubleshoot motor failures. In addition, only data thresholds are set to trigger alarms for parameters such as pressure, oil temperature, and speed when they exceed limits. On the other hand, the actual measured data is only used for testing on hydraulic motor test benches, and the application of various collected data of the installed motor is not widespread.

[0004] Collecting measured working data of the motor for test loading is beneficial for evaluating motor performance. However, during the actual tunneling process, due to the complex and varied geology and the differences in operation by tunneling personnel, the load on each in-service hydraulic motor varies greatly. Furthermore, the complex working conditions or improper operation by construction personnel may cause the motor to fail rapidly.

[0005] A GBDT-based monitoring method is primarily used for fault monitoring of the auger conveyor shaft of a tunnel boring machine (TBM). This method utilizes a pre-trained torque prediction model combined with actual operating data to determine the health of the auger shaft based on the deviation between the predicted and actual torque values. It exhibits high stability and good real-time performance. This monitoring function can assist on-site construction personnel in assessing the current condition of the auger shaft, thus mitigating significant losses due to serious equipment failures. However, while the auger shaft has a lower failure rate under high torque conditions, the auger motor, as the actuator driving the auger shaft, is more prone to damage under high torque. Furthermore, for motors, torque can only be considered one of many parameters for health monitoring. Therefore, this fault monitoring method is not suitable for performance monitoring of the hydraulic motor of the auger conveyor. Summary of the Invention

[0006] This application provides a system for testing and evaluating the installed performance of an internal curve hydraulic motor, in order to solve the technical problem that existing fault monitoring methods are not suitable for performance monitoring of screw conveyor hydraulic motors.

[0007] The technical solution adopted in this application is as follows:

[0008] A system for testing and evaluating the installation performance of an internal curve hydraulic motor includes a hydraulic system for motor installation testing and a motor performance data analysis system, wherein:

[0009] The hydraulic system for motor installation and testing includes a first motor pump unit capable of bidirectional hydraulic oil output, a first pressure sensor, a reducer, a speed sensor, a temperature sensor, a second flow meter, a second pressure sensor, a vibration sensor, an oil measuring instrument, a torque sensor, a filter, a third flow meter, a hydraulic oil tank, an oil direction control valve assembly, and a controller.

[0010] The A port of the motor-pump unit is sequentially connected to a filter, a third flow meter, an oil direction control valve group, a first flow meter, and the B port of the motor-pump unit. A second pressure sensor is connected in parallel to the pipeline between the third flow meter and the oil direction control valve group, and a first pressure sensor is connected in parallel to the pipeline between the oil direction control valve group and the B port of the motor-pump unit. The reducer is connected between the hydraulic motor and the screw conveyor shaft to reduce the output speed of the hydraulic motor. The speed sensor measures the speed of the hydraulic motor's output shaft. The temperature sensor measures the temperature of the leaking oil from the hydraulic motor. The second flow meter is connected between the hydraulic motor and the hydraulic oil tank to measure the flow rate of the leaking oil from the hydraulic motor. The vibration sensor measures the vibration of the hydraulic motor during operation. The oil composition meter measures the composition data of the oil in the hydraulic system. The torque sensor measures the output torque of the hydraulic motor. The controller controls the hydraulic system for motor installation and testing.

[0011] The motor performance data analysis system includes:

[0012] The data monitoring module is used to monitor and collect various measurement data of the hydraulic motor in the hydraulic system of the motor installation test.

[0013] The data analysis module is used to analyze various data of the hydraulic motor collected by the data monitoring module by combining commonly used formulas and standard data of hydraulic systems, and to quantify the degree of influence of each factor on the performance of the hydraulic motor.

[0014] The database correction module is used to continuously correct the calculation parameters for evaluating the installed performance of hydraulic motors by continuously collecting and storing actual working loads of hydraulic motors, thereby increasing sample diversity and sample base, and improving the accuracy of fault warning.

[0015] Furthermore, the hydraulic system for motor installation and testing also includes a second motor pump set and a shuttle valve. The output end of the second motor pump set is connected to the input end of the shuttle valve, and the two output ends of the shuttle valve are respectively connected to port A and port B of the first motor pump set for replenishing oil to the hydraulic main pump of the first motor pump set.

[0016] Furthermore, the hydraulic system for motor installation and testing also includes a relief valve, which is connected to the output end of the second motor pump set and is used to adjust the pressure of the replenishing pump.

[0017] Furthermore, the hydraulic direction control valve group includes a bridge circuit consisting of four check valves. Port A1 of the bridge circuit is connected to a third flow meter, port A2 is connected to a first flow meter, port B1 is connected to the hydraulic oil input end of the hydraulic motor, and port B2 is connected to the hydraulic oil output end of the hydraulic motor, which is used to control the hydraulic oil to flow in only from the hydraulic oil input end of the hydraulic motor.

[0018] Furthermore, the motor performance data analysis system also includes a data alarm module, which is used to set thresholds for various measurement data of the hydraulic system for motor installation testing, and to issue an alarm when the actual measurement data exceeds the set threshold.

[0019] Furthermore, the motor performance data analysis system also includes a data export module, which is used to download and export the various measurement data collected during monitoring for use.

[0020] Furthermore, the motor performance data analysis system also includes a database storage module for real-time storage of various measurement data collected during monitoring.

[0021] Furthermore, the motor performance data analysis system also includes a data display module, which is used to display various measurement data in real time in a graphical form and monitor all real-time operating conditions of the hydraulic motor.

[0022] Furthermore, the data display module uses polygonal graphics to display various measurement data in real time, forming a hydraulic motor performance monitoring graph.

[0023] Furthermore, the motor performance data analysis system is located in the cloud and interacts with the motor installation and testing hydraulic system via remote communication.

[0024] Compared with the prior art, this application has the following advantages:

[0025] This application addresses the performance evaluation and fault prediction requirements of hydraulic motors in tunnel boring machines (TBMs) under conditions of strong interference, high vibration, and cyclical operation. It proposes an on-site performance testing and evaluation system for internal curve hydraulic motors, comprising a motor on-site testing hydraulic system and a motor performance data analysis system. The motor on-site testing hydraulic system, based on the motor performance evaluation requirements, monitors various operating parameters of the hydraulic motor in real time by adding measurements of parameters such as motor inlet and outlet pressure, inlet flow rate, leakage oil flow rate, leakage oil temperature, motor torque, vibration, and leakage oil composition. Simultaneously, the motor performance data analysis system analyzes the hydraulic motor performance and predicts faults based on the real-time monitoring data, predicting hydraulic motor anomalies as early as possible and enabling timely shutdown and maintenance to avoid damage to the system during on-site testing and improve construction efficiency. Furthermore, by increasing the collected data and continuously iterating and correcting based on the obtained real-time monitoring data of the hydraulic motor, the accuracy of fault warnings is optimized. This is of great significance for the on-site application and experimental development of hydraulic components.

[0026] In addition to the purposes, features, and advantages described above, this application has other purposes, features, and advantages. The application will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0027] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings:

[0028] Figure 1 This is a schematic diagram of the hydraulic system principle for motor installation testing in the installation performance testing and evaluation system for an internal curve hydraulic motor according to a preferred embodiment of this application.

[0029] Figure 2 This is a schematic diagram of the motor performance data analysis system in the installation performance testing and evaluation system for the internal curve hydraulic motor of the preferred embodiment of this application.

[0030] Figure 3 This is a schematic diagram of the hydraulic motor performance monitoring graph according to a preferred embodiment of this application.

[0031] As shown in the figure:

[0032] 1. First motor pump unit; 2. Second motor pump unit; 3. Relief valve; 4. First pressure sensor; 5. First flow meter; 6. Vibration sensor; 7. Oil measuring instrument; 8. Torque sensor; 9. Oil direction control valve assembly; 10. Hydraulic motor; 11. Reducer; 12. Speed ​​sensor; 13. Temperature sensor; 14. Second flow meter; 15. Second pressure sensor; 16. Third flow meter; 17. Hydraulic oil tank; 18. Filter; 19. Shuttle valve; 20. Controller. Detailed Implementation

[0033] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0034] Reference Figure 1 and Figure 2 A preferred embodiment of this application provides a system for testing and evaluating the installation performance of an internal curve hydraulic motor, including a hydraulic system for motor installation testing and a motor performance data analysis system, wherein:

[0035] The hydraulic system for motor installation and testing includes a first motor pump unit 1 capable of bidirectional hydraulic oil output, a first pressure sensor 4, a reducer 11, a speed sensor 12, a temperature sensor 13, a second flow meter 14, a second pressure sensor 15, a vibration sensor 6, an oil measuring instrument 7, a torque sensor 8, a filter 18, a third flow meter 16, a hydraulic oil tank 17, an oil direction control valve group 9, and a controller 20.

[0036] The A port of the motor-pump assembly 1 is sequentially connected to the filter 18, the third flow meter 16, the oil direction control valve assembly 9, the first flow meter 5, and the B port of the motor-pump assembly 1. The second pressure sensor 15 is connected in parallel to the pipeline between the third flow meter 16 and the oil direction control valve assembly 9, and the first pressure sensor 4 is connected in parallel to the pipeline between the oil direction control valve assembly 9 and the B port of the motor-pump assembly 1. The reducer 11 is connected between the hydraulic motor 10 and the screw conveyor shaft to reduce the output speed of the hydraulic motor 10. The speed sensor 12 is used to measure the speed of the output shaft of the hydraulic motor 10. The temperature sensor 13 is used to measure the temperature of the leaking oil in the hydraulic motor 10. The second flow meter 14 is connected between the hydraulic motor 10 and the hydraulic oil tank 17 to measure the flow rate of the leaking oil in the hydraulic motor 10. The vibration sensor 6 is used to measure the vibration of the hydraulic motor 10 during operation. The oil measuring instrument 7 is used to measure the oil composition data in the hydraulic system. The torque sensor 8 is used to measure the output torque of the hydraulic motor 10. The controller 20 is used to control the hydraulic system for motor installation and testing.

[0037] The motor performance data analysis system includes a data monitoring module, a data analysis module, and a database correction module. The data monitoring module is used to monitor and collect various measurement data of the hydraulic motor 10 in the hydraulic system of the motor installation test. The data analysis module is used to analyze the various data of the hydraulic motor 10 collected by the data monitoring module in combination with commonly used formulas and standard data of the hydraulic system, and to quantify the influence of each factor on the performance of the hydraulic motor 10. The database correction module is used to continuously correct the calculation parameters of the hydraulic motor 10 installation performance evaluation by continuously collecting and storing the actual working load of the hydraulic motor 10, thereby increasing the sample diversity and sample base and improving the accuracy of fault early warning.

[0038] This embodiment addresses the performance evaluation and fault prediction requirements of hydraulic motors in tunnel boring machines (TBMs) under conditions of strong interference, high vibration, and cyclical operation. It proposes an on-site performance testing and evaluation system for internal curve hydraulic motors, comprising a motor on-site testing hydraulic system and a motor performance data analysis system. The motor on-site testing hydraulic system, based on the motor performance evaluation requirements, monitors various operating parameters of the hydraulic motor in real time by adding measurements of parameters such as motor inlet and outlet pressure, inlet flow rate, leakage oil flow rate, leakage oil temperature, motor torque, vibration, and leakage oil composition. Simultaneously, the motor performance data analysis system analyzes the hydraulic motor performance and predicts faults based on the real-time monitoring data, predicting hydraulic motor anomalies as early as possible and enabling timely shutdown and maintenance to avoid damage to the system during on-site testing and improve construction efficiency. Furthermore, by increasing the collected data and continuously iterating and correcting based on the obtained real-time monitoring data of the hydraulic motor, this embodiment optimizes the accuracy of fault warnings. This is of great significance for the on-site application and experimental development of hydraulic components.

[0039] Preferably, the hydraulic system for motor installation and testing further includes a second motor pump group 2 and a shuttle valve 19. The output end of the second motor pump group 2 is connected to the input end of the shuttle valve 19. The two output ends of the shuttle valve 19 are respectively connected to port A and port B of the first motor pump group 1, which is used to replenish the hydraulic main pump of the first motor pump group 1. The advantage of this is that it replenishes the system oil leakage and ensures the continuous and stable operation of the actuator.

[0040] Preferably, the hydraulic system for motor installation and testing further includes an overflow valve 3, which is connected to the output end of the second motor pump group 2 and is used to adjust the pressure of the replenishing pump in the second motor pump group 2. Its advantage is to maintain the stability of the replenishing pressure.

[0041] Preferably, the hydraulic direction control valve group 9 includes a bridge circuit composed of four check valves. Port A1 of the bridge circuit is connected to the third flow meter 16, port A2 is connected to the first flow meter 5, port B1 is connected to the hydraulic oil input end of the hydraulic motor 10, and port B2 is connected to the hydraulic oil output end of the hydraulic motor 10. The function of the hydraulic direction control valve group 9 is to allow hydraulic fluid to flow in one direction and cut off in the other direction, thereby controlling the hydraulic oil to flow in only from the hydraulic oil input end of the hydraulic motor 10.

[0042] Preferably, the motor performance data analysis system further includes a data alarm module, which is used to set thresholds for various measurement data of the hydraulic system for motor installation testing. When the actual measurement data exceeds the set threshold, an alarm is triggered to ensure timely understanding of whether the various measurement data meet the requirements. The alarm method can be an audible alarm, a photoelectric alarm, or a graphic image alarm.

[0043] Preferably, the motor performance data analysis system further includes a data export module, which is used to download and export the various measurement data collected during monitoring.

[0044] Preferably, the motor performance data analysis system further includes a database storage module for real-time storage of various measurement data collected during monitoring.

[0045] Preferably, the motor performance data analysis system further includes a data display module, which is used to display various measurement data in real time in a graphical form, and monitor all real-time operating conditions of the hydraulic motor 10, including hydraulic motor status (working / stopping), pressure of each working port, leakage oil temperature, leakage flow, inlet oil flow, as well as speed, working conditions, sensor electrical faults and other information.

[0046] Preferably, such as Figure 3 As shown, the data display module uses polygonal graphics to display various measurement data in real time, forming a hydraulic motor performance monitoring graph.

[0047] This embodiment uses a polygonal performance monitoring graph to display motor performance parameters. This method is more intuitive, makes the correlation between multiple parameters more direct, and makes it easier to analyze and resolve fault causes.

[0048] Preferably, the motor performance data analysis system is located in the cloud and interacts with the motor installation and testing hydraulic system via remote communication.

[0049] This embodiment establishes a cloud monitoring station by setting up the motor performance data analysis system in the cloud. This station collects and displays data on all in-service motors of the tunnel boring machine (TBM), enabling real-time online monitoring and real-time sharing of all collected data. The cloud monitoring station stores operating data and fault information for all in-service hydraulic motors. Hydraulic motor R&D personnel can also obtain real-time data from the hydraulic motors via the Internet of Things (IoT). Combining this data with actual installation application data and fault cases, they can analyze the areas where components need optimization in TBM applications, optimize the structure accordingly, and verify the effectiveness of the improvements through subsequent installation applications.

[0050] In the above embodiments, digital control consists of a PLC and electrical actuators, while analog control consists of an industrial computer combined with LabVIEW software. By analyzing the collected physical quantities such as motor pressure, flow rate, and temperature, the system adjusts the motor speed, solenoid valves, and other related components in the hydraulic system. Simultaneously, the motor performance data analysis system displays the test results and real-time monitoring screen on a human-machine interface, facilitating operator observation and saving of test results and understanding of the hydraulic motor's operating status.

[0051] The above embodiments use the hydraulic motor operating data collected in the early stage as the initial database, which serves as the judgment benchmark for the initial fault warning in the later stage. The analysis is carried out according to certain similarity criteria to predict fault information in advance and perform corresponding motor maintenance. By continuously enriching the collected data, the accuracy of fault warning in the database is iteratively optimized to reduce the impact of motor failure.

[0052] In addition to the embodiments described above, as an alternative, this application may also:

[0053] 1. The installation performance testing and evaluation system is not only applicable to the hydraulic motor of the screw conveyor, but also to hydraulic pumps, cylinders and other hydraulic components;

[0054] 2. The performance testing parameters for hydraulic motors include not only pressure and speed, but also embedded sensors installed in the hydraulic motor components to conduct structural life health monitoring and analysis.

[0055] In summary, the installation performance testing and evaluation system for the internal curve hydraulic motor provided in this application, based on an integrated design and optimization process of "mechanism-performance-structure," offers a solution for achieving the goals of installation performance monitoring, key performance evaluation, and rational structural optimization. The data obtained from this solution provides data support for the iterative optimization of the hydraulic motor structure and enables real-time monitoring of the hydraulic motor's operating data. Furthermore, it allows for performance analysis and fault prediction of the hydraulic motor through a cloud monitoring station, improving construction efficiency. This is of great significance for the installation application and experimental development of hydraulic components.

[0056] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0057] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A system for testing and evaluating the installation performance of an internal curve hydraulic motor, characterized in that, This includes a hydraulic system for motor installation and testing, and a motor performance data analysis system, among which: The hydraulic system for motor installation and testing includes a first motor pump group (1) capable of bidirectional hydraulic oil output, a first pressure sensor (4), a reducer (11), a speed sensor (12), a temperature sensor (13), a second flow meter (14), a second pressure sensor (15), a vibration sensor (6), an oil measuring instrument (7), a torque sensor (8), a filter (18), a third flow meter (16), a hydraulic oil tank (17), an oil direction control valve group (9), and a controller (20). The A port of the motor pump assembly (1) is sequentially connected to the filter (18), the third flow meter (16), the oil direction control valve assembly (9), the first flow meter (5), and the B port of the motor pump assembly (1). The second pressure sensor (15) is connected in parallel to the pipeline between the third flow meter (16) and the oil direction control valve assembly (9), and the first pressure sensor (4) is connected in parallel to the pipeline between the oil direction control valve assembly (9) and the B port of the motor pump assembly (1). The reducer (11) is connected between the hydraulic motor (10) and the screw conveyor shaft to reduce the output speed of the hydraulic motor (10). The speed sensor... (12) is used to measure the rotational speed of the output shaft of the hydraulic motor (10); the temperature sensor (13) is used to measure the temperature of the leaking oil of the hydraulic motor (10); the second flow meter (14) is connected between the hydraulic motor (10) and the hydraulic oil tank (17) to measure the flow rate of the leaking oil of the hydraulic motor (10); the vibration sensor (6) is used to measure the vibration of the hydraulic motor (10) during operation; the oil measuring instrument (7) is used to measure the oil composition data in the hydraulic system; the torque sensor (8) is used to measure the output torque of the hydraulic motor (10); the controller (20) is used to control the hydraulic system for motor installation and testing. The motor performance data analysis system includes: The data monitoring module is used to monitor and collect various measurement data of the hydraulic motor (10) in the hydraulic system of the motor installation test. The data analysis module is used to analyze the various data of the hydraulic motor (10) collected by the data monitoring module by combining commonly used formulas and standard data of hydraulic system, and to quantify the degree of influence of each factor on the performance of the hydraulic motor (10). The database correction module is used to continuously correct the calculation parameters for evaluating the installation performance of the hydraulic motor (10) by continuously collecting and storing the actual working load of the hydraulic motor (10), increasing the sample diversity and sample base, and improving the accuracy of fault warning.

2. The system for testing and evaluating the installation performance of an internal curve hydraulic motor according to claim 1, characterized in that, The hydraulic system for motor installation and testing also includes a second motor pump group (2) and a shuttle valve (19). The output end of the second motor pump group (2) is connected to the input end of the shuttle valve (19). The two output ends of the shuttle valve (19) are respectively connected to the A port and the B port of the first motor pump group (1) for replenishing oil to the hydraulic main pump of the first motor pump group (1).

3. The system for testing and evaluating the installation performance of an internal curve hydraulic motor according to claim 2, characterized in that: The hydraulic system for motor installation and testing also includes a relief valve (3), which is connected to the output end of the second motor pump group (2) and is used to adjust the pressure of the replenishing pump.

4. The system for testing and evaluating the installation performance of an internal curve hydraulic motor according to claim 1, characterized in that: The hydraulic direction control valve group (9) includes a bridge circuit consisting of four check valves. Port A1 of the bridge circuit is connected to the third flow meter (16), port A2 is connected to the first flow meter (5), port B1 is connected to the hydraulic oil input end of the hydraulic motor (10), and port B2 is connected to the hydraulic oil output end of the hydraulic motor (10). This is used to control the hydraulic oil to flow in only from the hydraulic oil input end of the hydraulic motor (10).

5. The system for testing and evaluating the installation performance of an internal curve hydraulic motor according to claim 1, characterized in that: The motor performance data analysis system also includes a data alarm module, which is used to set thresholds for various measurement data of the hydraulic system for motor installation testing, and to issue an alarm when the actual measurement data exceeds the set threshold.

6. The system for testing and evaluating the installation performance of an internal curve hydraulic motor according to claim 5, characterized in that: The motor performance data analysis system also includes a data export module, which is used to download and export various measurement data collected during monitoring.

7. The system for testing and evaluating the installation performance of an internal curve hydraulic motor according to claim 6, characterized in that: The motor performance data analysis system also includes a database storage module for real-time storage of various measurement data collected during monitoring.

8. The system for testing and evaluating the installation performance of an internal curve hydraulic motor according to claim 7, characterized in that: The motor performance data analysis system also includes a data display module, which is used to display various measurement data in real time in a graphical form and monitor the real-time operation of the hydraulic motor (10).

9. The system for testing and evaluating the installation performance of an internal curve hydraulic motor according to claim 8, characterized in that: The data display module uses polygonal graphics to display various measurement data in real time, forming a hydraulic motor performance monitoring graph.

10. The system for testing and evaluating the installation performance of an internal curve hydraulic motor according to claim 1, characterized in that: The motor performance data analysis system is located in the cloud and interacts with the motor installation and testing hydraulic system remotely.

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