A force analysis system and analysis method of a lateral pressure sensor

Abstract

The present invention relates to the field of intelligent sensor technology, and discloses a force analysis system and analysis method of a lateral pressure sensor, including a strain analysis module, a force analysis module, a frequency response module, a data compensation module, a data processing module, a dynamic test module, a data recording module and a sampling rate adjustment module; the strain analysis module is used to derive the force condition according to the strain of the elastic body, and the change of the elastic body is proportional to the force, and the force magnitude is calculated by the resistance change of the strain gauge; the force analysis module analyzes the force condition of the guide wheel according to the force of the middle wheel and the wire rope. The present invention collects the error of the external environment and its own mechanical loss to determine whether the error exceeds the value output of the sensor, and increases the frequency of data collection of the sensor electrical signal, temperature, etc. according to the excess influence, so that the force analysis and correction of the lateral pressure sensor can be effectively completed.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent sensors, and more specifically to a force analysis system and an analysis method of a lateral pressure sensor. Background Art

[0002] The lateral pressure sensor is a type of sensor commonly used to measure pressure. Its principle is to use the pressure of the measured medium on the sensor to convert the pressure signal into an electrical signal output through the internal sensitive elements (such as strain gauges, pressure sensor chips, etc.). The force analysis of the system usually involves the following key aspects.

[0003] The lateral pressure sensor, also known as the lateral pressure tension sensor, is specially used to measure the tension of wire ropes and flexible ropes. It is a weighing and force measuring type sensor with high reliability, good interchangeability, and easy use. The lateral pressure sensor is mainly used on lifting equipment such as electric hoists and wire rope straight hoists. It is suitable for overload control and process display in industries such as lifting, water conservancy, and coal mining.

[0004] The lateral pressure sensor is a double-hole shear beam structure, which is generally composed of a main body, a wire rope support seat, a pressure block, a clamping bolt, etc. The pressure block is fixed to the main body by two clamping bolts. The wire rope support seat is connected to both ends of the main body. The wire rope is embedded in the grooves on both sides of the sensor. The wire rope is fixed to the sensor by U-shaped bolts (or pressure blocks + bolts). When the wire rope is subjected to tension, it is transmitted to the circuit board inside the shell through the tension sensor to complete the collection of the wire rope tension.

[0005] When the existing lateral pressure sensor collects data information, the accuracy of the sensor output will be affected by wear and mechanical factors. In addition, the sampling rate of the existing sensor is relatively consistent and cannot be changed in real time. In the case of large errors, the sampling frequency cannot be increased to improve the accuracy of data optimization compensation. Summary of the invention

[0006] The main technical problem solved by the present invention is to provide a force analysis system and analysis method of a lateral pressure sensor, which solves the problems in the above-mentioned background technology.

[0007] To solve the above technical problems, according to one aspect of the present invention, more specifically, a force analysis system for a lateral pressure sensor includes a strain analysis module, a force analysis module, a frequency response module, a data compensation module, a data processing module, a dynamic test module, a data recording module, and a sampling rate adjustment module;

[0008] The strain analysis module is used to deduce the stress condition according to the strain of the elastic body, the change of the elastic body is proportional to the stress, and the magnitude of the stress is calculated by the resistance change of the strain gauge;

[0009] The force analysis module analyzes the force condition of the guide wheel according to the force of the middle wheel and the force of the wire rope;

[0010] The frequency response module is used to collect the force change data of the elastic body according to different sampling frequencies, and increase the sampling frequency when the sensor is greatly affected by the external environment and its own loss, and reduce the sampling frequency when the impact is small;

[0011] The data compensation module performs data correction and compensation based on known sensor characteristics and measured data to eliminate deviation or nonlinearity in the sensor output;

[0012] The data processing module is used to amplify and filter the electrical signal output by the sensor to facilitate subsequent data collection and analysis, and calibrate the sensor through standard tests to ensure that the pressure value output by the sensor is accurate and reliable;

[0013] The data recording module is used to record the data log of the sensor configuration change;

[0014] The dynamic test module is used to linearly output the data collected by the frequency response module at different frequencies to the data compensation module in a time sequence;

[0015] The sampling rate adjustment module is used to adjust the sampling frequency of the elastic body strain gauge, thereby adjusting the speed and accuracy of capturing and recording signal changes.

[0016] Furthermore, the data compensation module specifically includes a material property definition module, a temperature compensation module and a mechanical compensation module;

[0017] The material property definition module is used to determine the material properties of the sensor that will be affected by temperature changes, including the thermal expansion coefficient and strength of the elastic strain gauge;

[0018] The temperature compensation module is used to offset the influence of temperature changes on sensor performance and rope length changes, including using a temperature sensor to monitor the ambient temperature and adjusting the output signal of the sensor according to the temperature change to ensure its measurement accuracy at different temperatures;

[0019] The mechanical compensation module is used to compensate for the wear of the guide wheel and the middle wheel diameter caused by repeated mechanical movements.

[0020] Furthermore, the conductivity of the elastic material itself and the length of the steel wire rope change under different temperature changes. At the same time, different elastic bodies are affected by different materials and shapes and their stress characteristics also change, including:

[0021]

[0022] Among them, W represents the resistance index of the elastic material affected by its own shape and temperature, v represents the volume of the elastic body, s represents the area of ​​the elastic body, and T represents the affected ambient temperature; and there are:

[0023] K=R0·[1+α(T-T0)]

[0024] Among them, K represents the conductivity of the elastomer under the influence of temperature, T0 represents the standard value of temperature, R0 represents the resistance value of the elastomer at T0 temperature, and α represents the influence coefficient of temperature on the resistance of the elastomer; and:

[0025]

[0026] In the formula, c represents the index of the combined influence of environmental and mechanical factors on the elastic material;

[0027] When 1.6<c, the sensor detection data is greatly affected by the combined influence of environmental and mechanical factors, and its frequency response module needs to increase the data signal acquisition frequency.

[0028] Furthermore, the data processing module specifically includes a signal filtering module and a data correction module;

[0029] The signal filtering module is used to remove high-frequency noise, retain low-frequency signals, and perform real-time data processing to balance response speed and signal smoothness;

[0030] The data correction module is used to perform data correction according to the influence of the actual working environment on the elastic body and the degree of wear of the guide wheel and the middle wheel.

[0031] Furthermore, when the force analysis module performs force analysis on the middle wheel, the wire rope tension is T, the angle on the middle wheel is θ, the force on the middle wheel is F, and:

[0032]

[0033] Here, F increases as the angle θ decreases.

[0034] Furthermore, the force analysis module analyzes the force of the wire rope on the guide wheel, and the downward positive pressure of the wire rope is the longitudinal component of the resultant force at the pulley center O, and the positive pressure of the wire rope on the pulley from point A (or point B) to point P is 0 to T.

[0035] When the tension T remains unchanged, the larger the wrap angle θ, the greater the force exerted by the wire rope on the pulley; when the wrap angle θ is 180°, the resultant force is 2T.

[0036] The normal pressure of the wire rope tension T on the pulley only changes the direction of the force, but the magnitude of the force does not change;

[0037] Among them, the normal pressure on the guide wheel is calculated with the middle wheel as the fulcrum:

[0038]

[0039] In the formula, F 垂直 Indicates the magnitude of the positive pressure that the guide wheel bears on the wire rope.

[0040] Furthermore, the sampling rate adjustment module specifically includes a parameter calibration module and a parameter tracking module;

[0041] The parameter calibration module is used to ensure the accuracy and repeatability of the calibration process using specific gravity method and electrical calibration;

[0042] The parameter tracking module is used to record and track the results and historical data of each calibration, so as to analyze the long-term trend and changes of sensor performance and timely discover and deal with potential problems.

[0043] An analysis method for a lateral pressure sensor force analysis system comprises the following steps:

[0044] S1, the strain analysis module converts the elastic body change into an electrical signal change and transmits it to the force analysis module;

[0045] S2. The force analysis module outputs the force magnitude of the lateral pressure sensor according to the force condition and in combination with the optimized compensation data of the data compensation module, and the frequency response module is responsible for collecting the data.

[0046] S3, the frequency response module will also receive parameter information from the data compensation module. When the elastic body and the wire rope are greatly affected by the outside, the frequency response module will increase the frequency of signal acquisition;

[0047] S4, the data collected by the sensor is filtered and corrected by the data processing module and then output and stored, and the filtered and corrected data is also fed back to the data compensation module;

[0048] S5, the frequency response module also transmits the collected data to the data compensation module after passing through the dynamic test module;

[0049] S6, the data compensation module performs real-time optimization compensation based on the material, real-time temperature changes and real-time mechanical property changes.

[0050] The beneficial effects of the force analysis system and analysis method of the lateral pressure sensor of the present invention are as follows:

[0051] 1. The present invention collects the error of the external environment and its own mechanical loss to determine whether the error has an excessive impact on the numerical output of the sensor, and increases the frequency of collecting sensor electrical signals, temperature and other data based on the excessive impact, so that the force analysis and correction of the lateral pressure sensor can be effectively completed.

[0052] 2. The present invention analyzes the stress condition of the lateral pressure sensor, analyzes the stress on the wheel in the sensor, and the force applied by the wire rope to the pulley, so that the output data can be corrected in advance. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The present invention is further described in detail below with reference to the accompanying drawings and specific implementation methods.

[0054] Figure 1 It is a schematic diagram of the structure of the present invention;

[0055] Figure 2 This is a schematic diagram of the force on the wheel in the lateral pressure sensor;

[0056] Figure 3 Schematic diagram of the wire rope exerting force on the guide wheel. DETAILED DESCRIPTION

[0057] The present invention will be described in detail below with reference to the accompanying drawings and in combination with embodiments. It should be noted that the embodiments and features in the embodiments of the present application can be combined with each other without conflict.

[0058] like Figure 1 As shown, according to one aspect of the present invention, there is provided an analysis method for a force analysis system of a lateral pressure sensor, comprising the following steps:

[0059] Step 1: The strain analysis module converts the elastic body variation into an electrical signal variation and transmits it to the force analysis module;

[0060] Step 2: The force analysis module outputs the force magnitude of the lateral pressure sensor according to the force condition and in combination with the optimized compensation data of the data compensation module, and the frequency response module is responsible for collecting the data;

[0061] Step 3: The frequency response module will also receive parameter information from the data compensation module. When the elastic body and the wire rope are greatly affected by external factors, the frequency response module will increase the frequency of signal acquisition.

[0062] Step 4: The data collected by the sensor is filtered and corrected by the data processing module and then output and stored. The filtered and corrected data will also be fed back to the data compensation module;

[0063] Step 5: The frequency response module also transmits the collected data to the data compensation module after passing through the dynamic test module;

[0064] Step 6: The data compensation module performs real-time optimization compensation based on the material, real-time temperature changes, and real-time mechanical property changes.

[0065] like Figure 1-3 As shown, a force analysis system for a lateral pressure sensor includes a strain analysis module, a force analysis module, a frequency response module, a data compensation module, a data processing module, a dynamic test module, a data recording module and a sampling rate adjustment module; the strain analysis module is used to deduce the force condition according to the strain of the elastic body, the change of the elastic body is proportional to the force, and the force magnitude is calculated by the resistance change of the strain gauge; the force analysis module analyzes the force of the middle wheel and the force condition of the wire rope on the guide wheel; the frequency response module is used to collect the force change data of the elastic body according to different sampling frequencies, increase the sampling frequency when the sensor is greatly affected by the external environment and its own loss, and reduce the sampling frequency when the impact is small; by analyzing the force condition of the lateral pressure sensor, the force of the sensor middle wheel and the force analysis of the wire rope on the pulley are analyzed, so that the output data can be corrected in advance.

[0066] The data compensation module performs data correction and compensation according to the known sensor characteristics and measured data to eliminate the deviation or nonlinearity in the sensor output; the data processing module is used to amplify and filter the electrical signal output by the sensor to facilitate subsequent data collection and analysis, and calibrate the sensor through standard tests to ensure that the pressure value it outputs is accurate and reliable; the data recording module is used to record the data log of the sensor configuration change; the dynamic test module is used to linearly output the data collected by the frequency response module at different frequencies to the data compensation module in chronological order; the sampling rate adjustment module is used to adjust the sampling frequency of the elastic body strain gauge, thereby adjusting the speed and accuracy of capturing and recording signal changes, and by collecting the error of the external environment and its own mechanical loss, it is determined whether the error exceeds the value output of the sensor, and the frequency of collecting the sensor electrical signal, temperature and other data is increased according to the excess impact, so that the force analysis and correction of the lateral pressure sensor can be effectively completed.

[0067] In this embodiment, the data compensation module specifically includes a material property definition module, a temperature compensation module and a mechanical compensation module; the material property definition module is used to determine how temperature changes will affect the material properties of the sensor, including the thermal expansion coefficient and strength of the elastic strain gauge; the temperature compensation module is used to offset the impact of temperature changes on sensor performance and changes in rope length, including using a temperature sensor to monitor the ambient temperature and adjusting the output signal of the sensor according to temperature changes to ensure its measurement accuracy at different temperatures; the mechanical compensation module is used to compensate for the wear of the guide wheel and the middle wheel diameter caused by repeated mechanical movements.

[0068] In this embodiment, the conductivity of the elastic material itself and the length of the steel wire rope change when subjected to different temperature changes. At the same time, different elastic bodies are affected by different materials and shapes and their force characteristics also change, as follows:

[0069]

[0070] Among them, W represents the resistance index of the elastic material affected by its own shape and temperature, v represents the volume of the elastic body, s represents the area of ​​the elastic body, and T represents the affected ambient temperature; and there are:

[0071] K=R0·[1+α(T-T0)]

[0072] Among them, K represents the conductivity of the elastomer under the influence of temperature, T0 represents the standard value of temperature, R0 represents the resistance value of the elastomer at T0 temperature, and α represents the influence coefficient of temperature on the resistance of the elastomer; and:

[0073]

[0074] In the formula, c represents the index of the combined influence of environmental and mechanical factors on the elastic material;

[0075] When 1.6>c, the sensor detection data is greatly affected by the combined influence of environmental and mechanical factors, and its frequency response module needs to increase the data signal acquisition frequency.

[0076] In the sample, the volume of the elastic body is v=86, the area of ​​the elastic body is s=94, and the affected ambient temperature is T=31, so:

[0077]

[0078] Moreover, in the sample, the standard value of temperature is T0=28, at which the resistance value of the elastomer is R0=1.6, and the influence coefficient of temperature on the resistance of the elastomer is α=0.18, so:

[0079] K=1.6×[1+0.18×(31-28)]=2.5

[0080] Then the indexes of elastic materials affected by environmental and mechanical factors are:

[0081]

[0082] At this time, c=0.9, which does not satisfy the condition of 1.6>c. At this time, the sensor detection data is in a normal state due to the combined influence of environmental and mechanical factors.

[0083] In this embodiment, the data processing module specifically includes a signal filtering module and a data correction module; the signal filtering module is used to remove high-frequency noise, retain low-frequency signals, and perform real-time data processing to balance response speed and signal smoothness; the data correction module is used to perform data correction based on the impact of the actual working environment on the elastomer and the degree of wear of the guide wheel and the middle wheel.

[0084] In this embodiment, when the force analysis module performs force analysis on the middle wheel, the wire rope tension is T, the angle on the middle wheel is θ, the force on the middle wheel is F, and:

[0085]

[0086] Here, F increases as the angle θ decreases.

[0087] Among them, when the angle is 0°, 120°, 151°, and 180°, the calculated forces on the middle wheel are as follows:

[0088]

[0089] As can be seen from the table above, the tension T of the wire rope and the force F on the elastic body of the sensor are two different things. In this discussion, the tension T is fixed, and the change of F with the angle θ is explored.

[0090] The angle θ when the elastic body is subjected to half the tension of the wire rope. If the force F on the elastic body is to be half the tension T of the wire rope, that is, So θ=151°, so the θ angle of the general lateral pressure sensor is usually around 150°. Theory shows that no matter where the tangent point between the wire rope and the guide wheel is, the force direction of the wire rope on the guide wheel always passes through the axis, so its vertical force component also passes through the axis;

[0091] For a certain wire rope tension T, since the force on the elastic body is only related to the wire rope angle θ, it is only related to three mechanical factors: the diameter D and spacing L of the two guide wheels, and the height difference H between the guide wheel and the middle wheel. That is, when L is determined, a large range of tension changes can be changed to D; a small range of tension changes can be changed to H.

[0092] When conducting a simulation test on the sensor's middle wheel, the force on the middle wheel should be calculated based on the sensor size, and the guide wheels at both ends should be used as fulcrums to apply the pressure that the middle wheel should bear downward at the middle middle wheel.

[0093] In this embodiment, the force analysis module analyzes the force of the wire rope on the guide wheel. The downward positive pressure of the wire rope is the longitudinal component of the resultant force at the pulley center O, and the positive pressure of the wire rope on the pulley from point A (or point B) to point P is 0 to T. When the tension T remains unchanged, the greater the wrap angle θ, the greater the force of the wire rope on the pulley; when the wrap angle θ is 180°, the resultant force is 2T. The positive pressure of the wire rope tension T on the pulley only changes the direction of the force, but the magnitude of the force does not change;

[0094] Among them, the normal pressure on the guide wheel is calculated with the middle wheel as the fulcrum:

[0095]

[0096] In the formula, F 垂直 Indicates the magnitude of the positive pressure that the guide wheel bears on the wire rope.

[0097] In this embodiment, the sampling rate adjustment module specifically includes a parameter calibration module and a parameter tracking module; the parameter calibration module is used to use the specific gravity method and electrical calibration to ensure the accuracy and repeatability of the calibration process; the parameter tracking module is used to record and track the results and historical data of each calibration, so as to analyze the long-term trends and changes in sensor performance and promptly discover and deal with potential problems.

[0098] Of course, the above description is not a limitation of the present invention, and the present invention is not limited to the above examples. Changes, modifications, additions or substitutions made by ordinary technicians in this technical field within the essential scope of the present invention also fall within the protection scope of the present invention.

Claims

1. A force analysis system for a lateral pressure sensor, characterized in that: It includes a strain analysis module, a force analysis module, a frequency response module, a data compensation module, a data processing module, a dynamic test module, a data recording module and a sampling rate adjustment module; The strain analysis module is used to deduce the stress condition according to the strain of the elastic body, the change of the elastic body is proportional to the stress, and the magnitude of the stress is calculated by the resistance change of the strain gauge; The force analysis module analyzes the force condition of the guide wheel according to the force of the middle wheel and the force of the wire rope; The frequency response module is used to collect the force change data of the elastic body according to different sampling frequencies, and increase the sampling frequency when the sensor is greatly affected by the external environment and its own loss, and reduce the sampling frequency when the impact is small; The data compensation module performs data correction and compensation based on known sensor characteristics and measured data to eliminate deviation or nonlinearity in the sensor output; The data processing module is used to amplify and filter the electrical signal output by the sensor to facilitate subsequent data collection and analysis, and calibrate the sensor through standard tests to ensure that the pressure value output by the sensor is accurate and reliable; The data recording module is used to record the data log of the sensor configuration change; The dynamic test module is used to linearly output the data collected by the frequency response module at different frequencies to the data compensation module in a time sequence; The sampling rate adjustment module is used to adjust the sampling frequency of the elastic body strain gauge, thereby adjusting the speed and accuracy of capturing and recording signal changes; Among them, the strain analysis module converts the change of the elastic body into the change of the electrical signal and transmits it to the force analysis module; the force analysis module outputs the force size of the lateral pressure sensor according to the force condition and combined with the optimized compensation data of the data compensation module, and the frequency response module is responsible for collecting it; the frequency response module will also receive the parameter information of the data compensation module. When the elastic body and the wire rope are greatly affected by the outside, its frequency response module will increase the frequency of signal collection; the data collected by the sensor will be filtered and corrected by the data processing module before being output and stored, and the filtered and corrected data will also be fed back to the data compensation module; the frequency response module will also pass the collected data to the data compensation module after passing through the dynamic test module; the data compensation module will perform real-time optimization and compensation according to the material, real-time temperature changes and real-time mechanical property changes; The data compensation module specifically includes a material property definition module, a temperature compensation module and a mechanical compensation module; The material property definition module is used to determine the material properties of the sensor that will be affected by temperature changes, including the thermal expansion coefficient and strength of the elastic strain gauge; The temperature compensation module is used to offset the influence of temperature changes on sensor performance and rope length changes, including using a temperature sensor to monitor the ambient temperature and adjusting the output signal of the sensor according to the temperature change to ensure its measurement accuracy at different temperatures; The mechanical compensation module is used to compensate for the wear of the guide wheel and the middle wheel diameter caused by repeated mechanical movements; The conductivity of the elastic material itself and the length of the steel wire rope change under different temperature changes. At the same time, different elastic bodies are affected by different materials and shapes and their stress characteristics also change, including: Among them, W represents the resistance index of the elastic material affected by its own shape and temperature, v represents the volume of the elastic body, s represents the area of ​​the elastic body, and T represents the affected ambient temperature; and there are: K=R0·[1+α(T-T0)] Among them, K represents the conductivity of the elastomer under the influence of temperature, T0 represents the standard value of temperature, R0 represents the resistance value of the elastomer at T0 temperature, and α represents the influence coefficient of temperature on the resistance of the elastomer; and: In the formula, c represents the index of the combined influence of environmental and mechanical factors on the elastic material; When 1.6<c, the sensor detection data is greatly affected by the combined influence of environmental and mechanical factors, and its frequency response module needs to increase the data signal acquisition frequency.

2. The force analysis system of the lateral pressure sensor according to claim 1, characterized in that: The data processing module specifically includes a signal filtering module and a data correction module; The signal filtering module is used to remove high-frequency noise, retain low-frequency signals, and perform real-time data processing to balance response speed and signal smoothness; The data correction module is used to perform data correction according to the influence of the actual working environment on the elastic body and the degree of wear of the guide wheel and the middle wheel.

3. The force analysis system of the lateral pressure sensor according to claim 1, characterized in that: When the force analysis module performs force analysis on the middle wheel, the wire rope tension is T, the angle on the middle wheel is θ, the force on the middle wheel is F, and: Here, F increases as the angle θ decreases.

4. The force analysis system of the lateral pressure sensor according to claim 1, characterized in that: The force analysis module analyzes the force of the guide wheel under the steel wire rope, and the downward positive pressure of the steel wire rope is the longitudinal component of the resultant force at the pulley center O, and the positive pressure of the steel wire rope on the pulley from point A to point P is 0 to T; When the tension T remains unchanged, the larger the wrap angle θ, the greater the force exerted by the wire rope on the pulley; when the wrap angle θ is 180°, the resultant force is 2T; The normal pressure of the wire rope tension T on the pulley only changes the direction of the force, but the magnitude of the force does not change; Among them, the normal pressure on the guide wheel is calculated with the middle wheel as the fulcrum: In the formula, F 垂直 Indicates the magnitude of the positive pressure that the guide wheel bears on the wire rope.

5. The force analysis system of the lateral pressure sensor according to claim 1, characterized in that: The sampling rate adjustment module specifically includes a parameter calibration module and a parameter tracking module; The parameter calibration module is used to ensure the accuracy and repeatability of the calibration process using specific gravity method and electrical calibration; The parameter tracking module is used to record and track the results and historical data of each calibration, so as to analyze the long-term trend and changes of sensor performance and timely discover and deal with potential problems.

6. An analysis method for a force analysis system of a lateral pressure sensor according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1, the strain analysis module converts the elastic body change into an electrical signal change and transmits it to the force analysis module; S2. The force analysis module outputs the force magnitude of the lateral pressure sensor according to the force condition and in combination with the optimized compensation data of the data compensation module, and the frequency response module is responsible for collecting the data. S3, the frequency response module will also receive parameter information from the data compensation module. When the elastic body and the wire rope are greatly affected by the outside, the frequency response module will increase the frequency of signal acquisition; S4, the data collected by the sensor is filtered and corrected by the data processing module and then output and stored, and the filtered and corrected data is also fed back to the data compensation module; S5, the frequency response module also transmits the collected data to the data compensation module after passing through the dynamic test module; S6, the data compensation module performs real-time optimization compensation based on the material, real-time temperature changes and real-time mechanical property changes.

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