Extra large and extra long digital cylinder based on key components

Abstract

The present invention discloses an extra-large and extra-long digital oil cylinder based on new key components, including an oil cylinder body structure, an oil cylinder V-group main seal, a spherical bearing, a piston rod laser cladding coating, an oil cylinder state monitoring and adjustment unit, an oil cylinder bearing monitoring and evaluation unit, a piston rod coating monitoring and evaluation unit, an industrial computer, a display screen and an audible and visual alarm; the spherical bearing is a domestic self-lubricating spherical bearing. The V-group seal is a domestic seal, including a pressure ring, a sealing ring and a support ring. The laser cladding coating of the piston rod is a domestic self-developed powder and an ultra-high-speed laser cladding construction technology. The present invention can realize fine control of the main oil cylinder of the pile frame of the pile driving ship under different working conditions, significantly improve the safety of the use of the main oil cylinder of the pile frame of the pile driving ship; realize online performance evaluation and real-time status detection of the oil cylinder spherical bearing, and ensure the long-term safe use of the oil cylinder; predict the remaining life of the spherical bearing in service, plan the replacement of the spherical bearing in advance, and avoid delays in the construction period.

Description

Technical Field

[0001] The present invention relates to the technical field of oil cylinders, and more specifically, to an extra-large and extra-long digital oil cylinder based on a new type of key component. Background Art

[0002] With the development of science and technology, the application of super-large and super-long cylinders in the fields of metallurgical forging equipment, maritime and offshore ships, large-scale engineering construction, etc. is also increasing. The design difficulty, reliability requirements, raw material production difficulty, processing difficulty, and surface processing difficulty of super-large and super-long cylinders are much higher than those of ordinary cylinders. The current design and manufacturing level of super-large and super-long cylinders lags behind that of the world's leading companies. The complete cylinder machine mainly adopts foreign brands, and key components such as cylinder V-group seals, spherical bearing fabric liner raw materials, and piston rod laser cladding coating materials are completely dependent on imports, which poses a risk of "stuck neck".

[0003] The main oil cylinder of the pile frame of a pile-driving ship is a typical representative of super-large and super-long oil cylinders. It is the core component of a large pile-driving ship. It is mainly used for the pitching action of the pile frame, and mainly includes key components such as cylinder seals, spherical bearings and piston rod surface coatings. Domestic key components have problems such as rapid aging, poor batch stability, and short fatigue life, which leads to serious performance degradation and low reliability of the cylinder when the whole machine is working, and cannot meet the extreme service conditions of large pile-driving ships. As marine engineering construction continues to extend to deep water areas in the offshore area, major engineering projects such as cross-sea channels and deep-sea wind power construction are increasing, and there is an increasing reliance on large pile-driving ships, and their specifications are getting larger and larger. The world's largest 150m pile-driving ship currently being built by the Second Navigation Bureau has a cylinder diameter of more than 1.6m and a stroke of more than 21m.

[0004] The super-large pile-driving ship uses a single oil cylinder to achieve the boom operation of the pile frame weighing thousands of tons. Since the pile frame weighs thousands of tons and is very inconvenient to repair, when the main oil cylinder and key components fail or fail, the pile-driving ship will be unusable at the least, requiring a long maintenance cycle and expensive maintenance costs; at the worst, the boom will suddenly collapse, resulting in serious safety accidents. This requires the main oil cylinder of the pile frame of the pile-driving ship to meet high performance and high reliability requirements.

[0005] The main working conditions of pile driving operations of pile driving ships include laying, prone piles, upright piles, vertical piles and changing capstans. The stress characteristics and usage requirements of the cylinders under different working conditions are different. The current main cylinder of the pile frame of pile driving ships is relatively extensive when in use. The stress conditions of cylinders with different strokes are not controlled, and the usage requirements of cylinders under different working conditions are not distinguished. It only monitors key parameters such as the working pressure and stroke of the cylinder, and does not conduct online evaluation of the status of key components of the cylinder, which poses certain safety risks. Summary of the invention

[0006] The purpose of the present invention is to provide an extra-large and extra-long digital cylinder based on a new key component, so as to realize fine control of the main cylinder of the pile frame of a pile driving ship under different working conditions, and significantly improve the safety of the use of the main cylinder of the pile frame of the pile driving ship.

[0007] The technical solution adopted by the present invention to solve this technical problem is: an ultra-large and ultra-long digital oil cylinder based on new key components, including: an oil cylinder body structure, an oil cylinder V-group seal, key components such as spherical bearings, a piston rod laser cladding coating, an oil cylinder state monitoring and adjustment unit, an oil cylinder bearing monitoring and evaluation unit, a piston rod coating monitoring and evaluation unit, an industrial computer, a display screen and an audible and visual alarm;

[0008] The oil cylinder V group seal is a domestic seal, which is mainly composed of a pressure ring, a sealing ring and a support ring.

[0009] Preferably, the domestic V-group sealing material uses cloth-reinforced rubber, selects customized FKM as the basic raw rubber, uses N990 and special mineral carbon black as filler, and selects TAIC / double 2.5 combination as the vulcanization system, supplemented by ZnO, HT-290 and WS-280. This solves the problems of poor pressure resistance, poor impact resistance and short service life of domestic V-group seals, and breaks through the domestic V-group seal preparation technology for large-size cylinders.

[0010] The spherical plain bearing is a domestic self-lubricating spherical plain bearing, which is mainly composed of an inner ring, an outer ring and a self-lubricating liner.

[0011] Preferably, the self-lubricating gasket is prepared from domestic yarn through a special pre-treatment process, including soaking the yarn in a slurry and twisting the yarn to enhance the yarn strength. The specially treated domestic yarn can be continuously woven, which solves the problems of domestic yarn being easy to pilling, having low strength, and being unable to be continuously woven, and breaks through the technical problem that domestic yarn cannot be prepared into self-lubricating gaskets.

[0012] The piston rod laser cladding coating is an ultra-high-speed laser cladding coating, which is mainly prepared from domestically developed iron-based alloy powder.

[0013] Preferably, the coating preparation material is made of domestically developed iron-based alloy powder, and an ultra-high-speed laser cladding technology suitable for large-diameter and long-stroke rods is developed to perform surface protection treatment on the cylinder piston rod substrate, forming a highly corrosion-resistant coating metallurgically bonded to the substrate, and the powder utilization rate reaches 92%; self-developed domestic powder eliminates the dependence on imported products for metal powder for laser cladding, and the use of ultra-high-speed laser cladding technology solves the problems of easy coating shedding, low construction efficiency, low powder utilization rate and poor coating performance.

[0014] The oil cylinder state monitoring and adjustment unit includes a position sensor, a laser distance measuring sensor, a laser distance measuring target and a pressure sensor;

[0015] Position sensor 1# is arranged at the rear side of the cylinder body structure, position sensor 2# is arranged at the front side of the cylinder body, and position sensor 3# is arranged at the front side of the piston rod. The industrial computer calculates the equivalent deflection of the cylinder through the relative position distance between each position sensor;

[0016] A certain number of laser distance measuring sensors are evenly installed on the outside of the piston rod side of the cylinder body end of the oil cylinder body structure, and the laser distance measuring target is correspondingly installed on the end of the piston rod to measure the displacement value of the oil cylinder; the laser distance measuring sensor measures the displacement of the oil cylinder body structure in all directions and transmits the signal to the industrial computer;

[0017] At least two pressure sensors are used to detect the pressure P of the large cavity of the cylinder body structure. 1 , Small chamber pressure P of the cylinder body structure 2 ;

[0018] The cylinder bearing monitoring and evaluation unit is used to detect the bearing status of the cylinder body structure.

[0019] Preferably, the number of the laser distance measuring sensors is 2, which are arranged 180 degrees along the circumference of the cylinder body end of the oil cylinder body structure; the laser distance measuring target is installed at the circumferential position of the piston rod end, which can measure the real-time displacement X of the oil cylinder. 1 , X 2 ;

[0020] There are two pressure sensors installed on the valve group to detect the pressure of the large and small chambers of the cylinder body structure. The valve group is mounted on the cylinder body structure and is connected to the cylinder body structure through a pipeline.

[0021] Preferably, the industrial computer calculates according to the displacement value of the oil cylinder, according to the following formula X=(X 1 +X 2 ) / 2 Calculate the displacement of the cylinder, the maximum displacement of the cylinder is X 0 .

[0022] The industrial computer includes a cylinder body structure deflection monitoring unit, which divides the cylinder body structure stroke into a plurality of continuous first stroke ranges, and sets an equivalent deflection limit value for each first stroke range;

[0023] The industrial computer calculates the current equivalent deflection D of the oil cylinder;

[0024] The cylinder body structure deflection monitoring unit compares the current cylinder equivalent deflection D with the equivalent deflection limit value within the corresponding first stroke range. If the current cylinder equivalent deflection D reaches 90% of the equivalent deflection limit value, the sound and light alarm is activated; if the current cylinder equivalent deflection D reaches 100% of the equivalent deflection limit value, the sound and light alarm is activated, and the industrial computer control valve group stops working;

[0025] Preferably, the industrial computer includes a cylinder body structure pressure monitoring unit, which divides the cylinder body structure stroke into a plurality of continuous second stroke ranges, and sets a cylinder body structure large chamber pressure limit value for each second stroke range;

[0026] The cylinder body structure pressure monitoring unit will detect the current cylinder body structure large cavity pressure P 1 The pressure is compared with the large cavity pressure limit of the cylinder body structure corresponding to the second stroke range. If the large cavity pressure value reaches 100% of the large cavity pressure limit of the cylinder body structure, the sound and light alarm is activated and the industrial computer control valve group stops working.

[0027] Preferably, the industrial computer comprises a cylinder body structure working condition detection unit, and the cylinder body structure working condition detection unit is provided with an inverted standby working condition and an upright waiting working condition;

[0028] When the displacement position of the cylinder body structure is between 0-X 0 *c 1 The displacement change during the range is less than 5%, and the pressure P of the large cavity of the cylinder body structure is 1 When the change is less than 10%, the cylinder body structure working condition detection unit determines that the cylinder body structure is in an inverted frame shelving working condition;

[0029] When the displacement position of the cylinder body structure is at X 0 *c 2 -X 0 *c 3 The displacement change during the range is less than 5%, and the pressure P of the large cavity of the cylinder body structure is 1 When the change is less than 10%, the pressure of the small chamber of the cylinder body structure P 2 When the change is less than 10%, the cylinder body structure working condition detection unit determines that the cylinder body structure is in an upright working condition;

[0030] When the cylinder body structure working condition detection unit detects that the cylinder body structure is in the inverted frame shelving working condition for a cumulative time of more than H 1 When the alarm is on, the sound and light alarm will be activated;

[0031] When the cylinder body structure working condition detection unit monitors that the cylinder body structure is in the upright working condition for a cumulative time exceeding H 2 When the alarm is on, the sound and light alarm will be activated.

[0032] Preferably, the piston rod coating monitoring and evaluation unit comprises a linear array industrial camera, a data transfer computer and a display system computer;

[0033] Preferably, the linear array industrial camera uses a color CMOS global industrial camera, the number of which is X (X≥3), and a customized support frame is fixed to the outer edge of the cylinder body at the protruding end of the piston rod. The linear array industrial cameras are arranged in a circular and equidistant manner on the customized support frame to monitor the surface morphology and cleanliness of the piston rod in real time, with a focus on detecting damaged areas such as corrosion, scratches, and shedding of the coating surface.

[0034] The data transfer computer processes the image information taken by the linear array industrial camera, and performs classification and data analysis. The data analysis system divides the surface of the oil cylinder piston rod from bottom to top into multiple areas for monitoring. The area of ​​each area is Y square meters. Through the acquired image information, the number of rust spots in a single area and the area of ​​a single rust spot, or the area of ​​a single area of ​​a single area, is analyzed and calculated, and the result data is fed back to the display system computer;

[0035] The display system computer displays the surface morphology of the coating in each area of ​​the piston rod (each area is Y square meters), and issues an early warning based on the calculation and analysis results. When the piston rod is rubbed or hit, the local morphology of the surface of a single area is severely damaged; or the number of rust spots in a single area of ​​the coating surface exceeds Z, and the area of ​​each rust spot does not exceed D mm 2 (D is the appropriate data selected according to the specification); or the area of ​​a single area exceeds D mm 2 The display system sends out a red light warning signal, indicating that the coating needs to be repaired in this area; for various types of pollution falling on the surface of various areas of the piston rod, the display system sends out a yellow light warning signal, indicating that the coating in this area needs to be cleaned.

[0036] Preferably, the oil cylinder bearing monitoring and evaluation unit comprises: a pin sensor, a noise sensor, a vibration sensor, a red-hot external imager, an acceleration sensor, a high-definition camera and a high-precision displacement sensor;

[0037] The pin sensor replaces the original pin and is installed at the pin of the spherical bearing to monitor the load of the spherical bearing during service;

[0038] The noise sensor is installed at the spherical bearing seat to collect the sound information of the spherical bearing in real time when it is in service;

[0039] The vibration sensor is installed at the joint bearing seat to measure the real-time vibration of the joint bearing;

[0040] A red-hot external imager is installed at the end of the piston rod to perform real-time temperature detection on the friction point between the liner and the inner ring of the spherical bearing. When the heating rate reaches or exceeds 0.5°C / h and the temperature exceeds 100°C, the industrial computer controls the sound and light alarm to send out an alarm signal;

[0041] The acceleration sensor is installed at the joint bearing seat to detect the acceleration of the joint bearing;

[0042] There are multiple high-definition cameras, some of which are installed at the end of the piston rod to cover the entire monitoring range of the joint bearing and monitor the appearance of the joint bearing. Some high-definition cameras are installed at the joint bearing seat to shoot the joint bearing.

[0043] The high-precision displacement sensor is installed on the side of the spherical bearing. When the spherical bearing liner is worn, it will be displaced, and the movement will drive the displacement sensor to move.

[0044] Preferably, the industrial computer includes a bearing monitoring unit;

[0045] The bearing monitoring unit initializes the parameters of the pin sensor, noise sensor, vibration sensor, red-hot external imager, acceleration sensor, high-definition camera, and high-precision displacement sensor;

[0046] The bearing monitoring unit has a large amount of spherical bearing service process data and life test data obtained through machine learning database;

[0047] The bearing monitoring unit collects the load data F of the spherical bearing monitored by the pin shaft sensor. If the load data F reaches 95% of the rated load [F], the industrial computer determines that it is abnormal and reminds you to stop the machine for maintenance; if the load data F> [F], the industrial computer determines that the spherical bearing is crushed and fails, and reminds you to replace the spherical bearing;

[0048] The bearing monitoring unit collects real-time sound data S monitored by the noise sensor. If the sound data S exceeds the preset value and lasts for ≥2s, the industrial computer determines that it is abnormal and reminds you to stop the machine for maintenance.

[0049] The bearing monitoring unit collects the real-time frequency data ω of the spherical bearing measured by the vibration sensor. If the frequency data ω exceeds the preset value and lasts for ≥2s, the industrial computer determines that it is abnormal and reminds to shut down for maintenance;

[0050] The bearing monitoring unit collects the real-time temperature data T of the friction part of the joint bearing by the red-hot external imager. If the temperature data T reaches a heating rate of 0.5°C / h or the temperature exceeds 100°C, the industrial computer determines that it is abnormal and reminds to stop the machine for maintenance; if the temperature data T is ≥150°C, the industrial computer determines that the joint bearing temperature is too high and fails, and reminds to replace the joint bearing;

[0051] The bearing monitoring unit collects the acceleration value A and the state parameters of the spherical bearing output vibration monitored by the acceleration sensor in real time. If the acceleration value A exceeds the limit value [A], the industrial computer determines that it is abnormal and reminds to shut down for maintenance;

[0052] The bearing monitoring unit collects high-precision displacement sensors to monitor the wear amount L of the spherical bearing pad in real time. If the wear amount L is less than the pad thickness, but its increasing speed is ≥1mm / min, the industrial computer determines that it is abnormal and reminds you to stop the machine for maintenance; if the wear amount L is equal to the pad thickness, the industrial computer determines that the spherical bearing is failed and reminds you to replace the spherical bearing;

[0053] The bearing monitoring unit uses a high-definition camera to monitor the appearance of the spherical bearing in real time, and compares it with the content in the database to determine whether the appearance of the spherical bearing shows pitting or surface peeling. If it is identified that the liner is squeezed out and the spherical bearing fails, a reminder to replace the spherical bearing is given.

[0054] Preferably, the sound, vibration and acceleration data monitored by the sensor collected by the bearing monitoring unit are filtered to eliminate invalid data.

[0055] Preferably, the bearing monitoring unit predicts the remaining life of the spherical plain bearing by:

[0056] Theoretically, the remaining service life of spherical plain bearings is:

[0057] The remaining life of the spherical plain bearing = the design life - the equivalent of the service life;

[0058] A reduction coefficient α is obtained through test and actual service data of spherical plain bearings and calculation. Therefore, combined with the weight of online monitoring temperature and wear data of spherical plain bearings, the remaining life of spherical plain bearings is:

[0059]

[0060] Preferably, the oil cylinder body structure comprises a cylinder body and a piston arranged inside the cylinder body, the piston divides the interior of the cylinder body into a rod chamber and a rodless chamber, the rod chamber is a small chamber, and the rodless chamber is a large chamber, the piston is fixedly connected to a piston rod on the side facing the rod chamber, a seal is arranged between the piston rod and the cylinder body, and the rod chamber and the rodless chamber are respectively connected to oil pipes;

[0061] It also includes a cylinder seal monitoring device, which includes a piston rod outer peripheral surface detection device, an oil quality detection device, and a piston rod speed detection device;

[0062] A piston rod outer peripheral surface detection device, which is arranged at the end of the cylinder body, is used to detect whether there is hydraulic oil on the outer peripheral surface of the piston rod extending out of the cylinder body structure, and at the same time judge the defect state of the piston rod coating and evaluate the risk of seal damage;

[0063] An oil quality detection device, which is arranged on the two oil pipes and is used to detect the oil quality of the hydraulic oil in the oil pipes;

[0064] A piston rod speed detection device, which is arranged on the oil cylinder body structure and is used to detect the actual moving speed and theoretical moving speed of the piston rod;

[0065] The industrial computer includes a cylinder sealing control unit, which is respectively connected to each detection device, the display screen and the alarm, obtains data detected by each detection device, determines whether there is a leak in the cylinder body structure, and displays prompt information through the display screen; when there is a leak in the cylinder body structure, the industrial computer controls the alarm to send out an alarm message.

[0066] Preferably, the oil cylinder sealing control unit detects the external leakage condition and the internal leakage condition of the oil cylinder body structure respectively;

[0067] The external leakage working condition detection of the oil cylinder body structure specifically includes the following steps:

[0068] SA1, using the piston rod outer peripheral surface detection device to detect whether there is hydraulic oil leakage on the outer peripheral surface of the piston rod extending out of the cylinder body structure, and transmit it to the industrial computer cylinder seal control unit; if there is, proceed to step SA2, otherwise proceed to step SA3;

[0069] SA2. Detect the oil quality of the hydraulic oil in the two oil pipes through the oil quality detection device, obtain the moisture and particle content of the hydraulic oil in the two oil pipes, and transmit them to the industrial computer cylinder sealing control unit; when the moisture and particle content of the hydraulic oil in any of the oil pipes exceeds the set oil quality threshold, the industrial computer cylinder sealing control unit determines that there is an external leakage of the cylinder body structure, displays a prompt message through the display screen, and sends an alarm message through the alarm; when the moisture and particle content of the hydraulic oil in the two oil pipes do not exceed the set oil quality threshold, the industrial computer determines that there is a possibility of external leakage of the cylinder body structure, and displays a prompt message through the display screen;

[0070] SA3. Detect the oil quality of the hydraulic oil in the two oil pipes through the oil quality detection device, obtain the moisture and particle content of the hydraulic oil in the two oil pipes, and transmit them to the industrial computer cylinder sealing control unit; when the moisture and particle content of the hydraulic oil in the two oil pipes do not exceed the set oil quality threshold, the industrial computer cylinder sealing control unit determines that there is no external leakage of the cylinder body structure; when the moisture and particle content of the hydraulic oil in any of the oil pipes exceeds the set oil quality threshold, the industrial computer cylinder sealing control unit determines that there is a possibility of external leakage of the cylinder body structure, and displays a prompt message on the display screen;

[0071] The internal leakage working condition detection of the oil cylinder body structure specifically includes the following steps: SB1, detecting the oil pressure of the rod chamber and the rodless chamber of the oil cylinder body structure through two pressure sensors, and transmitting the oil pressure to the oil cylinder sealing control unit of the industrial computer; the oil cylinder sealing control unit of the industrial computer compares the pressure difference between the two chambers with the set pressure difference threshold, if the pressure difference in the two oil pipes reaches the set pressure difference threshold, proceed to step SB2, otherwise proceed to step SB3;

[0072] SB2. Detect the actual moving speed and theoretical moving speed of the piston rod through the piston rod speed detection device, and transmit them to the cylinder seal control unit of the industrial computer; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold, the industrial computer determines that there is an internal leakage in the cylinder body structure, displays a prompt message through the display screen, and sends an alarm message through the alarm; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold, the industrial computer determines that there is a possibility of internal leakage in the cylinder body structure, and displays a prompt message through the display screen;

[0073] SB3. The actual moving speed and theoretical moving speed of the piston rod are detected by the piston rod speed detection device, and transmitted to the industrial computer cylinder seal control unit; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold, the industrial computer determines that there is no internal leakage in the cylinder body structure; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold, the industrial computer determines that there is a possibility of internal leakage in the cylinder body structure, and displays a prompt message on the display screen.

[0074] Preferably, the oil cylinder seal control unit estimates the remaining life of the seal, and the estimated remaining life of the seal is calculated by the following formula:

[0075]

[0076] Where, T y is the remaining life of the seal, T s is the design life of the seal, T i is the equivalent of the service life of the seal, Q f is the non-metallic particle content of the hydraulic oil in any of the oil pipes; β is the threshold value of the non-metallic particle content of the hydraulic oil; is the variance of the periodic detection value of the pressure difference in the two oil pipes; Q is the threshold value of the variance of the pressure difference in the two oil pipes.

[0077] Taking the main oil cylinder of the pile frame of the pile driving ship as an example, the present invention at least has the following beneficial effects:

[0078] 1. It can realize real-time detection of the status of key components and complete machines such as cylinder seals, spherical bearings, piston rod coatings, etc., and form a design and application accumulation of large-scale piling ship pile frame cylinders based on domestic key components, ensure the reliable application and continuous iterative upgrade of key cylinder components and complete machines, improve the technical level of core key components and cylinder complete machines of large-scale piling ships, promote high-quality development of the industry, and promote the localization substitution of main cylinder complete machines and key components, which can effectively guarantee the construction of major national engineering projects such as cross-sea bridges and deep-sea wind power projects, and maintain the stability of the industrial chain and the security of the supply chain.

[0079] 2. Realize fine control of the main oil cylinder of the pile frame of the pile driving ship under different working conditions, and significantly improve the safety of the main oil cylinder of the pile frame of the pile driving ship. Through the position detection of different parts of the cylinder body structure, the deflection value of the cylinder body structure under long stroke is calculated in combination with a certain algorithm to achieve overload protection of the long-stroke cylinder; combined with the pressure and stroke detection of the cylinder body structure, the force of the super-large and super-long cylinder under different strokes is constrained to ensure the safe operation of the cylinder; for the idle working condition of the cylinder body structure, the idle working condition is managed by using pressure and displacement to prevent abnormal damage caused by long-term idleness of the cylinder body structure.

[0080] 3. Realize online performance evaluation of the joint bearing of the cylinder body structure, and promote the application and promotion of key technologies such as domestic glue and domestic yarn for joint bearings. Perform real-time status detection on joint bearings, timely discover abnormal conditions of joint bearings, repair and maintain joint bearings, and ensure long-term safe use of the cylinder; predict the remaining life of joint bearings in service to avoid various losses caused by sudden failure of bearings, predict the failure time of joint bearings in advance, plan the replacement of joint bearings in advance, and avoid delays in construction.

[0081] 4. Realize online performance evaluation of the cylinder body structure seal, and promote domestic substitution of key domestic seals of the cylinder body structure. The cylinder body structure seal status is detected online, and by combining the piston rod surface status and leakage situation and the oil quality of the hydraulic oil in the oil pipe, a double assessment is made to determine whether the cylinder body structure seal has external leakage and seal damage risks; by combining the pressure of the two chambers of the cylinder body structure and the difference between the actual moving speed of the piston rod and the theoretical moving speed, a double assessment is made to determine whether the cylinder seal has internal leakage; the cylinder body structure seal status can be detected in real time and accurately, providing safety protection for the use of pile driving vessels.

[0082] 5. Realize online performance evaluation of the surface state of the laser cladding coating on the piston rod of the oil cylinder body structure, and promote the application and promotion of key technologies such as domestic powder for laser cladding and ultra-high-speed laser cladding. Perform real-time status detection on the cladding coating, discover surface defects of the coating in time, facilitate timely maintenance of the cladding coating, and ensure long-term safe use of the oil cylinder.

[0083] Other advantages, objectives and features of the present invention will be embodied in part through the following description, and in part will be understood by those skilled in the art through study and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0084] Figure 1 This is a structural assembly diagram of the oil cylinder body of the pile driving ship of the present invention;

[0085] Figure 2 This is a flow chart of the working principle of the main oil cylinder monitoring system of the pile driving ship of the present invention;

[0086] Figure 3 It is a structural schematic diagram of the spherical bearing in the present invention;

[0087] Figure 4 It is a schematic diagram of the installation position of the monitoring sensor in the spherical bearing in a technical solution of the present invention;

[0088] Figure 5 A schematic diagram of the installation position of a monitoring sensor in a spherical bearing in another technical solution of the present invention;

[0089] Figure 6 This is a workflow diagram for monitoring spherical bearings in the present invention;

[0090] Figure 7 This is a system structure diagram of the oil cylinder seal monitoring device, industrial computer, display screen and alarm of the present invention;

[0091] Figure 8 This is a schematic structural diagram of a master oil cylinder according to one embodiment of the present invention;

[0092] Fig. 9 It is a schematic diagram of the internal structure of the oil cylinder body structure when there is eccentricity between the cylinder body and the piston of the present invention;

[0093] Fig.10 A flow chart for detecting the external leakage condition of the master oil cylinder of the present invention;

[0094] Fig.11 The present invention is a flow chart for detecting the internal leakage condition of the master cylinder.

[0095] Explanation of the reference numerals: 1-1# position sensor, 2-2# position sensor, 3-3# position sensor, 4-cylinder body, 5-piston rod, 6-laser ranging sensor, 7-valve group, 8-first pressure sensor, 9-second pressure sensor, 10-spherical bearing, 11-spherical bearing seat, 11-1-inner ring, 11-2-outer ring, 11-3 gasket, 12-pin sensor, 13-noise sensor, 14-vibration sensor, 15-red thermal imager, 16-acceleration sensor, 17-high-definition camera, 18-high-precision displacement sensor, 19-seal, 20-speed sensor, 21-linear scanning camera, 22-oil sensor, 23-oil pipe connected to the rod cavity, 24-flow sensor, 25-oil pipe connected to the rodless cavity. DETAILED DESCRIPTION

[0096] The present invention is described in detail and completely below in conjunction with the accompanying drawings. A person of ordinary skill in the art will be able to implement the present invention based on these descriptions. Before describing the present invention in conjunction with the accompanying drawings, it should be particularly pointed out that the technical solutions and technical features provided in each part of the present invention, including the following description, can be combined with each other without conflict.

[0097] In addition, the embodiments of the present invention involved in the following description are generally only a part of the embodiments of the present invention, rather than all the embodiments. Therefore, based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0098] The present invention is further described in detail below in conjunction with the accompanying drawings and implementations, and its specific implementation process is as follows:

[0099] like Figures 1 to 6 As shown, a preferred embodiment of the present invention provides an extra-large and extra-long digital oil cylinder based on new key components, including: an oil cylinder body structure, an oil cylinder V-group seal, a spherical bearing, a piston rod laser cladding coating, an oil cylinder state monitoring and adjustment unit, an oil cylinder bearing monitoring and evaluation unit, a piston rod coating monitoring and evaluation unit, an industrial computer, a display screen and an audible and visual alarm;

[0100] The oil cylinder state monitoring and adjustment unit includes a position sensor, a laser distance sensor 6 (preferably, the laser distance sensor 6 is a line laser distance sensor 6), a laser distance target and a pressure sensor;

[0101] A 1# position sensor 1 is arranged at the rear side of the cylinder body 4 of the oil cylinder body structure, a 2# position sensor 2 is arranged at the front side of the cylinder body 4, and a 3# position sensor 3 is arranged at the front side of the piston rod 5. The industrial computer calculates the equivalent deflection of the oil cylinder through the relative position distance between each position sensor;

[0102] A certain number of laser distance measuring sensors 6 are evenly installed on the outside of the piston rod 5 side of the cylinder body 4 end of the oil cylinder body structure, and a laser distance measuring target is correspondingly installed at the end of the piston rod 5 to measure the displacement value of the oil cylinder; the laser distance measuring sensor 6 measures the displacement of the oil cylinder body structure in all directions and transmits the signal to the industrial computer;

[0103] At least two pressure sensors, the first pressure sensor 8 is used to detect the pressure P of the large cavity of the oil cylinder body structure 1 The second pressure sensor 9 is used to detect the pressure P of the small cavity of the oil cylinder body structure. 2 ;

[0104] The cylinder bearing monitoring and evaluation unit is used to detect the bearing status of the cylinder body structure.

[0105] The technical solution may also include the following technical details to better achieve the technical effect: the number of the laser distance measuring sensors 6 is 2, which are arranged 180 degrees along the circumference of the end of the cylinder body 4 of the oil cylinder body structure; the laser distance measuring target is correspondingly installed at the circumferential position of the end of the piston rod 5, which can measure the displacement value of the oil cylinder;

[0106] There are two pressure sensors installed on the valve group 7 to detect the pressure of the large and small chambers of the cylinder body structure. The valve group 7 is mounted on the cylinder body structure and connected to the cylinder body structure through a pipeline, so as to realize functions such as oil supply pressure detection, cylinder pressure maintenance, extension and retraction, and reversing.

[0107] The technical solution may also include the following technical details to better achieve the technical effect: the industrial computer calculates the maximum displacement value X of the cylinder body structure according to the laser ranging sensor 6 0 ;

[0108] The industrial computer includes a cylinder body structure deflection monitoring unit, which divides the cylinder body structure stroke into a plurality of continuous first stroke ranges, and sets an equivalent deflection limit value for each first stroke range;

[0109] The industrial computer calculates the equivalent deflection D of the current oil cylinder. Specifically: measure the distance D between 1# position sensor 1 and 3# position sensor 3 respectively 1 , the distance D between 2# position sensor 2 and 3# position sensor 3 2 , combined with 1# position sensor 1 and 2# position sensor 2 to fix the distance D 3 , according to the following formula: D = D 3 *tan(arccos((D 3 2 +D 1 2 -D 2 2 ) / 2*D3 *D1)). According to the structural design of the cylinder body, the equivalent deflection limit conditions of the cylinder are formulated as shown in Table 1 below:

[0110] Table 1

[0111] Travel range <![CDATA[0-X 0 *n 1 ]]> <![CDATA[X 0 *n 1 -X 0 *n 2 ]]> <![CDATA[X 0 *n 2 -X 0 *n 3 ]]> <![CDATA[X 0 *n 3 -X 0 ]]> Equivalent deflection limit D4 D5 D6 D7

[0112] Note: n 1 、n 2 、n 3 Represents the percentage of the cylinder stroke, with a value range of 0-100%. It is selected according to the different cylinder stroke deflection limits. It can also be further subdivided according to the control requirements. In theory, the cylinder deflection limit within the full stroke range can be constrained one-to-one, where 0 < n 1 <n 2 <n 3 <100%.

[0113] The cylinder body structure deflection monitoring unit compares the current cylinder equivalent deflection D with the equivalent deflection limit value within the corresponding first stroke range. If the current cylinder equivalent deflection D reaches 90% of the equivalent deflection limit value, the sound and light alarm is activated; if the current cylinder equivalent deflection D reaches 100% of the equivalent deflection limit value, the sound and light alarm is activated, and the industrial computer control valve group 7 stops working (power off) to protect the cylinder;

[0114] The technical solution may also include the following technical details to better achieve the technical effect: the industrial computer includes a cylinder body structure pressure monitoring unit, which divides the cylinder body structure stroke into a number of continuous second stroke ranges, and sets a cylinder body structure large cavity pressure limit for each second stroke range. 0 , the pressure P of the large chamber of the oil cylinder is measured by the large and small chamber pressure sensors 1 , small cavity pressure P 2 . According to the load capacity of the cylinder, the cylinder large chamber pressure limit under different strokes is formulated, as shown in Table 2 below:

[0115] Table 2

[0116] Travel range <![CDATA[0-X 0 *a]]> <![CDATA[X 0 / a 1 -X 0 *a 2 ]]> <![CDATA[X 0 *a 2 -X 0 *a 3 ]]> <![CDATA[X 0 *a 3 -X 0 ]]> Pressure limit <![CDATA[P 0 ]]> <![CDATA[P 0 / b 1 ]]> <![CDATA[P 0 / b 2 ]]> <![CDATA[P 0 / b 3 ]]>

[0117] Note: a, a 1 、a 2 、a 3 , represents the percentage of the cylinder stroke, with a value range of 0-100%. It is determined according to the allowable load of different cylinder strokes. It can also be further subdivided according to the control requirements. In theory, the cylinder pressure limit within the full stroke range can be constrained one-to-one, where 0<a<a 1 <a 2 <a 3<100%.

[0118] The cylinder body structure pressure monitoring unit will detect the current cylinder body structure large cavity pressure P 1 The pressure is compared with the large cavity pressure limit of the cylinder body structure corresponding to the second stroke range. If the large cavity pressure value reaches 100% of the large cavity pressure limit of the cylinder body structure, the sound and light alarm is activated and the industrial computer control valve group 7 stops working to protect the cylinder.

[0119] The present technical solution may also include the following technical details to better achieve the technical effect: the industrial computer includes a cylinder body structure working condition detection unit, and the cylinder body structure working condition detection unit is provided with an inverted standby working condition and an upright waiting working condition, and the two working conditions are judged according to the following Table 3.

[0120] Table 3

[0121]

[0122] Note: c 1 、c 2 、c 3 , represents the percentage of cylinder stroke, with a value range of 0-100%, and is determined according to the design characteristics of different pile-driving vessels, where 0<c 1 <c 2 <c 3 <100%.

[0123] When the displacement position of the cylinder body structure is between 0-X 0 *c 1 The displacement change during the range is less than 5%, and the pressure P of the large cavity of the cylinder body structure is 1 When the change is less than 10%, the cylinder body structure working condition detection unit determines that the cylinder body structure is in an inverted frame shelving working condition;

[0124] When the displacement position of the cylinder body structure is at X 0 *c 2 -X 0 *c 3 The displacement change during the range is less than 5%, and the pressure P of the large cavity of the cylinder body structure is 1 When the change is less than 10%, the pressure of the small chamber of the cylinder body structure P 2 When the change is less than 10%, the cylinder body structure working condition detection unit determines that the cylinder body structure is in an upright working condition;

[0125] When the cylinder body structure working condition detection unit detects that the cylinder body structure is in the inverted frame shelving working condition for a cumulative time of more than H 1 When the alarm is on, the sound and light alarm will be activated to remind the operator to perform maintenance operations on the cylinder;

[0126] When the cylinder body structure working condition detection unit monitors that the cylinder body structure is in the upright working condition for a cumulative time exceeding H 2 When the oil cylinder is in a state of emergency, the sound and light alarm will be activated to remind the operator to perform maintenance operations on the cylinder.

[0127] This technical solution may also include the following technical details to better achieve the technical effect: the piston rod coating monitoring and evaluation unit includes: a linear array industrial camera, a data transfer computer and a display system computer;

[0128] The linear array industrial camera uses a color CMOS global industrial camera, and there are 6 of them. The customized support frame is fixed to the outer edge of the cylinder body at the end of the piston rod. The linear array industrial cameras are arranged in a circular and equidistant manner on the customized support frame. The camera head is aimed at the coating surface of the piston rod to monitor the coating surface morphology and cleanliness in real time. The coating surface image information obtained by the industrial camera has a direct impact on the accuracy of subsequent data processing and maintenance warning. Preferably, the high-resolution linear array industrial camera scans the surface of the piston rod, and judges the wear condition of the piston rod surface through visual processing and comparative analysis.

[0129] The data transfer computer processes the image information taken by the linear array industrial camera, and performs classification and data analysis. The data analysis system divides the surface of the oil cylinder piston rod from bottom to top into multiple areas for monitoring. The area of ​​each area is 1 square meter. Through the acquired image information, the number of rust spots in a single area, the area of ​​a single rust spot, or the area of ​​a single area of ​​a single area, as well as the images of various piston rod surface coating failure forms such as cracks, corrosion, crystallization, peeling, oxidation, etc., are analyzed and calculated. The collected images are pre-processed by cropping, scaling, rotating and other operations to maintain the consistency and quality of the images. Finally, the data is segmented and the images are divided into training set and verification set at a ratio of 5:1, and the result data is fed back to the display system computer;

[0130] The display system computer displays the surface morphology of the coating in each area of ​​the piston rod (1 square meter per area) and issues an early warning based on the calculation and analysis results. When the piston rod is rubbed or hit, the local morphology of the surface of a single area is severely damaged; or the number of rust spots in a single area of ​​the coating surface exceeds 10, and the area of ​​each rust spot does not exceed 19.63mm 2 ; or a single area with an area exceeding 19.63mm 2 The display system sends out a red light warning signal, indicating that the area needs to be repaired; for various types of pollution falling on the surface of various areas of the piston rod, the display system sends out a yellow light warning signal, indicating that the coating in this area needs to be cleaned. In this way, the intelligent maintenance warning function of the oil cylinder is realized.

[0131] This technical solution may also include the following technical details to better achieve the technical effect: the oil cylinder bearing monitoring and evaluation unit includes: a pin sensor 12, a noise sensor 13, a vibration sensor 14, a red-hot external imager 15, an acceleration sensor 16, a high-definition camera 17 and a high-precision displacement sensor 18;

[0132] The pin shaft sensor 12 replaces the original pin shaft and is installed at the pin shaft of the spherical bearing 10 to monitor the load of the spherical bearing 10 when it is in service. The pin shaft sensor 12 is connected to the industrial computer. When the load exceeds the specified load value, the industrial computer controls the sound and light alarm to send out an alarm signal.

[0133] The noise sensor 13 is installed at the joint bearing seat 11 to collect the sound information of the joint bearing 10 in real time when it is in service; the sound processing module removes the interfering sound data in the sound information and uploads it to the industrial computer for data processing. When the sound data is abnormal, the industrial computer controls the sound and light alarm to send out an alarm signal;

[0134] The vibration sensor 14 is installed at the joint bearing seat 11 to measure the real-time vibration of the joint bearing 10; the industrial computer processes the received frequency data, and if abnormal frequency data appears, the industrial computer controls the sound and light alarm to send out an alarm signal;

[0135] The red thermal external imager 15 is installed at the end of the piston rod 5 to perform real-time temperature detection on the friction point between the liner 11-3 and the inner ring 11-1 in the spherical bearing 10. When the heating rate reaches or exceeds 0.5°C / h and the temperature exceeds 100°C, the industrial computer controls the sound and light alarm to send out an alarm signal;

[0136] The acceleration sensor 16 is installed at the spherical bearing seat 11 to detect the acceleration of the spherical bearing 10;

[0137] There are multiple high-definition cameras 17, some of which are installed at the end of the piston rod 5 to cover the entire monitoring range of the spherical bearing 10 and monitor the appearance of the spherical bearing 10. Some high-definition cameras 17 are installed at the spherical bearing seat 11 to shoot the joint of the spherical bearing 10 and input the video into the trained model. The model is equipped with visual recognition, and the model provides real-time feedback on the clearance at the joint of the spherical bearing 10 and whether the liner 11-3 is detached or squeezed out;

[0138] A high-precision displacement sensor 18 is installed on the side of the spherical bearing 10. When the liner 11-3 of the spherical bearing 10 is worn, it will be displaced. The movement drives the movement of the displacement sensor. The wear amount of the liner 11-3 of the spherical bearing 10 is calculated by the difference between the measured value of the displacement sensor and the initial value.

[0139] In this embodiment, the joint bearing 10 of the cylinder body structure is installed on the joint bearing seat 11, one end of the piston rod 5 is movably arranged in the cylinder body, and the other end of the piston rod 5 is connected to the joint bearing 10. The joint bearing 10 includes an inner ring 11-1 and an outer ring 11-2, and a gasket 11-3 is pasted on the inner wall of the outer ring 11-2.

[0140] This technical solution may also include the following technical details to better achieve the technical effect: the industrial computer includes a bearing monitoring unit;

[0141] The bearing monitoring unit initializes the parameters of the pin sensor 12, the noise sensor 13, the vibration sensor 14, the red thermal external imager 15, the acceleration sensor 16, the high-definition camera 17, and the high-precision displacement sensor 18;

[0142] The bearing monitoring unit has a database with a large amount of service process data and life test data of the spherical plain bearing 10 obtained through machine learning;

[0143] The bearing monitoring unit collects the load data F of the spherical bearing 10 monitored by the pin sensor 12. If the load data F reaches 95% of the rated load [F], the industrial computer determines that it is abnormal and reminds you to stop the machine for maintenance; if the load data F> [F], the industrial computer determines that the spherical bearing 10 is crushed and fails, and reminds you to replace the spherical bearing 10;

[0144] The bearing monitoring unit collects real-time sound data S monitored by the noise sensor 13. If the sound data S exceeds a preset value and lasts for ≥2s, the industrial computer determines that it is abnormal and reminds the machine to shut down for maintenance.

[0145] The bearing monitoring unit collects the real-time frequency data ω of the spherical bearing 10 measured by the vibration sensor 14. If the frequency data ω exceeds the preset value and lasts for ≥2s, the industrial computer determines that it is abnormal and reminds to shut down for maintenance;

[0146] The bearing monitoring unit collects the real-time temperature data T of the friction point of the joint bearing 10 by the red-hot external imager 15. If the temperature data T reaches a heating rate of 0.5°C / h or the temperature exceeds 100°C, the industrial computer determines that it is abnormal and reminds to stop the machine for maintenance; if the temperature data T is ≥150°C, the industrial computer determines that the joint bearing 10 is overheated and fails, and reminds to replace the joint bearing 10;

[0147] The bearing monitoring unit collects the acceleration value A of the output vibration and the state parameters of the spherical bearing 10 monitored in real time by the acceleration sensor 16. If the acceleration value A exceeds the limit value [A], the industrial computer determines that it is abnormal and reminds to shut down for maintenance;

[0148] The bearing monitoring unit collects the high-precision displacement sensor 18 to monitor the wear amount L of the liner 11-3 of the spherical bearing 10 in real time. If the wear amount L is less than the thickness of the liner 11-3, but its increasing speed is ≥1mm / min, the industrial computer determines that it is abnormal and reminds you to stop the machine for maintenance; if the wear amount L is equal to the thickness of the liner 11-3, the industrial computer determines that the spherical bearing 10 is failed and reminds you to replace the spherical bearing 10;

[0149] The bearing monitoring unit collects data using a high-definition camera 17 to monitor the appearance of the spherical bearing 10 in real time, and compares it with the content in the database to determine whether pitting or surface peeling occurs on the appearance of the spherical bearing 10. If it is identified that the liner 11-3 is squeezed out and the spherical bearing 10 fails, a reminder to replace the spherical bearing 10 is given.

[0150] The technical solution may also include the following technical details to better achieve the technical effect: the sound, vibration, and acceleration data monitored by the sensor collected by the bearing monitoring unit are filtered to eliminate invalid data.

[0151] The technical solution may also include the following technical details to better achieve the technical effect: the bearing monitoring unit predicts the remaining life of the spherical bearing 10, specifically:

[0152] Theoretically, the remaining life of the spherical plain bearing 10 is:

[0153] The remaining life of the spherical bearing 10 = the design life - the equivalent of the service life;

[0154] A reduction coefficient α is obtained through experiments and calculations based on the data of actual service of the spherical plain bearing 10. Therefore, combined with the weight of the online monitoring temperature and wear data of the spherical plain bearing 10, the remaining life of the spherical plain bearing 10 is:

[0155]

[0156] This technical solution may also include the following technical details to better achieve the technical effect: Figures 7 to 11 As shown, the oil cylinder body structure includes a cylinder body and a piston arranged inside the cylinder body, the piston divides the interior of the cylinder body into a rod chamber and a rodless chamber, the rod chamber is a small chamber, and the rodless chamber is a large chamber, the piston is fixedly connected to a piston rod on one side facing the rod chamber, a seal 19 is arranged between the piston rod and the cylinder body, and the rod chamber and the rodless chamber are respectively connected to oil pipes (23, 25);

[0157] It also includes a cylinder seal monitoring device, which includes a piston rod outer peripheral surface detection device, an oil quality detection device, and a piston rod speed detection device;

[0158] The piston rod outer peripheral surface detection device is arranged at the end of the cylinder body to detect whether there is hydraulic oil on the outer peripheral surface of the piston rod extending out of the cylinder body structure; the piston rod outer peripheral surface detection device includes two linear scanning cameras, and the two linear scanning cameras 21 are symmetrically arranged at one end of the cylinder body close to the rod cavity. The scanning range of the two linear scanning cameras 21 jointly covers the entire outer peripheral surface of the piston rod. The linear scanning camera 21 transmits the photographed outer peripheral surface state data of the piston rod to the industrial computer. The industrial computer can analyze the data based on the YOLOv8 model to determine whether there is oil leakage on the surface of the piston rod, and at the same time determine the defect state of the piston rod coating and evaluate the risk of sealing damage. YOLOv8 is a SOTA model that supports a full range of visual AI tasks, including detection, segmentation, posture estimation, tracking and classification; first, you need to take a number of pictures of hydraulic oil leakage in the cylinder and pictures of piston rod coating defects to create a certain amount of data sets, which include pictures, labels, training sets, verification sets and test sets; then convert the data set format into yolo_txt format, and then select the required training model, provide s, m, l, x versions, and gradually increase (with the increase of the architecture, the training time is also gradually increased); then you can train, verify and predict. For the detection of external leakage of the cylinder body structure and defects in the piston rod coating, the linear scanning camera 21 is set at one end of the cylinder body close to the rod cavity to shoot the leak-prone position and the piston rod coating surface. The video is then transmitted to the trained model in real time. After processing, if there is external leakage and defects in the piston rod coating surface in the output video results, they will be marked in real time.

[0159] The oil quality detection device is arranged on the two oil pipes to detect the oil quality of the hydraulic oil in the oil pipes. The oil quality detection device includes two oil sensors 22, and the two oil sensors 227 are used to detect the moisture and particle content of the hydraulic oil in the two oil pipes. The oil sensor 22 communicates with the industrial computer using RS485. By comparing the moisture and particle (including metal particles and non-metal particles) content of the detected hydraulic oil with the set oil quality threshold, it is determined whether there is external leakage. The oil quality threshold can be determined by experimentally measuring the oil quality under different degrees of external leakage.

[0160] The two pressure sensors in the oil cylinder status monitoring and adjustment unit communicate with the industrial computer using RS485. Generally, during the actual operation of the oil cylinder, there is a pressure difference on both sides of the flowing liquid inside the plate and there is relative movement between the plates. The internal leakage formula is:

[0161]

[0162] In formula (1), b is the gap width; l is the gap length; h is the gap height; μ is the dynamic viscosity of the fluid; U is the relative speed; △p is the pressure difference between the rod chamber and the rodless chamber; in the actual internal leakage of the cylinder body structure, the gap width b that causes internal leakage corresponds to the circumference of the inner diameter of the hydraulic cylinder, that is, πd; in addition, it is also necessary to consider that the cylinder body and the piston have a certain eccentricity, such as Fig. 9 As shown, it is necessary to add the eccentricity coefficient into the internal leakage calculation formula, so that the calculation formula of the internal leakage of the oil cylinder body structure is obtained as follows:

[0163]

[0164] In formula (2), is the eccentricity;

[0165] It can be concluded that the internal leakage of the oil cylinder body structure is proportional to the pressure difference between the rod chamber and the rodless chamber, and inversely proportional to the oil viscosity: Therefore, the pressure difference between the rod chamber and the rodless chamber can effectively reflect the internal leakage of the cylinder body structure.

[0166] The piston rod speed detection device is arranged on the oil cylinder body structure to detect the actual moving speed and theoretical moving speed of the piston rod; the piston rod speed detection device includes a flow sensor 24 and a speed sensor 20; the flow sensor 24 is arranged on the oil pipe connected to the rodless cavity to detect the flow of hydraulic oil in the oil pipe; the speed sensor 20 is arranged at the end of the piston rod to detect the actual moving speed of the piston rod. The actual moving speed of the piston rod obtained by the industrial computer through the speed sensor 20 is V 1 , and the flow rate in the oil pipe detected by the flow sensor 24 is Q 1 , the corresponding cross-sectional area of ​​the piston is S 1 , Q 1 / S 1 That is the theoretical moving speed of the piston rod, and then the industrial computer compares |Q 1 / S 1 -V 1 | Whether there is internal leakage is determined by comparing the speed error threshold value set. The speed error threshold value can be determined by experimentally measuring the difference between the theoretical moving speed and the actual moving speed of the piston rod under different degrees of internal leakage.

[0167] The industrial computer includes a cylinder sealing control unit, which is respectively connected to each detection device, the display screen and the alarm, obtains data detected by each detection device, determines whether there is a leak in the cylinder body structure, and displays prompt information through the display screen; when there is a leak in the cylinder body structure, the industrial computer controls the alarm to send out an alarm message.

[0168] The technical solution may also include the following technical details to better achieve the technical effect: the oil cylinder sealing control unit detects the external leakage working condition and the internal leakage working condition of the oil cylinder body structure respectively;

[0169] In this technical solution, when the seal 19 of the cylinder body structure fails in different forms, the cylinder body structure will have internal and external leakage to varying degrees. The detection system detects multiple usage data of the cylinder body structure through each of the detection devices, and then processes the data through the industrial computer to determine whether the cylinder body structure has external leakage and internal leakage, and whether there is a possibility of external leakage and internal leakage, and displays prompt information on the display screen, and controls the alarm to send out an alarm message. Among them, external leakage refers to the leakage of hydraulic oil to the outside of the cylinder body through the connection between the piston rod and the cylinder body. At this time, when the piston rod extends out of the rod cavity from the cylinder body, its outer peripheral surface will bring out a certain amount of hydraulic oil, and as the piston rod extends and retracts, it will inevitably affect the oil quality of the hydraulic oil. Therefore, by detecting whether there is hydraulic oil on the outer peripheral surface of the piston rod extending out of the cylinder body and the oil quality of the hydraulic oil in the two oil pipes, it is judged whether there is external leakage; internal leakage refers to the leakage between the rod cavity and the rodless cavity. At this time, the oil pressure in the rod cavity and the rodless cavity will change, which will further affect the movement speed of the piston rod; therefore, by detecting the oil pressure of the hydraulic oil in the two oil pipes and the theoretical movement speed and actual movement speed of the piston rod, it is judged whether there is internal leakage.

[0170] like Fig.10 As shown, the external leakage condition detection of the master oil cylinder specifically includes the following steps:

[0171] SA1, using the piston rod outer peripheral surface detection device to detect whether there is hydraulic oil leakage on the outer peripheral surface of the piston rod extending out of the cylinder body structure, and transmit it to the industrial computer cylinder seal control unit; if there is, proceed to step SA2, otherwise proceed to step SA3;

[0172] SA2. Detect the oil quality of the hydraulic oil in the two oil pipes through the oil quality detection device, obtain the moisture and particle content of the hydraulic oil in the two oil pipes, and transmit them to the industrial computer cylinder sealing control unit; when the moisture and particle content of the hydraulic oil in any of the oil pipes exceeds the set oil quality threshold, the industrial computer cylinder sealing control unit determines that there is an external leakage of the cylinder body structure, displays a prompt message "Please note that there is an external leakage" on the display screen, and sends an alarm message through the alarm; when the moisture and particle content of the hydraulic oil in the two oil pipes do not exceed the set oil quality threshold, the industrial computer determines that there is a possibility of external leakage of the cylinder body structure, and displays a prompt message "Please note that there is a possibility of external leakage" on the display screen;

[0173] SA3. Detect the oil quality of the hydraulic oil in the two oil pipes through the oil quality detection device, obtain the moisture and particle content of the hydraulic oil in the two oil pipes, and transmit them to the industrial computer cylinder sealing control unit; when the moisture and particle content of the hydraulic oil in the two oil pipes do not exceed the set oil quality threshold, the industrial computer cylinder sealing control unit determines that there is no external leakage of the cylinder body structure, and at this time, the prompt message "no external leakage" can also be displayed on the display screen; when the moisture and particle content of the hydraulic oil in any of the oil pipes exceeds the set oil quality threshold, the industrial computer cylinder sealing control unit determines that there is a possibility of external leakage of the cylinder body structure, and displays a prompt message "Please note that there is a possibility of external leakage" on the display screen;

[0174] like Fig.11 As shown, the internal leakage working condition detection of the oil cylinder body structure specifically includes the following steps: SB1, detecting the oil pressure of the rod chamber and the rodless chamber of the oil cylinder body structure through two pressure sensors, and transmitting the oil pressure to the oil cylinder sealing control unit of the industrial computer; the oil cylinder sealing control unit of the industrial computer compares the pressure difference between the two chambers with the set pressure difference threshold value, if the pressure difference in the two oil pipes reaches the set pressure difference threshold value, proceed to step SB2, otherwise proceed to step SB3;

[0175] SB2. Detect the actual moving speed and theoretical moving speed of the piston rod through the piston rod speed detection device, and transmit them to the cylinder seal control unit of the industrial computer; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold, the industrial computer determines that there is an internal leakage in the cylinder body structure, displays a prompt message through the display screen, and sends an alarm message through the alarm; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold, the industrial computer determines that there is a possibility of internal leakage in the cylinder body structure, and displays a prompt message through the display screen;

[0176] SB3. The actual moving speed and theoretical moving speed of the piston rod are detected by the piston rod speed detection device, and transmitted to the industrial computer cylinder seal control unit; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold, the industrial computer determines that there is no internal leakage in the cylinder body structure; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold, the industrial computer determines that there is a possibility of internal leakage in the cylinder body structure, and displays a prompt message on the display screen.

[0177] This technical solution may also include the following technical details to better achieve the technical effect: the detection method also includes estimating the remaining life of the seal 19. When the seal 19 has not failed, the particle content in the hydraulic oil and the pressure of the rod cavity and the rodless cavity can be periodically monitored to determine the current health of the seal 19. After obtaining the particle content of the hydraulic oil in the oil pipe and the pressure of the two oil pipes, the industrial computer uses the change of the particle content and the pressure difference of the two oil pipes as the evaluation parameters of the cylinder seal life. The estimated value of the remaining life of the seal 19 is calculated by the following formula, and the calculated remaining life is displayed on the display screen;

[0178]

[0179] In formula (3), T y is the remaining life of the seal 19, T s is the design life of the seal 19, T i is the equivalent of the service life of the seal 19, Q f is the non-metallic particle content of the hydraulic oil in any of the oil pipes; β is the threshold value of the non-metallic particle content of the hydraulic oil; is the variance of the periodic detection value of the pressure difference in the two oil pipes; Q is the threshold of the variance of the pressure difference in the two oil pipes. The threshold β of the non-metallic particle content can be determined by experiment, and the threshold β can be determined by comparing it with the current non-metallic particle content Q f After comparison, the health of the seal 19 is evaluated. On the other hand, the construction of the pile-driving ship is repetitive and periodic. During the period of the oil cylinder pressure stabilization, the pressure of the rod chamber and the rodless chamber is periodically monitored to obtain the variance of the pressure difference between the two. In addition, the variance of the pressure difference between the rod chamber and the rodless chamber under different degrees of leakage is measured under the test environment as the threshold value Q.

[0180] Although the embodiments of the present invention have been disclosed as above, they are not limited to the applications listed in the specification and the implementation modes. They can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and the embodiments shown and described herein.

Claims

1. An extra-large and extra-long digital cylinder based on key components, characterized in that: include: Cylinder body structure, cylinder V-group seal, spherical bearing, piston rod laser cladding coating, cylinder status monitoring and adjustment unit, cylinder bearing monitoring and evaluation unit, piston rod coating monitoring and evaluation unit, industrial computer, display screen and sound and light alarm; The oil cylinder state monitoring and adjustment unit includes a position sensor, a laser distance measuring sensor, a laser distance measuring target and a pressure sensor; Arrange 1# position sensor on the rear side of the cylinder body, 2# position sensor on the front side of the cylinder body, and 3# position sensor on the front side of the piston rod. Measure the distance D1 between 1# position sensor and 3# position sensor, the distance D2 between 2# position sensor and 3# position sensor, and the fixed distance D3 between 1# position sensor and 2# position sensor respectively. Calculate the equivalent deflection D of the cylinder using the industrial computer: D=D3*tan(arccos((D3 2 +D1 2 -D2 2 ) / 2*D3*D1)): The industrial computer compares the current cylinder equivalent deflection D with the equivalent deflection limit set within the stroke range of the cylinder body structure. If the current cylinder equivalent deflection D reaches 90% of the equivalent deflection limit, the sound and light alarm is activated; if the current cylinder equivalent deflection D reaches 100% of the equivalent deflection limit, the sound and light alarm is activated, and the industrial computer control valve group stops working; A certain number of laser distance measuring sensors are evenly installed on the outside of the piston rod side of the cylinder body end of the oil cylinder body structure, and the laser distance measuring target is correspondingly installed on the end of the piston rod to measure the displacement value of the oil cylinder; the laser distance measuring sensor measures the displacement of the oil cylinder body structure in all directions and transmits the signal to the industrial computer; At least two pressure sensors, used to detect the pressure P1 of the large cavity of the oil cylinder body structure and the pressure P2 of the small cavity of the oil cylinder body structure; The oil cylinder bearing monitoring and evaluation unit is used to detect the bearing status of the oil cylinder body structure; The piston rod coating monitoring and evaluation unit is used to detect the coating status of the cylinder piston rod surface.

2. The super-large and super-long digital cylinder based on key components as claimed in claim 1 is characterized in that: There are two laser distance measuring sensors, which are arranged 180 degrees along the circumference of the cylinder body end of the oil cylinder body structure; the laser distance measuring target is installed at the circumferential position of the piston rod end, which can measure the displacement value of the oil cylinder; There are two pressure sensors installed on the valve group to detect the pressure of the large and small chambers of the cylinder body structure. The valve group is mounted on the cylinder body structure and is connected to the cylinder body structure through a pipeline.

3. The super-large and super-long digital cylinder based on key components as described in claim 1 or 2, characterized in that: The industrial computer calculates the maximum displacement value X0 of the cylinder body structure based on the laser ranging sensor; The industrial computer includes a cylinder body structure deflection monitoring unit, which divides the cylinder body structure stroke into a plurality of continuous first stroke ranges, and sets an equivalent deflection limit value for each first stroke range; The industrial computer calculates the current equivalent deflection D of the oil cylinder; The cylinder body structure deflection monitoring unit compares the current cylinder equivalent deflection D with the equivalent deflection limit value within the corresponding first stroke range. If the current cylinder equivalent deflection D reaches 90% of the equivalent deflection limit value, the sound and light alarm is activated; if the current cylinder equivalent deflection D reaches 100% of the equivalent deflection limit value, the sound and light alarm is activated, and the industrial computer control valve group stops working.

4. The super-large and super-long digital cylinder based on key components as claimed in claim 3 is characterized in that: The industrial computer includes a cylinder body structure pressure monitoring unit, which divides the cylinder body structure stroke into a plurality of continuous second stroke ranges, and sets a cylinder body structure large cavity pressure limit value for each second stroke range; The cylinder body structure pressure monitoring unit compares the detected current cylinder body structure large cavity pressure P1 with the cylinder body structure large cavity pressure limit corresponding to the second stroke range. If the large cavity pressure value reaches 100% of the cylinder body structure large cavity pressure limit, the sound and light alarm is activated and the industrial computer control valve group suspends work.

5. The super-large and super-long digital cylinder based on key components as claimed in claim 4 is characterized in that: The industrial computer includes a cylinder body structure working condition detection unit, and the cylinder body structure working condition detection unit is provided with an inverted standby working condition and an upright waiting working condition; When the displacement position of the oil cylinder body structure is within the range of 0-X0*c1, the displacement change is less than 5%, and the large chamber pressure P1 change of the oil cylinder body structure is less than 10%, the oil cylinder body structure working condition detection unit determines that the oil cylinder body structure is in the inverted frame shelving working condition; When the displacement position of the oil cylinder body structure is within the range of X0*c2-X0*c3, the displacement change is less than 5%, and the pressure P1 of the large chamber of the oil cylinder body structure changes less than 10%, and the pressure P2 of the small chamber of the oil cylinder body structure changes less than 10%, the oil cylinder body structure working condition detection unit determines that the oil cylinder body structure is in the upright working condition; wherein 0<c1<c2<c3<100%; When the oil cylinder body structure working condition detection unit detects that the accumulated time of the oil cylinder body structure in the inverted frame shelving working condition exceeds H1, the sound and light alarm is activated; When the cylinder body structure working condition detection unit detects that the cumulative time of the cylinder body structure in the upright working condition exceeds H2, the sound and light alarm is activated.

6. The super-large and super-long digital cylinder based on key components as claimed in claim 1, characterized in that: The piston rod coating monitoring and evaluation unit comprises: a linear array industrial camera, an optical fiber, a data transfer computer and a display system computer; Six linear array industrial cameras are arranged in a circular pattern at equal intervals on the outer edge of the cylinder body at the extended end of the piston rod to monitor the surface condition of the coating when the cylinder piston rod is extended or retracted; Optical fiber, arranged between the linear array industrial camera, the data transfer computer and the display system computer, is used for signal transmission; The data transfer computer is installed in the control room to collect the image information taken by the linear array industrial camera and perform data analysis and processing; The display system computer is installed in the control room to display the coating monitoring screen, data analysis interface and analyzed and processed data information.

7. The super-large and super-long digital cylinder based on key components as claimed in claim 1, characterized in that: The oil cylinder bearing monitoring and evaluation unit includes: a pin sensor, a noise sensor, a vibration sensor, a red-hot external imager, an acceleration sensor, a high-definition camera and a high-precision displacement sensor; The pin sensor replaces the original pin and is installed at the pin of the spherical bearing to monitor the load of the spherical bearing during service; The noise sensor is installed at the spherical bearing seat to collect the sound information of the spherical bearing in real time when it is in service; The vibration sensor is installed at the joint bearing seat to measure the real-time vibration of the joint bearing; A red-hot external imager is installed at the end of the piston rod to perform real-time temperature detection on the friction point between the liner and the inner ring of the spherical bearing. When the heating rate reaches or exceeds 0.5°C / h and the temperature exceeds 100°C, the industrial computer controls the sound and light alarm to send out an alarm signal; The acceleration sensor is installed at the joint bearing seat to detect the acceleration of the joint bearing; There are multiple high-definition cameras, some of which are installed at the end of the piston rod to cover the entire monitoring range of the joint bearing and monitor the appearance of the joint bearing. Some high-definition cameras are installed at the joint bearing seat to shoot the joint bearing. The high-precision displacement sensor is installed on the side of the spherical bearing. When the spherical bearing liner is worn, it will be displaced, and the movement will drive the displacement sensor to move.

8. The super-large and super-long digital cylinder based on key components as claimed in claim 7, characterized in that: The industrial computer includes a bearing monitoring unit; The bearing monitoring unit initializes the parameters of the pin sensor, noise sensor, vibration sensor, red-hot external imager, acceleration sensor, high-definition camera, and high-precision displacement sensor; The bearing monitoring unit has a large amount of spherical bearing service process data and life test data obtained through machine learning database; The bearing monitoring unit collects the load data F of the spherical bearing monitored by the pin shaft sensor. If the load data F reaches 95% of the rated load [F], the industrial computer determines that it is abnormal and reminds you to stop the machine for maintenance; if the load data F> [F], the industrial computer determines that the spherical bearing is crushed and fails, and reminds you to replace the spherical bearing; The bearing monitoring unit collects real-time sound data S monitored by the noise sensor. If the real-time sound data S exceeds the preset value and lasts for ≥2s, the industrial computer determines that it is abnormal and reminds the machine to stop for maintenance. The bearing monitoring unit collects the real-time frequency data ω of the spherical bearing measured by the vibration sensor. If the frequency data ω exceeds the preset value and lasts for ≥2s, the industrial computer determines that it is abnormal and reminds to shut down for maintenance; The bearing monitoring unit collects the real-time temperature data T of the friction part of the joint bearing by the red-hot external imager. If the temperature data T reaches a heating rate of 0.5°C / h or the temperature exceeds 100°C, the industrial computer determines that it is abnormal and reminds to stop the machine for maintenance; if the temperature data T is ≥150°C, the industrial computer determines that the joint bearing temperature is too high and fails, and reminds to replace the joint bearing; The bearing monitoring unit collects the acceleration value A and the state parameters of the spherical bearing output vibration monitored by the acceleration sensor in real time. If the acceleration value A exceeds the limit value [A], the industrial computer determines that it is abnormal and reminds to shut down for maintenance; The bearing monitoring unit collects high-precision displacement sensors to monitor the wear amount L of the spherical bearing pad in real time. If the wear amount L is less than the pad thickness, but its increasing speed is ≥1mm / min, the industrial computer determines that it is abnormal and reminds to stop the machine for maintenance; If the wear amount L is equal to the thickness of the liner, the industrial computer determines that the spherical plain bearing has failed and reminds you to replace the spherical plain bearing; The bearing monitoring unit uses a high-definition camera to monitor the appearance of the spherical bearing in real time, and compares it with the content in the database to determine whether the appearance of the spherical bearing shows pitting or surface peeling. If it is identified that the liner is squeezed out and the spherical bearing fails, a reminder to replace the spherical bearing is given.

9. The super-large and super-long digital cylinder based on key components as claimed in claim 8, characterized in that: The bearing monitoring unit predicts the remaining life of the spherical plain bearing, specifically: Theoretically, the remaining service life of spherical plain bearings is: The remaining life of the spherical plain bearing = the design life - the equivalent of the service life; A reduction coefficient α is obtained through test and actual service data of spherical plain bearings and calculation. Therefore, combined with the weight of online monitoring temperature and wear data of spherical plain bearings, the remaining life of spherical plain bearings is:

10. The super-large and super-long digital cylinder based on key components as claimed in claim 1, characterized in that: The oil cylinder body structure comprises a cylinder body and a piston arranged inside the cylinder body, the piston divides the interior of the cylinder body into a rod chamber and a rodless chamber, the rod chamber is a small chamber, and the rodless chamber is a large chamber, the piston is fixedly connected to a piston rod on the side facing the rod chamber, an oil cylinder V group seal is arranged between the piston rod and the cylinder body, and the rod chamber and the rodless chamber are respectively connected to oil pipes; It also includes a cylinder seal monitoring device, which includes a piston rod outer peripheral surface detection device, an oil quality detection device, and a piston rod speed detection device; A piston rod outer peripheral surface detection device, which is arranged at the end of the cylinder body and is used to detect whether there is hydraulic oil on the outer peripheral surface of the piston rod extending out of the cylinder body structure; An oil quality detection device, which is arranged on the two oil pipes and is used to detect the oil quality of the hydraulic oil in the oil pipes; A piston rod speed detection device, which is arranged on the oil cylinder body structure and is used to detect the actual moving speed and theoretical moving speed of the piston rod; The industrial computer includes a cylinder sealing control unit, which is respectively connected to each detection device, the display screen and the alarm, obtains data detected by each detection device, determines whether there is a leak in the cylinder body structure, and displays prompt information through the display screen; when there is a leak in the cylinder body structure, the industrial computer controls the alarm to send out an alarm message.

11. The super-large and super-long digital cylinder based on key components as claimed in claim 10, characterized in that: The oil cylinder sealing control unit detects the external leakage working condition and the internal leakage working condition of the oil cylinder body structure respectively; The external leakage working condition detection of the oil cylinder body structure specifically includes the following steps: SA1, using the piston rod outer peripheral surface detection device to detect whether there is hydraulic oil leakage on the outer peripheral surface of the piston rod extending out of the cylinder body structure, and transmit it to the industrial computer cylinder seal control unit; if there is, proceed to step SA2, otherwise proceed to step SA3; SA2. Detect the oil quality of the hydraulic oil in the two oil pipes through the oil quality detection device, obtain the moisture and particle content of the hydraulic oil in the two oil pipes, and transmit them to the industrial computer cylinder sealing control unit; when the moisture and particle content of the hydraulic oil in any of the oil pipes exceeds the set oil quality threshold, the industrial computer cylinder sealing control unit determines that there is an external leakage of the cylinder body structure, displays a prompt message through the display screen, and sends an alarm message through the alarm; when the moisture and particle content of the hydraulic oil in the two oil pipes do not exceed the set oil quality threshold, the industrial computer determines that there is a possibility of external leakage of the cylinder body structure, and displays a prompt message through the display screen; SA3. Detect the oil quality of the hydraulic oil in the two oil pipes through the oil quality detection device, obtain the moisture and particle content of the hydraulic oil in the two oil pipes, and transmit them to the industrial computer cylinder sealing control unit; when the moisture and particle content of the hydraulic oil in the two oil pipes do not exceed the set oil quality threshold, the industrial computer cylinder sealing control unit determines that there is no external leakage of the cylinder body structure; when the moisture and particle content of the hydraulic oil in any of the oil pipes exceeds the set oil quality threshold, the industrial computer cylinder sealing control unit determines that there is a possibility of external leakage of the cylinder body structure, and displays a prompt message on the display screen; The internal leakage working condition detection of the oil cylinder body structure specifically includes the following steps: SB1, detecting the oil pressure of the rod chamber and the rodless chamber of the oil cylinder body structure through two pressure sensors, and transmitting the oil pressure to the oil cylinder sealing control unit of the industrial computer; the oil cylinder sealing control unit of the industrial computer compares the pressure difference between the two chambers with the set pressure difference threshold, if the pressure difference in the two oil pipes reaches the set pressure difference threshold, proceed to step SB2, otherwise proceed to step SB3; SB2. Detect the actual moving speed and theoretical moving speed of the piston rod through the piston rod speed detection device, and transmit them to the cylinder seal control unit of the industrial computer; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold, the industrial computer determines that there is an internal leakage in the cylinder body structure, displays a prompt message through the display screen, and sends an alarm message through the alarm; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold, the industrial computer determines that there is a possibility of internal leakage in the cylinder body structure, and displays a prompt message through the display screen; SB3. The actual moving speed and theoretical moving speed of the piston rod are detected by the piston rod speed detection device, and transmitted to the industrial computer cylinder seal control unit; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold, the industrial computer determines that there is no internal leakage in the cylinder body structure; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold, the industrial computer determines that there is a possibility of internal leakage in the cylinder body structure, and displays a prompt message on the display screen.

12. The super-large and super-long digital cylinder based on key components according to claim 11, characterized in that: The oil cylinder seal control unit estimates the remaining life of the seal, and the estimated remaining life of the seal is calculated by the following formula: Where, T y is the remaining life of the seal, T s is the design life of the seal, T i is the equivalent of the service life of the seal, Q f is the non-metallic particle content of the hydraulic oil in any of the oil pipes; β is the threshold value of the non-metallic particle content of the hydraulic oil; is the variance of the periodic detection value of the pressure difference in the two oil pipes; Q is the threshold value of the variance of the pressure difference in the two oil pipes.

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