An intelligent diagnosis method for hydraulic system

Abstract

The present invention relates to the field of intelligent diagnosis technology, and in particular to an intelligent diagnosis method for a hydraulic system, the method comprising: detecting each major key point of a target hydraulic system to be started to obtain each major detection data; making a judgment based on each major detection data to determine whether to start a pre-operation mode or output an initial diagnosis result; performing no-load pre-operation according to the pre-operation mode, obtaining a type of real-time monitoring data and making a secondary judgment to determine whether to start a load operation mode and determine to output a first feedback correction result or output a pre-operation diagnosis result; performing a pressurized operation test and a continuous operation test in sequence based on the load operation mode, thereby making three judgments to output a load diagnosis result or a second feedback correction result of the target hydraulic system; and optimizing each operation monitoring plan in combination with the first feedback correction result and the second feedback correction result.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent diagnosis, and in particular to an intelligent diagnosis method for a hydraulic system. Background Art

[0002] At present, most of the diagnosis of hydraulic systems is carried out by monitoring during the actual operation process to diagnose the operating status of the hydraulic system. Even if there are individual preventive diagnosis measures before use, they are only put into use after a simple inspection, which cannot reduce unexpected failures and ensure the continuous operation of the hydraulic system. Therefore, a simple and effective diagnostic method is needed that can not only preventively check the hydraulic system, but also provide feedback on the actual operation process, so as to ensure the safety of the hydraulic system during operation and reduce the occurrence of accidents.

[0003] Chinese patent application publication number CN108730265A discloses a hydraulic system fault diagnosis system, including a signal conditioning module, a preliminary fault diagnosis and feature extraction module, a fault diagnosis terminal, a power supply device and a sensor device connected to the hydraulic system; the sensor device is connected to the preliminary fault diagnosis and feature extraction module through the signal conditioning module; the preliminary fault diagnosis and feature extraction module is connected to the fault diagnosis terminal; the power supply device is respectively connected to the signal conditioning module, the preliminary fault diagnosis and feature extraction module and the sensor device; the sensor device converts the collected physical signals of the hydraulic system into voltage signals and transmits them to the preliminary fault diagnosis and feature extraction module through the signal conditioning module; the preliminary fault diagnosis and feature extraction module transmits the fault feature data of the hydraulic system obtained by processing each voltage signal to the fault diagnosis terminal; the fault diagnosis terminal diagnoses and analyzes the fault of the hydraulic system by establishing a fault diagnosis model corresponding to each fault feature data.

[0004] It can be seen that the current intelligent diagnostic technology of hydraulic systems cannot guarantee the continuous operation of the hydraulic system, nor can it provide real-time feedback on the self-monitoring of the actual operation process. Summary of the invention

[0005] To this end, the purpose of the present invention is to provide an intelligent diagnosis method for a hydraulic system, which is used to overcome the problem that the current intelligent diagnosis technology of the hydraulic system cannot guarantee the continuous operation of the hydraulic system and cannot provide real-time feedback on the self-monitoring of the actual operation process.

[0006] To achieve the above object, the present invention provides an intelligent diagnosis method for a hydraulic system, comprising:

[0007] Test the key points of the target hydraulic system to be started to obtain the main test data;

[0008] Perform a judgment based on each main detection data, and determine whether to start the pre-operation mode or output the initial diagnosis result according to the result of the judgment;

[0009] Performing no-load pre-operation on the target hydraulic system according to the pre-operation mode, performing a type of real-time monitoring on the no-load pre-operation process, performing a secondary determination based on the type of real-time monitoring data, and determining whether to start the load operation mode and determine to output a first feedback correction result or output a pre-operation diagnosis result according to the secondary determination result;

[0010] Based on the load operation mode, the target hydraulic system is sequentially subjected to a pressurized operation test and a continuous operation test, and the loaded operation process and the continuous operation process are respectively subjected to a second type of real-time monitoring and a third type of periodic monitoring, and three determinations are made according to the second type of real-time monitoring data and the third type of periodic monitoring data, and a load diagnosis result or a second feedback correction result of the target hydraulic system is output according to the three determination results;

[0011] Optimize each operation monitoring plan by combining the first feedback correction result and the second feedback correction result.

[0012] Furthermore, the process of performing a determination based on each main detection data and determining whether to start the pre-operation mode or output the initial diagnosis result according to the determination result includes:

[0013] The oil level, pipeline and electrical connection of the target hydraulic system to be started are respectively detected to obtain oil level detection data, pipeline detection data and electrical connection detection data;

[0014] The oil level detection data, the pipeline detection data and the electrical connection detection data are respectively judged once to determine the number of qualified main points in each main key point;

[0015] Determining whether to start the pre-operation mode according to the number of the main points;

[0016] Among them, when the number of the main points is 3, it is determined to start the pre-operation mode, and when the number of the main points is less than 3, the initial diagnosis result is output; the main key points include: oil level, pipeline and electrical connection.

[0017] Furthermore, the process of performing a type of real-time monitoring on the no-load pre-operation process and performing a secondary determination based on the type of real-time monitoring data includes:

[0018] Detect each auxiliary key point of the target hydraulic system in no-load pre-operation to obtain each auxiliary detection data;

[0019] Conduct a type of real-time monitoring of the no-load pre-operation process to obtain a set of key characteristic parameters of the pre-operation;

[0020] Perform secondary determination based on each auxiliary detection data and the pre-operation key characteristic parameter set;

[0021] The one type of real-time monitoring data includes: various auxiliary detection data and the pre-operation key characteristic parameter set.

[0022] Furthermore, the process of performing a type of real-time monitoring on the no-load pre-operation process to obtain a set of pre-operation key characteristic parameters includes:

[0023] During the no-load pre-operation process, real-time monitoring is performed on the main pipeline of the target hydraulic system to obtain a type of actual pressure;

[0024] During the no-load pre-operation process, the oil tank of the target hydraulic system is monitored in real time to obtain an actual temperature;

[0025] During the no-load pre-operation process, the pump of the target hydraulic system is monitored in real time to obtain a type of actual flow;

[0026] The type of actual pressure, the type of actual temperature and the type of actual flow are integrated to obtain the pre-operation key characteristic parameter set.

[0027] Further, the process of determining whether to start the load operation mode and outputting the first feedback correction result or the pre-operation diagnosis result according to the secondary determination result includes:

[0028] Analyze each auxiliary detection data to determine the number of qualified auxiliary points in each auxiliary key point;

[0029] Determining whether to start the secondary determination mode according to the number of auxiliary points;

[0030] Based on starting the secondary determination mode, determining whether to start the load operation mode and determining to output the first feedback correction result or output the pre-operation diagnosis result according to the pre-operation key characteristic parameter set;

[0031] When the number of auxiliary points is 2, it is determined to start the secondary determination mode, and when the number of auxiliary points is less than 2, it is determined to output the pre-operation diagnosis result.

[0032] Further, the process of determining whether to start the load operation mode and determining to output the first feedback correction result or output the pre-operation diagnosis result according to the pre-operation key characteristic parameter set includes:

[0033] Based on starting the secondary determination mode, the first type of actual pressure, the first type of actual temperature and the first type of actual flow are respectively compared with the preset pre-operation evaluation threshold range, and the number of pre-operation anomalies in each key characteristic parameter and the corresponding single pre-operation anomaly degree are determined according to the comparison results;

[0034] Determining whether to start the load operation mode according to the number of pre-operation anomalies and the degree of each single pre-operation anomaly;

[0035] Among them, based on when the load operation mode is turned on, the first feedback correction result is determined according to the degree of each single pre-operation abnormality to send a first feedback signal, and the load operation monitoring plan is adjusted according to the first feedback signal; based on when the load operation mode is not turned on, the pre-operation diagnosis result is output according to the number of pre-operation abnormalities and the degree of each single pre-operation abnormality.

[0036] Furthermore, the process of performing two types of real-time monitoring and three types of periodic monitoring on the loading operation process and the continuous operation process respectively, and performing three determinations based on the two types of real-time monitoring data and the three types of periodic monitoring data includes:

[0037] Obtaining actual changes of key characteristic parameters at the marked time during the loading operation;

[0038] Determine the number of items in each key characteristic parameter that meet a single determination condition according to the actual change situation, and determine the loading determination result according to the number of items;

[0039] Determining whether to perform a continuous operation test based on the loading determination result;

[0040] The loading operation process is to gradually increase the load of the target hydraulic system with a preset initial increase amplitude and initial increase times until a preset upper limit workload is reached; the marking moment is the load change moment.

[0041] Furthermore, the process of performing two types of real-time monitoring and three types of periodic monitoring on the loading operation process and the continuous operation process respectively, and performing three determinations based on the two types of real-time monitoring data and the three types of periodic monitoring data also includes:

[0042] When the loading is judged to be qualified, starting a continuous operation test;

[0043] Perform periodic monitoring at preset time intervals during the continuous operation test to obtain a continuous set of key characteristic parameters;

[0044] For any monitoring period, obtain the current continuous key feature parameter set corresponding to the monitoring period, and determine whether to turn on the verification mode according to the current continuous key feature parameter set;

[0045] Based on the verification mode, a historical continuous key characteristic parameter set is obtained, an actual fluctuation set is determined according to the current continuous key characteristic parameter set and the historical continuous key characteristic parameter set, and the load diagnosis result or the second feedback correction result of the output target hydraulic system is determined according to the actual fluctuation set;

[0046] Among them, when the current number of continuous anomalies in the current continuous key feature parameter set is 0, it is determined to start the verification mode; the historical continuous key feature parameter set is three types of periodic monitoring data obtained in the previous monitoring period corresponding to the monitoring period.

[0047] Furthermore, the process of determining the number of items in each key characteristic parameter that meet a single determination condition according to the actual change situation includes:

[0048] For any key characteristic parameter, determine whether the key characteristic parameter meets a single determination condition according to the actual change rate and change duration corresponding to the key characteristic parameter;

[0049] Based on the fact that the actual change rate is within the preset standard change range and the change duration is less than the preset standard duration, it is determined that the key characteristic parameter meets the single determination condition;

[0050] The actual change condition includes: the actual change rate and the duration of the change.

[0051] Further, the process of determining the load diagnosis result or the second feedback correction result of the output target hydraulic system according to the actual fluctuation set includes:

[0052] Acquire the number of actual fluctuation anomalies in the actual fluctuation set, and determine to output the load diagnosis result or the second feedback correction result according to the number of actual fluctuation anomalies;

[0053] When the actual number of abnormal fluctuations is 0, determining that the second feedback correction result is to send a second feedback signal, and adjusting the actual operation monitoring plan according to the second feedback signal;

[0054] When the actual fluctuation anomaly number is not 0, the load diagnosis result is output, and the load diagnosis result includes: the actual fluctuation anomaly type and the actual fluctuation anomaly number.

[0055] Compared with the prior art, the beneficial effects of the present invention are that, through step-by-step judgment, it is ensured that the hydraulic system can meet the operating conditions at each stage, thereby improving the reliability of the entire hydraulic system; by identifying potential problems in advance and taking preventive maintenance measures, it helps to reduce unexpected failures and ensure the continuous operation of the hydraulic system; no-load pre-operation and load operation tests help to identify and solve potential performance bottlenecks, so as to timely discover and solve problems and reduce the overhaul costs caused by failures; through the first feedback correction and the second feedback correction, each operation monitoring plan is optimized to ensure the safety of the hydraulic system during operation and reduce the occurrence of accidents; continuous monitoring and timely correction help to extend the service life of the hydraulic system; ensuring the stable operation of the hydraulic system reduces the downtime in the production process and improves production efficiency.

[0056] Through detection and judgment, it is ensured that the basic components of the hydraulic system meet the safe operating conditions before startup, and the operating risks caused by basic problems are prevented; problems with oil levels, pipelines and electrical connections are discovered in a timely manner in a single judgment, avoiding more serious failures in subsequent operations; the initial diagnostic results provide maintenance personnel with a clear maintenance direction, which helps to quickly solve problems and reduce downtime; through a single judgment, it is possible to quickly decide whether to enter the pre-operation mode, avoid unnecessary operations in an unqualified state, and improve work efficiency; by promptly discovering and handling problems, the maintenance costs caused by the expansion of faults are reduced; ensuring that all major key points are qualified enhances the overall reliability and stability of the hydraulic system.

[0057] Through leakage detection and actuator movement detection, potential leakage and unstable movement problems of the hydraulic system can be discovered in advance to avoid failures during load operation; key characteristic parameters such as pressure, temperature and flow are monitored in real time to ensure stable performance of the hydraulic system during no-load pre-operation; through real-time monitoring and secondary judgment, the hydraulic system can be adjusted to optimize its performance to ensure that the hydraulic system can reach the best working state during load operation; through monitoring and judgment, the safety of the hydraulic system during no-load pre-operation is ensured to prevent equipment damage or safety accidents caused by abnormal parameters; problems are discovered and handled in a timely manner to reduce downtime caused by failures and improve production efficiency; through preventive maintenance, the maintenance cost caused by failures is reduced, and the same monitoring position and parameter type are used during no-load pre-operation and load operation to ensure data consistency and comparability, facilitate analysis of changes in hydraulic system performance, and fully verify and optimize the status of the hydraulic system before formal load operation, providing a guarantee for the long-term stable operation of the hydraulic system.

[0058] Through detailed auxiliary point detection and real-time monitoring, the status of the hydraulic system can be accurately diagnosed and potential problems can be discovered in advance; corrections can be made before the problem worsens to reduce failures and downtime; the load operation monitoring plan can be adjusted according to the degree of abnormality to ensure that the hydraulic system operates in the best condition; equipment damage or safety accidents caused by abnormal parameters can be avoided; it can ensure that all indicators of the hydraulic system are within the normal range before load operation, improve the overall reliability of the hydraulic system, and ensure that the hydraulic system is fully verified and prepared before entering the load operation mode, providing important guarantees for the long-term stable and efficient operation of the hydraulic system.

[0059] Through real-time and periodic monitoring, the performance of the hydraulic system under load changes can be accurately captured; by analyzing the changes in key characteristic parameters, the stability and reliability of the hydraulic system can be evaluated; the monitoring plan can be adjusted according to the actual fluctuations to improve monitoring efficiency; the safety of the hydraulic system before and after reaching the upper limit of the working load can be ensured; by feeding back the correction results, the hydraulic system operation and maintenance strategy can be continuously optimized, providing a solid guarantee for the long-term stable operation of the hydraulic system. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Figure 1 A flow chart of an intelligent diagnosis method for a hydraulic system according to an embodiment of the present invention;

[0061] Figure 2 A flow chart of a primary determination in an intelligent diagnosis method for a hydraulic system according to an embodiment of the present invention;

[0062] Figure 3 A flow chart of a secondary determination in an intelligent diagnosis method for a hydraulic system according to an embodiment of the present invention;

[0063] Figure 4 The figure is a flow chart of three determinations in the intelligent diagnosis method for hydraulic system according to an embodiment of the present invention. DETAILED DESCRIPTION

[0064] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0065] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the protection scope of the present invention.

[0066] It should be noted that, in the description of the present invention, terms such as "up", "down", "left", "right", "inside" and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the drawings. This is merely for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present invention.

[0067] See also Figure 1 As shown, the present invention provides an intelligent diagnosis method for a hydraulic system, comprising:

[0068] Step S100, detecting each key point of the target hydraulic system to be started to obtain each main detection data;

[0069] Step S200, performing a determination based on each main detection data, and determining whether to start the pre-operation mode or output the initial diagnosis result according to the determination result;

[0070] Step S300, performing no-load pre-operation on the target hydraulic system according to the pre-operation mode, performing a type of real-time monitoring on the no-load pre-operation process, performing a secondary determination based on the type of real-time monitoring data, and determining whether to start the load operation mode and determine to output the first feedback correction result or output the pre-operation diagnosis result according to the secondary determination result;

[0071] Step S400, based on the load operation mode, sequentially performing a pressurized operation test and a continuous operation test on the target hydraulic system, performing two types of real-time monitoring and three types of periodic monitoring on the loading operation process and the continuous operation process, respectively, performing three determinations based on the two types of real-time monitoring data and the three types of periodic monitoring data, and outputting a load diagnosis result or a second feedback correction result of the target hydraulic system based on the three determination results;

[0072] Step S500: Optimize each operation monitoring plan by combining the first feedback correction result and the second feedback correction result.

[0073] In this embodiment, the process of detecting the key points of the target hydraulic system to be started includes: oil level detection, pipeline detection and electrical connection detection; the oil level detection is to check the oil level in the oil tank to ensure that the oil level is between the minimum and maximum marks; the pipeline detection is to check whether the pipeline has signs of wear, cracks, expansion or other damage; the electrical connection detection is to check whether all electrical connections in the hydraulic system are firm and not loose or corroded;

[0074] In the specific implementation process, the present invention makes a primary judgment on each major key point of the target hydraulic system, determines whether the basic components of the target hydraulic system are qualified according to the oil level detection, pipeline detection and electrical connection detection, so as to determine whether the target hydraulic system can meet the initial conditions for normal operation; if the result of the primary judgment is unqualified, the initial diagnosis result of the target hydraulic system is output; if the result of the primary judgment is qualified, the target hydraulic system is pre-operated at no-load and a first feedback correction result is output; a secondary judgment is made according to the no-load pre-operation process to further determine whether the target hydraulic system can operate normally; if the result of the secondary judgment is unqualified, the pre-operation diagnosis result of the target hydraulic system is output; if the result of the secondary judgment is qualified, the target hydraulic system is loaded and operated; a third judgment is made according to the load operation process to determine again whether the target hydraulic system can operate normally and stably; based on the third judgment If the three judgment results are unqualified, the load diagnosis result of the target hydraulic system is output; if the three judgment results are qualified, the second feedback correction result of the target hydraulic system is output; if all the judgment results are qualified, the actual operation monitoring plan of the target hydraulic system when it is officially put into operation is determined according to the first feedback correction result and the second feedback correction result; through step-by-step judgment, it is ensured that the hydraulic system can meet the operating conditions at all stages, thereby improving the reliability of the entire hydraulic system; preventive maintenance measures help reduce unexpected failures and ensure the continuous operation of the hydraulic system; no-load pre-operation and load operation tests help identify and solve potential performance bottlenecks, so as to discover and solve problems in time and reduce the overhaul costs caused by failures; through the first feedback correction and the second feedback correction, the actual operation monitoring plan of the hydraulic system when it is officially put into operation is optimized to ensure the safety of the hydraulic system during operation and reduce the occurrence of accidents.

[0075] Specifically, the embodiment of the present invention ensures that the hydraulic system can meet the operating conditions at each stage through step-by-step determination, thereby improving the reliability of the entire hydraulic system; by identifying potential problems in advance and taking preventive maintenance measures, it helps to reduce unexpected failures and ensure the continuous operation of the hydraulic system; no-load pre-operation and load operation tests help to identify and solve potential performance bottlenecks, so as to promptly discover and solve problems and reduce the overhaul costs caused by failures; through the first feedback correction and the second feedback correction, each operation monitoring plan is optimized to ensure the safety of the hydraulic system during operation and reduce the occurrence of accidents; continuous monitoring and timely correction help to extend the service life of the hydraulic system; ensure the stable operation of the hydraulic system, reduce downtime in the production process, and improve production efficiency.

[0076] See also Figure 2As shown, it is a flowchart of a primary determination, wherein the process of performing a primary determination based on each main detection data and determining whether to start the pre-operation mode or output the initial diagnosis result according to the primary determination result includes:

[0077] Step S210, respectively detecting the oil level, pipeline and electrical connection of the target hydraulic system to be started to obtain oil level detection data, pipeline detection data and electrical connection detection data;

[0078] Step S220, performing a determination on the oil level detection data, the pipeline detection data, and the electrical connection detection data, respectively, to determine the number of qualified main points in each main key point;

[0079] Step S230, determining whether to start the pre-operation mode according to the number of the main points;

[0080] Among them, when the number of the main points is 3, it is determined to start the pre-operation mode, and when the number of the main points is less than 3, the initial diagnosis result is output; the main key points include: oil level, pipeline and electrical connection.

[0081] In a specific implementation process, if the oil level is determined to be between the lowest and highest marks according to the oil level detection data, the oil level is determined to be qualified; if the oil level is lower than the lowest mark or higher than the highest mark, the oil level is determined to be unqualified and recorded in the initial diagnosis result; if the pipeline appearance is determined to have no signs of wear, cracks, expansion or other damage according to the pipeline detection data, the pipeline is determined to be qualified; if the pipeline appearance has signs of wear, cracks, expansion or other damage, the pipeline is determined to be unqualified and recorded in the initial diagnosis result; if all electrical connections of the hydraulic system are determined to be free of looseness or corrosion according to the electrical connection detection data, the electrical connection is determined to be qualified; if any electrical connection of the hydraulic system is loose or corroded, the electrical connection is determined to be unqualified and recorded in the initial diagnosis result;

[0082] For example, based on the oil level being lower than the lowest mark, the oil level is determined to be unqualified; based on the appearance of the pipeline being cracked, the pipeline is determined to be unqualified; and based on all electrical connections being free of looseness or corrosion, the electrical connection is determined to be qualified. The corresponding number of main points is 1, and the initial diagnostic result output is [the oil level is too low and unqualified; the pipeline has cracks and is unqualified].

[0083] Specifically, the embodiments of the present invention ensure that the basic components of the hydraulic system meet safe operating conditions before startup through detection and judgment, thereby preventing operating risks caused by basic problems; timely discover problems with oil levels, pipelines and electrical connections in a single judgment, thereby avoiding more serious faults in subsequent operations; the initial diagnostic results provide maintenance personnel with a clear maintenance direction, which helps to quickly solve problems and reduce downtime; through a single judgment, it can quickly decide whether to enter the pre-operation mode, avoiding unnecessary operations in an unqualified state and improving work efficiency; by promptly discovering and handling problems, the maintenance cost caused by the expansion of faults is reduced; ensuring that all major key points are qualified, the overall reliability and stability of the hydraulic system are enhanced.

[0084] For example, if the oil level is unqualified, the pipeline is unqualified, but the electrical connection is qualified, then the number of major points is 1, and the output initial diagnosis result is [the oil level is too low and unqualified, and the pipeline has cracks and unqualified]; it helps to take appropriate measures immediately, such as adjusting the oil level and replacing damaged pipelines, to ensure that the system reaches a qualified state before entering the pre-operation mode.

[0085] Specifically, the process of performing a type of real-time monitoring on the no-load pre-operation process and performing a secondary determination based on the type of real-time monitoring data in this embodiment includes:

[0086] Step S311, detecting each auxiliary key point of the target hydraulic system in no-load pre-operation to obtain each auxiliary detection data;

[0087] Step S312, performing a type of real-time monitoring on the no-load pre-operation process to obtain a set of key characteristic parameters of the pre-operation;

[0088] Step S313, performing secondary determination according to each auxiliary detection data and the pre-operation key characteristic parameter set;

[0089] Wherein, the one type of real-time monitoring data includes: various auxiliary detection data and the pre-operation key characteristic parameter set;

[0090] In this embodiment, the process of detecting each auxiliary key point of the target hydraulic system in no-load pre-operation includes: leakage detection and actuator movement detection; the leakage detection is to identify whether there is leakage in the joints, hoses and seals of the hydraulic system; the actuator movement detection is to check whether the movement of the actuator is smooth when no-load, whether there is creeping or jamming, wherein the actuator is a hydraulic cylinder;

[0091] The process of performing a type of real-time monitoring on the no-load pre-operation process to obtain a set of pre-operation key characteristic parameters includes:

[0092] Step S3121, during the no-load pre-operation process, real-time monitoring is performed on the main pipeline of the target hydraulic system to obtain a type of actual pressure;

[0093] Step S3122, during the no-load pre-operation process, real-time monitoring is performed on the oil tank of the target hydraulic system to obtain an actual temperature;

[0094] Step S3123, during the no-load pre-operation process, real-time monitoring is performed on the pump of the target hydraulic system to obtain a type of actual flow;

[0095] Step S3124, integrating the one type of actual pressure, the one type of actual temperature and the one type of actual flow to obtain the pre-operation key characteristic parameter set;

[0096] In this embodiment, the monitoring positions and monitoring parameter types of the key characteristic parameters obtained during the no-load pre-operation process and the load operation process are consistent, which are pressure parameters obtained by detecting the main pipeline of the target hydraulic system, temperature parameters obtained by detecting the oil tank of the target hydraulic system, and flow parameters obtained by detecting the pump of the target hydraulic system.

[0097] Specifically, the embodiments of the present invention detect potential leakage and unstable movement of the hydraulic system in advance through leakage detection and actuator movement detection, thereby avoiding failures during load operation; real-time monitoring of key characteristic parameters, such as pressure, temperature and flow, ensures stable performance of the hydraulic system during no-load pre-operation; through real-time monitoring and secondary judgment, the hydraulic system can be adjusted to optimize its performance to ensure that the hydraulic system can reach the best working state during load operation; through monitoring and judgment, the safety of the hydraulic system during no-load pre-operation is ensured to prevent equipment damage or safety accidents caused by abnormal parameters; timely detection and handling of problems reduces downtime caused by failures and improves production efficiency; through preventive maintenance, the maintenance cost caused by failures is reduced, and the same monitoring position and parameter type are used during no-load pre-operation and load operation to ensure data consistency and comparability, facilitate analysis of changes in hydraulic system performance, and ensure that the state of the hydraulic system before formal load operation is fully verified and optimized, providing a guarantee for the long-term stable operation of the hydraulic system.

[0098] See also Figure 3 As shown, it is a flowchart of the secondary determination, wherein the process of determining whether to start the load operation mode and determining to output the first feedback correction result or output the pre-operation diagnosis result according to the secondary determination result includes:

[0099] Step S321, analyzing each auxiliary detection data to determine the number of qualified auxiliary points in each auxiliary key point;

[0100] Step S322, determining whether to start the secondary determination mode according to the number of auxiliary points;

[0101] Step S323, based on starting the secondary determination mode, determining whether to start the load operation mode and determining to output the first feedback correction result or output the pre-operation diagnosis result according to the pre-operation key characteristic parameter set;

[0102] When the number of auxiliary points is 2, it is determined to start the secondary determination mode, and when the number of auxiliary points is less than 2, it is determined to output the pre-operation diagnosis result.

[0103] In the specific implementation process, the reconnectors, hoses and seals of the hydraulic system are tested to obtain auxiliary leakage detection data, and the actuators of the hydraulic system are tested to obtain auxiliary operation detection data; wherein each auxiliary key point includes: leakage detection point and actuator; the leakage detection point includes: reconnectors, hoses, seals;

[0104] If it is determined according to the leakage auxiliary detection data that there is no leakage in the reconnector, the hose and the seal, the leakage detection point is determined to be qualified; if there is leakage in the reconnector, the hose or the seal, the leakage detection point is determined to be unqualified and recorded in the pre-operation diagnosis result; if it is determined according to the operation auxiliary detection data that there is no creeping or jamming phenomenon of the actuator when it is idling, the actuator is determined to be qualified; if there is creeping or jamming phenomenon of the actuator when it is idling, the actuator is determined to be unqualified and recorded in the pre-operation diagnosis result;

[0105] For example, when the leakage detection point is determined to be unqualified based on the presence of leakage at the hose, and the actuator is determined to be unqualified based on the presence of a jamming phenomenon at the actuator, the corresponding number of auxiliary points is 0, and the pre-operation diagnosis result is output as [the hose leakage is unqualified, the actuator is unqualified];

[0106] Specifically, the process of determining whether to start the load operation mode and determining to output the first feedback correction result or output the pre-operation diagnosis result according to the pre-operation key characteristic parameter set in this embodiment includes:

[0107] Step S3231, based on starting the secondary determination mode, the first type of actual pressure, the first type of actual temperature and the first type of actual flow are respectively compared with the preset pre-operation evaluation threshold range, and the number of pre-operation anomalies in each key characteristic parameter and the corresponding single pre-operation anomaly degree are determined according to the comparison results;

[0108] Step S3232, determining whether to start the load operation mode according to the number of pre-operation anomalies and the degree of each single pre-operation anomaly;

[0109] Wherein, when the load operation mode is turned on, the first feedback correction result is determined according to each single pre-operation abnormality degree to send a first feedback signal, and the load operation monitoring plan is adjusted according to the first feedback signal; when the load operation mode is not turned on, the pre-operation diagnosis result is output according to the number of pre-operation abnormalities and each single pre-operation abnormality degree;

[0110] In the specific implementation process, the pressure pre-operation evaluation threshold range corresponding to the first type of actual pressure is set to ±10% of the design pressure of the hydraulic system. For example, if the design pressure of the hydraulic system is 210 bar, the pressure pre-operation evaluation threshold range is 189 bar-231 bar; the temperature pre-operation evaluation threshold range corresponding to the first type of actual temperature is set to the normal operating temperature range of the hydraulic system. For example, the oil temperature should be maintained at 40°C to 60°C, then the temperature pre-operation evaluation threshold range is set to 40°C-60°C; the flow pre-operation evaluation threshold range corresponding to the first type of actual flow is set to ±5% of the pump design flow. For example, if the design flow is 100 L / min, the flow pre-operation evaluation threshold range is 95 L / min-105 L / min; use sensors and monitoring equipment to collect real-time data on the pressure of the main pipeline, the temperature of the oil tank and the flow rate of the pump; compare the actual pressure of a type monitored in real time with the preset pressure threshold; compare the actual temperature of a type monitored in real time with the preset temperature threshold; compare the actual flow of a type monitored in real time with the preset flow threshold; if the actual parameter is within the preset threshold range, it is considered normal; if the actual parameter exceeds the preset threshold range, it is recorded as a pre-operation abnormality;

[0111] Determination of the degree of abnormality of a single pre-operation: It is determined based on the degree to which the parameter exceeds the threshold; the higher the degree to which the parameter deviates from the preset threshold, the more serious the abnormality. The specific determination process is as follows:

[0112] Slightly abnormal: the parameter value exceeds the threshold range by less than 5%;

[0113] Moderate abnormality: parameter value exceeds the threshold range by 5% to 10%;

[0114] Severe abnormality: the parameter value exceeds the threshold range by more than 10%;

[0115] When the first type of actual pressure, the first type of actual temperature and the first type of actual flow are all normal or only slightly abnormal, it is determined to start the load operation mode, and the first feedback correction result is determined to send a first feedback signal according to the degree of each single pre-operation abnormality, and the load operation monitoring plan is adjusted according to the first feedback signal; when there are moderate abnormalities and severe abnormalities in the first type of actual pressure, the first type of actual temperature and the first type of actual flow, the number of pre-operation abnormalities is determined according to the number of parameters corresponding to the moderate abnormalities and the severe abnormalities; when the number of pre-operation is greater than or equal to 0, the load operation mode is not started, and the pre-operation diagnosis result is output according to the number of pre-operation abnormalities and the degree of each single pre-operation abnormality;

[0116] The load operation monitoring plan includes: a preset initial increase amplitude and initial increase times and an initial continuous duration of the continuous operation test; the specific adjustment standard is to obtain the number of slight anomalies in the first type of actual pressure, the first type of actual temperature and the first type of actual flow, and adjust the initial increase amplitude, initial increase times and initial continuous duration according to the slight number, and the slight number is positively correlated with the initial increase amplitude, initial increase times and initial continuous duration;

[0117] The specific process of outputting the pre-operation diagnosis result is as follows:

[0118] For example, if one type of actual pressure is seriously abnormal, and the one type of actual temperature and the one type of actual flow are normal, then it is determined that the pre-operation number is equal to 1, and the load operation mode is not turned on, and the pre-operation diagnosis result is output as [pressure is seriously abnormal, temperature is normal, flow is normal].

[0119] Specifically, the embodiments of the present invention can accurately diagnose the status of the hydraulic system and discover potential problems in advance through detailed auxiliary point detection and real-time monitoring; correct the problem before it worsens to reduce failures and downtime; adjust the load operation monitoring plan according to the degree of abnormality to ensure that the hydraulic system operates in the best state; avoid equipment damage or safety accidents caused by abnormal parameters; ensure that all indicators of the hydraulic system are within the normal range before load operation, improve the overall reliability of the hydraulic system, and ensure that the hydraulic system is fully verified and prepared before entering the load operation mode, providing important guarantees for the long-term stable and efficient operation of the hydraulic system.

[0120] See also Figure 4 As shown, it is a flowchart of three determinations, wherein the loading operation process and the continuous operation process are respectively subjected to two types of real-time monitoring and three types of periodic monitoring, and the process of performing three determinations based on the two types of real-time monitoring data and the three types of periodic monitoring data includes:

[0121] Step S410, obtaining actual changes of key characteristic parameters at the marking time during the loading operation;

[0122] Step S420, determining the number of items in each key characteristic parameter that meet a single determination condition according to the actual change situation, and determining a loading determination result according to the number of items;

[0123] Step S430, determining whether to perform a continuous operation test based on the loading determination result;

[0124] Step S440, when the loading determination result is that the loading is qualified, starting a continuous operation test;

[0125] Step S450, performing periodic monitoring at preset time intervals during the continuous operation test to obtain a continuous key characteristic parameter set;

[0126] Step S460: for any monitoring period, obtaining a current continuous key feature parameter set corresponding to the monitoring period, and determining whether to start the verification mode according to the current continuous key feature parameter set;

[0127] Step S470, based on the verification mode, obtaining a historical continuous key characteristic parameter set, determining an actual fluctuation set according to the current continuous key characteristic parameter set and the historical continuous key characteristic parameter set, and determining the load diagnosis result or the second feedback correction result of the output target hydraulic system according to the actual fluctuation set;

[0128] The loading operation process is to gradually increase the load of the target hydraulic system with a preset initial increase amplitude and initial increase times until a preset upper limit workload is reached; the marking moment is the load change moment;

[0129] When the current number of continuous anomalies in the current continuous key feature parameter set is 0, it is determined to start the verification mode; the historical continuous key feature parameter set is three types of periodic monitoring data obtained in the previous monitoring period corresponding to the monitoring period.

[0130] Specifically, the process of determining the number of items in each key characteristic parameter that meet a single determination condition according to the actual change situation includes:

[0131] Step S421, for any key characteristic parameter, determine whether the key characteristic parameter meets a single determination condition according to the actual change rate and change duration corresponding to the key characteristic parameter;

[0132] Step S422, based on the fact that the actual change rate is within the preset standard change range and the change duration is less than the preset standard duration, it is determined that the key characteristic parameter meets the single determination condition;

[0133] The actual change condition includes: the actual change rate and the duration of the change.

[0134] In the specific implementation process, for any key characteristic parameter, such as temperature, during the load change, a temperature sensor is used to monitor the oil temperature of the hydraulic system in real time, and the temperature data before and after the load is recorded, so as to obtain the actual temperature change rate during the load change process, and compare the actual temperature change rate with the standard change range; if the actual temperature change rate is within the standard change range (for example, the temperature rise does not exceed 10°C when the load changes, and the final temperature is still within the normal working range of 40°C to 60°C), it can be determined to be normal; when the load changes, if the temperature sensor shows that the temperature rises or falls rapidly, for example, it exceeds a certain value (such as 5°C) per minute, it is determined to be beyond the normal change range; if the duration of the temperature change fails to recover within the standard duration (such as more than 10 minutes), it is determined that the change duration is unqualified;

[0135] Only when both the duration of change and the actual rate of change are qualified, the key characteristic parameter is determined to meet the single determination condition; otherwise, the key characteristic parameter is determined to not meet the single determination condition;

[0136] Analyze the actual changes of each key characteristic parameter, determine the number of items that meet the single judgment condition, and when the number of items is 3, determine that the loading judgment result is qualified loading, thereby starting the continuous operation test; when the number of items is less than 3, determine that the loading judgment result is unqualified loading, and output the load diagnosis result as [pressurized operation test abnormality].

[0137] Specifically, the process of determining the load diagnosis result or the second feedback correction result of the output target hydraulic system according to the actual fluctuation set in this embodiment includes:

[0138] Step S471, obtaining the number of actual fluctuation anomalies in the actual fluctuation set, and determining to output the load diagnosis result or the second feedback correction result according to the number of actual fluctuation anomalies;

[0139] Step S472, when the actual number of fluctuation anomalies is 0, determining that the second feedback correction result is to send a second feedback signal, and adjusting the actual operation monitoring plan according to the second feedback signal;

[0140] Step S473: when the actual fluctuation anomaly number is not 0, output the load diagnosis result, the load diagnosis result includes: the actual fluctuation anomaly type and the actual fluctuation anomaly number.

[0141] In the specific implementation process, for any monitoring period, the current continuous key characteristic parameter set corresponding to the monitoring period is obtained, each key characteristic parameter in the current continuous key characteristic parameter set is analyzed to determine whether each key characteristic parameter is abnormal, and the abnormal key characteristic parameters are counted to obtain the current continuous abnormal number. When the current continuous abnormal number is 0, it is determined to turn on the verification mode. When the current continuous abnormal number is not 0, the load diagnosis result is output as [continuous operation test abnormality];

[0142] By periodically monitoring the continuous operation process to verify the stable operation of the hydraulic system, when the current monitoring cycle is stable, that is, the number of current continuous abnormalities is 0, the verification mode is turned on to further analyze whether the historical data monitored relative to the previous monitoring cycle, that is, the historical monitoring cycle, fluctuates, thereby further ensuring the stable operation of the hydraulic system;

[0143] Based on the verification mode, a historical continuous key feature parameter set is obtained, and the current continuous key feature parameter set is compared with the historical continuous key feature parameter set to determine the number of parameters with unqualified change fluctuations in each key feature parameter, thereby obtaining the actual fluctuation anomaly number and the corresponding actual fluctuation anomaly type, and the actual fluctuation anomaly type is the key feature parameter type with unqualified fluctuations;

[0144] When the actual number of abnormal fluctuations is 0, determining that the second feedback correction result is to send a second feedback signal, and adjusting the actual operation monitoring plan according to the second feedback signal;

[0145] The actual operation monitoring plan includes: a preset initial actual monitoring cycle;

[0146] The specific adjustment standard is to obtain the number of actual fluctuation anomalies in the actual fluctuation set, and adjust the initial actual monitoring period according to the number of actual fluctuation anomalies, and the number of actual fluctuation anomalies is negatively correlated with the initial actual monitoring period.

[0147] Specifically, the embodiments of the present invention can accurately capture the performance of the hydraulic system when the load changes through real-time and periodic monitoring; evaluate the stability and reliability of the hydraulic system by analyzing the changes in key characteristic parameters; adjust the monitoring plan according to the actual fluctuations to improve the monitoring efficiency; ensure the safety of the hydraulic system before and after reaching the upper limit of the working load; and continuously optimize the hydraulic system operation and maintenance strategy by feeding back the correction results, thereby providing a solid guarantee for the long-term stable operation of the hydraulic system.

[0148] The calculation compensation parameters and the calculation adjustment parameters described in the present invention have two functions: one is to balance the left and right dimensions of the formula, and the other is to adjust the numerical results. No specific assignment is performed in this embodiment. In addition, the calculation formulas in this embodiment are used to intuitively reflect the adjustment relationship between the numerical values, such as positive correlation and negative correlation. Unless otherwise specified, the parameter values ​​that are not specifically limited to numerical values ​​are all positive.

[0149] So far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

[0150] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An intelligent diagnostic method for a hydraulic system, comprising: Test the key points of the target hydraulic system to be started to obtain the main test data; Perform a judgment based on each main detection data, and determine whether to start the pre-operation mode or output the initial diagnosis result according to the result of the judgment; Performing no-load pre-operation on the target hydraulic system according to the pre-operation mode, performing a type of real-time monitoring on the no-load pre-operation process, performing a secondary determination based on the type of real-time monitoring data, and determining whether to start the load operation mode and determine to output a first feedback correction result or output a pre-operation diagnosis result according to the secondary determination result; Based on the load operation mode, the target hydraulic system is sequentially subjected to a pressurized operation test and a continuous operation test, and the loaded operation process and the continuous operation process are respectively subjected to a second type of real-time monitoring and a third type of periodic monitoring, and three determinations are made according to the second type of real-time monitoring data and the third type of periodic monitoring data, and a load diagnosis result or a second feedback correction result of the target hydraulic system is output according to the three determination results; Optimize each operation monitoring plan by combining the first feedback correction result and the second feedback correction result.

2. The intelligent diagnostic method for a hydraulic system according to claim 1, characterized in that: The process of performing a determination based on each main detection data and determining whether to start the pre-operation mode or output the initial diagnosis result according to the determination result includes: The oil level, pipeline and electrical connection of the target hydraulic system to be started are respectively detected to obtain oil level detection data, pipeline detection data and electrical connection detection data; The oil level detection data, the pipeline detection data and the electrical connection detection data are respectively judged once to determine the number of qualified main points in each main key point; Determining whether to start the pre-operation mode according to the number of the main points; Among them, when the number of the main points is 3, it is determined to start the pre-operation mode, and when the number of the main points is less than 3, the initial diagnosis result is output; the main key points include: oil level, pipeline and electrical connection.

3. The intelligent diagnostic method for a hydraulic system according to claim 2, characterized in that: The process of performing a first-class real-time monitoring on the no-load pre-operation process and performing a secondary determination based on the first-class real-time monitoring data includes: Detect each auxiliary key point of the target hydraulic system in no-load pre-operation to obtain each auxiliary detection data; Conduct a type of real-time monitoring of the no-load pre-operation process to obtain a set of key characteristic parameters of the pre-operation; Perform secondary determination based on each auxiliary detection data and the pre-operation key characteristic parameter set; The one type of real-time monitoring data includes: various auxiliary detection data and the pre-operation key characteristic parameter set.

4. The intelligent diagnostic method for a hydraulic system according to claim 3, characterized in that: The process of performing a type of real-time monitoring on the no-load pre-operation process to obtain a set of pre-operation key characteristic parameters includes: During the no-load pre-operation process, real-time monitoring is performed on the main pipeline of the target hydraulic system to obtain a type of actual pressure; During the no-load pre-operation process, the oil tank of the target hydraulic system is monitored in real time to obtain an actual temperature; During the no-load pre-operation process, the pump of the target hydraulic system is monitored in real time to obtain a type of actual flow; The type of actual pressure, the type of actual temperature and the type of actual flow are integrated to obtain the pre-operation key characteristic parameter set.

5. The intelligent diagnostic method for a hydraulic system according to claim 4, characterized in that: The process of determining whether to start the load operation mode and outputting the first feedback correction result or the pre-operation diagnosis result according to the secondary determination result includes: Analyze each auxiliary detection data to determine the number of qualified auxiliary points in each auxiliary key point; Determining whether to start the secondary determination mode according to the number of auxiliary points; Based on starting the secondary determination mode, determining whether to start the load operation mode and determining to output the first feedback correction result or output the pre-operation diagnosis result according to the pre-operation key characteristic parameter set; When the number of auxiliary points is 2, it is determined to start the secondary determination mode, and when the number of auxiliary points is less than 2, it is determined to output the pre-operation diagnosis result.

6. The intelligent diagnostic method for a hydraulic system according to claim 5, characterized in that: The process of determining whether to start the load operation mode and outputting the first feedback correction result or the pre-operation diagnosis result according to the pre-operation key characteristic parameter set includes: Based on starting the secondary determination mode, the first type of actual pressure, the first type of actual temperature and the first type of actual flow are respectively compared with the preset pre-operation evaluation threshold range, and the number of pre-operation anomalies in each key characteristic parameter and the corresponding single pre-operation anomaly degree are determined according to the comparison results; Determining whether to start the load operation mode according to the number of pre-operation anomalies and the degree of each single pre-operation anomaly; Among them, based on when the load operation mode is turned on, the first feedback correction result is determined according to the degree of each single pre-operation abnormality to send a first feedback signal, and the load operation monitoring plan is adjusted according to the first feedback signal; based on when the load operation mode is not turned on, the pre-operation diagnosis result is output according to the number of pre-operation abnormalities and the degree of each single pre-operation abnormality.

7. The intelligent diagnosis method for hydraulic system according to claim 6, characterized in that: The process of performing two types of real-time monitoring and three types of periodic monitoring on the loading operation process and the continuous operation process respectively, and performing three determinations based on the two types of real-time monitoring data and the three types of periodic monitoring data includes: Obtaining actual changes of key characteristic parameters at the marked time during the loading operation; Determine the number of items in each key characteristic parameter that meet a single determination condition according to the actual change situation, and determine a loading determination result according to the number of items; Determining whether to perform a continuous operation test based on the loading determination result; The loading operation process is to gradually increase the load of the target hydraulic system with a preset initial increase amplitude and initial increase times until a preset upper limit workload is reached; the marking moment is the load change moment.

8. The intelligent diagnosis method for hydraulic system according to claim 7, characterized in that: The process of performing two types of real-time monitoring and three types of periodic monitoring on the loading operation process and the continuous operation process respectively, and performing three determinations based on the two types of real-time monitoring data and the three types of periodic monitoring data also includes: When the loading is judged to be qualified, starting a continuous operation test; Perform periodic monitoring at preset time intervals during the continuous operation test to obtain a continuous set of key characteristic parameters; For any monitoring period, obtain the current continuous key feature parameter set corresponding to the monitoring period, and determine whether to turn on the verification mode according to the current continuous key feature parameter set; Based on the verification mode, a historical continuous key characteristic parameter set is obtained, an actual fluctuation set is determined according to the current continuous key characteristic parameter set and the historical continuous key characteristic parameter set, and the load diagnosis result or the second feedback correction result of the output target hydraulic system is determined according to the actual fluctuation set; Among them, when the current number of continuous anomalies in the current continuous key feature parameter set is 0, it is determined to start the verification mode; the historical continuous key feature parameter set is three types of periodic monitoring data obtained in the previous monitoring period corresponding to the monitoring period.

9. The intelligent diagnostic method for a hydraulic system according to claim 8, characterized in that: The process of determining the number of items in each key characteristic parameter that meet a single determination condition according to the actual change situation includes: For any key characteristic parameter, determine whether the key characteristic parameter meets a single determination condition according to the actual change rate and change duration corresponding to the key characteristic parameter; Based on the fact that the actual change rate is within the preset standard change range and the change duration is less than the preset standard duration, it is determined that the key characteristic parameter meets the single determination condition; The actual change condition includes: the actual change rate and the duration of the change.

10. The intelligent diagnosis method for a hydraulic system according to claim 9, characterized in that: The process of determining the load diagnosis result or the second feedback correction result of the output target hydraulic system according to the actual fluctuation set includes: Acquire the number of actual fluctuation anomalies in the actual fluctuation set, and determine to output the load diagnosis result or the second feedback correction result according to the number of actual fluctuation anomalies; When the actual number of fluctuation anomalies is 0, determining that the second feedback correction result is to send a second feedback signal, and adjusting the actual operation monitoring plan according to the second feedback signal; When the actual fluctuation anomaly number is not 0, the load diagnosis result is output, and the load diagnosis result includes: the actual fluctuation anomaly type and the actual fluctuation anomaly number.

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