New energy road simulation bench early warning system and judgment method thereof

Abstract

The invention relates to a new energy road simulation bench early warning system and a judgment method thereof. The early warning system comprises an eDAQ data acquisition instrument, a grating ruler, a stay wire displacement encoder and a PC terminal. The judgment method comprises the steps of point location fixing and debugging, formula input, data acquisition, real-time monitoring and fault point maintenance processing. According to the invention, a measuring mechanism is formed through related measuring equipment, the running distance of the vertical rod connecting rod mechanism of the new energy road simulation rack in the X-axis direction and the Y-axis direction is measured, related data are collected through a data acquisition instrument, and the interval relation between normal running data is calculated in real time through calculation PC end software; through data comparison and analysis, a fault point is accurately judged, after the fault point is confirmed, comparison is carried out on a fault associated bearing exceeding a three-time normal operation interval, the position of the fault bearing is confirmed, and a fault reason is diagnosed as soon as possible; according to the judgment method, the problems of aggravated equipment damage and increased maintenance cost caused by untimely discovery can be avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of test equipment detection and maintenance, and specifically relates to a new energy road simulation bench early warning system and a judgment method thereof. Background Art

[0002] The new energy road simulation bench is a whole vehicle road simulation equipment that can simulate all operating conditions of the whole vehicle road. The new energy road simulation bench is a large-scale equipment composed of 26 actuators and a multi-joint linkage structure. Its test intensity is high and the impact on the joint bearings is strong. Individual bearing failures are often caused by untimely detection of equipment failures, resulting in serious damage to the joint mechanism. In addition, the equipment is difficult to repair and the accessories are expensive. When the equipment is shut down and cannot be tested, a large amount of test outsourcing fees need to be paid. At present, the bearings of the new energy road simulation bench are mostly located inside the connecting joints in hidden and narrow spaces. When damaged, they cannot be directly diagnosed. Only when a major fault occurs in the new energy road simulation bench can the fault point be determined for repair. As a result, the diagnosis and repair at the initial stage of the fault will be missed, the best repair point will be wasted, and the damage will be further expanded, resulting in high repair costs and delays in the normal progress of the test project. Based on this, it is very necessary to develop a device for diagnosing primary faults. Summary of the invention

[0003] The purpose of the present invention is to provide a new energy road simulation bench early warning system and judgment method to solve the problem of diagnosing primary faults of the new energy road simulation bench.

[0004] The objective of the present invention is achieved through the following technical solutions:

[0005] A new energy road simulation bench early warning system, including an eDAQ data acquisition instrument, a grating ruler, a wire displacement encoder and a PC terminal;

[0006] The eDAQ data acquisition instrument is used to collect the wire travel data of the wire displacement encoder and transmit it to the PC-side recording unit and the PC-side computing unit;

[0007] The grating ruler is used to measure the longitudinal height of the measuring point of the test equipment, and transmit the height data to the PC-side calculation unit through the eDAQ data acquisition instrument, and is used to detect whether the position changes when the equipment stops running, and determine whether there is a z-direction fault;

[0008] The wire displacement encoder is used to measure the displacement data of the corresponding points and the eDAQ data acquisition instrument is used to collect data;

[0009] The modules involved in the PC-side recording unit include the Meters module, which is used to record and identify the displacement data of the wire displacement encoder and the grating ruler collected in real time by the eDAQ data acquisition instrument; the modules involved in the PC-side calculation unit include the Calculate module, which is used to calculate the real-time changing volume formula formed by the relevant points.

[0010] Furthermore, the grating ruler is used to determine z-direction faults. The grating ruler is installed and fixed on the bases on the left and right sides of the Z-axis direction, and measures the real-time height distance S of point A relative to plane BCDE. It is used to measure the longitudinal height of the measuring point of the test equipment, and transmit the height data to the Ncode software for calculation through the eDAQ data acquisition instrument. At the same time, it is used to detect whether the position of the equipment changes when it stops running, and determine whether there is a z-direction fault.

[0011] Furthermore, the wire displacement encoder is used in two positions. The wire encoder 1 is installed at position B on the left side of the base. A hole is punched and tapped on the vertical rod connecting rod mechanism to install the hook at position A to connect the wire encoder and measure the AB distance. The wire encoder is used to measure the displacement data of the corresponding points and the eDAQ data acquisition instrument performs data acquisition. The wire encoder 2 is installed at position C on the left side of the base. A hole is punched and tapped on the vertical rod connecting rod mechanism to install the hook at position A to connect the wire encoder and measure the AC distance.

[0012] Furthermore, the calculation formula of the real-time changing total volume V of AF-BCDE is V=V1+V2, V=1 / 3*L2*(L-L1)*S+1 / 2*L2*S*L1; the total volume V that changes in real time has a volume change range that satisfies all test conditions, so there are upper and lower limits for the changing volume, and the formula is as follows:

[0013] The minimum interval of the measured working condition before the test Vmin = 1 / 3*L2*(L-Lmin)

[0014] *Smin+1 / 2*L2*S*Lmin;

[0015] The maximum interval of the measured working condition before the test Vmax = 1 / 3*L2*(L-Lmax)

[0016] *Smax+1 / 2*L2*S*Lmax.

[0017] The total volume formed by the real-time motion trajectory interval of point A should meet the following conditions: Vmin≤V≤Vmax.

[0018] A judgment method for a new energy road simulation bench early warning system comprises the following steps:

[0019] S1. Point fixing and debugging;

[0020] S2, formula input, real-time calculation of the total volume V;

[0021] S3, data collection, conduct a whole vehicle road simulation test, collect the upper and lower limit ranges of the total volume that changes dynamically in real time, and set this range as the normal operating range of the test equipment;

[0022] S4, real-time monitoring, real-time judgment of the change of V to determine whether there is a dynamic fault in the test equipment;

[0023] S5. Repair the fault point.

[0024] Furthermore, step S1 specifically includes the following steps:

[0025] S11, select the point, fix the wire displacement encoder, connect the wire end, and fix the grating ruler;

[0026] S12, connect the eDAQ data acquisition instrument and the PC recording unit;

[0027] S13. Debug all devices to confirm whether their functions are normal.

[0028] Furthermore, step S2 specifically includes: inputting the calculation formula into the Calculate module of the PC-side calculation unit.

[0029] Further, step S3 is specifically as follows: a whole vehicle road simulation test is performed by controlling the MTS329 26-channel road simulation test machine, and in the process, all test conditions of a round of signals are run through, and the upper and lower limit ranges of the total volume that changes dynamically in real time are collected, and this range is set as the normal operating range of the test equipment.

[0030] Further, step S4 is specifically as follows: the Calculate module monitors the changes in the real-time changing total volume in real time, compares and analyzes the data of the real-time changing total volume that exceeds the upper and lower limits of the price increase, diagnoses the location of the fault point, completes fault analysis, fault prompts, fault alarms and other tasks, and can determine whether the test equipment has a dynamic fault by judging the changes in V in real time.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] The present invention forms a measuring mechanism through relevant measuring equipment, measures the running distance of the vertical rod connecting rod mechanism of the new energy road simulation test bench in the X-axis and Y-axis directions, collects relevant data through a data acquisition instrument, and uses the computing PC-side software to calculate the interval relationship between the normal operating data in real time; through data comparison and analysis, the fault point is accurately judged, and after the fault point is confirmed, the normal operating intervals of the problematic related bearings are compared for more than three times (excluding occasional faults, such as special working conditions causing individual signals to be too large, etc.), the position of the faulty bearing is confirmed, and the cause of the fault is diagnosed early; the judgment method can avoid the aggravation of equipment damage caused by untimely discovery, thereby increasing maintenance costs, and effectively expand the field of test equipment detection and maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0034] Figure 1 Structural diagram of the new energy road simulation bench warning system;

[0035] Figure 2 Calculation formula point distribution map;

[0036] Figure 3 Flow chart of the steps of the judgment method of the new energy road simulation bench warning system. DETAILED DESCRIPTION

[0037] The present invention will be further described below in conjunction with embodiments:

[0038] The present invention provides a new energy road simulation bench early warning system, comprising an eDAQ data acquisition instrument, a grating ruler, a wire displacement encoder and a PC terminal.

[0039] The eDAQ data acquisition instrument is used to collect the wire travel data of the wire displacement encoder and transmit it to the PC recording unit, which is recorded by the MTS software. At the same time, it is transmitted to the PC calculation unit and calculated by the Ncode software.

[0040] The grating ruler is used to measure the longitudinal height of the test equipment's measuring point and transmit the height data to the PC-side computing unit through the eDAQ data acquisition instrument. At the same time, it is used to detect whether the position changes when the equipment stops running and determine whether there is a z-direction fault.

[0041] In the present invention, the grating ruler is used to judge the z-direction fault. The grating ruler is installed and fixed on the base on the left and right sides of the Z-axis direction to measure the real-time height distance S of point A relative to plane BCDE. It is used to measure the longitudinal height of the measuring point of the test equipment, and transmit the height data to Ncode software for calculation through the eDAQ data acquisition instrument. At the same time, it is used to detect whether the position changes when the equipment stops running, and judge whether there is a z-direction fault.

[0042] The wire displacement encoder is used to measure the displacement data of corresponding points and the eDAQ data acquisition instrument is used to collect data.

[0043] In the present invention, the wire displacement encoder is used in 2 positions. The wire encoder 1 is installed at position B on the left side of the base, and a hole is punched and tapped on the vertical rod connecting rod mechanism to install the hook at position A to connect the wire encoder and measure the AB distance. It is used to measure the displacement data of the corresponding points and the eDAQ data acquisition instrument performs data acquisition. The wire encoder 2 is installed at position C on the left side of the base, and a hole is punched and tapped on the vertical rod connecting rod mechanism to install the hook at position A to connect the wire encoder and measure the AC distance. The selection of the positions of the wire encoders at AB and AC positions can maximize the measurement space without affecting the operation of the equipment.

[0044] In the present invention, when selecting the key point A, the position of the hook A for drilling and tapping on the vertical rod connecting rod mechanism is selected as the motion trajectory recording point. Position A is the end of the multi-joint bearing action, has a large stroke amplitude, and is easy to measure and calculate.

[0045] The calculation formula for the real-time changing total volume V of AF-BCDE is V=V1+V2, V=1 / 3*L2*(L-L1)*S+1 / 2*L2*S*L1.

[0046] The total volume V that changes with time has a volume change range that satisfies all test conditions, so there are upper and lower limits for the volume change, and the formula is as follows:

[0047] The minimum interval of the measured working condition before the test Vmin = 1 / 3*L2*(L-Lmin)

[0048] *Smin+1 / 2*L2*S*Lmin;

[0049] The maximum interval of the measured working condition before the test Vmax = 1 / 3*L2*(L-Lmax)

[0050] *Smax+1 / 2*L2*S*Lmax.

[0051] The total volume formed by the real-time motion trajectory interval of point A should meet the following conditions: Vmin≤V≤Vmax.

[0052] The modules involved in the PC-side recording unit include the Meters module, which is used to record and identify the displacement data of the wire displacement encoder and the grating ruler collected in real time by the eDAQ data acquisition instrument.

[0053] The modules involved in the PC-side calculation unit include a Calculate module, which is used to calculate the real-time changing volume formula formed by relevant points.

[0054] The judgment method of the new energy road simulation bench early warning system of the present invention can be used for the application of equipment operation fault judgment and early warning functions of the MTS329 type 26-channel road simulation test machine.

[0055] The judgment method of the new energy road simulation bench early warning system of the present invention comprises the following steps:

[0056] S1. Fix and debug the points. After selecting the points, fixing the wire displacement encoder, connecting the wire end, fixing the grating ruler, connecting the eDAQ data acquisition instrument and the PC recording unit, debug all the equipment to confirm whether the functions are normal.

[0057] S2. Formula input. Input the calculation formula to the Calculate module of the PC calculation unit. It is used to calculate the total volume in real time.

[0058] S3. Data collection. The whole vehicle road simulation test is carried out by controlling the MTS329 26-channel road simulation test machine, and all test conditions of a round of signals are run in the process, and the upper and lower limits of the total volume that changes dynamically in real time are collected. This range is set as the normal operating range of the test equipment.

[0059] S4, real-time monitoring. The Calculate module monitors the changes in the total volume in real time, compares and analyzes the data of the total volume that exceeds the upper and lower limits of the price increase, diagnoses the location of the fault point, completes fault analysis, fault prompts, fault alarms, etc., and can determine whether the test equipment has a dynamic fault by judging the changes in V in real time.

[0060] S5. Repair the fault point.

[0061] In this embodiment, when the point is fixed and debugged, the point is selected, the wire displacement encoder is fixed, the wire end is connected, the grating ruler is fixed, the eDAQ data acquisition instrument and the PC-side MTS software are connected, and all the equipment is debugged to confirm whether the function is normal. The calculation formula is input to the Calculate module of the Ncode software. It is used to calculate the real-time changing total volume V in real time. The whole vehicle road simulation test is carried out by controlling the MTS329 type 26-channel road simulation test machine, and all the test conditions of a round of signals are run in the process, and the upper and lower limit intervals of the dynamic real-time changing overall V are collected. And this interval is set as the normal operating interval of the test equipment. The Calculate module of the Ncode software monitors the change of the real-time changing total volume V in real time, compares the real-time changing total volume exceeding Vmin and Vmax data and analyzes it, diagnoses the location of the fault point, completes fault analysis, fault prompts, fault alarms and other tasks, and can judge whether the test equipment has a dynamic fault by judging the change of V in real time. Repair the fault point.

[0062] Example 1

[0063] To further illustrate the technical solution and specific working process of the present invention, the specific implementation of the present invention is as follows in conjunction with the accompanying drawings:

[0064] like Figure 1 and Figure 2 As shown, a new energy road simulation bench warning system includes an eDAQ data acquisition instrument, a grating ruler, a wire displacement encoder and a PC terminal.

[0065] The eDAQ data acquisition instrument is used to collect the wire travel data of the wire displacement encoder and transmit it to the PC-side MTS software for recording, and at the same time transmit it to the Ncode software for calculation.

[0066] The grating ruler is installed and fixed on the bases on the left and right sides of the Z-axis direction to measure the real-time height distance S of point A relative to plane BCDE. It is used to measure the longitudinal height of the measuring point of the test equipment, and transmit the height data to the Ncode software for calculation through the eDAQ data acquisition instrument. It is also used to detect whether the position changes when the equipment stops running, and determine whether there is a z-direction fault.

[0067] The wire displacement encoder is used in two locations. Among them, the wire encoder 1 is installed at position B on the left side of the base. A hole is punched and tapped on the vertical rod connecting rod mechanism to connect the wire encoder at position A to measure the AB distance. It is used to measure the displacement data of the corresponding points and the eDAQ data acquisition instrument performs data acquisition. The wire encoder 2 is installed at position C on the left side of the base. A hole is punched and tapped on the vertical rod connecting rod mechanism to connect the wire encoder at position A to measure the AC distance. The selection of the wire encoder positions at AB and AC can maximize the measurement space without affecting the operation of the equipment.

[0068] The PC-side recording unit includes a Meters module, which is used to record and identify the displacement data of the wire displacement encoder and the grating ruler collected in real time by the eDAQ data acquisition instrument.

[0069] The PC-side calculation unit includes a Calculate module, which is used to calculate the real-time change volume formula formed by relevant points.

[0070] Calculation formula and calculation process:

[0071] The position A where the hook is punched and tapped on the vertical rod connecting rod mechanism is selected as the motion trajectory recording point. Position A is the end of the multi-joint bearing action, with a large stroke range, which is easy to measure and calculate.

[0072] like Figure 2 As shown. A, B, C, D, E, F, G, and H are point marks (point A is a real-time motion point; B and C are fixed points of the wire encoder; D and E are fixed points at both ends of the grating ruler; F is a virtual point at the same height as point A, which is used for calculation formulas; G and H are virtual points, which are used for formula calculations.), S is the real-time height of point A relative to plane BCDE, and L represents the length.

[0073] The L-L1=2√AC2-AS2-SH2.

[0074] The data acquisition instrument collects the measured data of the variables AB and AC and the height S displacement, and calculates through the Calculate module of the Ncode software, and can deduce the volume of the motion track formed by AF-BCDE when point A moves in real time. The total volume of AF-BCDE changing in real time is V, the volume of A-BCGH is V1, and the volume of AF-GHED is V2.

[0075] Therefore, the calculation formula for the real-time changing total volume V of AF-BCDE is V=V1+V2, V=1 / 3*L2*(L-L1)*S+1 / 2*L2*S*L1.

[0076] The total volume V that changes in real time has a volume change range that satisfies all test conditions, so there are upper and lower limits for the change volume, and the formula is as follows:

[0077] The minimum interval of the measured working condition before the test is Vmin = 1 / 3*L2*(L-Lmin)*Smin+1 / 2*L2*S*Lmin;

[0078] The maximum interval of the working condition measured before the test is Vmax=1 / 3*L2*(L-Lmax)*Smax+1 / 2*L2*S*Lmax.

[0079] The total volume formed by the real-time motion trajectory interval of point A should satisfy the following conditions: Vmin≤V≤Vmax.

[0080] Based on the above-mentioned new energy road simulation test bench early warning system, this embodiment also provides a new energy road simulation test bench fault early warning system judgment method, such as Figure 3 As shown, the judging method comprises the following steps:

[0081] S1. Fix and debug the points. Select the points, fix the wire displacement encoder, connect the wire end, fix the grating ruler, connect the eDAQ data acquisition instrument and the PC-side MTS software, and debug all the equipment to confirm whether the functions are normal.

[0082] S2. Formula input. Input the calculation formula to the Calculate module of the Ncode software. It is used to calculate the total volume V in real time.

[0083] S3. Data collection. The whole vehicle road simulation test is carried out by controlling the MTS329 26-channel road simulation test machine, and all test conditions of a round of signals are run in the process, and the upper and lower limits of the overall V that changes dynamically in real time are collected. This range is set as the normal operating range of the test equipment.

[0084] S4. Real-time monitoring. The Calculate module of the Ncode software monitors the change of the real-time total volume V in real time, compares and analyzes the data of the real-time total volume exceeding Vmin and Vmax, diagnoses the location of the fault point, completes fault analysis, fault prompts, fault alarms, etc., and can determine whether the test equipment has a dynamic fault by judging the change of V in real time.

[0085] S5. Repair the fault point.

[0086] Note that the above are only preferred embodiments of the present invention and the technical principles used. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and that various obvious changes, readjustments and substitutions can be made by those skilled in the art without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in more detail through the above embodiments, the present invention is not limited to the above embodiments, and may include more other equivalent embodiments without departing from the concept of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

Claims

1. A new energy road simulation bench warning system, characterized by: Including eDAQ data acquisition instrument, grating ruler, wire displacement encoder and PC terminal; The eDAQ data acquisition instrument is used to collect the wire travel data of the wire displacement encoder and transmit it to the PC-side recording unit and the PC-side computing unit; The grating ruler is used to measure the longitudinal height of the measuring point of the test equipment, and transmit the height data to the PC-side calculation unit through the eDAQ data acquisition instrument, and is used to detect whether the position changes when the equipment stops running, and determine whether there is a z-direction fault; The wire displacement encoder is used to measure the displacement data of the corresponding points and the eDAQ data acquisition instrument is used to collect data; The modules involved in the PC-side recording unit include the Meters module, which is used to record and identify the displacement data of the wire displacement encoder and the grating ruler collected in real time by the eDAQ data acquisition instrument; the modules involved in the PC-side calculation unit include the Calculate module, which is used to calculate the real-time changing volume formula formed by the relevant points.

2. A new energy road simulation bench warning system according to claim 1, characterized in that: The grating ruler is used to judge the z-direction fault. The grating ruler is installed and fixed on the base on the left and right sides of the z-axis direction, and measures the real-time height distance S of point A relative to plane BCDE. It is used to measure the longitudinal height of the measuring point of the test equipment, and transmits the height data to Ncode software for calculation through the eDAQ data acquisition instrument. At the same time, it is used to detect whether the position of the equipment changes when it stops running, and judge whether there is a z-direction fault.

3. The new energy road simulation bench warning system according to claim 1 is characterized by: The wire-drawn displacement encoder is used in two positions in total. Wire-drawn encoder 1 is installed at position B on the left side of the base. A hole is punched and tapped on the vertical rod connecting rod mechanism to install a hook at position A to connect the wire-drawn encoder and measure the AB distance. It is used to measure the displacement data of the corresponding points and the eDAQ data acquisition instrument performs data acquisition; wire-drawn encoder 2 is installed at position C on the left side of the base. A hole is punched and tapped on the vertical rod connecting rod mechanism to install a hook at position A to connect the wire-drawn encoder and measure the AC distance.

4. A new energy road simulation bench warning system according to claim 3, characterized in that: The calculation formula of the real-time changing total volume V of AF-BCDE is V=V1+V2, V=1 / 3*L2*(L-L1)*S+1 / 2*L2*S*L1; the real-time changing total volume V has a volume change range that satisfies all test conditions, so there are upper and lower limits of the changing volume, and the formula is as follows: The minimum interval of the measured working condition before the test is Vmin = 1 / 3*L2*(L-Lmin)*Smin+1 / 2*L2*S*Lmin; The maximum interval of the working condition measured before the test is Vmax=1 / 3*L2*(L-Lmax)*Smax+1 / 2*L2*S*Lmax. The total volume formed by the real-time motion trajectory interval of point A should meet the following conditions: Vmin≤V≤Vmax.

5. A judgment method for a new energy road simulation bench warning system, characterized in that: The following steps are involved: S1. Point fixing and debugging; S2, formula input, real-time calculation of the total volume V; S3, data collection, conduct a whole vehicle road simulation test, collect the upper and lower limit ranges of the total volume that changes dynamically in real time, and set this range as the normal operating range of the test equipment; S4, real-time monitoring, real-time judgment of the change of V to determine whether there is a dynamic fault in the test equipment; S5. Repair the fault point.

6. The judgment method of a new energy road simulation bench warning system according to claim 5 is characterized in that: Step S1 specifically includes the following steps: S11, select the point, fix the wire displacement encoder, connect the wire end, and fix the grating ruler; S12, connect the eDAQ data acquisition instrument and the PC recording unit; S13. Debug all devices to confirm whether their functions are normal.

7. The judgment method of a new energy road simulation bench warning system according to claim 5 is characterized in that: Step S2 specifically includes: inputting the calculation formula into the Calculate module of the PC-side calculation unit.

8. The judgment method of a new energy road simulation bench warning system according to claim 5 is characterized in that: Step S3 is specifically as follows: a whole vehicle road simulation test is performed by controlling the MTS329 26-channel road simulation test machine, and all test conditions of a round of signals are run through the process, and the upper and lower limit ranges of the total volume that changes dynamically in real time are collected, and this range is set as the normal operating range of the test equipment.

9. The judgment method of a new energy road simulation bench warning system according to claim 5 is characterized in that: Step S4, specifically: the Calculate module monitors the changes in the real-time changing total volume in real time, compares and analyzes the data of the real-time changing total volume that exceeds the upper and lower limits of the price increase, diagnoses the location of the fault point, completes fault analysis, fault prompts, fault alarms and other tasks, and can determine whether there is a dynamic fault in the test equipment by judging the changes in V in real time.

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