Integrated hydraulic system health control method for hydraulic brake

Abstract

The invention relates to an integrated hydraulic system health control method for a hydraulic brake. The method comprises the steps that real-time working data of a limiting sensor, a pressure sensor, a liquid level sensor, a torque sensor, a temperature sensor and a stroke sensor are collected in real time; collecting the collected data into a data processing center through different channels; the data processing center compares the input data of each channel with the data set by the data processing center; sending out an early warning signal; and the data processing center summarizes the comparison results and respectively sends result instructions to corresponding channels, and synchronizes network intersection and docking and data exchange. According to the integrated hydraulic system health control method for the hydraulic brake, the hydraulic system can be managed autonomously, and early warning is conducted before a fault occurs; when a serious fault exists or a serious fault exists, the machine can be automatically shut down, disasters or secondary disasters are avoided, and the fault maintenance time and cost are reduced; and an embedded system is autonomously designed to be embedded into the equipment without manual guarding.

Description

Technical Field

[0001] The present invention relates to the field of hydraulic control technology, and in particular to an integrated hydraulic system health control method for a hydraulic brake. Background Art

[0002] Safety is a chronic problem threatening the hydraulic brake industry. The traditional method is to use sensors connected to the equipment externally, connect to the PLC in the control room through various cables, and display the status of each function on the driver's control panel. The working conditions of the hydraulic station are managed by manual supervision. Due to the attenuation of the cables themselves and connectors, the delay of signal transmission, the increase of mechanical wear under vibration conditions, the disadvantages of the application itself, the difficulty and labor intensity of manual supervision are high, and the project investment cost is also high. The above inherent design factors lead to frequent omissions, false alarms, and false alarms, and the safety risks cannot be reduced. At present, we can only rely on relay amplification, increase duty shifts, increase repair and maintenance efforts, and regularly replace consumable parts. This is equivalent to shortening the life of the equipment and increasing the cost of use. Summary of the invention

[0003] In view of the deficiencies in the above-mentioned prior art, the present invention provides an integrated hydraulic health management method for hydraulic brakes which can provide an early warning before a fault occurs, or automatically shut down the machine when a serious fault already exists, thereby avoiding disasters or secondary disasters, reducing the time for fault maintenance, and reducing maintenance costs.

[0004] The technical solution adopted by the present invention is: An integrated hydraulic system health control method for a hydraulic brake comprises the following steps: Real-time collection of real-time data from limit sensors, pressure sensors, liquid level sensors, torque sensors, temperature sensors, and stroke sensors; The collected data are divided into different channels and fed into the data processing center; The data processing center compares the data imported from each channel with the data set by the data processing center and issues an early warning signal; The data processing center will summarize the comparison results and send the result instructions to the corresponding channels respectively, and simultaneously connect with the network for data exchange.

[0005] Preferably, the limit information of the limit sensor is collected in real time, and the limit settings include upper limit A, upper transition area B, normal area C, lower transition area D, and lower limit E. There are five levels of health management. When the limit information exceeds the health management setting range, the data processing center outputs a timely stop instruction. The specific steps are as follows: Step 100, start; Step 101, collecting position information of the limit sensor in real time; Step 102, the location information is transmitted to a data processing center; Step 103, the data processing center determines whether the location data is within the normal area. If the location data is within the normal area, jump to step 116; otherwise, jump to step 104; Step 104, the data processing center determines whether the position data exceeds the limit, if not, jump to step 105, otherwise jump to step 117; Step 105, the data processing center determines whether the position data is in the upper transition area or the lower transition area; if it is in the upper transition area, jump to step 106, and if it is in the lower transition area, jump to step 111; Step 106, upper limit transition area counter A=A+1; Step 107, determining whether it is the first time to enter the upper limit transition area, if it is the first time to enter the upper limit area, jump to step 101, otherwise jump to step 108; Step 108, comparing the position data with the last time the position data entered the upper limit transition area, drawing a position data time function curve, and estimating the system operation time when the position data enters the upper limit position; Step 109, determining whether the system has been running in the upper transition area for less than 10 seconds. If the system has been running for less than 10 seconds, jump to step 101; otherwise, jump to step 110; Step 110, issue a warning and jump to step 101; Step 111, upper limit transition area counter B=B+1; Step 112, determining whether it is the first time to enter the lower limit transition area, if it is the first time to enter the lower limit area, jump to step 101, otherwise jump to step 113; Step 113, comparing the position data with the last time the position data entered the lower limit transition area, drawing a position data time function curve, and estimating the system operation time when the position data enters the lower limit position; Step 114, determining whether the system has been running in the transition area for less than 10 seconds. If the system has been running for less than 10 seconds, jump to step 101; otherwise, jump to step 115; Step 115, issue a warning and jump to step 101; Step 116, the equipment limit information is normal, the limit channel is opened, and the channel is unobstructed; jump to step 101; Step 117, the limit channel is disconnected, the device is shut down, and the end is completed. Preferably, data from the pressure sensor is collected in real time; According to the actual oil pressure state of the hydraulic oil in the hydraulic cylinder, set the five-level health management mode of high pressure upper limit, high pressure stop, normal pressure, low pressure start, and low pressure lower limit; When the oil pressure reaches the upper limit of high pressure, the equipment stops; When the oil pressure stops at high pressure, the microprocessor turns off the oil pump by shutting down the solid-state relay, and there is no need to increase the oil pressure; When the oil pressure is at normal pressure, the pressure path of the equipment is unobstructed; When the oil pressure is low-pressure start, the microprocessor turns on the oil pump by turning on the solid-state relay, increasing the pressure in the oil circuit until it is shut down by the high-pressure stop pressure.

[0006] Preferably, the liquid level information of the liquid level sensor is collected in real time, and the liquid level is set in three levels of health management mode: normal liquid level, low liquid level, and extremely low stop liquid level; When the liquid level is at the normal level, the liquid level passage of the equipment is unobstructed; When the liquid level is low, the device will display a low liquid level fault and simultaneously transmit the low liquid level information to the main control through the communication and fault ports. At this time, the device can be used normally temporarily. When the liquid level is at an extremely low stop, there is a leak in the hydraulic circuit of the equipment, and the microprocessor shuts down in time until the hydraulic oil is increased to the normal level before it can operate normally.

[0007] Preferably, the method comprises the following steps: Step 200, start; Step 201, collecting liquid level information from a liquid level sensor in real time; Step 202, the liquid level information is transmitted to a data processing center; Step 203, the data processing center determines whether the liquid level data reaches the extremely low stop liquid level. If it reaches the extremely low stop liquid level, jump to step 209, otherwise jump to step 204; Step 204, the data processing center determines whether the liquid level data is low level, if it is not low level, jump to step 208, otherwise jump to step 205; Step 205, comparing with the last liquid level data, drawing a liquid level data time function curve, and estimating the liquid level data entering the brake liquid level system operation time; Step 206, determining whether the system has been running at a low liquid level for less than 1 minute. If the system has been running for less than 1 minute, jump to step 207, otherwise jump to step 201; Step 207, issue a warning and jump to step 201; Step 208, the liquid level information is normal, the liquid level channel is opened, and the channel is unobstructed; jump to step 201; Step 209: The liquid level information is abnormal, the liquid level channel is closed, and the process ends.

[0008] Preferably, the torque sensor data is collected in real time; compared with the stored preset data, and the torque health status is determined according to the comparison result; Draw a torque-time curve to determine the system operating time.

[0009] Preferably, temperature sensor data is collected in real time; The temperature sensor uses PT100, which is divided into four channels: left pad temperature 1, right pad temperature 1, left pad temperature 2, and right pad temperature 2; Each channel is divided into extreme high temperature, high temperature warning, normal temperature, low temperature warning, and extreme low temperature health management modes; When the temperature sensor channel detects extreme high temperature and extreme low temperature, the equipment will stop in time and will not return to normal until the temperature channel returns to normal; When the temperature sensor channel detects high temperature warning and low temperature warning, the device highlights the temperature abnormality information and simultaneously shares the temperature channel abnormality information through the communication path and fault terminal.

[0010] Preferably, the method comprises the following steps: Step 300, start; Step 301, collecting temperature information of a temperature sensor in real time; Step 302, the temperature sensor transmits to the data processing center; Step 303, the data processing center determines whether the temperature sensor is within the normal temperature range. If the temperature data is within the normal temperature range, jump to step 316, otherwise jump to step 304; Step 304, the data processing center determines whether the temperature data exceeds the limit temperature, if it does not exceed the limit temperature, jump to step 305, otherwise jump to step 317; Step 305, the data processing center determines whether the temperature data is in the upper limit high temperature warning or the lower limit high temperature warning; if it is the upper limit high temperature warning, jump to step 306, and if it is the lower limit transition area, jump to step 311; Step 306, upper limit high temperature warning counter C=C+1; Step 307, determining whether it is the first time to enter the upper limit high temperature warning area, if it is the first time to enter the upper limit area, jump to step 301, otherwise jump to step 308; Step 308, compare the temperature data with the last time it entered the upper limit high temperature warning area, draw a temperature data time function curve, and estimate the system operation time when the temperature data enters the upper limit temperature limit; Step 309, determining whether the system has been running in the upper limit high temperature warning area for less than 5 minutes. If the system has been running for less than 5 minutes, jump to step 301; otherwise, jump to step 310; Step 310, issue a warning and jump to step 301; Step 311, lower limit high temperature warning counter D=D+1; Step 312, determining whether it is the first time to enter the lower limit low temperature warning area, if it is the first time to enter the lower limit low temperature area, jump to step 301, otherwise jump to step 313; Step 313, compare the temperature data with the last time it entered the lower limit low temperature warning area, draw a temperature data time function curve, and estimate the system operation time when the temperature data enters the lower limit temperature limit; Step 314, determining whether the system has been running in the lower limit low temperature warning area for less than 5 minutes. If the system has been running for less than 5 minutes, jump to step 301; otherwise, jump to step 315; Step 315, issue a warning and jump to step 301; Step 316: The temperature information is normal, the temperature channel is opened, and the channel is unobstructed; jump to step 301; Step 317, the temperature information is abnormal, the temperature channel is shut down, and the process ends.

[0011] Preferably, the stroke sensor is divided into two channels: left liner wear and right liner wear. Each channel is respectively provided with upper limit stop, upper limit warning, normal, lower limit warning, and lower limit stop health management modes; When the stroke sensor channel detects the upper limit stop and the lower limit stop, the equipment stops in time until the stroke channel returns to normal. When the stroke sensor channel detects the upper limit warning and the lower limit warning, the equipment highlights the abnormal pad wear information and simultaneously shares the abnormal pad wear channel information through the communication path and the fault terminal; at this time, the equipment enters a temporary usable state.

[0012] Preferably, the method comprises the following steps: Step 400, start; Step 401, collecting travel position information of the travel sensor in real time; Step 402, the travel position data of the travel sensor is transmitted to the data processing center; Step 403, the data processing center determines whether the travel position data is within the normal range. If the travel position data is within the normal travel position, jump to step 416, otherwise jump to step 404; Step 404, the data processing center determines whether the travel data exceeds the limit stop, if not, jump to step 405, otherwise jump to step 417; Step 405, the data processing center determines whether the wear data is at the upper limit wear warning or the lower limit wear warning; if the upper limit wear warning is set, jump to step 406, and if the lower limit wear warning is set, jump to step 411; Step 406, upper limit wear warning counter D=D+1; Step 407, determining whether it is the first time to enter the upper limit wear warning area, if it is the first time to enter the upper limit wear area, jump to step 401, otherwise jump to step 408; Step 408, comparing the wear data with the last time it entered the upper limit wear warning area, drawing a wear data time function curve, and estimating the system operation time when the wear data enters the upper limit wear limit area; Step 409, determining whether the system has been running in the upper limit wear warning area for less than 1 minute. If the system has been running for less than 1 minute, jump to step 401; otherwise, jump to step 410; Step 410, issue a warning and jump to step 401; Step 411, lower limit wear warning counter E=E+1; Step 412, determining whether it is the first time to enter the lower limit wear warning area, if it is the first time to enter the lower limit area, jump to step 401, otherwise jump to step 413; Step 413, comparing the wear data with the last time it entered the lower limit wear warning area, drawing a wear data time function curve, and estimating the system operation time when the wear data enters the lower limit wear limit; Step 414, determining whether the system lower limit wear warning area operation time is less than 1 minute. If the system operation time is less than 1 minute, jump to step 401, otherwise jump to step 415; Step 415, issue a warning and jump to step 401; Step 416, the travel position information is normal, the travel channel is open, and the channel is unobstructed; jump to step 401; Step 417, the trip location information is abnormal, the trip channel is closed, and the process ends.

[0013] The beneficial effects of the present invention compared with the prior art are as follows: The integrated hydraulic system health control method for hydraulic brakes of the present invention can autonomously manage the hydraulic system and issue an early warning before a fault occurs; or when a serious fault already exists, the machine can be autonomously shut down to avoid disasters or secondary disasters, and reduce the time and cost of fault maintenance; no manual supervision is required, and the system is autonomously designed and embedded in the device. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a safety brake and its hydraulic system structure diagram for the integrated hydraulic health management system of the hydraulic brake; Figure 2 is a schematic diagram of a structure of an integrated hydraulic system health control method for a hydraulic brake; Figure 3 is a schematic diagram of an integrated hydraulic health management system for hydraulic brakes; Figure 4 A control flow diagram of collecting position information of a limit sensor in an integrated hydraulic system health control method for a hydraulic brake; Figure 5It is a control flow diagram of collecting liquid level information of a liquid level sensor for an integrated hydraulic system health control method for a hydraulic brake; Figure 6 A control flow diagram of collecting temperature information of a temperature sensor of an integrated hydraulic system health control method for a hydraulic brake; Figure 7 The invention is a control flow diagram for collecting stroke position information of a stroke sensor in an integrated hydraulic system health control method for a hydraulic brake.

[0015] Description of the main components in the attached drawings: 1. Motor 2. Coupling 3. Hydraulic pump 4. Filter 5. One-way valve 6. Liquid level and temperature switch 7. Manual pump 8. First relief valve 9. Second relief valve 101. First solenoid valve 102. Second solenoid valve 11. Stop valve 12. Pressure switch 13. Pressure gauge 14. Hydraulic cylinder 15. Fuel tank.

[0016] 21. Liquid level sensor 22. Limit sensor 23. Travel sensor 24. Pressure sensor 25. Torque sensor 26. Temperature sensor. DETAILED DESCRIPTION

[0017] The present invention is described in detail below with reference to the accompanying drawings and embodiments: Attached Figure 1 It can be seen that the working principle of this system is: 1. Opening condition: The microprocessor of the power unit receives the main control opening command, and the microprocessor energizes the solid-state relay, which energizes the motor and drives the oil pump to work; at the same time, the microprocessor energizes the solenoid valve, which energizes the oil circuit, and the oil pressure in the hydraulic cylinder of the power unit pushes the brake to open. When the brake opens to the set opening position, the limit switch sends a signal, and the microprocessor controls the solenoid valve to cut off the power, thereby controlling the motor to stop working. At this time, the brake is in the open state.

[0018] 2. Pressure-maintaining condition: When the brake is in the open condition, the oil pressure of the power unit will slowly decrease due to power compression and partial leakage; when the oil pressure drops to the lower limit of the set value, the pressure switch sends a signal, the microprocessor energizes the solid-state relay, controls the motor to power on and run, and replenishes oil to the brake until the oil pressure rises to the set pressure, the pressure switch switches again and sends a signal, the microprocessor controls the motor to lose power and stop working.

[0019] 3. Closed gate condition: When the power unit microprocessor receives the closing gate command from the host, the microprocessor controls the solenoid valve and the motor to lose power at the same time, and the power unit oil pressure is released. At this time, the brake is restored, and the mechanical structure puts the brake in the closed state, and the host is in the braking state.

[0020] The system's alarm mechanism 1. The program records the motor's energized working time. When it is found that the number of motor starts exceeds the rated set value within a period of time, it indicates that an abnormal pressure leakage fault may occur. At this time, the microprocessor will issue a motor frequent start alarm message.

[0021] Under normal equipment conditions, according to actual calculations, when the motor runs for 10 seconds, the pressure in the hydraulic system can increase by 10MPa. If the motor starts three times within one minute of startup, the hydraulic pressure is theoretically 30MPa, but the actual demand is only 20MPa, that is, when the new machine is started after complete pressure relief, it is sufficient for the motor to work continuously for 20 seconds within one minute of startup. Therefore, if the motor is triggered to start three times within one minute of startup and runs for 10 seconds each time, it is abnormal and a leak has occurred.

[0022] 2. The program will also record the motor stop time. When it exceeds the rated set time, it indicates that an abnormal pressure leakage failure may occur. At this time, the microprocessor will issue a motor frequent start-up alarm message.

[0023] 3. When the program detects that the temperature sensor transmits a high temperature signal and it lasts for three sampling cycles, the high oil temperature will have an adverse effect on the hydraulic power unit. The microprocessor will control the motor to lose power and stop working until the oil temperature drops to normal. At the same time, the microprocessor will issue a high oil temperature alarm.

[0024] 4. When the program detects that the cumulative number of braking times is greater than the rated number (the hydraulic power unit will reach the designed service life), the microprocessor will issue an alarm message that the number of braking times exceeds the limit; If an alarm is generated in the system, the microprocessor controls the preset fault warning light to be powered on and flash. The light's lighting color or flashing frequency will be different depending on the alarm type. At the same time, the fault output terminal can be connected to the main control to synchronously share the abnormal operating condition alarm information of the brake with the main control. When the main control receives the alarm information, the operator can check and repair the abnormality in time.

[0025] When powered on, the system will perform self-test and synchronously detect the working conditions of peripherals in each channel; Channel 0 detects the left limit condition; Channel 1 detects the right limit condition; Channel 2 detects the left pressure condition; Channel 3 detects the right pressure condition; Channel 4 detects the left liquid level condition; Channel 5 detects the right liquid level condition; Channel 6 detects the left torque condition; Channel 7 detects the right torque condition; Channel 8 detects the left 1 temperature condition; Channel 9 detects the right 1 temperature condition; Channel 10 detects left 2 temperature condition; Channel 11 detects right 2 temperature condition; Channel 12 detects the left travel condition; Channel 13 detects the right travel condition; Channel 14 detects the power supply phase sequence.

[0026] When the signals detected by the above channels are normal, the microprocessor enters normal operating conditions and opens / closes the brake according to the main control requirements.

[0027] When channel 14 detects an abnormal phase sequence, the microprocessor automatically shuts down, the light shows an abnormality and simultaneously reports the abnormal information to the main control.

[0028] When any of channels 8, 9, 10, and 11 detects an abnormally high temperature, the microprocessor automatically shuts down, the light shows an abnormality, and simultaneously reports the abnormal information to the main control. When channels 0-13 detect common abnormalities, the microprocessor lights indicate the abnormalities and simultaneously reports the abnormal information to the main control. There is no forced shutdown at this time.

[0029] The brake can be opened / closed temporarily according to the master control requirements. When channels 0-13 detect an abnormality in the set limit, the microprocessor controls the device and forces it to shut down until the fault point is repaired to normal, and health management ensures safe use.

[0030] Working mode of the present invention: 1. Manual mode: 1. When the hydraulic oil in the hydraulic circuit is filled to the required level (it can be viewed visually through the transparent perspective window pre-installed at the corresponding position of the oil tank; 2. Turn the stop valve 11 counterclockwise to close it, and use the manual pump 7 to pressurize the hydraulic circuit; 3. Adjust the position of the hydraulic brake caliper so that the clearance between the brake caliper and the brake disc meets the requirements and the brake disc is centered; 4. When the pressure is too high, the flow can be released through the second relief valve 9; 5. Adjust the appropriate hydraulic pressure and brake clamp position by manually pressing and releasing the fluid; and record the pipeline pressure value at the optimal state at this time. Simultaneously enter the optimal pressure into the MCU health management standard control.

[0031] 2. Automatic health management mode, 1. After the manual mode debugging is completed, reset the stop valve 11 and power on the equipment to start the automatic mode; 2. The equipment starts, the motor starts 1, and the hydraulic system is automatically pressurized; 3. The motor pressure is transmitted to the hydraulic pump 3 through the coupling 2; 4. Filter 4, filter impurities in the hydraulic oil circuit; 5. The hydraulic pump pressure supplies pressure to the downstream pipeline in one direction through the one-way valve 5; 6. Liquid level and temperature switch 6 detects the corresponding liquid level and oil temperature of the hydraulic pipeline and shares them with the MCU; 7. When the main control requests the hydraulic brake to close the brake, the MCU receives the instruction and controls the first solenoid valve 101 and the second solenoid valve 102 to ensure accurate hydraulic orientation of the pipeline; the purpose of setting two solenoid valves is for safety considerations, and actually the two solenoid valves act as one solenoid valve; when one solenoid valve fails, the other solenoid valve can also do the job, and the hydraulic pressure in the cylinder is crucial to the safety of the entire machine, so a redundant design is adopted, and double protection is safer and has a lower probability of failure; the two solenoid valves work synchronously, and power is supplied and de-energized at the same time.

[0032] 8. The pressure switch 12 monitors the pipeline pressure and shares it with the MCU in real time; 9. Pressure gauge 13, real-time intuitive display of pipeline pressure status for on-site personnel to monitor; 10. Hydraulic cylinder 14 provides corresponding hydraulic thrust for opening / closing the gate according to the main control requirements; 11. The oil tank 15 stores an appropriate amount of required hydraulic oil.

[0033] Workflow of the present invention: Motor operation > Coupling transmission > Hydraulic pump boost > Liquid level, liquid temperature, pressure monitoring pipeline conditions > MCU extracts and controls pipeline conditions.

[0034] The main control closes the gate command > the solenoid valve is energized and works > the hydraulic cylinder works to overcome the mechanical spring tension and push the mechanical structure to move and close the gate for braking. The main control opens the gate command > the solenoid valve loses power and stops working > the hydraulic cylinder does not work, and the mechanical spring naturally contracts and pulls the machine back to open the gate.

[0035] Set the maximum safe operating time of the equipment: The maximum running time of the limit is 10 seconds; The maximum operating time of the liquid level is 1 minute; The maximum operating time of temperature is 5 minutes; The maximum running time for pad wear is 5 minutes.

[0036] Figure 1 This is the structure diagram of the safety brake and its hydraulic system. After the whole machine is installed, a sufficient amount of hydraulic oil is injected into the hydraulic pump 3 through the filter 4, and then flows into the hydraulic cylinder after passing through the one-way valve 5. At the same time, the pressure in the cylinder is displayed on the pressure gauge 13, and the pressure cylinder does work on the load; When the amount of hydraulic oil injected through the one-way valve 5 exceeds the safety limit of the safety valve 9, a small amount of excess oil flows back to the oil filling port, and the excess oil can also overflow to the oil filling port through the overflow valve 8. The hydraulic oil circuit is filled and the hydraulic system is closed; With the help of equipment, the pressure in the cylinder of the hydraulic system is detected, the manual pump 7 is assisted to increase / decrease the pressure, and the leakage and sealing performance are monitored and reset after normality; When the hydraulic system is powered on, the motor 1 starts immediately, and at the same time, the liquid level and temperature switch 6 and the pressure switch 12 detect the liquid level, temperature and pressure in the hydraulic system; when the pressure in the hydraulic system reaches the preset value, the system synchronously collects the pressure information and immediately issues a command to the first solenoid valve 101 and the second solenoid valve 102, and the stop valve 11 controls the motor to shut down immediately; when the pressure in the hydraulic system does not reach the preset value, the motor continues to turn on to supplement the pressure until the pressure reaches the preset value.

[0037] When the hydraulic system is working continuously and the natural consumption of hydraulic oil exceeds the low limit, the system will collect information about the pressure exceeding the low limit and start the pressure replenishment warning or send an alarm message to the terminal.

[0038] When the hydraulic system continues to work and the temperature in the cylinder exceeds the limit, the system collects the temperature limit information and starts a high temperature warning or sends an alarm message to the terminal.

[0039] When the hydraulic system continues to work and the liner wear exceeds the limit, the system collects the stroke sensor over-limit information and starts the liner wear warning or sends the alarm information to the terminal.

[0040] An integrated hydraulic system health control method for a hydraulic brake comprises the following steps: Real-time collection of real-time data from limit sensors, pressure sensors, liquid level sensors, torque sensors, temperature sensors, and stroke sensors; The collected data are divided into different channels and fed into the data processing center; The data processing center compares the data imported from each channel with the data set by the data processing center and issues an early warning signal; The data processing center will summarize the comparison results and send the result instructions to the corresponding channels respectively, and simultaneously connect with the network for data exchange.

[0041] Preferably, the limit information of the limit sensor is collected in real time, and the limit settings include upper limit A, upper transition area B, normal area C, lower transition area D, and lower limit E. There are five levels of health management. When the limit information exceeds the health management setting range, the data processing center outputs a timely stop instruction. The specific steps are as follows: Step 100, start; Step 101, collecting position information of the limit sensor in real time; Step 102, the location information is transmitted to a data processing center; Step 103, the data processing center determines whether the location data is within the normal area. If the location data is within the normal area, jump to step 116; otherwise, jump to step 104; Step 104, the data processing center determines whether the position data exceeds the limit, if not, jump to step 105, otherwise jump to step 117; Step 105, the data processing center determines whether the position data is in the upper transition area or the lower transition area; if it is in the upper transition area, jump to step 106, and if it is in the lower transition area, jump to step 111; Step 106, upper limit transition area counter A=A+1; Step 107, determining whether it is the first time to enter the upper limit transition area, if it is the first time to enter the upper limit area, jump to step 101, otherwise jump to step 108; Step 108, comparing the position data with the last time the position data entered the upper limit transition area, drawing a position data time function curve, and estimating the system operation time when the position data enters the upper limit position; Step 109, determining whether the system has been running in the upper transition area for less than 10 seconds. If the system has been running for less than 10 seconds, jump to step 101; otherwise, jump to step 110; Step 110, issue a warning and jump to step 101; Step 111, upper limit transition area counter B=B+1; Step 112, determining whether it is the first time to enter the lower limit transition area, if it is the first time to enter the lower limit area, jump to step 101, otherwise jump to step 113; Step 113, comparing the position data with the last time the position data entered the lower limit transition area, drawing a position data time function curve, and estimating the system operation time when the position data enters the lower limit position; Step 114, determining whether the system has been running in the transition area for less than 10 seconds. If the system has been running for less than 10 seconds, jump to step 101; otherwise, jump to step 115; Step 115, issue a warning and jump to step 101; Step 116, the equipment limit information is normal, the limit channel is opened, and the channel is unobstructed; jump to step 101; Step 117, the limit channel is disconnected, the device is shut down, and the end is completed. Preferably, data from the pressure sensor is collected in real time; According to the actual oil pressure state of the hydraulic oil in the hydraulic cylinder, set the five-level health management mode of high pressure upper limit, high pressure stop, normal pressure, low pressure start, and low pressure lower limit; When the oil pressure reaches the upper limit of high pressure, the equipment stops; When the oil pressure stops at high pressure, the microprocessor turns off the oil pump by shutting down the solid-state relay, and there is no need to increase the oil pressure; When the oil pressure is at normal pressure, the pressure path of the equipment is unobstructed; When the oil pressure is low-pressure start, the microprocessor turns on the oil pump by turning on the solid-state relay, increasing the pressure in the oil circuit until it is shut down by the high-pressure stop pressure.

[0042] Preferably, the liquid level information of the liquid level sensor is collected in real time, and the liquid level is set in three levels of health management mode: normal liquid level, low liquid level, and extremely low stop liquid level; When the liquid level is at the normal level, the liquid level passage of the equipment is unobstructed; When the liquid level is low, the device will display a low liquid level fault and simultaneously transmit the low liquid level information to the main control through the communication and fault ports. At this time, the device can be used normally temporarily. When the liquid level is at an extremely low stop, there is a leak in the hydraulic circuit of the equipment, and the microprocessor shuts down in time until the hydraulic oil is increased to the normal level before it can operate normally.

[0043] Preferably, the method comprises the following steps: Step 200, start; Step 201, collecting liquid level information from a liquid level sensor in real time; Step 202, the liquid level information is transmitted to a data processing center; Step 203, the data processing center determines whether the liquid level data reaches the extremely low stop liquid level. If it reaches the extremely low stop liquid level, jump to step 209, otherwise jump to step 204; Step 204, the data processing center determines whether the liquid level data is low level, if it is not low level, jump to step 208, otherwise jump to step 205; Step 205, comparing with the last liquid level data, drawing a liquid level data time function curve, and estimating the liquid level data entering the brake liquid level system operation time; Step 206, determining whether the system has been running at a low liquid level for less than 1 minute. If the system has been running for less than 1 minute, jump to step 207, otherwise jump to step 201; Step 207, issue a warning and jump to step 201; Step 208, the liquid level information is normal, the liquid level channel is opened, and the channel is unobstructed; jump to step 201; Step 209: The liquid level information is abnormal, the liquid level channel is closed, and the process ends.

[0044] Preferably, the torque sensor data is collected in real time; compared with the stored preset data, and the torque health status is determined according to the comparison result; Draw a torque-time curve to determine the system operating time.

[0045] Preferably, temperature sensor data is collected in real time; The temperature sensor uses PT100, which is divided into four channels: left pad temperature 1, right pad temperature 1, left pad temperature 2, and right pad temperature 2. Because the pad is long, sometimes eccentric wear will cause one end to be worn and the other end to be suspended, and the thermal conductivity of the friction material is poor. In order to collect temperature information in time, a temperature sensor probe is usually set at each end of the back of the same narrow pad for temperature collection.

[0046] Each channel is divided into extreme high temperature, high temperature warning, normal temperature, low temperature warning, and extreme low temperature health management modes; When the temperature sensor channel detects extreme high temperature and extreme low temperature, the equipment will stop in time and will not return to normal until the temperature channel returns to normal; When the temperature sensor channel detects high temperature warning and low temperature warning, the device highlights the temperature abnormality information and simultaneously shares the temperature channel abnormality information through the communication path and fault terminal.

[0047] Preferably, the method comprises the following steps: Step 300, start; Step 301, collecting temperature information of a temperature sensor in real time; Step 302, the temperature sensor transmits to the data processing center; Step 303, the data processing center determines whether the temperature sensor is within the normal temperature range. If the temperature data is within the normal temperature range, jump to step 316, otherwise jump to step 304; Step 304, the data processing center determines whether the temperature data exceeds the limit temperature, if it does not exceed the limit temperature, jump to step 305, otherwise jump to step 317; Step 305, the data processing center determines whether the temperature data is in the upper limit high temperature warning or the lower limit high temperature warning; if it is the upper limit high temperature warning, jump to step 306, and if it is the lower limit transition area, jump to step 311; Step 306, upper limit high temperature warning counter C=C+1; Step 307, determining whether it is the first time to enter the upper limit high temperature warning area, if it is the first time to enter the upper limit area, jump to step 301, otherwise jump to step 308; Step 308, compare the temperature data with the last time it entered the upper limit high temperature warning area, draw a temperature data time function curve, and estimate the system operation time when the temperature data enters the upper limit temperature limit; Step 309, determining whether the system has been running in the upper limit high temperature warning area for less than 5 minutes. If the system has been running for less than 5 minutes, jump to step 301; otherwise, jump to step 310; Step 310, issue a warning and jump to step 301; Step 311, lower limit high temperature warning counter D=D+1; Step 312, determining whether it is the first time to enter the lower limit low temperature warning area, if it is the first time to enter the lower limit low temperature area, jump to step 301, otherwise jump to step 313; Step 313, compare the temperature data with the last time it entered the lower limit low temperature warning area, draw a temperature data time function curve, and estimate the system operation time when the temperature data enters the lower limit temperature limit; Step 314, determining whether the system has been running in the lower limit low temperature warning area for less than 5 minutes. If the system has been running for less than 5 minutes, jump to step 301; otherwise, jump to step 315; Step 315, issue a warning and jump to step 301; Step 316: The temperature information is normal, the temperature channel is opened, and the channel is unobstructed; jump to step 301; Step 317, the temperature information is abnormal, the temperature channel is shut down, and the process ends.

[0048] Preferably, the stroke sensor is divided into two channels: left liner wear and right liner wear. Each channel is respectively provided with upper limit stop, upper limit warning, normal, lower limit warning, and lower limit stop health management modes; When the stroke sensor channel detects the upper limit stop and the lower limit stop, the equipment stops in time until the stroke channel returns to normal. When the stroke sensor channel detects the upper limit warning and the lower limit warning, the equipment highlights the abnormal pad wear information and simultaneously shares the abnormal pad wear channel information through the communication path and the fault terminal; at this time, the equipment enters a temporary usable state.

[0049] Preferably, the method comprises the following steps: Step 400, start; Step 401, collecting travel position information of the travel sensor in real time; Step 402, the travel position data of the travel sensor is transmitted to the data processing center; Step 403, the data processing center determines whether the travel position data is within the normal range. If the travel position data is within the normal travel position, jump to step 416, otherwise jump to step 404; Step 404, the data processing center determines whether the travel data exceeds the limit stop, if not, jump to step 405, otherwise jump to step 417; Step 405, the data processing center determines whether the wear data is at the upper limit wear warning or the lower limit wear warning; if the upper limit wear warning is set, jump to step 406, and if the lower limit wear warning is set, jump to step 411; Step 406, upper limit wear warning counter D=D+1; Step 407, determining whether it is the first time to enter the upper limit wear warning area, if it is the first time to enter the upper limit wear area, jump to step 401, otherwise jump to step 408; Step 408, comparing the wear data with the last time it entered the upper limit wear warning area, drawing a wear data time function curve, and estimating the system operation time when the wear data enters the upper limit wear limit area; Step 409, determining whether the system has been running in the upper limit wear warning area for less than 1 minute. If the system has been running for less than 1 minute, jump to step 401; otherwise, jump to step 410; Step 410, issue a warning and jump to step 401; Step 411, lower limit wear warning counter E=E+1; Step 412, determining whether it is the first time to enter the lower limit wear warning area, if it is the first time to enter the lower limit area, jump to step 401, otherwise jump to step 413; Step 413, comparing the wear data with the last time it entered the lower limit wear warning area, drawing a wear data time function curve, and estimating the system operation time when the wear data enters the lower limit wear limit; Step 414, determining whether the system lower limit wear warning area operation time is less than 1 minute. If the system operation time is less than 1 minute, jump to step 401, otherwise jump to step 415; Step 415, issue a warning and jump to step 401; Step 416, the travel position information is normal, the travel channel is open, and the channel is unobstructed; jump to step 401; Step 417, the trip location information is abnormal, the trip channel is closed, and the process ends.

[0050] The integrated hydraulic health control method for hydraulic brakes of the present invention can autonomously manage the hydraulic system and issue an early warning before a fault occurs; or when a serious fault already exists, the machine can be autonomously shut down to avoid disasters or secondary disasters, and reduce the time and cost of fault maintenance; no manual supervision is required, and the system is autonomously designed and embedded in the device.

[0051] The above is only a preferred embodiment of the present invention, and does not limit the structure of the present invention in any form. Any simple modification, equivalent change and modification made to the above embodiment according to the technical essence of the present invention are within the scope of the technical solution of the present invention.

Claims

1. An integrated hydraulic system health control method for a hydraulic brake, characterized in that: The following steps are involved: Real-time collection of real-time data from limit sensors, pressure sensors, liquid level sensors, torque sensors, temperature sensors, and stroke sensors; The collected data are divided into different channels and fed into the data processing center; The data processing center compares the data imported from each channel with the data set by the data processing center and issues an early warning signal; The data processing center will summarize the comparison results and send the result instructions to the corresponding channels respectively, and simultaneously connect with the network for data exchange.

2. The integrated hydraulic system health control method for a hydraulic brake according to claim 1, characterized in that: Real-time collection of limit information of limit sensors, limit settings upper limit A; upper transition area B; normal area C; lower transition area D; lower limit E, five levels of health management, when the limit information exceeds the health management setting range, the data processing center outputs a timely stop instruction, the specific steps are as follows: Step 100, start; Step 101, collecting position information of the limit sensor in real time; Step 102, the location information is transmitted to a data processing center; Step 103, the data processing center determines whether the location data is within the normal area. If the location data is within the normal area, jump to step 116; otherwise, jump to step 104; Step 104, the data processing center determines whether the position data exceeds the limit, if not, jump to step 105, otherwise jump to step 117; Step 105, the data processing center determines whether the position data is in the upper transition area or the lower transition area; if it is in the upper transition area, jump to step 106, and if it is in the lower transition area, jump to step 111; Step 106, upper limit transition area counter A=A+1; Step 107, determining whether it is the first time to enter the upper limit transition area, if it is the first time to enter the upper limit area, jump to step 101, otherwise jump to step 108; Step 108, comparing the position data with the last time the position data entered the upper limit transition area, drawing a position data time function curve, and estimating the system operation time when the position data enters the upper limit position; Step 109, determining whether the system has been running in the upper transition area for less than 10 seconds. If the system has been running for less than 10 seconds, jump to step 101; otherwise, jump to step 110; Step 110, issue a warning and jump to step 101; Step 111, upper limit transition area counter B=B+1; Step 112, determining whether it is the first time to enter the lower limit transition area, if it is the first time to enter the lower limit area, jump to step 101, otherwise jump to step 113; Step 113, comparing the position data with the last time the position data entered the lower limit transition area, drawing a position data time function curve, and estimating the system operation time when the position data enters the lower limit position; Step 114, determining whether the system has been running in the transition area for less than 10 seconds. If the system has been running for less than 10 seconds, jump to step 101; otherwise, jump to step 115; Step 115, issue a warning and jump to step 101; Step 116, the equipment limit information is normal, the limit channel is opened, and the channel is unobstructed; jump to step 101; Step 117, the limit channel is disconnected, the device is shut down, and the process ends.

3. The integrated hydraulic system health control method for a hydraulic brake according to claim 1, characterized in that: Collect data from pressure sensors in real time; According to the actual oil pressure state of the hydraulic oil in the hydraulic cylinder, set the five-level health management mode of high pressure upper limit, high pressure stop, normal pressure, low pressure start, and low pressure lower limit; When the oil pressure reaches the upper limit of high pressure, the equipment stops; When the oil pressure stops at high pressure, the microprocessor turns off the oil pump by shutting down the solid-state relay, and there is no need to increase the oil pressure; When the oil pressure is at normal pressure, the pressure path of the equipment is unobstructed; When the oil pressure is low-pressure start, the microprocessor turns on the oil pump by turning on the solid-state relay, increasing the pressure in the oil circuit until it is shut down by the high-pressure stop pressure.

4. The integrated hydraulic system health control method for a hydraulic brake according to claim 1, characterized in that: Real-time collection of liquid level information from the liquid level sensor, and three-level health management modes of liquid level setting: normal liquid level, low liquid level, and extremely low stop liquid level; When the liquid level is at the normal level, the liquid level passage of the equipment is unobstructed; When the liquid level is low, the device will display a low liquid level fault and simultaneously transmit the low liquid level information to the main control through the communication and fault ports. At this time, the device can be used normally temporarily. When the liquid level is at an extremely low stop, there is a leak in the hydraulic circuit of the equipment, and the microprocessor shuts down in time until the hydraulic oil is increased to the normal level before it can operate normally.

5. The integrated hydraulic system health control method for a hydraulic brake according to claim 4, characterized in that: The steps include: Step 200, start; Step 201, collecting liquid level information from a liquid level sensor in real time; Step 202, the liquid level information is transmitted to a data processing center; Step 203, the data processing center determines whether the liquid level data reaches the extremely low stop liquid level. If it reaches the extremely low stop liquid level, jump to step 209, otherwise jump to step 204; Step 204, the data processing center determines whether the liquid level data is low level, if it is not low level, jump to step 208, otherwise jump to step 205; Step 205, comparing with the last liquid level data, drawing a liquid level data time function curve, and estimating the liquid level data entering the brake liquid level system operation time; Step 206, determining whether the system has been running at a low liquid level for less than 1 minute. If the system has been running for less than 1 minute, jump to step 207, otherwise jump to step 201; Step 207, issue a warning and jump to step 201; Step 208, the liquid level information is normal, the liquid level channel is opened, and the channel is unobstructed; jump to step 201; Step 209: The liquid level information is abnormal, the liquid level channel is closed, and the process ends.

6. The integrated hydraulic system health control method for a hydraulic brake according to claim 1, characterized in that: Collect torque sensor data in real time; compare it with the stored preset data, and judge the torque health status based on the comparison results; Draw a torque-time curve to determine the system operating time.

7. The integrated hydraulic system health control method for a hydraulic brake according to claim 1, characterized in that: Real-time collection of temperature sensor data; The temperature sensor uses PT100, which is divided into four channels: left pad temperature 1, right pad temperature 1, left pad temperature 2, and right pad temperature 2; Each channel is divided into extreme high temperature, high temperature warning, normal temperature, low temperature warning, and extreme low temperature health management modes; When the temperature sensor channel detects extreme high temperature and extreme low temperature, the equipment will stop in time and will not return to normal until the temperature channel returns to normal; When the temperature sensor channel detects high temperature warning and low temperature warning, the device highlights the temperature abnormality information and simultaneously shares the temperature channel abnormality information through the communication path and fault terminal.

8. The integrated hydraulic system health control method for a hydraulic brake according to claim 7, characterized in that: The steps include: Step 300, start; Step 301, collecting temperature information of a temperature sensor in real time; Step 302, the temperature sensor transmits to the data processing center; Step 303, the data processing center determines whether the temperature sensor is within the normal temperature range. If the temperature data is within the normal temperature range, jump to step 316, otherwise jump to step 304; Step 304, the data processing center determines whether the temperature data exceeds the limit temperature, if not, jump to step 305, otherwise jump to step 317; Step 305, the data processing center determines whether the temperature data is in the upper limit high temperature warning or the lower limit high temperature warning; if it is the upper limit high temperature warning, jump to step 306, and if it is the lower limit transition area, jump to step 311; Step 306, upper limit high temperature warning counter C=C+1; Step 307, determining whether it is the first time to enter the upper limit high temperature warning area, if it is the first time to enter the upper limit area, jump to step 301, otherwise jump to step 308; Step 308, compare the temperature data with the last time it entered the upper limit high temperature warning area, draw a temperature data time function curve, and estimate the system operation time when the temperature data enters the upper limit temperature limit; Step 309, determining whether the system has been running in the upper limit high temperature warning area for less than 5 minutes. If the system has been running for less than 5 minutes, jump to step 301; otherwise, jump to step 310; Step 310, issue a warning and jump to step 301; Step 311, lower limit high temperature warning counter D=D+1; Step 312, determining whether it is the first time to enter the lower limit low temperature warning area, if it is the first time to enter the lower limit low temperature area, jump to step 301, otherwise jump to step 313; Step 313, compare the temperature data with the last time it entered the lower limit low temperature warning area, draw a temperature data time function curve, and estimate the system operation time when the temperature data enters the lower limit temperature limit; Step 314, determining whether the system has been running in the lower limit low temperature warning area for less than 5 minutes. If the system has been running for less than 5 minutes, jump to step 301; otherwise, jump to step 315; Step 315, issue a warning and jump to step 301; Step 316: The temperature information is normal, the temperature channel is opened, and the channel is unobstructed; jump to step 301; Step 317, the temperature information is abnormal, the temperature channel is shut down, and the process ends.

9. The integrated hydraulic system health control method for a hydraulic brake according to claim 1, characterized in that: The stroke sensor is divided into two channels: left liner wear and right liner wear. Each channel is set with upper limit stop, upper limit warning, normal, lower limit warning, and lower limit stop health management modes; When the stroke sensor channel detects the upper limit stop and the lower limit stop, the equipment stops in time until the stroke channel returns to normal. When the stroke sensor channel detects the upper limit warning and the lower limit warning, the equipment highlights the abnormal pad wear information and simultaneously shares the abnormal pad wear channel information through the communication path and the fault terminal; at this time, the equipment enters a temporary usable state.

10. The integrated hydraulic system health control method for a hydraulic brake according to claim 9, characterized in that: The steps include: Step 400, start; Step 401, collecting travel position information of the travel sensor in real time; Step 402, the travel position data of the travel sensor is transmitted to the data processing center; Step 403, the data processing center determines whether the travel position data is within the normal range. If the travel position data is within the normal travel position, jump to step 416, otherwise jump to step 404; Step 404, the data processing center determines whether the travel data exceeds the limit stop, if not, jump to step 405, otherwise jump to step 417; Step 405, the data processing center determines whether the wear data is at the upper wear warning limit or the lower wear warning limit; If the upper limit wear warning occurs, the process jumps to step 406 ; if the lower limit wear warning occurs, the process jumps to step 411 ; Step 406, upper limit wear warning counter D=D+1; Step 407, determining whether it is the first time to enter the upper limit wear warning area, if it is the first time to enter the upper limit wear area, jump to step 401, otherwise jump to step 408; Step 408, comparing the wear data with the last time it entered the upper limit wear warning area, drawing a wear data time function curve, and estimating the system operation time when the wear data enters the upper limit wear limit area; Step 409, determining whether the system has been running in the upper limit wear warning area for less than 1 minute. If the system has been running for less than 1 minute, jump to step 401; otherwise, jump to step 410; Step 410, issue a warning and jump to step 401; Step 411, lower limit wear warning counter E=E+1; Step 412, determining whether it is the first time to enter the lower limit wear warning area, if it is the first time to enter the lower limit area, jump to step 401, otherwise jump to step 413; Step 413, comparing the wear data with the last time it entered the lower limit wear warning area, drawing a wear data time function curve, and estimating the system operation time when the wear data enters the lower limit wear limit; Step 414, determining whether the system lower limit wear warning area operation time is less than 1 minute. If the system operation time is less than 1 minute, jump to step 401, otherwise jump to step 415; Step 415, issue a warning and jump to step 401; Step 416, the travel position information is normal, the travel channel is open, and the channel is unobstructed; jump to step 401; Step 417, the trip location information is abnormal, the trip channel is closed, and the process ends.

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