Fault detection method and device for hydraulic system of car dumper and medium

Abstract

The invention relates to a fault detection method and device for a hydraulic system of a car dumper and a medium, and the method comprises the steps: obtaining the pressure data of each pressure measurement point during operation, and generating an actual pressure data curve corresponding to each pressure measurement point based on the pressure data; the actual pressure data curve is compared with a preset normal pressure data model curve, a first comparison result is output, and whether a fault exists or not is determined according to the first comparison result; when a fault exists, the actual pressure data curve is compared with a preset data fault model curve, a second comparison result is output, and a fault point location is determined according to the second comparison result; the data fault model curve is a plurality of curves generated according to the pressure data of each pressure measuring point when at least one pressure measuring point fails. The method has the beneficial effects that a specific fault point location can be accurately positioned, the fault finding time is saved, the maintenance efficiency is improved, and the downtime of equipment is shortened.

Description

Technical Field

[0001] The present invention relates to the technical field of hydraulic systems for electromechanical equipment, and in particular to a method, equipment and medium for detecting faults in a hydraulic system of a dumper. Background Art

[0002] A car tipper is a large mechanical device used to tip and unload bulk materials from railway open wagons. It can flip or tilt rail vehicles to unload materials, and is suitable for ports with large transportation volumes. The hydraulic system of the car tipper plays a vital role in the unloading process. If the hydraulic system of the car tipper's car pressure beam fails, it will cause a train derailment accident in serious cases. At present, when hydraulic failures occur in equipment such as car pressure beams and car support plates and the cause of the failure cannot be determined, they can only be operated remotely or manually through the on-site operation box in the tipping control room, and maintenance personnel are required to connect a mechanical pressure gauge to the valve block on site for pressure measurement, and analyze and judge the failure based on the pressure. The maintenance efficiency is low and the operation is extremely inconvenient. On the other hand, after the failure repair or overhaul of the car pressure beam is completed, it is necessary to perform an action test on the repaired car pressure beam and measure the pressure of each part to see if it meets the requirements. The maintenance operation is time-consuming and labor-intensive, and the data cannot be automatically recorded. Furthermore, when conducting the action test on site, it is impossible to conduct a separate test on each car pressing beam, and only the 8 car pressing beams can be tested for simultaneous action. The monitoring curve of the human-machine interface can only display the pressure of a single chamber of the hydraulic cylinder. Other pressure tests are visually inspected and observed through the 4 pressure measuring points on the on-site valve block connected to the pointer pressure gauge, and the data change process cannot be recorded. The effect of the maintenance can only be judged through on-site observation and experience, and complete pressure process data information cannot be provided. The fault handling efficiency is low, and the fault point cannot be judged in a timely and accurate manner, which seriously affects the efficiency of the unloading operation. Therefore, the development of a fault detection method for the hydraulic system of a tipping machine has great application prospects. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a fault detection method, equipment and medium for the hydraulic system of a tipping machine. The method can analyze and judge hydraulic faults by conducting simulated fault tests on the hydraulic equipment of the tipping machine, collecting the real-time pressure of each pressure measuring point of the equipment and displaying it on a touch screen in the form of a pressure curve. The touch screen monitors all actions and data change processes online, and saves all collected data historically for comparison and reference, thereby improving the efficiency of fault analysis and fault handling. The pressure data collection and recording functions of the method can predict hydraulic faults, eliminate hidden dangers of equipment failures in advance, and achieve preventive maintenance, thereby providing strong technical support for the safe and efficient operation of the tipping machine system.

[0004] The technical solution of the present invention to solve the above technical problems is as follows: In a first aspect, the present application provides a method for detecting faults in a hydraulic system of a dumper, which adopts the following technical solution: A method for detecting faults in a hydraulic system of a dumper, the method comprising: Acquire pressure data of each pressure measuring point during operation, and generate actual pressure data curves corresponding to each pressure measuring point based on the pressure data; Comparing the actual pressure data curve with a preset normal pressure data model curve, outputting a first comparison result, and determining whether there is a fault according to the first comparison result; When a fault occurs, the actual pressure data curve is compared with a preset data fault model curve, a second comparison result is output, and the fault point is determined according to the second comparison result; The data fault model curves are a plurality of curves generated according to the pressure data of each of the pressure measuring points when at least one of the pressure measuring points fails.

[0005] The beneficial effects of the present invention are as follows: by using a pressure sensor installed on the hydraulic system of a dumper to detect and collect pressure data in real time, by comparing the actual pressure data curve during actual operation with the preset normal pressure data model curve, it is possible to quickly identify whether the hydraulic system is in a normal state or whether there is a fault; when a fault is detected, the actual pressure data curve is further compared with the preset data fault model curve, so that the specific fault point can be accurately located, saving time in finding the fault, improving maintenance efficiency, reducing equipment downtime, reducing unnecessary inspection and replacement of parts, and thus reducing maintenance costs; timely detection and repair of hydraulic system faults can also avoid equipment damage or personal injury caused by the fault, thereby improving production safety.

[0006] Based on the above technical solution, the present invention can also be improved as follows.

[0007] Furthermore, the normal pressure data model curve is generated based on the pressure data of each of the pressure measuring points during normal operation.

[0008] The beneficial effect of adopting the above further solution is that the normal pressure data model curve can reflect the performance of the test object under normal working conditions, and serve as a judgment basis for the actual pressure data curve to determine whether the hydraulic system is operating normally.

[0009] Furthermore, a pressure measuring point is set at the position corresponding to each hydraulic solenoid valve in the hydraulic system.

[0010] The beneficial effect of adopting the above-mentioned further scheme is that the pressure measuring point at each hydraulic solenoid valve position can monitor the pressure changes at that position in real time and accurately, thereby more accurately reflecting the working status of the solenoid valve; once a system failure occurs, the faulty solenoid valve can be quickly located by comparing the normal pressure data model curve and the real-time pressure data, thereby improving the efficiency and accuracy of fault diagnosis.

[0011] Furthermore, the data fault model curve is a plurality of curves stored in the fault pressure data model, and the generation process of the data fault model curve includes: Acquire the pressure data of each of the pressure measuring points when at least one of the hydraulic solenoid valves is powered on or off, the pressure data comprising: a pressure value P and a pressure interval P', -0.05P≤P'≤+0.05P; The pressure data is matched with the corresponding hydraulic solenoid valve, the power-on and power-off states of the hydraulic solenoid valve and the corresponding fault types to generate a plurality of data fault model curves, wherein the fault types include the fault conditions of various devices in the hydraulic system of the dumper.

[0012] The beneficial effects of adopting the above further scheme are: through the fault simulation function, the power-on and power-off states of various hydraulic solenoid valves can be simulated, thereby simulating various possible fault conditions, which helps to predict hydraulic faults before actual faults occur, improve the accuracy and reliability of fault diagnosis, and thus facilitate the subsequent judgment of fault points, reduce the possibility of misjudgment and misoperation, improve the efficiency of fault analysis and fault handling, and provide strong technical support for the safe and efficient operation of the tipping machine system; by matching pressure data with the power-on and power-off states of hydraulic solenoid valves and fault types, a complete fault database is established, which not only contains known fault information, but can also be continuously updated and expanded in subsequent production to adapt to new fault conditions. The fault simulation function can simulate various fault conditions without actually damaging the equipment, thereby avoiding equipment damage and safety accidents caused by actual faults.

[0013] By setting the pressure interval P', the system can more accurately determine whether the pressure value on the actual pressure data curve is within the normal range. When the pressure data at the corresponding point exceeds or approaches this interval, the system can predict potential failures or abnormal conditions, so as to take measures in advance to avoid equipment damage or production interruption.

[0014] Furthermore, the actual pressure data curve, the normal pressure data model curve and the data fault model curve all include the pressure value P and the pressure range P' of each pressure measuring point at any time within the production process cycle T.

[0015] The beneficial effect of adopting the above further solution is that the real-time collected pressure data can immediately reflect the pressure status within a production process cycle T, helping operators to promptly discover whether there are any abnormal conditions within a production process cycle.

[0016] Further, comparing the actual pressure data curve with a preset normal pressure data model curve, outputting a first comparison result, and determining whether a fault exists according to the first comparison result includes: If the actual pressure data curve falls within the normal pressure data model curve, outputting the first comparison result indicating that the hydraulic system of the dumper operates normally; If the actual pressure data curve does not fall within the normal pressure data model curve, the first comparison result of the tipper hydraulic system alarm is output.

[0017] The beneficial effect of adopting the above further scheme is: when the actual pressure data curve exceeds the range of the normal pressure data model curve, the system can immediately issue an alarm to promptly alert the operator or maintenance personnel; by comparing with the normal pressure data model curve, the system can quickly identify pressure data anomalies, and timely fault warning and diagnosis can reduce equipment downtime and improve equipment operating efficiency.

[0018] Furthermore, when a fault occurs, the actual pressure data curve is compared with a preset data fault model curve, a second comparison result is output, and the fault point is determined according to the second comparison result, including: When the first comparison result is an output alarm, the actual pressure data curve is compared with the plurality of data fault model curves one by one. If the actual pressure data curve falls within one of the data fault model curves, the second comparison result indicating that the hydraulic system of the dumper has an equipment fault corresponding to the fault type is output, and the corresponding fault point is determined; If the actual pressure data curve does not fall within all the data fault model curves, the second comparison result indicating that the current hydraulic system of the dumper has equipment hidden dangers rather than equipment failure is output and an alarm is given.

[0019] The beneficial effect of adopting the above further scheme is: by comparing with the data fault model curve, the fault type that matches the data fault model curve can be quickly identified, so as to quickly locate the fault point, and accurate fault location and fault type identification can guide maintenance personnel to take corresponding measures quickly to improve maintenance efficiency, thereby reducing equipment downtime and improving production efficiency and equipment utilization; preventive maintenance is achieved through the identification of equipment hidden dangers, and maintenance personnel can take preventive maintenance measures to avoid the occurrence of faults, providing strong technical support for the safe and efficient operation of the tipping machine system.

[0020] Furthermore, when there is an equipment hidden danger in the hydraulic system of the tipping machine, the changing trend of the actual pressure data curve and the changing trend of the data fault model curve are obtained; the changing trend of the actual pressure data curve is compared with the changing trend of the data fault model curve. When the changing trend of the actual pressure data curve is inconsistent with the changing trend of the data fault model curve, it is predicted that there is an equipment hidden danger at the corresponding pressure measuring point.

[0021] The beneficial effects of adopting the above further scheme are: by comparing the historical pressure curve with the data failure model curve, potential hidden dangers can be identified before the equipment failure actually occurs, which allows maintenance personnel to intervene in advance and implement preventive maintenance measures, thereby avoiding production interruptions and potential safety risks caused by sudden equipment shutdown; preventive maintenance can ensure that the equipment operates in the best condition, reduce production delays and product quality problems caused by equipment failure, and help improve the overall reliability and production efficiency of the equipment; compared with emergency repairs after equipment failure, preventive maintenance is usually less expensive, and by promptly discovering and solving potential problems, more expensive repair and replacement costs can be avoided.

[0022] In a second aspect, the present application provides an electronic device, which adopts the following technical solution: An electronic device comprises a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executes the method for detecting faults in the hydraulic system of a car tipping machine as described in any one of the first aspects.

[0023] In a third aspect, the present application provides a computer-readable storage medium, which adopts the following technical solution: A computer-readable storage medium stores a computer program that can be loaded by a processor and execute the method for detecting faults in the hydraulic system of a car tipping machine as described in any one of the first aspects. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 A schematic flow chart of a method for detecting a fault in a hydraulic system of a car tipper according to an embodiment of the present invention; Figure 2 It is a logic judgment block diagram of an embodiment of the present invention; Figure 3 The present invention is a structural block diagram of an electronic device according to an embodiment of the present application. DETAILED DESCRIPTION

[0025] The present application is further described in detail below in conjunction with the accompanying drawings.

[0026] The embodiment of the present application provides a method for detecting a fault in a hydraulic system of a car tipper, which is executed by a hydraulic system fault detection device for a car tipper, and the device comprises: a CPU, an analog input module, a switch, a wireless remote control module and a power supply module. The control program of the hydraulic system fault detection device for a car tipper is stored in the CPU, and is used for logic control, data processing and calculation, collecting external input switch signals, and outputting switch output signals of external devices. In this embodiment, the CPU can adopt CPU1214C DC / DC / DC; the analog input module collects analog signals of pressure sensors on hydraulic equipment, and transmits them to the CPU through electrical signal connection, and can adopt: 6ES7 231-4HF32-0XB0; the switch is used to realize data communication between the CPU, analog input module, switch, wireless remote control module and touch screen device. The data processed by the CPU is transmitted to the touch screen or other remote display terminals (for example: control room display screen) through the switch and the wireless remote control module for display and storage; various types of data such as input data, output data, fault detection signals, etc. are remotely transmitted through the wireless remote control module. In this embodiment, the wireless remote control module can adopt GRM112NR-C (GZJK); the power module converts AC power into DC power, and stabilizes the output DC power within a certain voltage range through a voltage stabilizer; the power module is used to provide a stable and reliable power supply for the CPU, analog input module, switch, wireless remote control module and other equipment in the hydraulic system fault detection device of the tipping machine, wherein the power module can adopt: QUINT-PS / 1AC / 24DC / 5-2866750.

[0027] Common components such as air switch, fuse, terminal block and isolated output module are also provided to ensure the safe and stable operation of the hydraulic system fault detection device of the tipping machine. The air switch is an electrical component that controls the connection and disconnection of the total circuit of the hydraulic system fault detection device of the tipping machine. The action of the air switch is controlled by the CPU. The DZ47-C10 can be used. The fuse is an electrical protection device of the hydraulic system fault detection device of the tipping machine. Its main function is short circuit protection and overload protection. The RT18-32 5A can be used. The terminal block is a connecting wire in the hydraulic system fault detection device of the tipping machine to ensure the transmission of current and the normal operation of the circuit. The PCT211 can be used. The isolated output module is composed of a relay and a freewheeling diode to prevent the reverse electromotive force generated when the solenoid valve coil of the hydraulic equipment of the tipping machine is turned off from damaging the digital output module on the CPU. The G2R-2-SNDI(S) 13Y3W2 / 24VDC can be used. Since the air switch, fuse, terminal block and isolated output module are widely used in daily life, they will not be described in detail here.

[0028] At the same time, multiple pressure sensors and touch screens are also provided. Multiple pressure sensors are provided at various pressure measuring points of the hydraulic system. During the specific installation, one end of the pressure measuring hose is connected to the pressure measuring interface of each hydraulic equipment of the tipping machine. The pressure measuring hose and the pressure measuring interface are connected by a quick connector, which is convenient for quick disassembly and assembly. The other end of the pressure measuring hose is connected to a pressure sensor for collecting pressure signals; the pressure measuring hose is an accessory of the hydraulic system fault detection device of the tipping machine. The data collected by the pressure sensor is transmitted to the analog input module through the wiring terminal as a 4-20mA electrical signal, and the analog input module uses a serial bus to transmit the pressure data to the CPU.

[0029] The touch screen of the tipper hydraulic system fault detection device can display the change trend of the actual pressure data in real time and store it as a historical pressure curve. The CPU processes the collected pressure data and displays the actual pressure data curve on the touch screen.

[0030] The touch screen is used to display the pressure data of the detected equipment and the real-time curve of the pressure data, the historical curve of the pressure data, and control the fault information of the detected equipment. The control button for controlling the hydraulic equipment of the tipping machine is set on it. The touch screen is provided with an operation panel, and the operation panel is provided with: output interface a and input interface b. The solenoid valve coil of the hydraulic valve of the tipping machine equipment is connected through the output interface a to drive the hydraulic equipment of the tipping machine to perform the process action. The input interface b is connected to the analog input signal of the pressure sensor, that is, the pressure data collected by the pressure sensor is transmitted to the input interface b. The pressure sensor is used to measure the working pressure of each hydraulic component in the hydraulic system of the tipping machine, such as: the working pressure of the rod chamber of the hydraulic cylinder of the car pressing beam, the working pressure of the rodless chamber, the second oil chamber pressure, the system pressure, etc.

[0031] By setting an operation panel on the above-mentioned touch screen and setting multiple interfaces on the operation panel, in actual practical use, corresponding input and output signals can be connected according to the functions of each interface on the panel; the operator performs corresponding operations and settings through the touch screen to perform fault detection on the hydraulic system of the tipping machine, and the fault detection results can also be displayed through the touch screen.

[0032] The CPU can be mounted on an electronic device, which can be a server or a mobile terminal device. The server can be an independent physical server, a server cluster or distributed system composed of multiple physical servers, or a cloud server that provides cloud computing services. The mobile terminal device can be a laptop computer, a desktop computer, etc., but is not limited to this.

[0033] The following is a further detailed description of the embodiments of the present application in conjunction with the accompanying drawings. Figure 1-2As shown, a fault detection method for a hydraulic system of a dumper is described as follows: S1: Obtain the pressure data of each pressure measuring point during operation, and generate an actual pressure data curve corresponding to each pressure measuring point based on the pressure data.

[0034] In step S1, the pressure data of each pressure measuring point of the hydraulic system of the car tipper during daily actual operation is obtained through the pressure sensor installed on the hydraulic system of the car tipper. The pressure sensor transmits the pressure data to the analog input module through a 4-20mA electrical signal, and the analog input module transmits the signal to the CPU. The CPU processes the collected pressure data and displays the actual pressure data curve on the touch screen, wherein each pressure measuring point generates an actual pressure data curve.

[0035] When the car tipper equipment is running, the pressure sensor collects the pressure data on the car tipper hydraulic equipment and transmits it to the CPU. The CPU performs analog-to-digital conversion, linear conversion, input signal fault detection, output value filtering and other functions on the pressure signal. It can perform fault analysis, linear conversion and signal filtering on the collected analog signals and output stable and reliable pressure data.

[0036] In this embodiment, the output value filtering function adopts a first-order lag filtering method, which calculates a new filtering result by weighted averaging the historical data and the current data. Specifically, for the input data P1, the filtering coefficient a and the last filtering result P0, the new filtering result P can be obtained by the following formula: 0+ IN Among them, IN represents the input pressure value, and the value range of the filter coefficient a is generally between 0 and 1. When a is closer to 0, the new filter result is more stable, but it will cause hysteresis; when a is closer to 1, the new filter result is more susceptible to noise and fluctuations, but the response is more sensitive. The first-order lag filtering method is an existing well-known technology, which effectively eliminates fast noise and fluctuations, realizes data smoothing, and obtains more stable data results. No further restrictions are made here.

[0037] S2: Compare the actual pressure data curve with the preset normal pressure data model curve, output a first comparison result, and determine whether there is a fault according to the first comparison result.

[0038] In this embodiment, the normal pressure data model curve is generated by obtaining the pressure data of each pressure measuring point during normal operation. Specifically, the pressure data of each pressure measuring point of the hydraulic system of the tipping machine during normal operation is obtained through a pressure sensor, and the pressure sensor transmits the data to the analog input module through a 4-20mA electrical signal, and the analog input module transmits the data to the CPU. After the CPU processes the collected pressure data, the normal pressure data model curve is displayed on the touch screen. A normal pressure data model curve is generated for each pressure measuring point.

[0039] In step S2, the first comparison result outputted is that the hydraulic system operates normally or the hydraulic system operates faultily.

[0040] S3: When a fault exists, the actual pressure data curve is compared with the preset data fault model curve, a second comparison result is output, and the fault point is determined according to the second comparison result.

[0041] In this embodiment, whether step S3 is to be executed is determined based on the first comparison result, and step S3 is performed only when the output first comparison result is a hydraulic system operation failure.

[0042] In step S3, it is necessary to simulate and reproduce the fault phenomenon in advance to establish a fault pressure data model, and the fault pressure data model includes a plurality of data fault model curves generated according to the pressure data of each pressure measuring point when at least one pressure measuring point fails.

[0043] By installing a pressure sensor on the hydraulic system of the dumper to detect and collect pressure data in real time, the actual pressure data curve during actual operation is compared with the preset normal pressure data model curve to quickly identify whether the hydraulic system is in a normal state or whether there is a fault. When a fault is detected, the actual pressure data curve is further compared with the preset data fault model curve to accurately locate the specific fault point, saving time in finding the fault, improving maintenance efficiency, reducing equipment downtime, and reducing unnecessary inspections and replacement of parts, thereby reducing maintenance costs. Timely detection and repair of hydraulic system faults can also avoid equipment damage or personal injury caused by the fault, thereby improving production safety.

[0044] In this embodiment, a pressure measuring point is set corresponding to the position of each hydraulic solenoid valve in the hydraulic system, so that the pressure changes of each hydraulic solenoid valve can be collected and monitored in real time, thereby more accurately reflecting the working status of the solenoid valve; once a system failure occurs, the faulty solenoid valve can be quickly located by comparing the normal pressure data model curve and the real-time pressure data, thereby improving the efficiency and accuracy of fault diagnosis.

[0045] In step S3, the data fault model curves are multiple curves stored in the fault pressure data model, and the touch screen interface on the tipper hydraulic system fault detection device is provided with a fault simulation function and a linkage function. When the linkage function is selected, the CPU controls the hydraulic solenoid valve according to the logic output of the normal operation of the tipper hydraulic system, that is, in the daily actual working process, the daily operation of the tipper is performed by selecting the linkage function; when the fault simulation function is selected, a single hydraulic solenoid valve can be controlled to be energized or de-energized, or multiple hydraulic solenoid valves can be controlled to be energized and / or de-energized.

[0046] In this embodiment, the data fault model curve generation process includes: Obtaining pressure data of each pressure measuring point when at least one hydraulic solenoid valve is energized or de-energized; The pressure data is matched with the corresponding hydraulic solenoid valve, the power-on and power-off states of the hydraulic solenoid valve, and the corresponding fault type to generate multiple data fault model curves.

[0047] The following is an example of the car pressing beam equipment in the hydraulic system of the car tipper. When the linkage function is selected, the rising button is operated on the touch screen, and a2 and a4 in the output interface a transmit electrical signals to the CPU. The CPU outputs electrical signals to control the car pressing beam solenoid valve Y2 and solenoid valve Y4 in the hydraulic system of the car tipper to be energized to make the car pressing beam perform the rising action. Similarly, the descending button is operated on the touch screen, and a1, a3 and a4 in the output interface a output electrical signals to the CPU. The CPU outputs electrical signals to control the car pressing beam solenoid valve Y1, solenoid valve Y3 and solenoid valve Y4 in the hydraulic system of the car tipper to be energized to make the car pressing beam perform the descending action.

[0048] When the fault simulation function is selected, the touch screen can simulate any combination of commands through the manual buttons SB1, SB2, SB3, and SB4 set on the operation panel to control the transmission of electrical signals from a1, a2, a3, and a4 in the output interface a to the CPU. The CPU outputs electrical signals to control the power or power-off of the press beam solenoid valves Y1, Y2, Y3, and Y4 in the hydraulic system of the tipper, that is, the power or power-off of at least one hydraulic solenoid valve is manually controlled. The manual button is a self-holding button. Pressing the manual button means no output of electrical signals, and lifting the manual button means output of electrical signals.

[0049] Taking the car pressing beam equipment in the hydraulic system of the car tipper as an example, when the fault simulation function is selected, the touch screen operates the descending button, and a1, a3 and a4 in the output interface a output electrical signals to the CPU. The CPU outputs electrical signals according to the input information to control the car pressing beam solenoid valve Y1, solenoid valve Y3 and solenoid valve Y4 in the hydraulic system of the car tipper to be energized, so that the car pressing beam performs the descending action. At this time, pressing the manual button SB1 controls a1 in the output interface a not to output electrical signals to the CPU. The CPU controls not to output electrical signals according to the input information. The car pressing beam solenoid valve Y1 in the hydraulic system of the car tipper loses power, and the solenoid valve Y3 and the solenoid valve Y4 are energized. The car pressing beam fails and cannot perform the descending action. The fault simulated this time is the car pressing beam descending fault caused by the abnormality of the car pressing beam solenoid valve Y1. The fault code is defined as E1. A new database is created on the touch screen, and the data in the temporary database is imported into the fault database in the database for data update. The data fault model curve 1 is generated. This method can generate data fault model curves 2, 3, ...N. The data fault model curves 1…N are all curve sets, and each curve set includes multiple data fault model curves generated corresponding to multiple pressure measuring points under the current fault type. It can be imagined that the touch screen is a control panel mounted on the controller, and the established database includes: a temporary database and a fault database, etc. are all stored in the controller, and the controller is the CPU.

[0050] By manually controlling at least one hydraulic solenoid valve to be energized or de-energized, and obtaining the pressure data of each pressure measuring point in this state, the pressure data is matched with the corresponding hydraulic solenoid valve, the energization state of the hydraulic solenoid valve, and the corresponding fault type, thereby generating multiple data fault model curves. For example: Data fault model curve 1 contains the pressure data of each pressure measuring point, and the matching solenoid valve energization state is: the solenoid valve Y1 of the car pressing beam in the hydraulic system of the car tipper is de-energized, and the solenoid valve Y3 and the solenoid valve Y4 are energized. The recorded fault model includes the fault conditions of each device in the hydraulic system of the car tipper. For example, the fault model in the above example is: the car pressing beam fails and the descending action cannot be performed.

[0051] This solution uses an independent PLC controller for output control and pressure signal acquisition, which is independent of the production control system. The control circuits are powered by low-voltage 24VDC and will not affect other control systems.

[0052] Through the fault simulation function, the power-on and power-off states of various hydraulic solenoid valves can be simulated, thereby simulating various possible fault conditions, which helps to predict hydraulic faults before actual faults occur, improve the accuracy and reliability of fault diagnosis, and thus facilitate the subsequent judgment of fault points, reduce the possibility of misjudgment and misoperation, improve the efficiency of fault analysis and fault handling, and provide strong technical support for the safe and efficient operation of the tipping machine system; by matching pressure data with the power-on and power-off states of hydraulic solenoid valves and fault types, a complete fault database is established. This database not only contains known fault information, but can also be continuously updated and expanded in subsequent production to adapt to new fault conditions. The fault simulation function can simulate various fault conditions without actually damaging the equipment, thereby avoiding equipment damage and safety accidents caused by actual faults.

[0053] In this embodiment, the pressure data includes: pressure value P and pressure interval P', -0.05P≤P'≤+0.05P; in the above two modes, namely the fault simulation function and the linkage function, the hydraulic system fault detection device of the tipping machine will automatically record the pressure value P and the pressure interval P' and store them in the database during the operation of the hydraulic system equipment of the tipping machine, and finally intuitively display the pressure value and the pressure interval in the form of a pressure curve on the screen of the touch screen, that is, a pressure curve is generated by the pressure value of each pressure measuring point at each moment, and two pressure curves are generated by the pressure interval of each pressure measuring point at each moment. It can be imagined that the corresponding relationship between the pressure interval P' and the pressure value P can be adjusted to meet different production needs, which also makes the device more adaptable to complex and changeable production environments.

[0054] In the above scheme, by setting the pressure interval P', the system can more accurately determine whether the pressure value on the actual pressure data curve is within the normal range. When the pressure data of the corresponding point exceeds or approaches this interval, the system can predict potential faults or abnormal conditions, so as to take measures in advance to avoid equipment damage or production interruption; even if the pressure value fluctuates briefly due to some reasons, as long as it remains within the set interval, the hydraulic system can still operate normally and will not trigger unnecessary shutdowns or alarms due to misjudgment. This method also makes the system flexible. The pressure value P and pressure interval P' are displayed in the form of a pressure curve on the touch screen, so that the operator can intuitively understand the operating status of the system.

[0055] In this embodiment, the database contains the pressure data of each pressure measuring point collected in real time at any time within a production process cycle T; similarly, the actual pressure data curve, the normal pressure data model curve and the data fault model curve also contain the pressure data of each pressure measuring point at any time within the production process cycle T.

[0056] In this embodiment, the data fault model curve simulates the hydraulic system fault through the tipping machine hydraulic system fault detection device. Within a production process cycle T, the tipping machine hydraulic system fault detection device collects the pressure data of each pressure measuring point in each device in the hydraulic system in real time, and the collected continuous pressure value P and pressure interval P' are stored in the corresponding fault pressure database in the database. The fault pressure database includes the pressure value P and pressure interval P' at any time within the production process cycle T. The data fault model curve is also stored in the fault pressure database. The fault pressure database is the fault database.

[0057] In the above scheme, the real-time collected pressure data can immediately reflect the pressure status within a production process cycle T, helping operators to promptly discover whether there are any abnormal conditions within a production process cycle.

[0058] Step S2 comprises: S21: If the actual pressure data curve falls within the normal pressure data model curve, a first comparison result indicating that the hydraulic system of the car tipper operates normally is output.

[0059] Under different working conditions, the working pressure of each hydraulic component in the hydraulic system of the tipping machine hydraulic equipment will be different; before comparing the actual pressure data curve with the normal pressure data model curve, it is necessary to collect the pressure data of the hydraulic equipment in real time through the tipping machine hydraulic system fault detection device within a production process cycle T under the normal operation of the tipping machine hydraulic equipment, and store the collected continuous pressure value P and pressure interval P' in the normal pressure database in the database. The normal pressure database includes the pressure value and pressure interval value of each pressure measuring point at any time within the production process cycle T. The pressure value and pressure interval value in the normal pressure database can be intuitively displayed on the screen of the touch screen in the form of a pressure curve through the touch screen, that is, a normal pressure data model curve is generated by the pressure value of each pressure measuring point at each time, and two normal pressure data model curves are generated by the pressure interval of each pressure measuring point at each time. The two normal pressure data model curves generated by the pressure interval limit the upper and lower fluctuation range.

[0060] If the actual pressure data curve of each pressure measuring point falls within the normal pressure data model curve of the corresponding pressure measuring point generated by the pressure value and the pressure interval, it is determined that the hydraulic system of the dumper is operating normally.

[0061] S22: If the actual pressure data curve does not fall within the normal pressure data model curve, the first comparison result of the tipping machine hydraulic system alarm is output: when the actual pressure data curve of each pressure measuring point falls outside the normal pressure data model curve of the corresponding pressure measuring point, a fault alarm is issued, and the alarm information is displayed on the touch screen at the same time. On this basis, it is necessary to further judge the fault point, and the fault point of the hydraulic system is obtained through subsequent data comparison and analysis with the data fault model curve through online automatic diagnosis.

[0062] In the above scheme, when the actual pressure data curve exceeds the range of the normal pressure data model curve, the system can immediately issue an alarm to promptly alert the operator or maintenance personnel; by comparing with the normal pressure data model curve, the system can quickly identify pressure data anomalies, and timely fault warning and diagnosis can reduce equipment downtime and improve equipment operating efficiency.

[0063] Step S3 includes: S31: When the first comparison result is an output alarm, that is, when a fault exists, the actual pressure data curve is compared with multiple data fault model curves one by one. If the actual pressure data curve of each pressure measuring point falls into one of the data fault model curves (that is, the curve set), the second comparison result of the equipment fault of the corresponding fault type in the hydraulic system of the tipping machine is output, and the corresponding fault point is determined.

[0064] Taking the car pressing beam equipment in the hydraulic system of the tipping machine as an example, in this embodiment, the actual pressure data curves of each pressure measuring point generated by the real-time collection of pressure data of the hydraulic equipment by the fault detection device of the hydraulic system of the tipping machine are compared with the data fault model curves 1, 2, 3...N in sequence. If the actual pressure data curves of each pressure measuring point fall within the data fault model curve 1, it is determined that an E1 fault occurs in the hydraulic system of the tipping machine. The E1 fault is the fault code of the hydraulic system of the tipping machine, indicating that there is an abnormality in the hydraulic component Y1 of the hydraulic system of the tipping machine, and the hydraulic component Y1 needs to be repaired.

[0065] If the actual pressure data curve of each pressure measuring point does not fall within the data fault model curve 1, the tipper hydraulic system fault detection device collects the pressure data of the hydraulic equipment in real time and compares it with the data fault model curve 2. If the collected pressure data falls within the data fault model curve 2, it is determined that the tipper hydraulic system has an E2 fault. The E2 fault is the fault code of the tipper hydraulic system, indicating that the hydraulic element Y2 of the tipper hydraulic system is abnormal and needs to be repaired. If the collected pressure data does not fall within the data fault model curve 2, the judgment is made by analogy until the equipment fault point is determined.

[0066] S32: If the actual pressure data curve does not fall within all the data fault model curves, a second comparison result indicating that the current tipper hydraulic system has equipment hidden dangers rather than equipment failure is output and an alarm is given.

[0067] In the above example, if the fault point is still not determined after comparing the data fault model curve N, the tipper hydraulic system fault detection device determines that the current tipper hydraulic system has equipment hidden dangers rather than equipment failure, and an equipment alarm message is issued on the touch screen interface.

[0068] In the above scheme, by comparing with the data fault model curve, the fault type that matches the data fault model curve can be quickly identified, so as to quickly locate the fault point. Accurate fault location and fault type identification can guide maintenance personnel to take corresponding measures quickly and improve maintenance efficiency, thereby reducing equipment downtime and improving production efficiency and equipment utilization. Preventive maintenance is achieved through the identification of equipment hidden dangers. Maintenance personnel can take preventive maintenance measures to avoid the occurrence of faults, providing strong technical support for the safe and efficient operation of the tipping machine system.

[0069] Furthermore, the actual pressure data curve of each of the above-mentioned pressure measuring points is stored as historical data as a historical pressure curve. When there is an equipment hidden danger in the hydraulic system of the dumper, the changing trend of the historical pressure curve and the changing trend of the data fault model are obtained or calculated, and the changing trend of the historical pressure curve is compared with the data fault model curve. The changing trend of the historical pressure curve and the data fault model curve is determined by judging the slope of the curve. When the slope or trend of a certain node of the historical pressure curve is inconsistent with the data fault model curve, it is determined that there is an equipment hidden danger at a certain pressure measuring point, and equipment failure may occur in the future, so preventive maintenance is performed on the pressure measuring point.

[0070] In the above scheme, by comparing the historical pressure curve with the data failure model curve, potential hidden dangers can be identified before the equipment failure actually occurs, which allows maintenance personnel to intervene in advance and implement preventive maintenance measures, thereby avoiding production interruptions and potential safety risks caused by sudden equipment shutdown; preventive maintenance can ensure that the equipment operates in the best condition, reduce production delays and product quality problems caused by equipment failure, and help improve the overall reliability and production efficiency of the equipment; compared with emergency repairs after equipment failure, preventive maintenance is usually less expensive, and by promptly discovering and solving potential problems, more expensive repair and replacement costs can be avoided.

[0071] Based on the same technical concept, the present application also provides an electronic device, such as Figure 3As shown, the electronic device 300 includes a processor 301 and a memory 302 , and may further include an information input / information output (I / O) interface 303 , one or more of a communication component 304 , and a communication bus 305 .

[0072] The processor 301 is used to control the overall operation of the electronic device 300 to complete all or part of the steps in the above-mentioned tipper hydraulic system fault detection method; the memory 302 is used to store various types of data to support the operation of the electronic device 300, and these data may include, for example, instructions for any application or method used to operate on the electronic device 300, and data related to the application. The memory 302 can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (Static Random Access Memory, SRAM), electrically erasable programmable read-only memory (Electrically Erasable Programmable Read-Only Memory, EEPROM), erasable programmable read-only memory (Erasable Programmable Read-Only Memory, EPROM), programmable read-only memory (Programmable Read-Only Memory, PROM), read-only memory (Read-Only Memory, ROM), magnetic memory, flash memory, magnetic disk or optical disk.

[0073] The I / O interface 303 provides an interface between the processor 301 and other interface modules, and the above-mentioned other interface modules can be keyboards, mice, buttons, etc. These buttons can be virtual buttons or physical buttons. The communication component 304 is used to test the wired or wireless communication between the electronic device 300 and other devices. Wireless communication, such as Wi-Fi, Bluetooth, Near Field Communication (NFC), 2G, 3G or 4G, or a combination of one or more of them, so the corresponding communication component 304 can include: Wi-Fi components, Bluetooth components, NFC components.

[0074] The communication bus 305 may include a path to transmit information between the above components. The communication bus 305 may be a PCI (Peripheral Component Interconnect) bus or an EISA (Extended Industry Standard Architecture) bus, etc. The communication bus 305 may be divided into an address bus, a data bus, a control bus, etc.

[0075] The electronic device 300 can be implemented by one or more application specific integrated circuits (ASIC), digital signal processors (DSP), digital signal processing devices (DSPD), programmable logic devices (PLD), field programmable gate arrays (FPGA), controllers, microcontrollers, microprocessors or other electronic components to execute the multi-vehicle collaborative decision-making method based on the game tree given in the above embodiment.

[0076] The electronic device 300 may include, but is not limited to, a mobile terminal such as a digital broadcast receiver, a PDA (Personal Digital Assistant), a PMP (Portable Multimedia Player), etc., and a fixed terminal such as a digital TV, a desktop computer, etc., and may also be a server, etc.

[0077] The present application also provides a computer-readable storage medium, on which a computer program is stored. When the computer program is executed by a processor, the steps of the above-mentioned tipper hydraulic system fault detection method are implemented.

[0078] The computer-readable storage medium may include: a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk, and other media that can store program codes.

[0079] The terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not expressly listed, or also includes elements inherent to such process, method, article, or apparatus.

[0080] The above description is only a preferred embodiment of the present application and an explanation of the technical principles used. Those skilled in the art should understand that the scope of application involved in the present application is not limited to the technical solution formed by a specific combination of the above technical features, but should also cover other technical solutions formed by any combination of the above technical features or their equivalent features without departing from the aforementioned application concept. For example, the above features are replaced with (but not limited to) technical features with similar functions applied in the present application.

Claims

1. A method for detecting faults in a hydraulic system of a dumper, characterized in that: The method comprises: Acquire pressure data of each pressure measuring point during operation, and generate actual pressure data curves corresponding to each pressure measuring point based on the pressure data; Comparing the actual pressure data curve with a preset normal pressure data model curve, outputting a first comparison result, and determining whether there is a fault according to the first comparison result; When a fault occurs, the actual pressure data curve is compared with a preset data fault model curve, a second comparison result is output, and the fault point is determined according to the second comparison result; The data fault model curves are a plurality of curves generated according to the pressure data of each of the pressure measuring points when at least one of the pressure measuring points fails.

2. A method for detecting faults in a hydraulic system of a dumper according to claim 1, characterized in that: The normal pressure data model curve is generated based on the pressure data of each of the pressure measuring points during normal operation.

3. A method for detecting faults in a hydraulic system of a dumper according to claim 1, characterized in that: A pressure measuring point is set at the position corresponding to each hydraulic solenoid valve in the hydraulic system.

4. A method for detecting faults in a hydraulic system of a dumper according to claim 3, characterized in that: The data fault model curves are multiple curves stored in the fault pressure data model. The generation process of the data fault model curves includes: Obtain the pressure data of each of the pressure measuring points when at least one of the hydraulic solenoid valves is powered on or off, the pressure data comprising: a pressure value P and a pressure interval P', -0.05P≤P'≤+0.05P; The pressure data is matched with the corresponding hydraulic solenoid valve, the power-on and power-off states of the hydraulic solenoid valve and the corresponding fault types to generate a plurality of data fault model curves, wherein the fault types include the fault conditions of various devices in the hydraulic system of the dumper.

5. A method for detecting faults in a hydraulic system of a dumper according to claim 4, characterized in that: The actual pressure data curve, the normal pressure data model curve and the data fault model curve all include the pressure value P and the pressure range P' of each pressure measuring point at any time within the production process cycle T.

6. A method for detecting faults in a hydraulic system of a dumper according to claim 4, characterized in that: The comparing the actual pressure data curve with a preset normal pressure data model curve, outputting a first comparison result, and determining whether there is a fault according to the first comparison result, includes: If the actual pressure data curve falls within the normal pressure data model curve, outputting the first comparison result indicating that the hydraulic system of the dumper operates normally; If the actual pressure data curve does not fall within the normal pressure data model curve, the first comparison result of the tipper hydraulic system alarm is output.

7. A method for detecting faults in a hydraulic system of a dumper according to claim 6, characterized in that: When a fault occurs, the actual pressure data curve is compared with a preset data fault model curve, a second comparison result is output, and the fault point is determined according to the second comparison result, including: When the first comparison result is an output alarm, the actual pressure data curve is compared with the plurality of data fault model curves one by one. If the actual pressure data curve falls within one of the data fault model curves, the second comparison result indicating that the hydraulic system of the dumper has an equipment fault corresponding to the fault type is output, and the corresponding fault point is determined; If the actual pressure data curve does not fall within all the data fault model curves, the second comparison result indicating that the current hydraulic system of the dumper has equipment hidden dangers rather than equipment failure is output and an alarm is given.

8. A method for detecting faults in a hydraulic system of a dumper according to claim 7, characterized in that: When there is a hidden danger in the hydraulic system of the dumper, obtaining a change trend of the actual pressure data curve and a change trend of the data fault model curve; The changing trend of the actual pressure data curve is compared with the changing trend of the data fault model curve. When the changing trend of the actual pressure data curve is inconsistent with the changing trend of the data fault model curve, it is predicted that there is an equipment hidden danger at the corresponding pressure measuring point.

9. An electronic device, characterized in that: comprising a processor coupled to a memory; The processor is used to execute the computer program stored in the memory, so that the electronic device executes the method according to any one of claims 1 to 8.

10. A computer-readable storage medium, characterized in that: The method comprises a computer program or an instruction, which, when executed on a computer, causes the computer to execute the method according to any one of claims 1 to 8.

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