Steel scrap metal material hydraulic packaging equipment control system and method

Abstract

The invention discloses a steel scrap metal material hydraulic packaging equipment control system and method, and particularly relates to the technical field of equipment control. Hydraulic oil pollution data and pressure change data are collected in real time and analyzed, a hydraulic system pressure output comprehensive stability value is generated, a pressure output state is divided into a stability output state and an instability output state according to the comprehensive stability value, and compression force and running speed are dynamically adjusted through trend analysis, so that the stability of the hydraulic system pressure output is improved. Therefore, the operation parameters of the hydraulic system are optimized; under an unstable output state, the influence of a large-load task on the system is reduced by redistributing a compression task and preferentially processing a small-size metal piece, so that the problems of aggravated wear, reduced operation efficiency, equipment damage and the like caused by pollution and unstable pressure in the existing hydraulic system are effectively solved; and the stability and the control precision of a hydraulic system and the overall safety of equipment are remarkably improved.

Description

Technical Field

[0001] The present invention relates to the technical field of equipment control, and in particular to a control system and method for hydraulic packaging equipment of scrap steel and metal materials. Background Art

[0002] Scrap metal hydraulic baling equipment is a kind of equipment specially used for processing scrap metal materials. It compresses scrap steel, scrap iron and other metal materials into dense metal blocks that are convenient for transportation, storage and recycling by applying high pressure through the hydraulic system. Its control system usually adopts automation technology to accurately adjust the hydraulic pressure, baling speed and equipment operation mode to ensure the compression process is efficient and safe, while reducing energy consumption and equipment loss.

[0003] In automobile manufacturing, the steel parts after the dismantling of scrap car bodies will generate a large amount of metal waste. Scrap steel hydraulic baling equipment can compress these scattered scrap steel materials (such as scrap car doors and frames) into high-density metal blocks for transportation to steel mills for smelting and reuse. For example, in automobile dismantling plants, dismantled scrap car shells are quickly packaged through an automated compression process controlled by equipment, reducing storage space and improving transportation efficiency, thereby significantly reducing the processing cost of recycled metals.

[0004] The prior art has the following deficiencies: Rust, sand or hard metal impurities in the shells of scrap cars may enter the hydraulic system or transmission components during the compression process, directly causing damage to the equipment. Impurities entering the hydraulic pump or hydraulic cylinder will aggravate the wear of internal components and weaken the pressure output performance of the hydraulic system; the sliding parts may be stuck due to impurities, which may cause stagnation of operation or abnormal stress accumulation, further accelerating equipment damage. In addition, unstable pressure output of the hydraulic system will directly cause the control system to lose the ability to accurately adjust the compression process, thereby affecting the operation effect of the equipment. When the pressure is insufficient, the scrap metal cannot be effectively compressed, resulting in substandard density of the finished product, increasing the difficulty of transportation and subsequent processing; when the pressure is overloaded, it may cause serious damage to the equipment structure and even cause deformation or cracking of the compression chamber. This unstable hydraulic state makes it difficult for the control system to accurately execute the compression program, undermining the overall efficiency and safety of the equipment operation. Summary of the invention

[0005] The purpose of the present invention is to provide a control system and method for hydraulic packaging equipment of scrap steel and metal materials to solve the shortcomings of the background technology.

[0006] In order to achieve the above object, the present invention provides the following technical solution: a control method for hydraulic packaging equipment of scrap steel and metal materials, comprising the following steps: S1: Install online oil monitoring sensors at the hydraulic pump outlet and hydraulic cylinder inlet of the hydraulic circuit to detect the number of pollutant particles and water content in the hydraulic oil in real time and generate hydraulic oil contamination data, and install high-frequency pressure sensors in the hydraulic circuit to collect real-time pressure change data during the compression cycle; S2: Analyze the collected hydraulic oil contamination data and pressure change data, determine the weighted values ​​of the hydraulic system pressure output stability in different time periods, and perform weighted average calculation on the weighted values ​​of the hydraulic system pressure output stability in different time periods to obtain the comprehensive stability value of the hydraulic system pressure output; S3: according to the calculated comprehensive stability value of the pressure output of the hydraulic system, dividing the pressure output state of the hydraulic system into a stable output state and an unstable output state; S4: judging the change trend of the pressure stability output state of the hydraulic system, if the comprehensive stability value of the pressure output shows an upward trend, gradually increasing the compression force and running speed of the hydraulic system, if the comprehensive stability value of the pressure output shows a downward trend, reducing the compression force and extending the compression cycle; S5: For unstable output states, reallocate compression tasks; for long-term unstable states, reduce large-load compression tasks and give priority to small-volume metal parts.

[0007] Preferably, in S2, after analyzing the particle concentration increment feature in the extracted hydraulic oil pollution data, a particle concentration increment abnormal value is generated, and the method for obtaining the particle concentration increment abnormal value is: Collect the incremental data of particle concentration to form an ordered data set: ;in, represents the nth particle concentration increment value, n is the total number of data points, and the data set X is sorted in ascending order to obtain a new ordered set X′: ; Calculate the quartiles, which are divided into the lower quartile Q1, the median Q2, and the upper quartile Q3; Q1 is the 25th position value in the sorted data set, indicating the part of the data that is less than or equal to Q1, Q3 is the 75th position value in the sorted data set, indicating the part of the data that is greater than or equal to Q3, and Q2 is the middle position value of the sorted data, indicating the 50th position; Calculate the interquartile range IQR, the interquartile range represents the range of the middle 50% of the data set, and the calculation formula is: IQR=Q3−Q1; Calculate the upper and lower boundaries of the outliers of the data through the interquartile range: upper boundary UB: ; Lower boundary LB: ; Judge each particle concentration increment value in the data set, collect the particle concentration increment values ​​greater than the upper boundary and the particle concentration increment values ​​less than the lower boundary, and calculate the standard deviation of all collected particle concentration increment values ​​as the particle concentration increment abnormal value.

[0008] Preferably, in S2, the pressure fluctuation amplitude characteristics in the extracted pressure change data are analyzed to generate a pressure fluctuation amplitude change value, and the pressure fluctuation amplitude change value is obtained by: Set the pressure fluctuation amplitude data set to ;in, is the pressure fluctuation amplitude value at the tth moment, t is the current moment, select a smoothing coefficient e, and calculate the exponentially weighted moving average of the pressure fluctuation amplitude data. The expression is: ; is the exponentially weighted moving average at the current time t, is the actual pressure fluctuation amplitude at the current moment, is the exponentially weighted moving average of the previous moment, and the pressure fluctuation amplitude change value is calculated. The expression is: ; Where SCX is the change in pressure fluctuation amplitude.

[0009] Preferably, the abnormal values ​​of the incremental particle concentration and the pressure fluctuation amplitude change values ​​are normalized, and the weighted values ​​of the stability of the hydraulic system pressure output in different time periods are calculated based on the normalized abnormal values ​​of the incremental particle concentration and the pressure fluctuation amplitude change values. After weighted averaging the weighted values ​​of the stability of the hydraulic system pressure output in different time periods, the comprehensive stability value of the pressure output of the hydraulic system is obtained.

[0010] Preferably, in S3, the pressure output state of the hydraulic system is divided into a stable output state and an unstable output state according to the calculated comprehensive stability value of the pressure output of the hydraulic system; The calculated comprehensive stability value of the hydraulic system's pressure output is compared with the stability reference threshold value pre-set based on historical data. If the comprehensive stability value of the hydraulic system's pressure output is less than the stability reference threshold value, it means that the comprehensive stability of the hydraulic system's pressure output is low. At this time, a warning signal is generated, and the pressure output state of the hydraulic system is classified as an unstable output state; if the comprehensive stability value of the hydraulic system's pressure output is greater than or equal to the stability reference threshold value, it means that the comprehensive stability of the hydraulic system's pressure output is high. At this time, no warning signal is generated, and the pressure output state of the hydraulic system is classified as a stable output state.

[0011] Preferably, in S4, the change trend of the pressure stability output state of the hydraulic system is judged, specifically: For the stability output state, that is, the comprehensive stability value of the pressure output of the hydraulic system generated within a fixed time period is greater than or equal to the stability reference threshold, the comprehensive stability values ​​of the pressure output generated within the subsequent fixed time period that are greater than or equal to the stability reference threshold are collected, and a data set is established. The mean and standard deviation of the data set are calculated. After analyzing them, the changing trend of the pressure stability output state of the hydraulic system is judged.

[0012] Preferably, if the mean value of the pressure output comprehensive stability value in the data set is greater than or equal to the reference threshold value of the pressure output comprehensive stability value, and the standard deviation of the pressure output comprehensive stability value is less than the reference threshold value of the pressure output comprehensive stability value standard deviation, it means that the hydraulic system has good stability and small fluctuation, and the operating state is optimal. At this time, the compression force and operating speed of the hydraulic system should be gradually increased; If the mean value of the comprehensive stability value of the pressure output is greater than or equal to the reference threshold value of the mean value of the comprehensive stability value of the pressure output, and the standard deviation of the comprehensive stability value of the pressure output is greater than or equal to the reference threshold value of the standard deviation of the comprehensive stability value of the pressure output, it means that the overall stability of the hydraulic system is good, but the fluctuation is large. At this time, do not increase the operating parameters temporarily, check whether there is any abnormal fluctuation in the hydraulic system, and then increase the compression force and operating speed after optimizing the stability of the hydraulic system; If the mean value of the pressure output comprehensive stability value is less than the reference threshold value of the pressure output comprehensive stability value, and the standard deviation of the pressure output comprehensive stability value is greater than or equal to the reference threshold value of the pressure output comprehensive stability value standard deviation, it means that the overall stability of the hydraulic system is poor and the fluctuation is significant. At this time, the compression force should be reduced, the compression cycle should be extended, and the hydraulic system diagnosis and maintenance should be carried out immediately; If the mean value of the comprehensive stability value of the pressure output is less than the reference threshold value of the mean value of the comprehensive stability value of the pressure output, and the standard deviation of the comprehensive stability value of the pressure output is less than the reference threshold value of the standard deviation of the comprehensive stability value of the pressure output, it means that the overall stability of the hydraulic system is poor but the fluctuation is small, indicating that the state of the hydraulic system tends to be stable. At this time, the operation should be maintained under the existing compression force and compression cycle conditions.

[0013] The present invention also provides a control system for hydraulic packaging equipment for scrap steel metal materials, including a data acquisition module, a pressure stability analysis module, a pressure output state classification module, a dynamic adjustment module and a task management module; Data acquisition module: online oil monitoring sensors are installed at the hydraulic pump outlet and hydraulic cylinder inlet of the hydraulic circuit to detect the number of pollutant particles and water content in the hydraulic oil in real time and generate hydraulic oil pollution data; high-frequency pressure sensors are installed in the hydraulic circuit to collect real-time pressure change data during the compression cycle; Pressure stability analysis module: Analyze the collected hydraulic oil contamination data and pressure change data, determine the weighted values ​​of the hydraulic system pressure output stability in different time periods, and perform weighted average calculation on the weighted values ​​of the hydraulic system pressure output stability in different time periods to obtain the comprehensive stability value of the hydraulic system pressure output; Pressure output state classification module: according to the calculated comprehensive stability value of the pressure output of the hydraulic system, the pressure output state of the hydraulic system is divided into a stable output state and an unstable output state; Dynamic adjustment module: judge the changing trend of the pressure stability output state of the hydraulic system. If the comprehensive stability value of the pressure output shows an upward trend, the compression force and running speed of the hydraulic system are gradually increased. If the comprehensive stability value of the pressure output shows a downward trend, the compression force is reduced and the compression cycle is extended. Task management module: For unstable output states, reallocate compression tasks; for long-term unstable states, reduce large-load compression tasks and give priority to small-volume metal parts.

[0014] In the above technical solution, the technical effects and advantages provided by the present invention are: 1. The present invention realizes an accurate assessment of the comprehensive stability of the hydraulic system pressure output by real-time monitoring of the contamination level of the hydraulic oil and the pressure fluctuation characteristics of the hydraulic system, combined with the normalized analysis of the abnormal value of the particle concentration increment and the pressure fluctuation amplitude change value. Based on the comprehensive stability value, the pressure output state of the hydraulic system is dynamically divided, and the operating parameters are optimized through trend analysis, which effectively improves the operating efficiency and control accuracy of the hydraulic system. In addition, the compression tasks are redistributed in an unstable state, small load tasks are processed first, the system load is reduced, and potential faults are diagnosed in a timely manner to ensure the safe operation of the equipment.

[0015] 2. The present invention effectively solves the problem of unstable hydraulic system performance caused by pollution and pressure fluctuations in the prior art, and significantly improves the reliability, life and work efficiency of the equipment. Through scientific task scheduling and dynamic parameter optimization, the present invention not only reduces the losses caused by downtime due to failures, but also further improves the consistency of the compressed density of the finished product, providing an important guarantee for the efficient and safe operation of the hydraulic baling equipment for scrap steel and metal materials in practical applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0017] Figure 1The figure is a flow chart of the method of the present invention.

[0018] Figure 2 It is a system module diagram of the present invention. DETAILED DESCRIPTION

[0019] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] Example 1, please refer to Figure 1 As shown, the control method of the hydraulic packaging equipment for scrap steel and metal materials described in this embodiment includes the following steps: S1: Install online oil monitoring sensors at the hydraulic pump outlet and hydraulic cylinder inlet of the hydraulic circuit to detect the number of pollutant particles and water content in the hydraulic oil in real time and generate hydraulic oil contamination data, and install high-frequency pressure sensors in the hydraulic circuit to collect real-time pressure change data during the compression cycle; S2: Analyze the collected hydraulic oil contamination data and pressure change data, determine the weighted values ​​of the hydraulic system pressure output stability in different time periods, and perform weighted average calculation on the weighted values ​​of the hydraulic system pressure output stability in different time periods to obtain the comprehensive stability value of the hydraulic system pressure output; S3: according to the calculated comprehensive stability value of the pressure output of the hydraulic system, dividing the pressure output state of the hydraulic system into a stable output state and an unstable output state; S4: judging the change trend of the pressure stability output state of the hydraulic system, if the comprehensive stability value of the pressure output shows an upward trend, gradually increasing the compression force and running speed of the hydraulic system, if the comprehensive stability value of the pressure output shows a downward trend, reducing the compression force and extending the compression cycle; S5: For unstable output states, reallocate compression tasks; for long-term unstable states, reduce large-load compression tasks and give priority to small-volume metal parts.

[0021] In S1, online oil monitoring sensors are installed at the hydraulic pump outlet and hydraulic cylinder inlet respectively to ensure that the contamination status data of the hydraulic oil can be collected during the entire process from the pump to the actuator.

[0022] Hydraulic pump outlet: monitor the change in particle concentration of hydraulic oil after pressurization to determine whether there is secondary pollution caused by pump body wear. Hydraulic cylinder inlet: monitor the quality of hydraulic oil entering the hydraulic cylinder, evaluate the purification effect of the filter and the environmental pollution impact of the hydraulic cylinder operation.

[0023] Laser scattering technology or light obstruction method is used to detect the number and size distribution of particles in hydraulic oil, and the pollution index is generated according to ISO4406 standard. Capacitive or infrared absorption sensors are used to detect the content of free water and dissolved water in hydraulic oil, and the results are expressed in percentage (ppm).

[0024] Collect the particle concentration and water content of hydraulic oil in real time to generate hydraulic oil contamination data stream. Transmit data to the data processing module in the control system through Modbus, CAN bus or Ethernet interface. Install high-frequency pressure sensors at key locations in the hydraulic circuit: Hydraulic pump outlet: monitor the output pressure changes of the hydraulic pump and identify the fluctuation of pump performance. Compression cylinder inlet: monitor the pressure fluctuations during the compression action and capture the transient characteristics during the compression process.

[0025] Using piezoresistive or thin-film pressure sensors, a sampling rate of 1kHz or higher can be achieved to capture transient pressure changes, including peak pressure, pressure drop, and oscillation amplitude. The sensor response time is less than 1 millisecond, which can accurately record the dynamic pressure characteristics of the hydraulic system, such as rapidly changing pressure peaks and fluctuation frequencies.

[0026] Collect the complete pressure change curve within a single compression cycle, including the maximum pressure, minimum pressure and fluctuation amplitude. Output the original pressure data or pre-processed statistical features (such as standard deviation, peak position, etc.) to the control system.

[0027] The data acquisition modules of online oil monitoring sensors and high-frequency pressure sensors are connected to the control system through industrial communication protocols. Independent power supply and signal isolation devices are provided for the sensors to ensure the stability and anti-interference ability of data transmission.

[0028] Verify the measurement accuracy and response speed of the sensor to ensure that the data is consistent with the actual hydraulic system status. According to the hydraulic system design requirements, set initial thresholds for oil contamination index and pressure fluctuations to facilitate rapid response to abnormal conditions.

[0029] Online oil monitoring sensors provide pollution index data, including the number of particles (ISO4406 grade) and water content (ppm). High-frequency pressure sensors provide pressure change curves during the compression cycle, including maximum pressure, minimum pressure and transient fluctuation amplitude. Real-time data is transmitted to the control system through the industrial communication network for storage, forming a historical data log, which provides a basis for subsequent analysis and fault diagnosis.

[0030] In this application, by installing online oil monitoring sensors at the outlet of the hydraulic pump and the inlet of the hydraulic cylinder, and installing high-frequency pressure sensors in the hydraulic circuit, the hydraulic oil contamination status and pressure fluctuation characteristics can be detected in real time. These data provide key support for the evaluation of the stability of the hydraulic system pressure output, and lay a data foundation for the dynamic adjustment of equipment operating parameters.

[0031] S2: Analyze the collected hydraulic oil contamination data and pressure change data, determine the weighted values ​​of the hydraulic system pressure output stability in different time periods, and perform weighted average calculation on the weighted values ​​of the hydraulic system pressure output stability in different time periods to obtain the comprehensive stability value of the hydraulic system pressure output.

[0032] The time periods are divided according to the operating cycle of the hydraulic equipment, so that the hydraulic oil contamination data and pressure change data collected in each time period can be analyzed one by one. The time periods include: Start-up phase: When the equipment starts to run, the hydraulic system starts, the pressure fluctuates greatly, and the weight can be appropriately reduced.

[0033] Stable operation stage: The equipment enters normal working state, and the hydraulic system pressure output tends to be stable. The data in this stage has a higher weight for stability assessment.

[0034] Stop phase: During the equipment shutdown process, the hydraulic system gradually reduces the pressure. The pressure fluctuation is large but less important, so the weight can be appropriately reduced.

[0035] Preprocess and extract features of hydraulic oil contamination data. Preprocessing includes: using filtering algorithms (such as low-pass filtering or median filtering) to remove random noise during the acquisition process to ensure data smoothness. Using statistical methods (such as the 3-times standard deviation method) to eliminate outliers, such as extreme data points caused by sensor failure or environmental interference. Standardize the hydraulic oil contamination index (ISO4406 grade) and moisture content (ppm) to a unified dimension to facilitate subsequent comprehensive analysis.

[0036] Feature extraction includes: Particle concentration feature: Average particle concentration: The average value of the number of particles in the hydraulic oil, reflecting the overall pollution level of the system. Particle concentration increment: The change in the number of particles in a specific time period, characterizing the dynamic trend of system pollution. Moisture content feature: Average moisture content: The average content of dissolved water and free water in the hydraulic oil, used to evaluate the lubrication performance and oxidation resistance of the hydraulic oil. Moisture change rate: The rate of change of moisture content in a specific time period, reflecting whether there is an environmental leak or sealing problem in the hydraulic system.

[0037] Preprocess and extract features of pressure change data. Preprocessing includes: using wavelet transform or Kalman filtering to remove high-frequency noise from pressure curve data collected by high-frequency pressure sensors. Using interpolation algorithms to complete lost data points caused by sensor response delays or communication interruptions during data collection. According to the operating cycle of the hydraulic equipment, the pressure change data is divided into multiple compression cycles to ensure that feature extraction is based on the complete compression process.

[0038] Feature extraction includes: Static pressure features: Maximum pressure value: peak pressure within a single compression cycle, reflecting the compression capacity of the equipment. Minimum pressure value: the lowest pressure within the compression cycle, evaluating the effectiveness of the hydraulic system pressure relief. Dynamic pressure features: Pressure fluctuation amplitude: the maximum pressure difference within a single compression cycle, reflecting the stability of the pressure output. Pressure fluctuation frequency: the number of pressure oscillations per unit time, used to evaluate the dynamic response performance of the system. Time features: Pressure peak position: the time position of the pressure peak in the pressure curve, indicating the delay characteristics of the pressure output. Pressure change rate: the average rate of pressure change per unit time, indicating the pressure adjustment ability of the hydraulic system.

[0039] The hydraulic oil contamination data and pressure change data are synchronized in time to ensure that the feature extraction is based on the system status of the same period. The interpolation method is used to align the data with different sampling frequencies to form a unified feature data set.

[0040] After analyzing the particle concentration increment characteristics in the extracted hydraulic oil pollution data, the particle concentration increment abnormal value is generated. The method for obtaining the particle concentration increment abnormal value is as follows: Collect the incremental data of particle concentration to form an ordered data set: ;in, represents the nth particle concentration increment value, n is the total number of data points, and the data set X is sorted in ascending order to obtain a new ordered set X′: ; Calculate the quartiles, which are divided into the lower quartile Q1, the median Q2, and the upper quartile Q3; Q1 is the 25% position value in the sorted data set, indicating the part of the data that is less than or equal to Q1. If n is an odd number, the calculation formula is: ; If n is an even number, it is calculated by two-point interpolation: ; Q3 is the 75% position value in the sorted data set, indicating the portion of the data that is greater than or equal to Q3. The calculation formula is: or ; Q2 is the middle position value of the sorted data, indicating the 50% position: odd number: ;even: ; Calculate the interquartile range (IQR). The IQR represents the range of the middle 50% of the data set, and the calculation formula is: IQR = Q3 - Q1. Calculate the upper and lower bounds of the outliers in the data through the IQR: Upper bound UB: ; Lower bound LB: ; Judge each particulate matter concentration increment value in the data set, collect the particulate matter concentration increment values greater than the upper bound and those less than the lower bound, and calculate the standard deviation of all the collected particulate matter concentration increment values as the outlier of the particulate matter concentration increment.

[0041] The larger the outlier of the particulate matter concentration increment, the more剧烈 the change in the particulate matter concentration in the hydraulic oil, indicating that the pollution situation of the hydraulic system has deteriorated rapidly. This situation usually indicates that there may be serious wear inside the hydraulic system or external environmental pollution sources entering the system. For example, the friction of key components such as hydraulic pumps and hydraulic cylinders increases due to particulate matter, which increases the pressure fluctuation amplitude of the system, significantly reduces the stability of pressure output, and进而 affects the operation efficiency and safety of the equipment.

[0042] On the contrary, the smaller the outlier of the particulate matter concentration increment, the gentler the change in the particulate matter concentration in the hydraulic oil, the more stable the system pollution situation, indicating that the hydraulic system is in a better operating state and the wear degree of key components is controllable. In this case, the pressure output of the hydraulic system is more stable, and the pressure fluctuation amplitude is smaller, which is conducive to the precise control and efficient operation of the equipment, and reduces the risk of equipment damage or operation interruption caused by unstable pressure.

[0043] After analyzing the pressure fluctuation amplitude characteristics in the extracted pressure change data, generate the pressure fluctuation amplitude change value. The method for obtaining the pressure fluctuation amplitude change value is as follows: Set the pressure fluctuation amplitude data set as ; where is the pressure fluctuation amplitude value at the t-th moment, and t is the current moment. Select a smoothing coefficient e (0 < e ≤ 1): A larger e: Pays more attention to the recent data and is suitable for quickly responding to short-term changes. A smaller e: Pays more attention to historical data and is suitable for smoothing long-term trends.

[0044] Calculate the exponentially weighted moving average of the pressure fluctuation amplitude data. The expression is: ; is the exponentially weighted moving average at the current moment t, is the actual pressure fluctuation amplitude value at the current moment, is the exponentially weighted moving average at the previous moment (the initial value is or the historical mean). Calculate the pressure fluctuation amplitude change value. The expression is: ; In the formula, SCX is the pressure fluctuation amplitude change value.

[0045] The greater the change in the pressure fluctuation amplitude, the worse the stability of the hydraulic system's pressure output. This is because drastic changes in the fluctuation amplitude usually reflect the dynamic instability of the hydraulic system, which may be caused by abnormal hydraulic pump output, pipeline blockage, component aging or external interference. This instability makes it difficult for the system to maintain pressure uniformity, thereby affecting the precise control and safe operation of the equipment, and may eventually cause equipment failure and other problems.

[0046] The smaller the pressure fluctuation amplitude change value, the higher the pressure output stability of the hydraulic system. Smaller change values ​​mean that the system's pressure fluctuation amplitude is within the normal range, the dynamic adjustment ability is good, and the components work together stably. In this way, the hydraulic system can continuously output stable pressure, ensuring high equipment operation efficiency and stable product quality, while reducing the risk of abnormal wear and failure, helping to extend the service life of the system.

[0047] The abnormal values ​​of the particle matter concentration increment and the pressure fluctuation amplitude change values ​​are normalized, and the weighted values ​​of the stability of the hydraulic system pressure output in different time periods are calculated by the normalized abnormal values ​​of the particle matter concentration increment and the pressure fluctuation amplitude change values. After weighted average calculation of the weighted values ​​of the stability of the hydraulic system pressure output in different time periods, the comprehensive stability value of the pressure output of the hydraulic system is obtained.

[0048] For example, the present invention may use the following formula to calculate the weight assignment of the hydraulic system pressure output stability in different time periods, and the calculation expression is: ; In the formula, is the weight assignment of the hydraulic system pressure output stability in different time periods, XCV is the abnormal value of the particle concentration increment, SCX is the pressure fluctuation amplitude change value, is the proportional coefficient of the abnormal value of the particle concentration increment and the pressure fluctuation amplitude change value, and .

[0049] S3: According to the calculated comprehensive stability value of the pressure output of the hydraulic system, the pressure output state of the hydraulic system is divided into a stable output state and an unstable output state.

[0050] The calculated comprehensive stability value of the hydraulic system's pressure output is compared with the stability reference threshold value pre-set based on historical data. If the comprehensive stability value of the hydraulic system's pressure output is less than the stability reference threshold value, it means that the comprehensive stability of the hydraulic system's pressure output is low. At this time, a warning signal is generated, and the pressure output state of the hydraulic system is classified as an unstable output state; if the comprehensive stability value of the hydraulic system's pressure output is greater than or equal to the stability reference threshold value, it means that the comprehensive stability of the hydraulic system's pressure output is high. At this time, no warning signal is generated, and the pressure output state of the hydraulic system is classified as a stable output state.

[0051] S4: judging the change trend of the pressure stability output state of the hydraulic system, if the comprehensive stability value of the pressure output shows an upward trend, gradually increasing the compression force and running speed of the hydraulic system, if the comprehensive stability value of the pressure output shows a downward trend, reducing the compression force and extending the compression cycle; For the stability output state, that is, the comprehensive stability value of the pressure output of the hydraulic system generated within a fixed time period is greater than or equal to the stability reference threshold, the comprehensive stability values ​​of the pressure output generated within the subsequent fixed time period that are greater than or equal to the stability reference threshold are collected, and a data set is established. The mean and standard deviation of the data set are calculated. After analyzing them, the changing trend of the pressure stability output state of the hydraulic system is judged.

[0052] If the mean value of the comprehensive stability value of pressure output in the data set is greater than or equal to the reference threshold value of the mean value of the comprehensive stability value of pressure output, and the standard deviation of the comprehensive stability value of pressure output is less than the reference threshold value of the standard deviation of the comprehensive stability value of pressure output, it means that the hydraulic system has good stability and small fluctuation, and the operating state is optimal. At this time, the compression force and operating speed of the hydraulic system should be gradually increased to further improve production efficiency.

[0053] If the mean value of the pressure output comprehensive stability value is greater than or equal to the reference threshold value of the pressure output comprehensive stability value, and the standard deviation of the pressure output comprehensive stability value is greater than or equal to the reference threshold value of the pressure output comprehensive stability value standard deviation, it means that the overall stability of the hydraulic system is good, but the fluctuation is large, which may be disturbed by the external environment or the instability of internal components. At this time, do not increase the operating parameters, check whether there is any abnormal fluctuation reason in the hydraulic system (such as external environment interference or hydraulic oil quality problems), and consider increasing the compression force and operating speed after optimizing the system stability.

[0054] If the mean value of the pressure output comprehensive stability value is less than the reference threshold value of the pressure output comprehensive stability value, and the standard deviation of the pressure output comprehensive stability value is greater than or equal to the reference threshold value of the pressure output comprehensive stability value standard deviation, it means that the overall stability of the hydraulic system is poor and the fluctuation is significant, indicating that there are potential problems in the hydraulic system (such as component wear and severe hydraulic oil contamination). At this time, the compression force should be reduced, the compression cycle should be extended, and the system diagnosis and maintenance should be performed immediately to restore the system stability.

[0055] If the mean value of the pressure output comprehensive stability value is less than the reference threshold value of the pressure output comprehensive stability value, and the standard deviation of the pressure output comprehensive stability value is less than the reference threshold value of the pressure output comprehensive stability value standard deviation, it means that the overall stability of the hydraulic system is poor but the fluctuation is small, indicating that the system state tends to be stable, but the low stability value may be related to the operating conditions or task load. At this time, the operation should be maintained under the existing compression force and compression cycle conditions, and subsequent changes should be monitored to avoid further deterioration.

[0056] S5: For unstable output states, reallocate compression tasks; for long-term unstable states, reduce large-load compression tasks and give priority to small-volume metal parts.

[0057] Determining unstable output conditions The system is judged to be in an unstable output state through the evaluation result of the comprehensive stability value of the pressure output. Check the duration of instability. If the duration exceeds the set threshold (such as three consecutive task cycles or longer), it is considered to be a long-term unstable state.

[0058] According to the physical characteristics of metal parts, compression tasks are divided into: Large load tasks: processing large and high-density metal parts (such as the entire vehicle shell, large doors). Medium load tasks: processing medium-sized and medium-density metal parts (such as frame parts). Small load tasks: processing small and low-density metal parts (such as scrap iron bars, metal plates).

[0059] Specific measures to redistribute compression tasks include: Large load tasks require high compression force from the hydraulic system, which can easily lead to increased system pressure fluctuations and increased equipment load. Temporarily suspend or reduce the frequency of large load tasks and lower the task priority. Split large load tasks into multiple small tasks (such as breaking up a large car shell and then compressing it).

[0060] Small load tasks require less compression force from the hydraulic system, which helps reduce equipment load and system pressure fluctuations. Adjust the task scheduling system to prioritize the processing of small metal parts. Maintain equipment operating efficiency by processing small load tasks in batches.

[0061] Reduce the output pressure of the hydraulic system to make it run in a more stable working range and reduce the fluctuation range. According to the current instability, dynamically adjust the compression force to 70%-90% of the rated value.

[0062] Prolong the time of each compression, slow down the response rate of the hydraulic system, and reduce transient pressure fluctuations. Prolong the cycle of a single compression action (such as adjusting from 10 seconds to 15 seconds).

[0063] Record the trend of comprehensive stability value changes after reassigning tasks and evaluate the adjustment effect: If the comprehensive stability value gradually recovers to above the threshold, continue to optimize task allocation. If it still has not recovered, further reduce the load or suspend the task. Analyze the impact of different load tasks on the operating status of the hydraulic system to provide a basis for subsequent optimization.

[0064] According to the historical task data, a correlation model between task load and system stability is established to dynamically optimize the task allocation strategy. Prioritize small load tasks and balance the execution order of each task. During the unstable state, shorten the maintenance cycle, focus on checking the hydraulic pump, valve and filter, and replace the worn parts in time.

[0065] Assuming that the hydraulic system is assessed to be in a long-term unstable state, the specific tasks are adjusted as follows: Original task: compress the whole vehicle shell within 1 hour (large load task). After adjustment: suspend the whole vehicle shell compression task. Process 20 batches of small-volume metal plates, each batch compression time is 3 minutes, a total of 60 minutes. After adjustment: the load of the hydraulic system is reduced, the pressure fluctuation amplitude is reduced, the comprehensive stability value returns to the normal range, and the equipment operation returns to stable.

[0066] In this application, by reducing large load tasks and giving priority to small load tasks, the pressure fluctuation amplitude of the hydraulic system can be effectively reduced, the equipment load can be relieved, and the stability of the system can be gradually restored. At the same time, the compression force and compression cycle are dynamically adjusted, combined with monitoring and optimization measures, to ensure the safe and efficient operation of hydraulic equipment in a long-term unstable state.

[0067] In this embodiment, first, an online oil monitoring sensor and a high-frequency pressure sensor are arranged in the hydraulic circuit to collect hydraulic oil contamination data and pressure change data in real time; then, the data is analyzed, and the pressure output comprehensive stability value of the hydraulic system is generated by determining the pressure output stability weights of different time periods and calculating the weighted average; then, according to the comprehensive stability value, the pressure output state of the hydraulic system is divided into a stable output state and an unstable output state; further, the change trend of the pressure stability state is analyzed, and if the comprehensive stability value increases, the compression force and the operating speed are gradually increased, and if it decreases, the compression force is reduced and the compression cycle is extended; finally, the compression tasks are reallocated in an unstable state, and small load tasks are processed first to reduce the system pressure load, especially reducing large load compression tasks in a long-term unstable state. This method effectively improves the operating efficiency and stability of the hydraulic system, while reducing the risk of equipment failure.

[0068] Example 2, please refer to Figure 2 As shown, the control system of the hydraulic packaging equipment for scrap steel metal materials described in this embodiment includes a data acquisition module, a pressure stability analysis module, a pressure output state classification module, a dynamic adjustment module and a task management module; Data acquisition module: online oil monitoring sensors are installed at the hydraulic pump outlet and hydraulic cylinder inlet of the hydraulic circuit to detect the number of pollutant particles and water content in the hydraulic oil in real time and generate hydraulic oil pollution data; high-frequency pressure sensors are installed in the hydraulic circuit to collect real-time pressure change data during the compression cycle; Pressure stability analysis module: Analyze the collected hydraulic oil contamination data and pressure change data, determine the weighted values ​​of the hydraulic system pressure output stability in different time periods, and perform weighted average calculation on the weighted values ​​of the hydraulic system pressure output stability in different time periods to obtain the comprehensive stability value of the hydraulic system pressure output; Pressure output state classification module: according to the calculated comprehensive stability value of the pressure output of the hydraulic system, the pressure output state of the hydraulic system is divided into a stable output state and an unstable output state; Dynamic adjustment module: judge the changing trend of the pressure stability output state of the hydraulic system. If the comprehensive stability value of the pressure output shows an upward trend, the compression force and running speed of the hydraulic system are gradually increased. If the comprehensive stability value of the pressure output shows a downward trend, the compression force is reduced and the compression cycle is extended. Task management module: For unstable output states, reallocate compression tasks; for long-term unstable states, reduce large-load compression tasks and give priority to small-volume metal parts.

[0069] The above description is only a specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application.

Claims

1. A control method for hydraulic packaging equipment of scrap steel and metal materials, characterized in that: The following steps are involved: S1: Install online oil monitoring sensors at the hydraulic pump outlet and hydraulic cylinder inlet of the hydraulic circuit to detect the number of pollutant particles and water content in the hydraulic oil in real time and generate hydraulic oil contamination data, and install high-frequency pressure sensors in the hydraulic circuit to collect real-time pressure change data during the compression cycle; S2: Analyze the collected hydraulic oil contamination data and pressure change data, determine the weighted values ​​of the hydraulic system pressure output stability in different time periods, and perform weighted average calculation on the weighted values ​​of the hydraulic system pressure output stability in different time periods to obtain the comprehensive stability value of the hydraulic system pressure output; S3: according to the calculated comprehensive stability value of the pressure output of the hydraulic system, dividing the pressure output state of the hydraulic system into a stable output state and an unstable output state; S4: judging the change trend of the pressure stability output state of the hydraulic system, if the comprehensive stability value of the pressure output shows an upward trend, gradually increasing the compression force and running speed of the hydraulic system, if the comprehensive stability value of the pressure output shows a downward trend, reducing the compression force and extending the compression cycle; S5: For unstable output states, reallocate compression tasks; for long-term unstable states, reduce large-load compression tasks and give priority to small-volume metal parts.

2. A method for controlling a hydraulic packaging equipment for scrap steel and metal materials according to claim 1, characterized in that: In S2, after analyzing the particle concentration increment feature in the extracted hydraulic oil pollution data, a particle concentration increment abnormal value is generated. The method for obtaining the particle concentration increment abnormal value is: Collect the incremental data of particle concentration to form an ordered data set: ;in, represents the nth particle concentration increment value, n is the total number of data points, and the data set X is sorted in ascending order to obtain a new ordered set X′: ; Calculate the quartiles, which are divided into the lower quartile Q1, the median Q2, and the upper quartile Q3; Q1 is the 25th position value in the sorted data set, indicating the part of the data that is less than or equal to Q1, Q3 is the 75th position value in the sorted data set, indicating the part of the data that is greater than or equal to Q3, and Q2 is the middle position value of the sorted data, indicating the 50th position; Calculate the interquartile range IQR, the interquartile range represents the range of the middle 50% of the data set, and the calculation formula is: IQR=Q3−Q1; Calculate the upper and lower boundaries of the outliers of the data through the interquartile range: upper boundary UB: ; Lower boundary LB: ; Judge each particle concentration increment value in the data set, collect the particle concentration increment values ​​greater than the upper boundary and the particle concentration increment values ​​less than the lower boundary, and calculate the standard deviation of all collected particle concentration increment values ​​as the particle concentration increment abnormal value.

3. A method for controlling a hydraulic packaging equipment for scrap steel and metal materials according to claim 2, characterized in that: In S2, the pressure fluctuation amplitude characteristics in the extracted pressure change data are analyzed to generate a pressure fluctuation amplitude change value, and the method for obtaining the pressure fluctuation amplitude change value is: Set the pressure fluctuation amplitude data set to ;in, is the pressure fluctuation amplitude value at the tth moment, t is the current moment, select a smoothing coefficient e, and calculate the exponentially weighted moving average of the pressure fluctuation amplitude data. The expression is: ; is the exponentially weighted moving average at the current time t, is the actual pressure fluctuation amplitude at the current moment, is the exponentially weighted moving average of the previous moment, and the pressure fluctuation amplitude change value is calculated. The expression is: ; Where SCX is the change in pressure fluctuation amplitude.

4. A method for controlling a hydraulic packaging equipment for scrap steel and metal materials according to claim 3, characterized in that: The abnormal values ​​of the particle matter concentration increment and the pressure fluctuation amplitude change values ​​are normalized, and the weighted values ​​of the stability of the hydraulic system pressure output in different time periods are calculated by the normalized abnormal values ​​of the particle matter concentration increment and the pressure fluctuation amplitude change values. After weighted average calculation of the weighted values ​​of the stability of the hydraulic system pressure output in different time periods, the comprehensive stability value of the pressure output of the hydraulic system is obtained.

5. A method for controlling a hydraulic packaging equipment for scrap steel and metal materials according to claim 4, characterized in that: In S3, according to the calculated comprehensive stability value of the pressure output of the hydraulic system, the pressure output state of the hydraulic system is divided into a stable output state and an unstable output state; The calculated comprehensive stability value of the hydraulic system's pressure output is compared with the stability reference threshold value pre-set based on historical data. If the comprehensive stability value of the hydraulic system's pressure output is less than the stability reference threshold value, it means that the comprehensive stability of the hydraulic system's pressure output is low. At this time, a warning signal is generated, and the pressure output state of the hydraulic system is classified as an unstable output state; if the comprehensive stability value of the hydraulic system's pressure output is greater than or equal to the stability reference threshold value, it means that the comprehensive stability of the hydraulic system's pressure output is high. At this time, no warning signal is generated, and the pressure output state of the hydraulic system is classified as a stable output state.

6. A method for controlling a hydraulic packaging equipment for scrap steel and metal materials according to claim 5, characterized in that: In S4, the change trend of the pressure stability output state of the hydraulic system is judged, specifically: For the stability output state, that is, the comprehensive stability value of the pressure output of the hydraulic system generated within a fixed time period is greater than or equal to the stability reference threshold, the comprehensive stability values ​​of the pressure output generated within the subsequent fixed time period that are greater than or equal to the stability reference threshold are collected, and a data set is established. The mean and standard deviation of the data set are calculated. After analyzing them, the changing trend of the pressure stability output state of the hydraulic system is judged.

7. A method for controlling a hydraulic packaging equipment for scrap steel and metal materials according to claim 6, characterized in that: If the mean value of the comprehensive stability value of the pressure output in the data set is greater than or equal to the reference threshold value of the mean value of the comprehensive stability value of the pressure output, and the standard deviation of the comprehensive stability value of the pressure output is less than the reference threshold value of the standard deviation of the comprehensive stability value of the pressure output, it means that the hydraulic system has good stability and small fluctuations, and the operating state is optimal. At this time, the compression force and operating speed of the hydraulic system should be gradually increased; If the mean value of the comprehensive stability value of the pressure output is greater than or equal to the reference threshold value of the mean value of the comprehensive stability value of the pressure output, and the standard deviation of the comprehensive stability value of the pressure output is greater than or equal to the reference threshold value of the standard deviation of the comprehensive stability value of the pressure output, it means that the overall stability of the hydraulic system is good, but the fluctuation is large. At this time, do not increase the operating parameters temporarily, check whether there is any abnormal fluctuation in the hydraulic system, and then increase the compression force and operating speed after optimizing the stability of the hydraulic system; If the mean value of the pressure output comprehensive stability value is less than the reference threshold value of the pressure output comprehensive stability value, and the standard deviation of the pressure output comprehensive stability value is greater than or equal to the reference threshold value of the pressure output comprehensive stability value standard deviation, it means that the overall stability of the hydraulic system is poor and the fluctuation is significant. At this time, the compression force should be reduced, the compression cycle should be extended, and the hydraulic system diagnosis and maintenance should be carried out immediately; If the mean value of the comprehensive stability value of the pressure output is less than the reference threshold value of the mean value of the comprehensive stability value of the pressure output, and the standard deviation of the comprehensive stability value of the pressure output is less than the reference threshold value of the standard deviation of the comprehensive stability value of the pressure output, it means that the overall stability of the hydraulic system is poor but the fluctuation is small, indicating that the state of the hydraulic system tends to be stable. At this time, the operation should be maintained under the existing compression force and compression cycle conditions.

8. A control system for a hydraulic packing equipment for scrap steel and metal materials, used to implement a control method for a hydraulic packing equipment for scrap steel and metal materials as claimed in any one of claims 1 to 7, characterized in that: It includes data acquisition module, pressure stability analysis module, pressure output state classification module, dynamic adjustment module and task management module; Data acquisition module: online oil monitoring sensors are installed at the hydraulic pump outlet and hydraulic cylinder inlet of the hydraulic circuit to detect the number of pollutant particles and water content in the hydraulic oil in real time and generate hydraulic oil pollution data; high-frequency pressure sensors are installed in the hydraulic circuit to collect real-time pressure change data during the compression cycle; Pressure stability analysis module: Analyze the collected hydraulic oil contamination data and pressure change data, determine the weighted values ​​of the hydraulic system pressure output stability in different time periods, and perform weighted average calculation on the weighted values ​​of the hydraulic system pressure output stability in different time periods to obtain the comprehensive stability value of the hydraulic system pressure output; Pressure output state classification module: according to the calculated comprehensive stability value of the pressure output of the hydraulic system, the pressure output state of the hydraulic system is divided into a stable output state and an unstable output state; Dynamic adjustment module: judge the changing trend of the pressure stability output state of the hydraulic system. If the comprehensive stability value of the pressure output shows an upward trend, the compression force and running speed of the hydraulic system are gradually increased. If the comprehensive stability value of the pressure output shows a downward trend, the compression force is reduced and the compression cycle is extended. Task management module: For unstable output states, reallocate compression tasks; for long-term unstable states, reduce large-load compression tasks and give priority to small-volume metal parts.

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