Online monitoring sensor performance evaluation system and testing method thereof

Abstract

The invention discloses an online monitoring sensor performance evaluation system and a test method thereof.The evaluation system comprises a control workbench, a detection oil way and a bubble generation system, an oil tank, a gear pump, a flow transmitter, a pressure regulator and a to-be-tested sensor are sequentially connected to the detection oil way in series, a closed loop is formed, and the oil tank is of a fully-closed structure; a temperature control heating device is arranged at the bottom of the bubble generating system, and the bubble generating system is connected with the oil tank through a gas delivery pipe and comprises a compressed gas cylinder and a flowmeter; according to the evaluation system, the actual working environment of the sensor to be tested is simulated more truly by controlling temperature, flow, oil pressure and bubble factors, the test result is more real, the accuracy is higher, and the parameter correction reliability is better; the bubble generation system is combined with a closed oil tank, bubbles are injected in a quantitative gas transmission mode, environments with different bubble quantities are simulated, and the performance of the to-be-tested sensor in various bubble environments can be evaluated; the test method provides a specific means for reproducing the bubble environment, and is high in operability and high in test accuracy.

Description

Technical Field

[0001] The present invention relates to the technical field of sensor performance testing, and in particular to an online monitoring sensor performance evaluation system and a testing method thereof. Background Art

[0002] At present, online oil monitoring sensors have been widely used in wind turbine gearboxes, mainly monitoring the viscosity, moisture, dielectric constant, density, dynamic viscosity, ferromagnetic abrasive particles and non-ferromagnetic abrasive particles and abrasive particle concentration of gear oil. However, judging from the current application situation, there are still many problems to be solved and further studied. The most important is the hardware system. The accuracy and consistency of sensors from different manufacturers are difficult to solve. Compared with the offline oil detection results, there is still a certain gap in the accuracy of online oil sensing monitoring of oil. The results of some sensor monitoring have no practical significance and cannot be used for oil status analysis and normal maintenance of equipment. Therefore, it is necessary to evaluate and calibrate the performance of existing oil monitoring sensors, optimize and calibrate sensors for enterprises, improve analysis accuracy, speed up analysis, shorten analysis time, and provide data support to meet the needs of on-site monitoring;

[0003] The sensor performance evaluation system of the prior art is unable to conduct a comprehensive performance evaluation under multiple working conditions and environments, such as the detection performance of the sensor under different working temperatures, different oil pressures, and different flow rates. In particular, in an actual dynamic working environment, the lubricating oil usually has bubbles. Therefore, in order to better simulate the actual working environment, the evaluation system should simulate a variety of bubble environments and conduct a comprehensive test on the sensor. Patent 201711004557.2 Impurity Particle Detection Sensor Testing Device and Method discloses injecting bubbles into the detection oil to simulate the actual working environment, but it does not provide practical and operational means for the specific implementation method of injecting bubbles, the composition of the evaluation system with bubbles, and the actual operation. The simulated environment is single and the test accuracy cannot be guaranteed. Summary of the invention

[0004] The purpose of the present invention is to overcome the defects of the prior art and provide an online monitoring sensor performance evaluation system and a testing method thereof to solve the problems raised in the above background technology.

[0005] In order to achieve the above object, the technical solution of the present invention is as follows:

[0006] An online monitoring sensor performance evaluation system, comprising:

[0007] A control workbench is electrically connected to the sensor to be tested and is provided with a display screen for displaying actual test parameters and detection parameters of the sensor to be tested;

[0008] Detection oil circuit, the sensor to be tested is connected in series to the detection oil circuit; the detection oil circuit is connected in series with the oil tank, gear pump, flow transmitter, pressure regulator and the sensor to be tested in sequence to form a closed loop, the gear pump, flow transmitter and pressure regulator are electrically connected to the control workbench, the oil tank is a fully enclosed structure, and a temperature control and heating device is provided at the bottom;

[0009] The bubble generating system is connected to the oil tank through an air pipe, and comprises a compressed gas cylinder and a flow meter, and the flow meter is electrically connected to the control workbench.

[0010] Furthermore, it also includes an ultrasonic debubbler arranged in the oil tank, an exhaust valve is arranged on the top of the oil tank, and the ultrasonic debubbler is located directly below the exhaust valve.

[0011] Furthermore, the oil outlet pipe and oil return pipe of the detection oil circuit are respectively inserted into the oil tank from the top of both ends and extend under the oil. The port of the oil outlet pipe is lower than the port of the oil return pipe. The air pipe is arranged close to the oil outlet pipe, and its port is located below the oil. The port of the oil return pipe is arranged close to the ultrasonic debubbler.

[0012] Furthermore, an integrally formed protrusion on the top of the fuel tank is provided with an air collecting cavity, and the exhaust valve is located on the top of the air collecting cavity.

[0013] Preferably, the oil in the oil tank is working lubricating oil.

[0014] Furthermore, the detection oil circuit is arranged in the test cabinet, and the sensor to be tested is arranged outside the test cabinet. The detection oil circuit has two connecting pipes extending out of the test cabinet. Both connecting pipes are provided with oil shut-off valves, and both ends are provided with threaded joints for serially connecting the sensor to be tested.

[0015] A testing method for an online monitoring sensor performance evaluation system, comprising:

[0016] Calibration stage: connect the sensor to be tested, heat the oil in the oil tank to the preset detection temperature, preset test parameters, including preset flow rate, oil pressure and air delivery volume, start the gear pump to circulate the oil, and after the detection parameter value of the sensor to be tested is stable, record the detection parameter calibration value of the sensor to be tested in the bubble-free state;

[0017] Testing phase: Start the bubble generation system, control its gas delivery rate, so that it can complete the preset gas delivery volume within one oil replacement cycle, and cycle at least two oil replacement cycles until the detection parameter value of the sensor to be tested stabilizes within the acceptable variation range, record the detection parameter value of the sensor to be tested under the gas delivery volume, and compare and evaluate the detection performance of the sensor to be tested in a bubble-free environment and in various bubble environments;

[0018] Defoaming stage: open the exhaust valve and ultrasonic debubbler, cycle at least one oil replacement cycle, and observe the parameter value of the sensor to be tested until it returns to the calibration value of the detection parameter and stabilizes within the acceptable range of variation.

[0019] Compared with the prior art, the online monitoring sensor performance evaluation system and the testing method thereof of the present invention have the following beneficial effects:

[0020] 1. The evaluation system can simulate the actual working environment of the sensor to be tested more realistically by controlling the temperature, flow, oil pressure and bubble factors. Therefore, the test results of the sensor to be tested are more realistic and more accurate. The parameters of the sensor to be tested are calibrated and corrected according to the test results of the evaluation system, which has better reliability.

[0021] 2. The bubble generation system integrated in the evaluation system is combined with a closed oil tank, and bubbles are injected by quantitative gas delivery to simulate different bubble volume environments, which can evaluate the performance of the sensor under various bubble environments;

[0022] 3. The test method of the evaluation system provides a specific implementation means for reproducing the bubble environment. A quantitative gas volume is injected, and the bubbles are evenly distributed in the oil tank and the detection oil circuit through circulating oil. The detection performance of the sensor to be tested in a bubble-free environment and a bubble environment with various gas volumes is collected. At the same time, the detection parameters in the bubble-free environment can also be used as a reference for the defoaming stage. Therefore, the test method is highly operational and has high test accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is a three-dimensional diagram of the overall structure of the evaluation system of the present invention;

[0024] Figure 2 It is a composition diagram of the evaluation system of the present invention.

[0025] In the figure: 1. Control workbench; 2. Test cabinet; 3. Sensor to be tested; 4. Bubble generation system; 41. Compressed gas cylinder; 42. Flow meter; 43. Gas pipeline; 44. Air flow shut-off valve; 5. Oil tank; 6. Gear pump; 7. Flow transmitter; 8. Pressure regulator; 9. Detection oil circuit; 91. Oil outlet pipe; 92. Oil return pipe; 93. Oil shut-off valve; 10. Exhaust valve. DETAILED DESCRIPTION

[0026] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only the best embodiments of the present invention, not all 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.

[0027] The online monitoring sensor has a high integration level and can generally monitor the viscosity, moisture, working temperature, working oil pressure and oil density of the lubricating oil online at the same time. The performance of online monitoring sensors from different manufacturers varies. Therefore, this embodiment provides an online monitoring sensor performance evaluation system, which simulates the actual working environment of the online monitoring sensor. Therefore, the evaluation and parameter correction work are performed according to the test results, which can effectively improve the detection accuracy in the actual working environment.

[0028] Specifically, Figure 1-Figure 2 As shown, the evaluation system includes a control workbench 1, a detection oil circuit 9 and a bubble generation system 4; the control workbench 1 is provided with a display screen, which respectively displays the actual test parameters and the detection parameters of the sensor 3 to be tested, and is provided with an adjustment input button, and the flow rate, oil pressure and temperature of the oil are set according to the working speed, working temperature and working oil pressure of the actual working environment; the control workbench 1 is located on the top of the test cabinet 2, and the detection oil circuit 9 is set in the test cabinet 2;

[0029] The oil tank 5, gear pump 6, flow transmitter 7, pressure regulator 8 and sensor 3 to be tested are connected in series in sequence on the detection oil circuit 9 to form a closed loop. In order to improve the automation performance, the flow transmitter 7 and the gear pump 6 are electrically connected to the control workbench 1 respectively, and form a closed-loop control of the oil flow rate in the detection oil circuit 9. The gear pump 6 is driven by a servo motor with stepless speed regulation. The pressure regulator 8 is an electromagnetic pressure regulating valve, which is electrically connected to the control workbench 1 with the oil pressure detection sensor provided on the detection oil circuit 9. Similarly, a closed-loop control is formed to adjust and stabilize the oil pressure in the detection oil circuit 9 according to the preset oil pressure.

[0030] The oil tank 5 is a fully enclosed structure, and a temperature control and heating device is provided at the bottom thereof, which can heat the oil in the oil tank 5 according to a preset temperature. The oil in the oil tank 5 is working lubricating oil;

[0031] The bubble generating system 4 is arranged outside the test cabinet 2. The gas supply pipe 43 is provided with a compressed gas cylinder 41 and a flow meter 42. The compressed gas cylinder 41 is connected to the oil tank 5 through the gas supply pipe 43. The flow meter 42 and the air flow cut-off valve 44 are arranged on the gas supply pipe 43 in sequence. The flow meter 42 is electrically connected to the control workbench 1. The ventilation volume is controlled according to the preset gas supply volume. By inputting different ventilation volumes into a quantitative flowing oil liquid, the working environment under various bubble volumes is simulated. In order to make the input air flow form bubbles evenly and quickly, the gas supply pipe 43 is connected to the oil tank 5 of the closed structure, and the output port of the gas supply pipe 43 is inserted into the oil liquid and close to the port of the oil outlet pipe 91. A larger flow rate can be formed at the inlet of the oil outlet pipe 91 to accelerate the formation and flow of bubbles. In addition, since the closed oil tank 5, the oil outlet pipe 91 and the return oil pipe 92 form a closed loop, the injected bubbles cannot escape. Therefore, the gas supply volume basically forms bubbles in the oil liquid.

[0032] In order to ensure the accuracy of the detection, it is necessary to defoam the oil after completing a single test. The system also includes an ultrasonic defoamer vertically arranged in the oil tank 5. At the same time, an electronic exhaust valve 10 is arranged on the top of the oil tank 5. The ultrasonic defoamer and the exhaust valve 10 are electrically connected to the control workbench 1, and the exhaust operation can be automatically controlled. The ultrasonic defoamer is located directly below the exhaust valve 10. In order to facilitate the convergence of escaping gas, an air collecting cavity is arranged in an integrally formed protrusion on the top of the oil tank 5. The exhaust valve 10 is located at the top of the air collecting cavity and is connected to the air collecting cavity. In order to reduce the liquid-free space in the oil tank 5, the oil level in the oil tank 5 should be close to the top surface of the oil tank 5 to reduce the amount of gas escaping from the oil during the circulation and heating of the oil.

[0033] In addition, in order to speed up the uniform mixing speed of the bubbles, the oil outlet pipe 91 and the oil return pipe 92 of the detection oil circuit 9 are inserted into the oil tank 5 from the top of both ends of the oil tank 5 and extend under the oil. At the same time, the port of the oil outlet pipe 91 and the port of the oil return pipe 92 are staggered, and the port of the oil outlet pipe 91 is lower than the port of the oil return pipe 92.

[0034] In order to quickly flow and defoam, the oil return pipe 92 port is set close to the ultrasonic defoamer;

[0035] In order to improve the convenience of operation, the sensor 3 to be tested is installed outside the test cabinet 2, and the detection oil circuit 9 has two connecting pipes extending out of the test cabinet 2. Both connecting pipes are provided with oil shut-off valves 93, and both ends are provided with threaded joints adapted to the interface of the sensor 3 to be tested, which facilitates the series installation and disassembly of the sensor 3 to be tested.

[0036] The present invention also provides a testing method for an online monitoring sensor performance evaluation system, which includes the following contents:

[0037] First, the oil in the bubble-free state is used as the reference environment for calibration, the sensor 3 to be tested is connected through the connecting pipe, the oil shut-off valve 93 is opened, the test parameters are preset, including the preset detection temperature, flow, oil pressure and gas delivery volume, the hydraulic oil in the oil tank 5 is heated to the preset detection temperature, and at the same time, the gear pump 6 is turned on to circulate the oil, the oil in the oil tank 5 and the detection oil circuit 9 is evenly heated and circulated at a uniform speed, after the detection parameter value of the sensor 3 to be tested is stable, the detection parameter correction value of the sensor 3 to be tested in the bubble-free state is recorded; the detection parameter correction value can be used to evaluate the detection performance of the sensor 3 to be tested in the bubble-free environment and the bubble environment;

[0038] Next, enter the bubble environment test phase for each gas delivery volume; start the bubble generation system 4, control its gas delivery flow rate, match the gas delivery flow rate with the oil circulation flow rate, so that the preset gas delivery volume is completed within an oil replacement cycle. The oil replacement cycle is the time required for the oil tank 5 with a fixed amount of oil to completely discharge the oil at the preset circulation flow rate. It should be ensured that at least two oil replacement cycles are circulated, and the detection parameter value of the sensor to be tested 3 is observed. When it stabilizes within an acceptable variation range, it is considered that the bubble environment under the gas delivery volume is completely generated, and the detection parameter value of the sensor to be tested 3 under the gas delivery volume is recorded to evaluate the detection performance of the sensor to be tested 3;

[0039] If it is necessary to simulate the bubble environment with multiple gas delivery volumes, in order to improve the test efficiency, the test should be carried out in the order of small gas delivery volume to large gas delivery volume. Since the oil tank 5 and the detection oil circuit 9 are closed environments, it can be considered that there is no bubble escape. Therefore, with the same operation method, it is only necessary to input the gradient difference between the gas delivery volumes in the circulating oil to obtain the bubble simulation environment of the next gas delivery volume;

[0040] After completing the test of each sensor, defoaming is required. The exhaust valve 10 and the ultrasonic defoamer are automatically opened to break the bubbles through ultrasonic vibration waves, and exhaust is performed through the exhaust valve 10. The defoaming stage is carried out for at least one oil replacement cycle. The parameter value of the sensor 3 to be tested is judged with the help of the detection parameter correction value, and the parameter value is observed until it returns to the detection parameter correction value and stabilizes within the acceptable range of variation. It is considered that the oil has completed defoaming; the gear pump 6 and the temperature device are turned off.

[0041] The directional words such as "inside", "outside", "top", "bottom", and "end" mentioned in this article are based on Figure 1-Figure 2 The orientation or position relationship shown. These terms are mainly used to better describe the present invention and its embodiments, and are not used to limit the indicated devices, elements or components to have a specific orientation, or to be constructed and operated in a specific orientation;

[0042] In addition, some of the above terms may be used to express other meanings in addition to indicating orientation or positional relationship. For example, the terms "on" and "inside" may also be used to express a certain dependency or connection relationship in some cases. For those skilled in the art, the specific meanings of these terms in the present invention can be understood according to specific circumstances.

[0043] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An online monitoring sensor performance evaluation system, characterized in that: include: A control workbench is electrically connected to the sensor to be tested and is provided with a display screen for displaying actual test parameters and detection parameters of the sensor to be tested; The detection oil circuit is connected in series with the oil tank, the gear pump, the flow transmitter, the pressure regulator and the sensor to be tested in sequence to form a closed loop. The gear pump, the flow transmitter and the pressure regulator are electrically connected to the control workbench. The oil tank is a fully enclosed structure, and a temperature control and heating device is provided at the bottom thereof; The bubble generating system is connected to the oil tank via an air pipe and comprises a compressed gas cylinder and a flow meter, wherein the flow meter is electrically connected to the control workbench.

2. The online monitoring sensor performance evaluation system according to claim 1, characterized in that: It also includes an ultrasonic debubbler arranged in the oil tank. An exhaust valve is arranged on the top of the oil tank, and the ultrasonic debubbler is located directly below the exhaust valve.

3. The online monitoring sensor performance evaluation system according to claim 2 is characterized in that: The oil outlet pipe and oil return pipe of the detection oil circuit are respectively inserted into the oil tank from the top of both ends and extend under the oil. The port of the oil outlet pipe is lower than the port of the oil return pipe. The air pipe is arranged close to the oil outlet pipe, and its port is located below the oil. The port of the oil return pipe is arranged close to the ultrasonic debubbler.

4. The online monitoring sensor performance evaluation system according to claim 3 is characterized in that: The integrally formed protrusion on the top of the oil tank is provided with an air collecting cavity, and the exhaust valve is located on the top of the air collecting cavity.

5. The online monitoring sensor performance evaluation system according to any one of claims 1 to 4, characterized in that: The oil in the oil tank is working lubricating oil.

6. The online monitoring sensor performance evaluation system according to any one of claims 1 to 4, characterized in that: The detection oil circuit is arranged in the test cabinet, and the sensor to be tested is arranged outside the test cabinet. The detection oil circuit has two connecting pipes extending out of the test cabinet. Both connecting pipes are provided with oil shut-off valves, and both ends are provided with threaded joints for serially connecting the sensor to be tested.

7. A testing method for an online monitoring sensor performance evaluation system, characterized in that: include: Correction phase; Connect the sensor to be tested, heat the oil in the oil tank to the preset detection temperature, preset test parameters, including preset flow rate, oil pressure and gas delivery volume, start the gear pump to circulate the oil, and after the detection parameter value of the sensor to be tested is stable, record the detection parameter correction value of the sensor to be tested in the bubble-free state; Testing phase: start the bubble generation system, control its gas delivery velocity, so that it completes the preset gas delivery volume within one oil replacement cycle, and cycles at least two oil replacement cycles until the detection parameter value of the sensor to be tested stabilizes within an acceptable variation range, and records the detection parameter value of the sensor to be tested under the gas delivery volume, and compares and evaluates the detection performance of the sensor to be tested in a bubble-free environment and in various bubble environments; Defoaming stage: open the exhaust valve and ultrasonic defoamer on the oil tank, cycle at least one oil replacement cycle, and observe the parameter value of the sensor to be tested until it returns to the detection parameter correction value and stabilizes within the acceptable variation range.

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