PLC-based bearing starting torque test bench electrical control system

Abstract

The invention relates to the technical field of bearing starting torque test bench electrical control systems, and discloses a PLC-based bearing starting torque test bench electrical control system, which comprises a PLC, a servo motor, a circuit breaker, a load simulation module, a rotating speed driving module, a signal acquisition module, a data processing module and a man-machine interaction module, the PLC controller is electrically connected with the load simulation module, the rotating speed driving module, the signal acquisition module and the man-machine interaction module, and controls and monitors the action state of each module. Specifically, through the system, various working conditions can be simulated, the torque and the load condition of the bearing during operation can be monitored in real time, meanwhile, a single-time or multi-time test result report can be automatically generated, a user can conveniently store and record, the test efficiency is improved, manual intervention is reduced, the test consistency is ensured, and the test controllability and flexibility are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of electrical control systems for bearing starting torque test benches, and in particular relates to an electrical control system for a bearing starting torque test bench based on a PLC. Background Art

[0002] Bearing starting torque test is of great significance to the design, operation and maintenance of mechanical systems, mainly in the following aspects: (1) Evaluate bearing performance: Starting torque is the torque required by the bearing at the moment of starting, which directly reflects the performance of the bearing during the starting process of the mechanical system. By testing the starting torque of the bearing, we can fully understand its starting performance under various working conditions and provide key data for bearing performance evaluation.

[0003] (2) Ensure smooth system startup: The starting torque test helps ensure that the mechanical system will not be subject to excessive torque resistance during startup, thereby ensuring a smooth start of the system. This is especially true for some large special bearings, where the torque required for startup is much greater than the torque required for stable operation. This is crucial for improving the operating efficiency of the mechanical system, reducing energy consumption, and reducing mechanical losses during startup.

[0004] (3) Predicting system life: Starting torque directly affects the fatigue life of the bearing. By testing the torque applied to the bearing during the startup process, the life of the bearing can be predicted more accurately, which helps to carry out maintenance and replacement in advance and reduce system downtime.

[0005] (4) Improve system reliability: Starting torque test helps to find possible problems with bearings during the starting process, such as abnormalities in friction, lubrication, etc. Through timely detection and adjustment, the reliability of the mechanical system can be improved and the risk of failure caused by bearing problems can be reduced.

[0006] Domestic research on bearing starting torque is conducted through theoretical calculations. Since there are many factors that affect the starting torque of bearings in actual working conditions, there is often a large deviation between the actual results and the theoretical results. At present, there is also a method of manually pulling the bearing to rotate through a spring scale to obtain the actual starting torque of the bearing, but there are usually the following problems: First, subjectivity and error: Manual testing is easily affected by the subjective factors of the operator. For example, it is difficult for the tester to maintain consistency when applying torque, which may lead to subjective errors in the test results. In addition, differences in operating skills and experience between different operators may also introduce different test errors.

[0007] Second, low testing efficiency: Manual testing requires a lot of manpower and time, especially in large-scale or repetitive tests, the testing efficiency is relatively low. Manual testing often needs to be performed periodically, which may lead to long delays in the testing process.

[0008] Furthermore, it is not possible to fully cover a variety of working conditions: different bearings perform very differently under different load, speed and temperature conditions, and manual testing is difficult to simulate all possible working conditions.

[0009] Finally, it is difficult to obtain real-time data: manual testing is usually difficult to monitor and collect data in real time, resulting in the inability to obtain detailed starting torque curves. This limits the in-depth understanding of the dynamic performance of the bearing at the moment of starting.

[0010] In summary, manual testing of bearing starting torque has problems such as complex operation, inaccurate data collection, and lack of automated control. Taking these factors into consideration, an automated bearing starting torque test system, especially one that uses advanced electrical control systems, can effectively overcome these shortcomings of manual testing and improve test efficiency and data accuracy. Therefore, we propose a PLC-based electrical control system for the bearing starting torque test bench. Summary of the invention

[0011] The purpose of the present invention is to improve test efficiency, reduce manual intervention, ensure test consistency, and improve test controllability and flexibility. The present application provides a PLC-based bearing starting torque test bench electrical control system.

[0012] The technical solution adopted by the present invention is as follows: A PLC-based bearing starting torque test bench electrical control system, comprising a PLC controller, a servo motor, a circuit breaker, a load simulation module, a speed drive module, a signal acquisition module, a data processing module and a human-computer interaction module, characterized in that: the PLC controller is electrically connected to the load simulation module, the speed drive module, the signal acquisition module and the human-computer interaction module respectively to control and monitor the action status of each module; The load simulation module is electrically connected to the speed driving module, and loads of different sizes are applied to the bearing by weight loading. The speed driving module is connected to the servo motor to control the speed of the bearing; The signal acquisition module is electrically connected to the data processing module, and the data processing module is connected to the human-computer interaction module, and the collected signal data can be monitored, analyzed, processed and stored in the human-computer interaction module; The PLC controller is electrically interconnected with the human-machine interaction module to realize the automatic control of the test bench and is responsible for coordinating and controlling the operation of each module. The human-machine interaction module is designed with a computer-designed human-machine interaction interface. The user can set test parameters, monitor real-time data, adjust the speed drive module and other operations, and automatically generate single or multiple test reports for easy record keeping. A network connection is introduced to realize remote control and monitoring functions. The user can remotely access the test bench through the network, observe the test process in real time, adjust parameters, and improve the flexibility of the test.

[0013] In a preferred embodiment of the invention, the PLC controller includes a CPU, a power module, an input module, and an output module.

[0014] In a preferred embodiment of the invention, the signal acquisition module is composed of a sensor.

[0015] In a preferred embodiment of the invention, the sensor includes a torque sensor and a pressure sensor.

[0016] In a preferred embodiment of the invention, the torque sensor is used to detect the torque condition of the bearing during operation.

[0017] In a preferred embodiment of the invention, the pressure sensor is used to detect the load condition borne by the bearing.

[0018] In a preferred embodiment of the invention, the circuit breaker is connected to the speed driving module and the load simulation module respectively, and when problems occur in the speed control module and the load simulation module, power is forcibly cut off.

[0019] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: 1. In the present invention, the human-machine interaction module is interconnected with the PLC controller, the PLC controller is connected with other modules, the human-machine interaction module sends a control instruction to the PLC controller, and the PLC controller sends a control signal to the speed drive module, the load simulation module and the signal acquisition module, so as to realize the speed control of the bearing and the size of the load borne, simulate various working conditions, and monitor the torque and load conditions of the bearing in real time during operation. At the same time, a single or multiple test result report can be automatically generated, which is convenient for users to store and record; the PLC controller is used to realize the automatic control of the test bench, which improves the test efficiency, reduces manual intervention, and ensures the consistency of the test.

[0020] 2. In the present invention, a servo motor and a load simulation module are used to perform multi-operating condition simulations, thereby simulating the starting torque under different load and speed conditions and comprehensively evaluating the bearing performance.

[0021] 3. In the present invention, real-time monitoring and data acquisition are carried out, and a signal acquisition module is provided to realize real-time monitoring of key data of the bearing startup process, thereby ensuring the accuracy of the test data.

[0022] 4. In the present invention, through the human-computer interaction module, the user can conveniently set the test parameters, monitor the real-time data, and improve the controllability and flexibility of the test. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is the electrical control structure diagram of the bearing starting torque test bench of the present invention; Figure 2 It is a test flow chart of the present invention; Figure 3 It is a structural schematic diagram of the bearing starting torque test bench of the present invention. DETAILED DESCRIPTION

[0024] 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 combination with 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.

[0025] The following will be combined Figure 1-Figure 3 A PLC-based electrical control system for a bearing starting torque test bench according to an embodiment of the present invention is described in detail. Example

[0026] Reference Figure 1-Figure 3 , an electrical control system for a bearing starting torque test bench based on PLC, including a PLC controller, a servo motor, a circuit breaker, a load simulation module, a speed drive module, a signal acquisition module, a data processing module and a human-computer interaction module; specifically, the present invention adopts a combination of different weights to achieve load size control, and a screw lifting device is designed under the test bench, which can make the central bearing of the bearing to be tested coincide with the central axis of the weight by lifting the screw, avoiding the situation of axial force loading and uneven loading. The overall driving method is to output the torque to the driving gear after the servo motor is decelerated and increased by the reducer, and the loading disk is driven by the driving gear to rotate. The loading disk is in direct contact with the moving ring of the bearing to be tested. Under the action of sliding friction, the moving ring of the bearing rotates synchronously with the loading disk, and the starting torque of the bearing is indirectly obtained through the torque sensor.

[0027] Reference Figure 1-Figure 3The automatic control strategy for the drive gear and the loading plate gear to reach the best meshing state is as follows: First, the two servo motors rotate separately, and the angle signal feedback is used to control the drive gear and the loading plate gear ring to reach a specific matching position; first, the horizontal stepper motor rotates to drive the horizontal support plate to move toward the gear ring side. When the horizontal proximity switch receives the signal, the horizontal stepper motor rotates in the opposite direction for several seconds, so that the horizontal proximity switch loses the signal again; then, the vertical stepper motor is started to stop the movement after the vertical proximity switch receives the signal; finally, the horizontal stepper motor rotates again so that the horizontal proximity switch receives the signal. At this time, the drive gear and the loading plate gear reach the best meshing state.

[0028] Reference Figure 1-Figure 3 The PLC controller is electrically connected to the load simulation module, the speed drive module, the signal acquisition module and the human-computer interaction module respectively to control and monitor the action status of each module; the load simulation module is electrically connected to the speed drive module, and loads of different sizes are applied to the bearing by weight loading. The speed drive module is connected to the servo motor to control the speed of the bearing; specifically, the weight is a weight of customized weight, and the load size is controlled by a combination of weights of different weights; the speed drive module is connected to the servo motor to control the speed of the bearing; RS485 communication is adopted between the servo motor driver and the PLC, and the motor speed is written and read by polling in the PLC program for communication control to ensure normal communication. The rated power of the servo motor is 1000W, the rated speed is 2500r / min, the speed of the bearing to be tested is set to 0.1r / min, the acceleration time is 5s, and when the motor is overloaded, it is automatically shut down to ensure the safe and stable operation of the servo motor. Various working conditions of the bearing during operation are simulated in combination with different loads and speeds. Through the servo motor and load simulation module, multi-condition simulation is performed to realize the starting torque simulation under different load and speed conditions, and comprehensively evaluate the bearing performance.

[0029] Reference Figure 1-Figure 3 , the signal acquisition module is electrically connected to the data processing module; specifically, real-time monitoring and data acquisition, equipped with a signal acquisition module, to achieve real-time monitoring of key data of the bearing startup process to ensure the accuracy of the test data.

[0030] Reference Figure 1-Figure 3The PLC controller is electrically interconnected with the human-machine interaction module to realize the automatic control of the test bench and is responsible for coordinating and controlling the operation of each module. The human-machine interaction module is designed with a human-machine interaction interface in a computer. The user can set test parameters, monitor real-time data, adjust the speed drive module and other operations, and automatically generate single or multiple test reports for easy record keeping. The network connection is introduced to realize remote control and monitoring functions. The user can remotely access the test bench through the network, observe the test process in real time, adjust parameters, and improve the flexibility of the test. Specifically, the human-machine interaction module uses KingView to write the human-machine interaction interface. The model of the PLC controller is Siemens 1200, and Ethernet communication is used with the human-machine interaction module. The human-machine interaction interface mainly includes parameter setting, status monitoring, report generation and printing and other functions. The bit state in the PLC controller program is controlled by a virtual button switch. The parameter values ​​in the PLC controller program are set through the input box, and various signals in the signal acquisition module are monitored through real-time charts. The network connection is introduced to realize remote control and monitoring functions. The user can remotely access the test bench through the network, observe the test process in real time, adjust parameters, and improve the flexibility of the test; the human-computer interaction module is interconnected with the PLC controller, and the PLC controller is connected with other modules. The human-computer interaction module sends control instructions to the PLC controller, and the PLC controller sends control signals to the speed drive module, the load simulation module and the signal acquisition module to realize the speed of the bearing and the size of the load it bears, simulate various working conditions, and monitor the torque and load conditions of the bearing during operation in real time. At the same time, it can automatically generate single or multiple test result reports for user storage and recording; the use of PLC controllers to realize automatic control of the test bench improves test efficiency, reduces manual intervention, and ensures test consistency.

[0031] Reference Figure 1-Figure 3 The signal acquisition module is composed of sensors, including torque sensors and pressure sensors. The torque sensor is used to detect the torque condition of the bearing during operation, and the pressure sensor is used to detect the load condition of the bearing. Specifically, the sensors all use 4~20mA current signals as output signals, and the acquisition frequency is set to 20HZ. The torque sensor uses a dynamic torque sensor, which can be connected to a servo motor and rotate synchronously with the servo motor. The 4~20mA current signal is set to correspond to a torque value of 0~300N·m. The pressure sensor uses a spoke wheel pressure sensor, and the 4~20mA current signal is set to correspond to a pressure value of 0~40t.

[0032] Reference Figure 1-Figure 3, the data processing module is connected to the human-computer interaction module, in which the collected signal data can be monitored, analyzed, processed and stored; specifically, the torque value obtained by the torque sensor during the test is automatically saved in the historical database of the KingView, and a historical data query button is provided in the human-computer interaction interface, which can query historical data according to time and generate historical curves. The system automatically divides the historical curve into two parts, namely the bearing speed acceleration stage and the stable operation stage. For the acceleration stage, the maximum value of the torque data is taken as the starting torque; for the stable operation stage, the average value of the torque data is taken as the operating torque and the maximum and minimum values ​​of this stage are obtained. All the above results are reflected in the test report for user storage and recording.

[0033] Reference Figure 1-Figure 3 , the circuit breaker is connected to the speed control module and the load simulation module respectively. When there is a problem with the speed control module and the load simulation module, the power is forced to be cut off; specifically, after the load is loaded, the servo motor will rotate at the specified speed and acceleration time, and the system will record the acquired torque value according to the acquisition frequency of the sensor. When the torque value exceeds the set torque threshold, the system will determine that the torque is abnormal and retest. When the torque value does not exceed the set torque threshold, but the test duration reaches the set time, the test is officially ended. Users can export historical data according to time and generate and print test reports.

[0034] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0035] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A PLC-based bearing starting torque test bench electrical control system, including a PLC controller, a servo motor, a circuit breaker, a load simulation module, a speed drive module, a signal acquisition module, a data processing module and a human-computer interaction module, characterized in that: The PLC controller is electrically connected to the load simulation module, the speed driving module, the signal acquisition module and the human-computer interaction module respectively to control and monitor the action status of each module; The load simulation module is electrically connected to the speed driving module, and loads of different sizes are applied to the bearing by weight loading. The speed driving module is connected to the servo motor to control the speed of the bearing; The signal acquisition module is electrically connected to the data processing module, and the data processing module is connected to the human-computer interaction module, and the collected signal data can be monitored, analyzed, processed and stored in the human-computer interaction module; The PLC controller is electrically interconnected with the human-machine interaction module to realize the automatic control of the test bench and is responsible for coordinating and controlling the operation of each module. The human-machine interaction module is designed with a computer-designed human-machine interaction interface. The user can set test parameters, monitor real-time data, adjust the speed drive module and other operations, and automatically generate single or multiple test reports for easy record keeping. A network connection is introduced to realize remote control and monitoring functions. The user can remotely access the test bench through the network, observe the test process in real time, adjust parameters, and improve the flexibility of the test.

2. The PLC-based bearing starting torque test bench electrical control system according to claim 1, characterized in that: The PLC controller includes a CPU, a power module, an input module, and an output module.

3. The PLC-based bearing starting torque test bench electrical control system according to claim 1, characterized in that: The signal acquisition module is composed of sensors.

4. The PLC-based bearing starting torque test bench electrical control system according to claim 3, characterized in that: The sensors include a torque sensor and a pressure sensor.

5. The PLC-based bearing starting torque test bench electrical control system according to claim 4, characterized in that: The torque sensor is used to detect the torque condition of the bearing during operation.

6. The PLC-based bearing starting torque test bench electrical control system according to claim 4, characterized in that: The pressure sensor is used to detect the load condition borne by the bearing.

7. The PLC-based bearing starting torque test bench electrical control system according to claim 1, characterized in that: The circuit breaker is connected to the speed driving module and the load simulation module respectively, and when problems occur in the speed control module and the load simulation module, power is forcibly cut off.

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