Fault diagnosis method for electro-hydraulic system

Abstract

The invention provides an electro-hydraulic system fault detection method, which belongs to the technical field of electro-hydraulic control, and comprises the following steps: obtaining actual parameters of an electro-hydraulic system, and constructing a visual interactive virtual environment; acquiring operation data of the electro-hydraulic system in real time, and synchronizing the operation data to the virtual environment; electric control logic interlocking and hydraulic control interlocking are interpreted; writing a fault detection logic code based on the operation data of the electro-hydraulic system; and performing fault detection on the electro-hydraulic system based on the fault detection logic code, and synchronizing a fault detection result to the virtual environment for visual feedback. The operation data of the electro-hydraulic system are collected in real time, fault judgment is carried out on the electro-hydraulic system based on the operation data, and the fault judgment result is synchronized to the visual interactive interface in real time, so that a technician can visually check the operation state of the electro-hydraulic system and timely and visually check whether the electro-hydraulic system breaks down or not.

Description

Technical Field

[0001] The invention belongs to the technical field of electronically controlled hydraulic systems, and in particular relates to a fault diagnosis method for an electro-hydraulic system. Background Art

[0002] In a modern industrial production environment, the efficient operation of automated production lines is crucial to improving production efficiency and product quality. Such production lines usually rely on two core control systems: electronic control systems and hydraulic systems. Electronic control systems use electrical signals for precise control, while hydraulic systems drive various mechanical equipment through hydraulic pressure and flow. In order to integrate the advantages of both, the electro-hydraulic system came into being. The system combines the dual characteristics of electronic control and hydraulics to achieve a more complex and efficient automatic hydraulic control function, further improving the flexibility and efficiency of the production line.

[0003] However, the complexity of the electro-hydraulic system also brings significant maintenance challenges, especially in troubleshooting. Since the electro-hydraulic system integrates devices from the two major fields of electrical automation and hydraulic control, including proportional valves, servo valves, reversing valves, hydraulic actuators (hydraulic cylinders, hydraulic motors, etc.), manual valves, etc., this requires maintenance personnel to not only be proficient in electrical control logic, but also have a deep understanding of the structure and working principle of the hydraulic system. However, in actual operation, since it involves two majors, electronic control and hydraulics, and there is a professional and technical knowledge barrier between electrical technicians and hydraulic technicians, when a fault occurs in the electronic control hydraulic system, the fault point cannot be quickly found, and the troubleshooting of the two professionals cannot be effectively combined, which is prone to blind spots and misleading. And when a fault occurs, technicians from both the electronic control and hydraulic professions are required to gradually troubleshoot all the equipment, which is inefficient and takes a long time.

[0004] Therefore, there is an urgent need for a visual fault diagnosis method that can break the knowledge barriers between electrical and hydraulic professional technicians and achieve rapid and accurate diagnosis and positioning of electronically controlled hydraulic system faults. Summary of the invention

[0005] The purpose of the present invention is to provide an electro-hydraulic system fault diagnosis method for solving the technical problem that a visual fault diagnosis method is urgently needed to achieve rapid and accurate diagnosis and positioning of electronically controlled hydraulic system faults.

[0006] The present application provides a method for diagnosing a fault in an electro-hydraulic system, the method comprising: Obtain the actual parameters of the electro-hydraulic system and build a visual and interactive virtual environment; Collecting operating data of the electro-hydraulic system in real time and synchronizing the operating data to the virtual environment; Interpretation of electronic control logic interlocking and hydraulic control interlocking; Write fault detection logic code based on the operating data of the electro-hydraulic system; Fault detection is performed on the electro-hydraulic system based on the fault detection logic code, and the fault detection result is synchronized to the virtual environment for visual feedback.

[0007] Furthermore, the actual parameters of the electro-hydraulic system are obtained and a visual and interactive virtual environment is constructed, including the following specific steps: Obtain the physical entity parameters of hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits, and controllers in the electro-hydraulic system, and establish the corresponding three-dimensional digital model; Importing the three-dimensional digital model into virtual reality software and establishing an interactive interface; The operating status of the electro-hydraulic system is presented graphically. The real-time status of the electro-hydraulic system can be intuitively understood by presenting the operating status of the electro-hydraulic system in a graphical way, including parameters such as pressure, flow, temperature of hydraulic components, and the connection status of hydraulic pipelines.

[0008] Furthermore, the physical entity parameters of the hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits, and controllers in the electro-hydraulic system are obtained, and the corresponding three-dimensional digital models are established, including: Collecting physical entity parameters of hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits, and controllers in the electro-hydraulic system, wherein the physical entity parameters include size, material, and location; According to the collected physical entity parameters, a corresponding three-dimensional digital model is established using three-dimensional modeling software; The hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits and controllers in the electro-hydraulic system are combined to generate a three-dimensional digital model of the entire electro-hydraulic system.

[0009] Furthermore, real-time collection of operating data of the electro-hydraulic system and synchronization of the operating data to the virtual environment include: Collect the operating data of each device of the electro-hydraulic system; Acquire the collected operating data of each device in the electro-hydraulic system, and synchronously upload the operating data to the virtual environment; The virtual environment displays device information of each device in the electro-hydraulic system and operation data of the corresponding device in real time.

[0010] Furthermore, each of the devices includes: a proportional valve, a servo valve, a reversing valve, a hydraulic actuator and a manual valve; The device information includes name, number and alarm signal; The alarm signal includes a red flashing signal, a yellow flashing signal and a green flashing signal.

[0011] Furthermore, the operation data of each device of the electro-hydraulic system is collected, including: An electric signal converter and a voltage pressure gauge are provided on both the proportional valve and the servo valve. The electric signal converter converts the opening degree of the proportional valve and the servo valve into an opening degree electric signal. The voltage pressure gauge detects the voltage value signal of the proportional valve and the servo valve in real time. A magnetic switch is provided on the reversing valve, and the magnetic switch is used to detect the power-on state signal of the coil of the reversing valve in real time; A pressure sensor is provided on the hydraulic actuator, and the pressure sensor is used to detect the action signal of the hydraulic actuator in real time; A limit switch is arranged on the manual valve, and the limit switch is used to detect an opening and closing state signal of the manual valve.

[0012] Further, the collected operation data of each device in the electro-hydraulic system is obtained, and the operation data is synchronously uploaded to the virtual environment, including: A first PLC controller is provided, and the first PLC controller is used to obtain the opening degree electrical signals of the proportional valve and the servo valve collected by the electrical signal converter; A second PLC controller is provided, and the second PLC controller is used to obtain the coil power-on state signal of the reversing valve collected by the magnetic switch; A third PLC controller is provided, and the third PLC controller is used to obtain the action signal of the hydraulic actuator collected by the pressure sensor; A fourth PLC controller is provided, and the fourth PLC controller is used to obtain the opening and closing state signal of the manual valve collected by the limit switch; A fifth PLC controller is provided, and the fifth PLC controller is used to obtain voltage value signals of the proportional valve and the servo valve collected by the voltage tester; A main controller is provided, which is electrically connected to the first PLC controller, the second PLC controller, the third PLC controller, the fourth PLC controller and the fifth PLC controller respectively, and is used to obtain operation data collected by the first PLC controller, the second PLC controller, the third PLC controller, the fourth PLC controller and the fifth PLC controller, and synchronously upload the operation data to the virtual environment.

[0013] Further, the electro-hydraulic system is subjected to fault detection based on the fault detection logic code, and the fault detection result is synchronized to the virtual environment for visual feedback, including: When the fourth PLC controller detects through the limit switch that the opening and closing state of the manual valve controlling the oil inlet and outlet in the electro-hydraulic control system is not open, the main controller controls the virtual environment to output the alarm information that the manual valve is not open, and controls the alarm signal corresponding to the manual valve to change to a red flashing signal; when the fourth PLC controller detects that the opening and closing state of the manual valve changes to open, the main controller controls the alarm information corresponding to the manual valve to change to a green flashing signal; When the second PLC controller detects through the magnetic switch that the directional control valve is not powered: If the third PLC controller does not detect that the hydraulic actuator has any action through the pressure sensor, the main controller controls the interactive interface to output an alarm message of "Please check the line voltage and the reversing valve", and controls the alarm signal corresponding to the reversing valve to become a red flashing signal; If the third PLC controller detects that the hydraulic actuator is in motion through the pressure sensor, the main controller controls the interactive interface to output an alarm message of "Please check the feedback signal of the reversing valve" and controls the alarm signal corresponding to the reversing valve to become a yellow flashing signal.

[0014] Further, the electro-hydraulic system is fault-detected based on the fault detection logic code, and the fault detection result is synchronized to the virtual environment for visual feedback, further comprising: When the third PLC controller does not detect that the hydraulic actuator has any action through the pressure sensor, the main controller controls the interactive interface to output an alarm message of "Please check the power supply voltage and electrical signal of the proportional valve or servo valve. If the electrical signal is normal, replace the proportional valve or servo valve, including the external amplifier board and the signal isolation converter", and controls the alarm signal corresponding to the proportional valve or servo valve to become a red flashing signal; When the third PLC controller detects that the hydraulic actuator has moved through the pressure sensor, the controller controls the interactive interface to output "Please check the feedback circuit and signal of the proportional valve or servo valve core", and controls the corresponding alarm signal of the proportional valve or servo valve to change to a yellow flashing signal; When the second PLC controller detects through the magnetic switch that the directional control valve is powered, the voltage value signal of the proportional valve or servo valve collected by the fifth PLC controller through the voltage gauge, and the opening degree electrical signal of the proportional valve and servo valve collected by the first PLC controller through the electrical signal converter do not exceed the preset threshold value, but the third PLC controller does not detect that the hydraulic actuator has any action through the pressure sensor: If the voltage value signal of the proportional valve or servo valve collected by the fifth PLC controller is in the high-speed output state, the main controller controls the interactive interface to output "Please check and replace the non-electrically controlled hydraulic components in the electronically controlled hydraulic system"; If the voltage value signal of the proportional valve or servo valve collected by the fifth PLC controller is in a low-speed output state, the main controller controls the interactive interface to output "Please check whether there is a mechanical card group or a leak on site. If there is no such situation, try to increase the low-speed output", and controls the alarm signal corresponding to the proportional valve or servo valve to become a red flashing signal; If the movement direction of the hydraulic actuator detected by the third PLC controller through the pressure sensor is opposite to the set direction, the main controller controls the interactive interface to output "the oil pipe is connected reversely, please check the hydraulic actuator mark and connect the oil pipe correctly."

[0015] Further, the electro-hydraulic system is fault-detected based on the fault detection logic code, and the fault detection result is synchronized to the virtual environment for visual feedback, further comprising: When the data detected by the voltage tester of the fifth PLC controller is abnormal: If the detected data anomaly is a voltage tester fault signal, the controller controls the interactive interface to output "Please check the voltage tester"; When the detected data abnormality is that the voltage value is lower than the preset voltage lower limit threshold, the main controller controls the interactive interface to output "Please check the line and power module. If normal, check and replace the load"; When the detected data abnormality is that the voltage value is higher than the preset voltage upper limit threshold, the main controller controls the interactive interface to output "The power supply voltage is too high, please adjust the power supply voltage in time", and changes the alarm signal corresponding to the proportional valve or servo valve to a red flashing signal.

[0016] It can be seen from the above technical solutions that the present invention has the following advantages: In the electro-hydraulic system fault diagnosis method provided in the present application, by real-time collection of the operating data of the electro-hydraulic system, and based on the operating data, the electro-hydraulic system fault diagnosis is performed, and the fault diagnosis results are synchronized in real time to a visual interactive interface. The technicians can intuitively view the operating status of the electro-hydraulic system and promptly and intuitively check whether the electro-hydraulic system has faults, which significantly improves the reliability and safety of the electro-hydraulic control system and reduces downtime and production losses caused by faults. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solution of the present invention, the accompanying drawings required for use in the description will be briefly introduced below. Obviously, the accompanying drawings in the following description are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0018] Figure 1 The present invention is a flow chart of a method for detecting faults in an electro-hydraulic system. DETAILED DESCRIPTION

[0019] In the electro-hydraulic system fault detection method described in detail below, various embodiments of the present disclosure will be described more fully. The present disclosure may have various embodiments, and adjustments and changes may be made therein. However, it should be understood that there is no intention to limit the various embodiments of the present disclosure to the specific embodiments disclosed herein, but rather the present disclosure should be understood to cover all adjustments, equivalents and / or alternatives that fall within the spirit and scope of the various embodiments of the present disclosure.

[0020] Hereinafter, the terms "include" or "may include" used in various embodiments of the present disclosure indicate the presence of disclosed functions, operations, or elements, and do not limit the addition of one or more functions, operations, or elements. In addition, as used in various embodiments of the present disclosure, the terms "include", "have", and their cognates are intended only to indicate specific features, numbers, steps, operations, elements, components, or a combination of the foregoing, and should not be understood as first excluding the presence of one or more other features, numbers, steps, operations, elements, components, or a combination of the foregoing or the possibility of adding one or more features, numbers, steps, operations, elements, components, or a combination of the foregoing.

[0021] In various embodiments of the present disclosure, the expression "or" or "at least one of A or / and B" includes any combination or all combinations of the words listed at the same time. For example, the expression "A or B" or "at least one of A or / and B" may include A, may include B, or may include both A and B.

[0022] The expressions (such as "first", "second", etc.) used in the various embodiments of the present disclosure may modify the various constituent elements in the various embodiments, but may not limit the corresponding constituent elements. For example, the above expressions do not limit the order and / or importance of the elements. The above expressions are only used for the purpose of distinguishing one element from other elements. For example, the first user device and the second user device indicate different user devices, although both are user devices. For example, without departing from the scope of the various embodiments of the present disclosure, the first element may be referred to as the second element, and similarly, the second element may also be referred to as the first element.

[0023] It should be noted that if it is described that one component element is “connected” to another component element, the first component element may be directly connected to the second component element, and a third component element may be “connected” between the first component element and the second component element. Conversely, when one component element is “directly connected” to another component element, it can be understood that there is no third component element between the first component element and the second component element.

[0024] The term “user” used in various embodiments of the present disclosure may indicate a person who uses an electronic device, and may be a monitoring person, a test person, or an operator.

[0025] 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 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.

[0026] It should be noted that the servo valve and proportional valve, as amplifying and converting elements, can amplify the deviation signal and convert it into a hydraulic signal (flow or pressure), thereby completing the control of the actuator. In a typical cylinder control system, the movement of the cylinder can be achieved by switching the oil circuit at different valve positions. Such a valve can use an ordinary reversing valve. The servo valve and proportional valve can not only control the movement direction of the cylinder, but also accurately control the valve opening to accurately control the flow while keeping the working state unchanged.

[0027] In hydraulic systems, 4-20mA is a common analog control signal standard used to control the output of servo valves or proportional valves. This signal represents the control range of the valve, with 4mA representing the minimum output and 20mA representing the maximum output. When the control signal is close to 4mA, it means that the output required by the system is in a lower range, at which point the servo valve or proportional valve is opened smaller and the amount of liquid flowing through is smaller. In this case, the hydraulic system will provide a smaller flow rate and the actuator will move slower, that is, it is in a low-speed output state. Low-speed output is suitable for situations where precise control is required, such as fine positioning or small adjustments. When the control signal is close to 20mA, it means that the output required by the system is close to the maximum range, at which point the valve is opened wider, allowing more liquid to pass through. This means that the hydraulic system provides a larger flow rate, the actuator moves quickly, and is in a high-speed output state. High-speed output is suitable for operating scenarios that require fast response and a large amount of fluid to pass through, such as fast startup or large-range movements. Intermediate current values ​​(such as 12mA) represent medium outputs, with valve openings, liquid flow rates, and actuator movement speeds between low and high speeds. Therefore, the present application selects that when the output signal range of the proportional valve or servo valve is 4-12mA, it is a low-speed output state, and when the output signal range is 12-20mA, it is a high-speed output state.

[0028] The embodiment of the present application provides an electro-hydraulic system fault diagnosis method to solve the technical problem that a visual fault diagnosis method is urgently needed to achieve rapid and accurate diagnosis and location of electronic control and hydraulic system faults.

[0029] The technical solution proposed in the embodiments of the present application is described in detail below with reference to the accompanying drawings.

[0030] Figure 1This is a flow chart of a method for diagnosing electro-hydraulic system faults provided in an embodiment of the present application. Figure 1 As shown, an electro-hydraulic system fault diagnosis method provided in an embodiment of the present application specifically includes the following steps: Obtain the actual parameters of the electro-hydraulic system and build a visual and interactive virtual environment.

[0031] The operating data of the electro-hydraulic system is collected in real time, and the operating data is synchronized to the virtual environment.

[0032] Interpret the electronic control logic interlock and hydraulic control interlock.

[0033] Write fault detection logic code based on the operating data of the electro-hydraulic system.

[0034] Fault detection is performed on the electro-hydraulic system based on the fault detection logic code, and the fault detection result is synchronized to the virtual environment for visual feedback.

[0035] By collecting the operating data of the electro-hydraulic system in real time and synchronizing the operating data to the virtual environment, the real-time and consistency of the data is ensured, which helps to quickly identify potential problems. In addition, operation and maintenance personnel can instantly understand the operating status of the electro-hydraulic system without waiting for on-site inspections, thereby improving work efficiency. By building a visual and interactive virtual environment, complex electro-hydraulic system parameters and operating status can be presented in a graphical manner, which is convenient for non-professionals to quickly understand and master. Fault detection based on the operating data of the electro-hydraulic system, the fault detection results are visualized in the virtual environment to help operation and maintenance personnel quickly locate the fault point and improve the efficiency and accuracy of fault handling.

[0036] In an exemplary embodiment, obtaining actual parameters of an electro-hydraulic system and constructing a visual interactive virtual environment include the following specific steps: Obtain the physical entity parameters of hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits, and controllers in the electro-hydraulic system, and establish the corresponding three-dimensional digital model.

[0037] The three-dimensional digital model is imported into virtual reality software, and an interactive interface is established.

[0038] In this embodiment, some preprocessing and conversion are required to import the 3D digital model into the virtual reality software. First, the 3D digital model is converted into a format supported by the virtual reality software, such as FBX, OBJ, 3DS, etc. Secondly, the 3D digital model is adjusted in terms of material, texture, lighting, etc. according to the requirements of the virtual reality software. Finally, the adjusted 3D digital model is imported into the virtual reality software, and the interactive interface is designed, such as menu bar, buttons and handles.

[0039] When establishing an interactive interface, it is necessary to design it according to the needs and application scenarios. For example, by adding a user handle, the user can zoom, rotate, move, and perform other operations on the 3D digital model through the handle, making it easier to observe and analyze. In addition, a data display window can be added to display the operating parameters and diagnostic results of the electro-hydraulic system in real time, making it easier for users to conduct real-time monitoring and diagnosis.

[0040] The operating status of the electro-hydraulic system is presented graphically. The real-time status of the electro-hydraulic system can be intuitively understood by presenting the operating status of the electro-hydraulic system in a graphical way, including parameters such as pressure, flow, temperature of hydraulic components, and the connection status of hydraulic pipelines.

[0041] For example, the logic of interactive operation with the controller is added to adjust the operating state of the electro-hydraulic system. The electro-hydraulic system can be adjusted, such as adjusting the working pressure and flow of the hydraulic components, changing the connection mode of the hydraulic pipeline, and adjusting the switch state of the electromagnetic switch to simulate the operating state of the electro-hydraulic system under different working conditions.

[0042] According to another embodiment of the present invention, obtaining physical entity parameters of hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits, and controllers in an electro-hydraulic system and establishing corresponding three-dimensional digital models include: Collect the physical entity parameters of hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits, and controllers in the electro-hydraulic system, wherein the physical entity parameters include size, material, and position.

[0043] According to the collected physical entity parameters, the corresponding three-dimensional digital model is established using three-dimensional modeling software.

[0044] For example, the 3D modeling software may be SolidWorks or CATIA.

[0045] The hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits and controllers in the electro-hydraulic system are combined to generate a three-dimensional digital model of the entire electro-hydraulic system.

[0046] It should be noted that the three-dimensional digital model can be optimized and modified as needed to better reflect the operation of the electro-hydraulic system.

[0047] In a feasible embodiment of the present application, by combing the electro-hydraulic system schematic, the structural diagram of the entire electro-hydraulic system is presented in an interactive interface, including the inlet and outlet oil identifications of electronically controlled hydraulic devices, non-electronically controlled hydraulic devices and actuators, and the electronically controlled commands, feedback signals and hydraulic system device control logic are combined to dynamically present the real-time changes in the flow direction, pressure, and movement direction of the inlet and outlet oil pipelines of the electronically controlled hydraulic devices, non-electronically controlled hydraulic devices, and actuators.

[0048] Further, as a refinement and extension of the specific implementation of the above embodiment, in order to fully illustrate the specific implementation process in this embodiment, another electro-hydraulic system fault detection method is provided, wherein the operation data of the electro-hydraulic system is collected in real time and the operation data is synchronized to the virtual environment, including: Collect the operating data of each device in the electro-hydraulic system.

[0049] The collected operating data of each device in the electro-hydraulic system is obtained, and the operating data is synchronously uploaded to the virtual environment.

[0050] The virtual environment displays device information of each device in the electro-hydraulic system and operation data of the corresponding device in real time.

[0051] According to an embodiment of the present application, the devices include: a proportional valve, a servo valve, a reversing valve, a hydraulic actuator and a manual valve.

[0052] The device information includes name, number and alarm signal.

[0053] The alarm signal includes a red flashing signal, a yellow flashing signal and a green flashing signal.

[0054] It should be noted that the "green flashing signal" means the device is normal; the "yellow flashing signal" means the warning only affects detection; the "red flashing signal" means the fault has affected the use of the device. In addition to the interactive interface prompt alarm, in a feasible embodiment, the background code can also be used to control the speaker to broadcast the alarm content in a voice loop, and it has a fault reset mute function.

[0055] It should be further explained that the operating data of each device of the electro-hydraulic system is collected, including: The proportional valve and the servo valve are both provided with an electric signal converter and a voltage pressure meter. The electric signal converter converts the opening degree of the proportional valve and the servo valve into an opening degree electric signal. The voltage pressure meter detects the voltage value signal of the proportional valve and the servo valve in real time.

[0056] A magnetic switch is arranged on the reversing valve, and the magnetic switch is used for detecting the power-on state signal of the coil of the reversing valve in real time.

[0057] A pressure sensor is provided on the hydraulic actuator, and the pressure sensor is used to detect the action signal of the hydraulic actuator in real time.

[0058] A limit switch is arranged on the manual valve, and the limit switch is used to detect an opening and closing state signal of the manual valve.

[0059] In one embodiment, acquiring the collected operating data of each device in the electro-hydraulic system and synchronously uploading the operating data to the virtual environment includes: A first PLC controller is provided, and the first PLC controller is used to obtain the opening degree electrical signals of the proportional valve and the servo valve collected by the electrical signal converter.

[0060] A second PLC controller is provided, and the second PLC controller is used to obtain the coil power-on state signal of the reversing valve collected by the magnetic switch.

[0061] A third PLC controller is provided, and the third PLC controller is used to obtain the action signal of the hydraulic actuator collected by the pressure sensor.

[0062] A fourth PLC controller is provided, and the fourth PLC controller is used to obtain the opening and closing state signal of the manual valve collected by the limit switch.

[0063] A fifth PLC controller is provided, and the fifth PLC controller is used to obtain voltage value signals of the proportional valve and the servo valve collected by the voltage tester.

[0064] A main controller is provided, which is electrically connected to the first PLC controller, the second PLC controller, the third PLC controller, the fourth PLC controller and the fifth PLC controller respectively, and is used to obtain operation data collected by the first PLC controller, the second PLC controller, the third PLC controller, the fourth PLC controller and the fifth PLC controller, and synchronously upload the operation data to the virtual environment.

[0065] By setting detection components on each device of the electro-hydraulic system and connecting them to the PLC controller, and each PLC controller is connected to the main controller, the status data of these devices can be obtained in real time, and the preset interactive interface can display the device information and status data corresponding to each device in the electro-hydraulic system, including the device name, number and alarm signal, etc. This intuitive visual display method enables operators to quickly understand the system status, which is convenient for troubleshooting and daily maintenance; when the system fails, the controller can quickly determine the cause of the failure according to the preset rules, and display it through the human-computer interaction interface, and output the corresponding alarm signal at the same time. The timely fault warning mechanism established helps to reduce the downtime of failure and improve production efficiency. The technical solution of this application can significantly improve the reliability and safety of the electro-hydraulic control system through real-time monitoring of the device, intuitive visual interface and convenient fault handling function, which helps to reduce downtime and production losses caused by failures, and at the same time reduce the safety risks caused by improper fault handling.

[0066] In addition, drawings usually have hundreds of pages, and people who are not familiar with the drawings cannot find them in a short time. Through the human-computer interaction interface and background code writing, mechanical, hydraulic, and electrical drawings can be quickly indexed and searched, and fault points can be confirmed and processed in time, reducing the time to find drawings.

[0067] According to an embodiment of the present application, fault detection is performed on the electro-hydraulic system based on the fault detection logic code, and the fault detection result is synchronized to the virtual environment for visual feedback, including: When the fourth PLC controller detects through the limit switch that the opening and closing state of the manual valve controlling the oil inlet and outlet in the electro-hydraulic control system is not open, the main controller controls the virtual environment to output an alarm message that the manual valve is not open, and controls the alarm signal corresponding to the manual valve to become a red flashing signal; when the fourth PLC controller detects that the opening and closing state of the manual valve becomes open, the main controller controls the alarm message corresponding to the manual valve to become a green flashing signal.

[0068] When the second PLC controller detects through the magnetic switch that the directional control valve is not powered: If the third PLC controller does not detect any action of the hydraulic actuator through the pressure sensor, the main controller controls the interactive interface to output the alarm message "Please check the line voltage and the reversing valve", and controls the alarm signal corresponding to the reversing valve to become a red flashing signal.

[0069] If the third PLC controller detects that the hydraulic actuator is in motion through the pressure sensor, the main controller controls the interactive interface to output an alarm message of "Please check the feedback signal of the reversing valve" and controls the alarm signal corresponding to the reversing valve to become a yellow flashing signal.

[0070] According to an embodiment of the present application, the electro-hydraulic system is fault-detected based on the fault detection logic code, and the fault detection result is synchronized to the virtual environment for visual feedback, which also includes: When the third PLC controller does not detect any movement of the hydraulic actuator through the pressure sensor, the main controller controls the interactive interface to output the alarm message "Please check the power supply voltage and electrical signal of the proportional valve or servo valve. If the electrical signal is normal, replace the proportional valve or servo valve, including the external amplifier board and signal isolation converter", and controls the alarm signal corresponding to the proportional valve or servo valve to become a red flashing signal.

[0071] When the third PLC controller detects that the hydraulic actuator has moved through the pressure sensor, the controller controls the interactive interface to output "Please check the feedback circuit and signal of the proportional valve or servo valve core", and controls the corresponding alarm signal of the proportional valve or servo valve to become a yellow flashing signal.

[0072] When the second PLC controller detects through the magnetic switch that the directional control valve is powered, the voltage value signal of the proportional valve or servo valve collected by the fifth PLC controller through the voltage gauge, and the opening degree electrical signal of the proportional valve and servo valve collected by the first PLC controller through the electrical signal converter do not exceed the preset threshold value, but the third PLC controller does not detect that the hydraulic actuator has any action through the pressure sensor: If the voltage value signal of the proportional valve or servo valve collected by the fifth PLC controller is in a high-speed output state, the main controller controls the interactive interface to output "Please check and replace the non-electrically controlled hydraulic components in the electronically controlled hydraulic system."

[0073] If the voltage value signal of the proportional valve or servo valve collected by the fifth PLC controller is in a low-speed output state, the main controller controls the interactive interface to output "Please check whether there is a mechanical card group or a leak on site. If there is no such situation, try to increase the low-speed output", and controls the alarm signal corresponding to the proportional valve or servo valve to become a red flashing signal.

[0074] If the movement direction of the hydraulic actuator detected by the third PLC controller through the pressure sensor is opposite to the set direction, the main controller controls the interactive interface to output "the oil pipe is connected reversely, please check the hydraulic actuator mark and connect the oil pipe correctly."

[0075] According to another embodiment of the present invention, the electro-hydraulic system is subjected to fault detection based on the fault detection logic code, and the fault detection result is synchronized to the virtual environment for visual feedback, further comprising: When the data detected by the voltage tester of the fifth PLC controller is abnormal: If the detected data abnormality is a voltage gauge fault signal, the controller controls the interactive interface to output "Please check the voltage gauge".

[0076] When the detected data is abnormal, that is, the voltage value is lower than the preset voltage lower limit threshold, the main controller controls the interactive interface to output "Please check the circuit and power module, if normal, check and replace the load". In this embodiment, the load includes components such as coils and amplifier boards.

[0077] When the detected data abnormality is that the voltage value is higher than the preset voltage upper limit threshold, the main controller controls the interactive interface to output "The power supply voltage is too high, please adjust the power supply voltage in time", and changes the alarm signal corresponding to the proportional valve or servo valve to a red flashing signal.

[0078] By setting detection components on each device of the electro-hydraulic system and connecting them to the PLC controller, and each PLC controller is connected to the main controller, the status data of these devices can be obtained in real time, and the preset interactive interface can display the device information and status data corresponding to each device in the electro-hydraulic system, including the device name, number and alarm signal, etc. This intuitive visual display method enables operators to quickly understand the system status, which is convenient for troubleshooting and daily maintenance; when the system fails, the controller can quickly determine the cause of the failure according to the preset rules, and display it through the human-computer interaction interface, and output the corresponding alarm signal at the same time. The timely fault warning mechanism established helps to reduce the downtime of failure and improve production efficiency. The technical solution of this application can significantly improve the reliability and safety of the electro-hydraulic control system through real-time monitoring of the device, intuitive visual interface and convenient fault handling function, which helps to reduce downtime and production losses caused by failures, and at the same time reduce the safety risks caused by improper fault handling.

[0079] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

[0080] For those skilled in the art, designing different forms of control circuits according to the teachings of the present invention does not require creative work. These changes, modifications, substitutions and variations of the embodiments without departing from the principles and spirit of the present invention still fall within the scope of protection of the present invention.

Claims

1. A method for diagnosing faults in an electro-hydraulic system, characterized in that: The method comprises: Obtain the actual parameters of the electro-hydraulic system and build a visual and interactive virtual environment; Collecting operating data of the electro-hydraulic system in real time and synchronizing the operating data to the virtual environment; Interpret the electronic control logic interlock and hydraulic control interlock; Write fault detection logic code based on the operating data of the electro-hydraulic system; Fault detection is performed on the electro-hydraulic system based on the fault detection logic code, and the fault detection result is synchronized to the virtual environment for visual feedback.

2. The fault diagnosis method according to claim 1, characterized in that: Obtaining the actual parameters of the electro-hydraulic system and building a visual and interactive virtual environment include the following specific steps: Obtain the physical entity parameters of hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits, and controllers in the electro-hydraulic system, and establish the corresponding three-dimensional digital model; Importing the three-dimensional digital model into virtual reality software and establishing an interactive interface; The operating status of the electro-hydraulic system is presented graphically.

3. The fault diagnosis method according to claim 2, characterized in that: Obtain the physical entity parameters of hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits, and controllers in the electro-hydraulic system, and establish the corresponding three-dimensional digital model, including: Collecting physical entity parameters of hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits, and controllers in the electro-hydraulic system, wherein the physical entity parameters include size, material, and location; According to the collected physical entity parameters, a corresponding three-dimensional digital model is established using three-dimensional modeling software; The hydraulic components, hydraulic pipelines, electronic control components, electronic control circuits and controllers in the electro-hydraulic system are combined to generate a three-dimensional digital model of the entire electro-hydraulic system.

4. The fault diagnosis method according to claim 3, characterized in that: Collecting the operating data of the electro-hydraulic system in real time and synchronizing the operating data to the virtual environment, including: Collect the operating data of each device of the electro-hydraulic system; Acquire the collected operating data of each device in the electro-hydraulic system, and synchronously upload the operating data to the virtual environment; The virtual environment displays device information of each device in the electro-hydraulic system and operation data of the corresponding device in real time.

5. The fault diagnosis method according to claim 4, characterized in that: The devices include: a proportional valve, a servo valve, a reversing valve, a hydraulic actuator and a manual valve; The device information includes name, number and alarm signal; The alarm signal includes a red flashing signal, a yellow flashing signal and a green flashing signal.

6. The fault diagnosis method according to claim 5, characterized in that: Collect the operating data of each device of the electro-hydraulic system, including: An electric signal converter and a voltage pressure gauge are provided on both the proportional valve and the servo valve. The electric signal converter converts the opening degree of the proportional valve and the servo valve into an opening degree electric signal. The voltage pressure gauge detects the voltage value signal of the proportional valve and the servo valve in real time. A magnetic switch is provided on the reversing valve, and the magnetic switch is used to detect the power-on state signal of the coil of the reversing valve in real time; A pressure sensor is provided on the hydraulic actuator, and the pressure sensor is used to detect the action signal of the hydraulic actuator in real time; A limit switch is arranged on the manual valve, and the limit switch is used to detect an opening and closing state signal of the manual valve.

7. The fault diagnosis method according to claim 6, characterized in that: Acquiring the collected operating data of each device in the electro-hydraulic system and synchronously uploading the operating data to the virtual environment, including: A first PLC controller is provided, and the first PLC controller is used to obtain the opening degree electrical signals of the proportional valve and the servo valve collected by the electrical signal converter; A second PLC controller is provided, and the second PLC controller is used to obtain the coil power-on state signal of the reversing valve collected by the magnetic switch; A third PLC controller is provided, and the third PLC controller is used to obtain the action signal of the hydraulic actuator collected by the pressure sensor; A fourth PLC controller is provided, and the fourth PLC controller is used to obtain the opening and closing state signal of the manual valve collected by the limit switch; A fifth PLC controller is provided, and the fifth PLC controller is used to obtain voltage value signals of the proportional valve and the servo valve collected by the voltage tester; A main controller is provided, which is electrically connected to the first PLC controller, the second PLC controller, the third PLC controller, the fourth PLC controller and the fifth PLC controller respectively, and is used to obtain operation data collected by the first PLC controller, the second PLC controller, the third PLC controller, the fourth PLC controller and the fifth PLC controller, and synchronously upload the operation data to the virtual environment.

8. The fault diagnosis method according to claim 7, characterized in that: Performing fault detection on the electro-hydraulic system based on the fault detection logic code and synchronizing the fault detection result to the virtual environment for visual feedback, including: When the fourth PLC controller detects through the limit switch that the opening and closing state of the manual valve controlling the oil inlet and outlet in the electro-hydraulic control system is not open, the main controller controls the virtual environment to output the alarm information that the manual valve is not open, and controls the alarm signal corresponding to the manual valve to change to a red flashing signal; when the fourth PLC controller detects that the opening and closing state of the manual valve changes to open, the main controller controls the alarm information corresponding to the manual valve to change to a green flashing signal; When the second PLC controller detects through the magnetic switch that the directional control valve is not powered: If the third PLC controller does not detect that the hydraulic actuator has any action through the pressure sensor, the main controller controls the interactive interface to output the alarm message "Please check the line voltage and the reversing valve", and controls the alarm signal corresponding to the reversing valve to become a red flashing signal; If the third PLC controller detects that the hydraulic actuator is in motion through the pressure sensor, the main controller controls the interactive interface to output an alarm message of "Please check the feedback signal of the reversing valve" and controls the alarm signal corresponding to the reversing valve to become a yellow flashing signal.

9. The fault diagnosis method according to claim 7, characterized in that: Performing fault detection on the electro-hydraulic system based on the fault detection logic code, and synchronizing the fault detection result to the virtual environment for visual feedback, further comprising: When the third PLC controller does not detect that the hydraulic actuator has any action through the pressure sensor, the main controller controls the interactive interface to output the alarm message "Please check the power supply voltage and electrical signal of the proportional valve or servo valve. If the electrical signal is normal, replace the proportional valve or servo valve, including the external amplifier board and the signal isolation converter", and controls the alarm signal corresponding to the proportional valve or servo valve to change to a red flashing signal; When the third PLC controller detects that the hydraulic actuator is in motion through the pressure sensor, the controller controls the interactive interface to output "Please check the feedback circuit and signal of the proportional valve or servo valve core", and controls the corresponding alarm signal of the proportional valve or servo valve to change to a yellow flashing signal; When the second PLC controller detects through the magnetic switch that the directional control valve is powered, the voltage value signal of the proportional valve or servo valve collected by the fifth PLC controller through the voltage gauge, and the opening degree electrical signal of the proportional valve and servo valve collected by the first PLC controller through the electrical signal converter do not exceed the preset threshold value, but the third PLC controller does not detect that the hydraulic actuator has any action through the pressure sensor: If the voltage value signal of the proportional valve or servo valve collected by the fifth PLC controller is in the high-speed output state, the main controller controls the interactive interface to output "Please check and replace the non-electrically controlled hydraulic components in the electronically controlled hydraulic system"; If the voltage value signal of the proportional valve or servo valve collected by the fifth PLC controller is in a low-speed output state, the main controller controls the interactive interface to output "Please check whether there is a mechanical card group or a leak on site. If there is no such situation, try to increase the low-speed output", and controls the alarm signal corresponding to the proportional valve or servo valve to become a red flashing signal; If the movement direction of the hydraulic actuator detected by the third PLC controller through the pressure sensor is opposite to the set direction, the main controller controls the interactive interface to output "The oil pipe is connected reversely, please check the hydraulic actuator mark and connect the oil pipe correctly." 10. The fault diagnosis method according to claim 7, characterized in that: Performing fault detection on the electro-hydraulic system based on the fault detection logic code, and synchronizing the fault detection result to the virtual environment for visual feedback, further comprising: When the data detected by the voltage tester of the fifth PLC controller is abnormal: If the detected data abnormality is a voltage tester fault signal, the controller controls the interactive interface to output "Please check the voltage tester"; When the detected data abnormality is that the voltage value is lower than the preset voltage lower limit threshold, the main controller controls the interactive interface to output "Please check the line and power module. If normal, check and replace the load"; When the detected data abnormality is that the voltage value is higher than the preset voltage upper limit threshold, the main controller controls the interactive interface to output "the power supply voltage is too high, please adjust the power supply voltage in time", and changes the alarm signal corresponding to the proportional valve or servo valve into a red flashing signal.

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