One-way valve test method and device based on hydraulic integrated valve block

Abstract

The invention discloses a one-way valve test method and device based on a hydraulic integrated valve block, and belongs to the technical field of intelligent detection of coal mine supporting equipment. The method comprises the steps that hydraulic system operation parameters are collected in real time through a fault sensing sensor, sensor data are mapped into initial parameters of a hydraulic schematic diagram, and the hydraulic schematic diagram conforming to actual working conditions is output; an initial layout of the hydraulic integrated valve block is generated through a mapping rule, and a three-dimensional layout design of the hydraulic integrated valve block is obtained; hydraulic integrated valve block internal oil hole communication design is carried out through external circulation, and hydraulic integrated valve block internal oil hole communication design is obtained; and performing software aided design analysis on the hydraulic pile-up valve block to obtain a simulation model of the hydraulic pile-up valve block so as to realize the one-way valve test based on the hydraulic pile-up valve block. The high-reliability one-way valve testing device provided by the invention can meet the requirement of testing the durability of the one-way valve in the standard; and the fault diagnosis accuracy is high.

Description

Technical Field

[0001] The present invention belongs to the technical field of intelligent detection of coal mine support equipment, and more specifically, relates to a check valve test method and device based on a hydraulic integrated valve block. Background Art

[0002] The support hydraulic system consists of five parts: a power element, an actuator, a control element, an auxiliary element, and a working medium. The control element includes various valves, and commonly used ones are directional control valve types, check valve types, safety valve types, and globe valve types. The check valve used in a hydraulic support is an important component of the hydraulic support system, and it has two main functions: one is to control the normal telescoping of the hydraulic support columns and jacks and maintain a reasonable working position; the other is to lock the liquid in the working chamber and maintain the supporting external force.

[0003] Commonly used check valves for hydraulic supports include pilot-operated check valves, double locks, single locks, alternating check valves, double alternating check valves, return liquid cut-off valves, differential pressure combination valves, etc. Among them, the pilot-operated check valve is particularly important because it is commonly used in columns.

[0004] After years of use, the existing detection equipment for hydraulic supports and their components has the following problems: first, the reliability of the detection equipment is poor, the maintenance volume is large, the number of failures of a single device exceeds 50 times per 100 hours, and the intelligent hardware foundation is poor; second, the intelligent level of the detection equipment is insufficient and cannot meet functions such as fault diagnosis; third, the shortage of personnel is serious, and the age structure is aging, making it difficult to meet the maintenance work of a large number of devices.

[0005] The prior art document (CN112213958A) discloses an electro-hydraulic control comprehensive simulation test platform. Its deficiency lies in the lack of in-depth consideration for the specific requirements of check valve testing, and it is not specifically set around aspects such as the testing requirements and fault diagnosis of check valves. In terms of fineness, its design and optimization of components in the hydraulic system are not deep enough, and it does not specifically involve the precise calculation and optimization of oil hole parameters inside the hydraulic integrated valve block, and cannot meet the scenarios with high-precision requirements for the performance of the valve block. Summary of the Invention

[0006] To solve the deficiencies in the prior art, the present invention provides a check valve test method and device based on a hydraulic integrated valve block, which realizes high integration and high reliability of the check valve test hydraulic system through forms such as the design of the hydraulic integrated valve block, and significantly reduces the failure rate.

[0007] The present invention adopts the following technical solutions:

[0008] The first aspect of the present invention provides a check valve test method based on a hydraulic integrated valve block, specifically including:

[0009] Collect the operating parameters of the hydraulic system in real time through a fault perception sensor, map the sensor data to the initial parameters of the hydraulic schematic diagram, and output a hydraulic schematic diagram that conforms to the actual working conditions;

[0010] Generate the initial layout of the hydraulic integrated valve block from the hydraulic schematic diagram through mapping rules to obtain the three-dimensional layout design of the hydraulic integrated valve block;

[0011] Carry out the internal oil hole connection design of the hydraulic integrated valve block through an outer loop for the three-dimensional layout design of the hydraulic integrated valve block to obtain the internal oil hole connection design of the hydraulic integrated valve block;

[0012] According to the internal oil hole connection design of the hydraulic integrated valve block, conduct software-assisted design analysis on the hydraulic integrated valve block to obtain the simulation model of the hydraulic integrated valve block and realize the check valve test based on the hydraulic integrated valve block.

[0013] Preferably, the generating the initial layout of the hydraulic integrated valve block from the hydraulic schematic diagram through mapping rules to obtain the three-dimensional layout design of the hydraulic integrated valve block specifically includes:

[0014] Determine the external dimensions of the hydraulic integrated valve block;

[0015] Set the component installation positions of the hydraulic integrated valve block according to the hydraulic schematic diagram through mapping rules;

[0016] Set the external connection interfaces according to the hydraulic schematic diagram.

[0017] Preferably, the carrying out the internal oil hole connection design of the hydraulic integrated valve block through an outer loop for the three-dimensional layout design of the hydraulic integrated valve block to obtain the internal oil hole connection design of the hydraulic integrated valve block specifically includes:

[0018] According to the main oil circuit interface position, branch oil circuit path, and cross-node layout obtained from the hydraulic integrated valve block layout design, input the internal oil hole connection design of the hydraulic integrated valve block through an outer loop to obtain the paths of the main oil circuit and branch oil circuits, and the layout of the cross-nodes;

[0019] Verify whether the paths of the main oil circuit and branch oil circuits meet the standards. If not, perform an inner loop iteration to adjust the parameters of the main oil circuit and branch oil circuits until they meet the standards.

[0020] Preferably, the according to the main oil circuit interface position, branch oil circuit path, and cross-node layout obtained from the hydraulic integrated valve block layout design, input the internal oil hole connection design of the hydraulic integrated valve block through an outer loop to obtain the paths of the main oil circuit and branch oil circuits, and the layout of the cross-nodes specifically includes:

[0021] Set the main oil circuit path. The main oil circuit path adopts a straight-through layout. The main oil circuit goes straight from the oil inlet to the boost interface and then extends to the oil outlet. Set the minimum flow channel diameter as the main oil circuit diameter;

[0022] Set the path of the branch oil circuit. The branch oil circuit diverges from the cross node and finally converges into the fuel tank. Solve the flow channel angle and bending radius between the branch oil circuits.

[0023] Layout the cross nodes. The cross points adopt a T-shaped connection, and the wall thickness is strengthened to 1.5 times the wall thickness of the main oil circuit.

[0024] Preferably, according to the internal oil hole connection design of the hydraulic integrated valve block, perform software-assisted design analysis on the hydraulic integrated valve block to obtain a simulation model of the hydraulic integrated valve block, specifically including:

[0025] Construct a simulation model of the preliminary hydraulic integrated valve block according to the internal oil hole connection design model.

[0026] Perform fault diagnosis on the simulation model of the hydraulic integrated valve block, correct the layout design of the hydraulic integrated valve block, and obtain an optimal simulation model of the hydraulic integrated valve block.

[0027] Preferably, the constructing a simulation model of the preliminary hydraulic integrated valve block according to the internal oil hole connection design model specifically includes:

[0028] Combine the internal oil hole connection design model with the fluid continuity, thermodynamics conservation, and PID control theory. Based on CAD, construct a three-dimensional geometric model, mark the main oil circuit interfaces and cross nodes, and generate a three-dimensional valve block model.

[0029] Divide the three-dimensional valve block model into a power unit, a booster unit, a test stand column unit, and a servo control unit to obtain a simulation model of the preliminary hydraulic integrated valve block.

[0030] Preferably, the dividing the three-dimensional valve block model into a power unit, a booster unit, a test stand column unit, and a servo control unit to obtain a simulation model of the preliminary hydraulic integrated valve block specifically includes:

[0031] Define the displacement-pressure relationship curve of the pump in the power unit, simulate the output characteristics of the hydraulic pump, drive the system flow rate and pressure, set the flow rate value, and obtain the pressure of the main oil circuit of the power unit.

[0032] Set the piston area ratio in the booster unit, multiply it by the pressure of the main oil circuit of the received power unit, and obtain the output pressure.

[0033] The test stand column unit, based on the received pressure fluctuation data of the booster unit, simulates the load of the hydraulic cylinder through the mechanical library components to obtain the load force.

[0034] The servo control unit builds a three-position four-way servo valve through the joint signal library and the hydraulic library, sets the PID parameters, receives the actual load force of the test column unit, and triggers the PID algorithm to calculate the adjustment amount based on the difference between the set load force and the actual load force. The three-position four-way servo valve receives the PID control instruction, dynamically adjusts the spool displacement, changes the flow rate of the branch oil circuit, and inputs the changed flow rate into the booster unit to adjust the inlet flow rate of the booster unit.

[0035] Preferably, for fault diagnosis of the simulation model of the hydraulic integrated valve block and correction of the layout design of the hydraulic integrated valve block to obtain the optimal simulation model of the hydraulic integrated valve block, it specifically includes:

[0036] Obtain simulation parameters by simulating the pressure difference of the main oil circuit, the stress tensor of the cross node, and the temperature gradient;

[0037] Conduct fault diagnosis based on the simulation parameters;

[0038] According to the fault diagnosis results, correct the flow channel diameter, flow channel angle, and bending radius.

[0039] Preferably, according to the fault diagnosis results, correcting the flow channel diameter, flow channel angle, and bending radius specifically includes:

[0040] According to Poiseuille's law in the fluid mechanics formula, the volume flow rate of the leaked main oil circuit is proportional to the cube of the flow channel diameter. Therefore, take the cube root of the ratio of the leakage rate threshold to the actual leakage rate and multiply it by the current flow channel diameter to obtain the corrected flow channel diameter;

[0041] Subtract the stress tensor monitored by simulation from the allowable stress threshold of the material, and then divide by the allowable stress threshold of the material to obtain the percentage of stress exceeding the allowable value; multiply the percentage of stress exceeding the allowable value by the empirical correction coefficient to obtain the angle adjustment amount. The empirical correction coefficient reflects the sensitivity of the cross node geometry to stress changes; then subtract the angle adjustment amount from the current flow channel angle to obtain the corrected flow channel angle;

[0042] According to the thermodynamic empirical model, the temperature rise is approximately proportional to the flow resistance, and the flow resistance is inversely proportional to the bending radius R. Therefore, divide the oil temperature rise monitored by simulation by the allowable maximum temperature rise threshold and take the square root to obtain the temperature adjustment amount, and then multiply it by the current bending radius to obtain the corrected bending radius.

[0043] In the second aspect of the present invention, a check valve test device based on a hydraulic integrated valve block is proposed. Running the check valve test method based on a hydraulic integrated valve block described in the first aspect includes:

[0044] The hydraulic schematic diagram generation module is used to collect the operating parameters of the hydraulic system in real time through the fault perception sensor, map the sensor data into the initial parameters of the hydraulic schematic diagram, and output the hydraulic schematic diagram that conforms to the actual working conditions;

[0045] The three-dimensional layout generation module is used to generate the initial layout of the hydraulic integrated valve block from the hydraulic schematic diagram through the mapping rule, and obtain the three-dimensional layout design of the hydraulic integrated valve block;

[0046] The internal oil hole connection generation module is used to design the internal oil hole connection of the hydraulic integrated valve block through an external loop for the three-dimensional layout design of the hydraulic integrated valve block, and obtain the internal oil hole connection design of the hydraulic integrated valve block;

[0047] The output module is used to perform software-assisted design analysis on the hydraulic integrated valve block according to the internal oil hole connection design of the hydraulic integrated valve block, obtain the simulation model of the hydraulic integrated valve block, and realize the one-way valve test based on the hydraulic integrated valve block.

[0048] The beneficial effects of the present invention are as follows: compared with the prior art:

[0049] The present invention focuses on the one-way valve test device and method, and is set around the one-way valve test. From the design of the hydraulic integrated valve block to the construction of the test device, it is closely centered around the one-way valve test requirements. For example, it meets the requirements for the durability performance test of the one-way valve in the standard GB25974.3-2010, and is more targeted for the one-way valve detection in the field of coal mine support equipment;

[0050] The setting of the hydraulic integrated valve block goes deep into the calculation of the internal oil hole parameters. The minimum flow channel diameter, flow channel angle, etc. are accurately determined through multiple formulas, and corrections are also made for different situations. This refined design can better ensure the performance of the test device;

[0051] The high-reliability one-way valve test device provided by the present invention has a rated pressure of 100 MPa, a rated flow rate of 125 L / min, a pressure measurement accuracy of not less than 0.5%, can meet the requirements for the durability performance test of the one-way valve in the standard GB25974.3-2010, the number of failures per 100 hours is not more than 1 time, and the fault diagnosis accuracy rate is not less than 95%. It clearly puts forward high-reliability requirements, and the number of failures of the overall device per 100 hours is not more than 1 time, ensuring the safety and stability of the high-pressure environment;

[0052] The present invention is applicable to the field of intelligent detection of coal mine support equipment. Considering the coal mine operation environment, the valve block design is solved by taking into account the dust characteristics. Description of the Drawings

[0053] Figure 1 It is the design block diagram of the key module - the hydraulic integrated valve block design;

[0054] Figure 2It is the structure diagram of the hydraulic integrated valve block;

[0055] Figure 3 It is the detailed structure diagram of the hydraulic integrated valve block. Specific implementation manners

[0056] To make the objectives, technical solutions and advantages of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. The embodiments described in this application are only a part of the embodiments of the present invention, rather than all embodiments. Based on the spirit of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0057] The first embodiment of the present invention provides a check valve test method based on a hydraulic integrated valve block, as Figure 1 shown, including:

[0058] Step 1, collect the operating parameters of the hydraulic system in real time through a fault perception sensor, map the sensor data to the initial parameters of the hydraulic schematic diagram, and output a hydraulic schematic diagram that conforms to the actual working conditions.

[0059] In a preferred but non-limiting embodiment of the present invention, Step 1 specifically includes:

[0060] Collect the operating parameters of the hydraulic system in real time according to the fault perception sensor. Among them, the fault perception sensor specifically includes a pressure sensor, a flow sensor, a temperature sensor and a vibration sensor;

[0061] Map the operating parameters of the hydraulic system to the initial parameters of the hydraulic schematic diagram according to the GB25974.3-2010 standard. The hydraulic schematic diagram includes the interface positions and oil circuit directions of components such as hydraulic pumps, the types and positions of fault perception sensors, the initial flow channel diameters, flow channel angles and bending radii of the oil holes connected, and the theoretical parameters of pressure, flow, temperature and vibration.

[0062] Step 2, generate the initial layout of the hydraulic integrated valve block through the mapping rule based on the hydraulic schematic diagram obtained in Step 1, and obtain the three-dimensional layout design of the hydraulic integrated valve block.

[0063] In a preferred but non-limiting embodiment of the present invention, Step 2 specifically includes:

[0064] Step 2.1, determine the external dimensions of the hydraulic integrated valve block.

[0065] Further preferably, Step 2.1 includes:

[0066] Alloy steel is selected for the hydraulic integrated valve block. The length, width, and height of the hydraulic integrated valve block are determined according to the complexity of the oil circuit in the hydraulic schematic diagram. The surface of the valve block is sprayed with a nickel-based coating to adapt to the high-dust environment in coal mines; a dust cover installation groove is reserved on the surface.

[0067] Step 2.2: Set the installation positions of the components of the hydraulic integrated valve block according to the hydraulic schematic diagram through the mapping rules.

[0068] Further preferably, Step 2.2 includes:

[0069] Locate the main oil circuit interface of the hydraulic integrated valve block. The main oil inlet / outlet is vertically arranged at the top of the valve block.

[0070] The control unit is arranged at the top of the hydraulic integrated valve block. The servo valve group is arranged in the middle. The electric control signal interface is separated from the hydraulic flow channel to avoid electromagnetic interference.

[0071] Cross oil hole nodes are arranged at the bottom of the hydraulic integrated valve block, which are set as horizontal cylinders, and the wall thickness is set to 1.5 times that of the main oil circuit.

[0072] Step 2.3: Set the external connection interfaces according to the hydraulic schematic diagram.

[0073] Further preferably, Step 2.3 includes:

[0074] Design a dust cover on the surface of the hydraulic integrated valve block. The main oil circuit interface adopts a double seal of a rubber seal ring and a polytetrafluoroethylene seal ring to prevent dust from entering the interior of the integrated valve block during coal mine operations;

[0075] Multiple-direction bolt holes are reserved at the bottom base of the hydraulic integrated valve block to adapt to the installation requirements of coal mine equipment.

[0076] Step 3: Carry out the internal oil hole connection design of the hydraulic integrated valve block through an outer loop for the three-dimensional layout design of the hydraulic integrated valve block, and obtain the internal oil hole connection design of the hydraulic integrated valve block.

[0077] In a preferred but non-limiting embodiment of the present invention, Step 3 specifically includes:

[0078] Step 3.1: Obtain the main oil circuit interface position, branch oil circuit path, and cross-node layout from the hydraulic integrated valve block layout design in Step 2, and input the internal oil hole connection design of the hydraulic integrated valve block through an outer loop to obtain the paths of the main oil circuit and branch oil circuits, as well as the layout of the cross nodes.

[0079] Further preferably, Step 3.1 includes:

[0080] Step 3.1.1: Set the main oil circuit path. The main oil circuit path adopts a direct-through layout. The main oil circuit goes directly from the oil inlet to the supercharging interface and then extends to the oil outlet. Set the minimum flow channel diameter as the main oil circuit diameter. The solution for the minimum flow channel diameter specifically includes:

[0081] Calculate the ideal flow channel diameter of the main oil circuit without dust influence based on the volume of oil delivered by the hydraulic pump per unit time and the maximum allowable flow velocity of the main oil circuit.

[0082] Under the coal mine operation environment, construct a correction factor for the main oil circuit flow channel diameter based on the mass concentration of suspended dust in the air of the operation area.

[0083] Multiply the ideal flow channel diameter of the main oil circuit without dust influence by the correction factor of the main oil circuit flow channel diameter to obtain the minimum flow channel diameter, which is expressed by the following formula:

[0084]

[0085] In the formula,

[0086] d min represents the minimum flow channel diameter,

[0087] Q represents the flow rate,

[0088] C dust represents the dust concentration,

[0089] v max represents the maximum allowable flow velocity;

[0090] Step 3.1.2: Set the branch oil circuit path. The branch oil circuit branches out from the intersection node and finally converges into the fuel tank. Solve the flow channel angle and bending radius between the branch oil circuits, which is expressed by the following formula:

[0091]

[0092] In the formula,

[0093] σ von represents the von Mises stress corresponding to the flow channel angle θ, which is calculated by finite element analysis. When θ = 60°, it is the minimum and the vibration suppression is optimal.

[0094] E vib represents the vibration energy caused by fluid turbulence or pressure pulsation in the coal mine environment. Set the elbow radius when the flow channel angle θ increases.

[0095] The flow channel bending radius is expressed by the following formula:

[0096] R = 3.8d min (3)

[0097] The vibration energy is effectively suppressed.

[0098] Step 3.1.3: Layout the cross nodes. The cross points are connected in a T shape, and the wall thickness is strengthened to 1.5 times the wall thickness of the main oil path.

[0099] Step 3.2: Verify whether the paths of the main oil path and the branch oil path in Step 3.1 meet the standards. If they do not meet the standards, perform an internal loop iteration to adjust the parameters of the main oil path and the branch oil path until they meet the standards.

[0100] More preferably, Step 3.2 includes:

[0101] Confirm that the diameter of the main oil path in Step 3.1 meets the flow velocity requirement;

[0102] Confirm that the bending radius and wall thickness of the branch oil path in Step 3.1 meet the standards, which are expressed by the following formula:

[0103]

[0104] In the formula,

[0105] R is the bending radius of the flow channel;

[0106] P is the working pressure of the hydraulic system;

[0107] σ s is the material yield strength.

[0108] Confirm that the von Mises stress corresponding to the flow channel angle in Step 3.1 is less than the corresponding threshold, and the vibration energy meets the corresponding threshold.

[0109] Step 4: According to the internal oil hole connection design model in Step 3, perform software-assisted design analysis on the hydraulic integrated valve block to obtain the simulation model of the hydraulic integrated valve block.

[0110] In a preferred but non-limiting embodiment of the present invention, Step 4 specifically includes:

[0111] Step 4.1: According to the internal oil hole connection design model in Step 3, construct a simulation model of the preliminary hydraulic integrated valve block;

[0112] More preferably, Step 4.1 includes:

[0113] Step 4.1.1: Combine the internal oil hole connection design model in Step 3 with the fluid continuity, thermodynamics conservation, and PID control theory, and construct a three-dimensional geometric model based on CAD, mark the main oil path interfaces and cross nodes, and generate a three-dimensional valve block model.

[0114] Step 4.1.2: As Figure 2 and Figure 3As shown, the three-dimensional valve block model is divided into a power unit, a booster unit, a test stand column unit, and a servo control unit to obtain a simulation model of the preliminary hydraulic integrated valve block. Among them, the corresponding interface coordinates are directly mapped to the connection positions of the corresponding units.

[0115] Further preferably, step 4.1.2 includes:

[0116] Define the displacement-pressure relationship curve of the pump in the power unit, simulate the output characteristics of the hydraulic pump, drive the system flow rate and pressure, set the flow rate value, and obtain the pressure of the main oil circuit of the power unit;

[0117] Set the piston area ratio in the booster unit, multiply it by the pressure of the main oil circuit of the received power unit to obtain the output pressure, and achieve pressure multiplication;

[0118] The test stand column unit obtains the load force by simulating the hydraulic cylinder load through the mechanical library components according to the received pressure fluctuation data of the booster unit;

[0119] The servo control unit builds a three-way four-way servo valve through the combined signal library and the hydraulic library, sets the PID parameters, receives the actual load force of the test stand column unit, triggers the PID algorithm to calculate the adjustment amount according to the difference between the set load force and the actual load force, the three-way four-way servo valve receives the PID control instruction, dynamically adjusts the spool displacement, changes the flow rate of the branch oil circuit, inputs the changed flow rate into the booster unit, and adjusts the inlet flow rate of the booster unit.

[0120] Step 4.2: Conduct fault diagnosis on the simulation model of the hydraulic integrated valve block, correct the layout design of the hydraulic integrated valve block in step 2, and obtain the optimal simulation model of the hydraulic integrated valve block to realize the check valve test based on the hydraulic integrated valve block.

[0121] Further preferably, step 4.2 includes:

[0122] Step 4.2.1: Through AMESim simulation, simulate the pressure difference of the main oil circuit, the stress tensor of the cross node, and the temperature gradient to obtain the simulation parameters.

[0123] More preferably, step 4.2.1 includes:

[0124] Simulate the pressure distribution of the main oil circuit to obtain the pressure difference of the main oil circuit;

[0125] Simulate the stress distribution of the cross node, extract the von Mises stress and set it as the stress tensor of the cross node;

[0126] Simulate the oil temperature rise by simulation and set it as the temperature gradient.

[0127] Step 4.2.2: Conduct fault diagnosis based on the simulation parameters.

[0128] More preferably, step 4.2.2 includes:

[0129] Solving the leakage rate based on the pressure difference of the main oil circuit, specifically including:

[0130] According to the pressure difference of the main oil circuit, solving the volume flow rate of the main oil circuit with the hydrodynamic formula;

[0131] Multiplying the volume flow rate of the main oil circuit by the oil density and dividing by the effective area of the sealing surface to obtain the leakage rate, which is expressed by the following formula:

[0132]

[0133] In the formula,

[0134] R leak represents the actual leakage rate,

[0135] ρ represents the oil density,

[0136] A represents the effective area of the sealing surface,

[0137] Q leak represents the volume flow rate of the leaking main oil circuit, which is expressed by the following formula:

[0138]

[0139] In the formula,

[0140] h represents the height of the sealing gap;

[0141] B represents the width of the sealing gap;

[0142] ΔP represents the pressure difference between the inlet and outlet of the main oil circuit;

[0143] μ represents the dynamic viscosity of the oil

[0144] L represents the length of the sealing gap.

[0145] Judge whether the leakage rate, the stress tensor of the cross node, and the temperature gradient meet the thresholds. If they do not meet the corresponding thresholds, diagnose as a fault.

[0146] Step 4.2.3, according to the fault diagnosis result of step 4.2.2, correct the flow channel diameter, the flow channel angle, and the bending radius.

[0147] More preferably, step 4.2.3 includes:

[0148] According to Poiseuille's law in the hydrodynamic formula, the volume flow rate of the leaking main oil circuit is proportional to the cube of the flow channel diameter. Therefore, taking the cube root of the ratio of the leakage rate threshold to the actual leakage rate and multiplying it by the current flow channel diameter to obtain the corrected flow channel diameter;

[0149] Subtract the stress tensor monitored by simulation from the allowable stress threshold of the material, and then divide the result by the allowable stress threshold of the material to obtain the percentage of stress exceeding the allowable value; multiply the percentage of stress exceeding the allowable value by the empirical correction coefficient to obtain the included angle adjustment amount. The empirical correction coefficient reflects the sensitivity of the cross-node geometry to stress changes; then subtract the included angle adjustment amount from the current flow channel included angle to obtain the corrected flow channel included angle.

[0150] According to the thermodynamic empirical model, the temperature rise is approximately proportional to the flow resistance, and the flow resistance is inversely proportional to the bending radius R. Therefore, divide the oil temperature rise monitored by simulation by the allowable maximum temperature rise threshold and take the square root to obtain the temperature adjustment amount, and then multiply it by the current bending radius to obtain the corrected bending radius.

[0151] Repeat the above cyclic simulation to update the corrected flow channel diameter, flow channel included angle, and bending radius until the final leakage rate, temperature rise, and tension meet the thresholds.

[0152] The second embodiment of the present invention provides a check valve test device based on a hydraulic integrated valve block. The hydraulic integrated valve block operates based on the check valve test method for a hydraulic integrated valve block described in Embodiment 1, specifically including:

[0153] A data acquisition module, configured to set a hydraulic schematic diagram according to the check valve life test and map the hydraulic schematic diagram to the surface of the hydraulic integrated valve block, and obtain the data of the fault perception sensor mapped to the surface of the hydraulic integrated valve block.

[0154] An internal oil hole setting module, configured to set the internal oil holes of the hydraulic integrated valve block according to the data of the fault perception sensor to obtain internal oil hole parameters. Among them, the internal oil hole parameters include the minimum flow channel diameter, flow channel included angle, flow channel bending radius, and oil channel wall thickness of the internal oil holes.

[0155] A simulation model construction module, configured to establish a simulation model of the hydraulic integrated valve block according to the internal oil hole parameters.

[0156] A test module, configured to perform a check valve test verification on the simulation model of the hydraulic integrated valve block, and optimize the internal oil hole parameters of the hydraulic integrated valve block according to the test results until the reliability requirements are met, so as to realize the check valve test based on the hydraulic integrated valve block.

[0157] The third embodiment of the present invention provides a computer-readable storage medium. The computer-readable storage medium stores a computer program, and when the computer program is executed by a processor, it implements a hydraulic integrated valve block design method according to Embodiment 1.

[0158] Embodiment 4 of the present invention provides an electronic device, including a memory, a processor, and a computer program stored on the memory and executable on the processor. When the computer program is loaded into the processor, it implements a hydraulic integrated valve block design method according to Embodiment 1.

[0159] The beneficial effects of the present invention are as follows. Compared with the prior art:

[0160] The present invention focuses on the one-way valve test device and method, which are set around the one-way valve test. From the design of the hydraulic integrated valve block to the construction of the test device, they are all closely centered around the one-way valve test requirements. For example, it meets the requirements for the durability performance test of the one-way valve in Standard GB25974.3-2010, and is more targeted for the detection of one-way valves in the field of coal mine support equipment.

[0161] The setting of the hydraulic integrated valve block goes deep into the calculation of the internal oil hole parameters. The minimum flow channel diameter, flow channel angle, etc. are accurately determined through multiple formulas, and corrections are also made for different situations. This refined design can better ensure the performance of the test device.

[0162] The highly reliable one-way valve test device provided by the present invention has a rated pressure of 100 MPa, a rated flow rate of 125 L / min, a pressure measurement accuracy of not less than 0.5%, can meet the requirements for the durability performance test of the one-way valve in Standard GB25974.3-2010, the number of failures per 100 hours is not more than 1 time, and the fault diagnosis accuracy rate is not less than 95%. It clearly puts forward high-reliability requirements, and the number of failures of the overall device per 100 hours is not more than 1 time, ensuring the safety and stability of the high-pressure environment.

[0163] The present invention is applicable to the field of intelligent detection of coal mine support equipment. Considering the coal mine operation environment, the valve block design is solved by taking into account the dust characteristics.

[0164] The present disclosure can be a system, a method, and / or a computer program product. The computer program product may include a computer-readable storage medium having computer-readable program instructions thereon for causing a processor to implement various aspects of the present disclosure.

[0165] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that: still can modify the specific implementation manners of the present invention or make equivalent substitutions, and any modification or equivalent substitution without departing from the spirit and scope of the present invention should be covered within the protection scope of the claims of the present invention.

Claims

1. A check valve test method based on a hydraulic integrated valve block, characterized in that: The operating parameters of the hydraulic system are collected in real time through a fault perception sensor, and the sensor data is mapped to the initial parameters of the hydraulic schematic diagram to output a hydraulic schematic diagram that conforms to the actual working conditions; The initial layout of the hydraulic integrated valve block is generated from the hydraulic schematic diagram through mapping rules to obtain the three-dimensional layout design of the hydraulic integrated valve block; The three-dimensional layout design of the hydraulic integrated valve block is used for the internal oil hole connection design of the hydraulic integrated valve block through an outer loop to obtain the internal oil hole connection design of the hydraulic integrated valve block; Based on the internal oil hole connection design of the hydraulic integrated valve block, software-assisted design analysis is performed on the hydraulic integrated valve block to obtain a simulation model of the hydraulic integrated valve block, realizing the check valve test based on the hydraulic integrated valve block.

2. The check valve test method based on a hydraulic integrated valve block according to claim 1, characterized in that: The step of generating the initial layout of the hydraulic integrated valve block from the hydraulic schematic diagram through mapping rules to obtain the three-dimensional layout design of the hydraulic integrated valve block specifically includes: Determine the external dimensions of the hydraulic integrated valve block; Set the component installation positions of the hydraulic integrated valve block according to the hydraulic schematic diagram through mapping rules; Set the external connection interfaces according to the hydraulic schematic diagram.

3. The check valve test method based on a hydraulic integrated valve block according to claim 1, characterized in that: The step of using the three-dimensional layout design of the hydraulic integrated valve block for the internal oil hole connection design of the hydraulic integrated valve block through an outer loop to obtain the internal oil hole connection design of the hydraulic integrated valve block specifically includes: According to the main oil circuit interface position, branch oil circuit path, and cross-node layout obtained from the hydraulic integrated valve block layout design, input the internal oil hole connection design of the hydraulic integrated valve block through an outer loop to obtain the paths of the main oil circuit and branch oil circuits, and the layout of the cross nodes; Verify whether the paths of the main oil circuit and branch oil circuits meet the standards. If not, perform an inner loop iteration to adjust the parameters of the main oil circuit and branch oil circuits until they meet the standards.

4. The check valve test method based on a hydraulic integrated valve block according to claim 3, characterized in that: The step of inputting the internal oil hole connection design of the hydraulic integrated valve block through an outer loop according to the main oil circuit interface position, branch oil circuit path, and cross-node layout obtained from the hydraulic integrated valve block layout design to obtain the paths of the main oil circuit and branch oil circuits, and the layout of the cross nodes specifically includes: Set the main oil circuit path. The main oil circuit path adopts a straight-through layout. The main oil circuit goes straight from the oil inlet to the boost interface and then extends to the oil outlet, and the minimum flow channel diameter is set as the main oil circuit diameter; Set the branch oil circuit path. The branch oil circuit branches out from the cross node and finally converges into the fuel tank, and solve the flow channel angle and bending radius between the branch oil circuits; Layout the cross nodes. The cross points adopt a T-shaped connection, and the wall thickness is strengthened to 1.5 times the wall thickness of the main oil circuit.

5. The check valve test method based on a hydraulic integrated valve block according to claim 1, characterized in that: The step of performing software-assisted design analysis on the hydraulic integrated valve block based on the internal oil hole connection design of the hydraulic integrated valve block to obtain a simulation model of the hydraulic integrated valve block specifically includes: According to the internal oil hole connection design model, construct the simulation model of the preliminary hydraulic integrated valve block; Conduct fault diagnosis on the simulation model of the hydraulic integrated valve block, correct the layout design of the hydraulic integrated valve block, and obtain the simulation model of the optimal hydraulic integrated valve block.

6. A check valve test method based on a hydraulic integrated valve block according to claim 5, characterized in that: The construction of the simulation model of the preliminary hydraulic integrated valve block according to the internal oil hole connection design model specifically includes: Combining the internal oil hole connection design model with the fluid continuity, thermodynamic conservation, and PID control theories, construct a three-dimensional geometric model based on CAD, mark the main oil circuit interfaces and cross nodes, and generate a three-dimensional valve block model; Divide the three-dimensional valve block model into a power unit, a booster unit, a test stand column unit, and a servo control unit to obtain the simulation model of the preliminary hydraulic integrated valve block.

7. A check valve test method based on a hydraulic integrated valve block according to claim 6, characterized in that: The division of the three-dimensional valve block model into a power unit, a booster unit, a test stand column unit, and a servo control unit to obtain the simulation model of the preliminary hydraulic integrated valve block specifically includes: Define the displacement-pressure relationship curve of the pump in the power unit, simulate the output characteristics of the hydraulic pump, drive the system flow rate and pressure, set the flow rate value, and obtain the pressure of the main oil circuit of the power unit; Set the piston area ratio in the booster unit, multiply it by the pressure of the main oil circuit of the received power unit, and obtain the output pressure; Based on the pressure fluctuation data received by the test stand column unit, simulate the hydraulic cylinder load through the mechanical library components to obtain the load force; The servo control unit builds a three-way four-way servo valve through the combined signal library and the hydraulic library, sets the PID parameters, receives the actual load force of the test stand column unit, and triggers the PID algorithm to calculate the adjustment amount according to the difference between the set load force and the actual load force. The three-way four-way servo valve receives the PID control instruction, dynamically adjusts the spool displacement, changes the flow rate of the branch oil circuit, inputs the changed flow rate into the booster unit, and adjusts the inlet flow rate of the booster unit.

8. A check valve test method based on a hydraulic integrated valve block according to claim 1, characterized in that: The fault diagnosis of the simulation model of the hydraulic integrated valve block, the correction of the layout design of the hydraulic integrated valve block, and the obtaining of the simulation model of the optimal hydraulic integrated valve block specifically include: Obtain the simulation parameters by simulating the pressure difference of the main oil circuit, the stress tensor of the cross node, and the temperature gradient; Conduct fault diagnosis based on the simulation parameters; According to the fault diagnosis results, correct the flow channel diameter, flow channel angle, and bending radius.

9. A check valve test method based on a hydraulic integrated valve block according to claim 8, characterized in that: The correction of the flow channel diameter, flow channel angle, and bending radius according to the fault diagnosis results specifically includes: According to Poiseuille's law in the fluid mechanics formula, the volumetric flow rate of the leaking main oil circuit is proportional to the cube of the flow channel diameter. Therefore, take the cube root of the ratio of the leakage rate threshold to the actual leakage rate and multiply it by the current flow channel diameter to obtain the corrected flow channel diameter; Subtract the stress tensor monitored by simulation from the allowable stress threshold of the material, and then divide the result by the allowable stress threshold of the material to obtain the percentage of stress exceeding the allowable value; multiply the percentage of stress exceeding the allowable value by the empirical correction factor to obtain the included angle adjustment amount. The empirical correction factor reflects the sensitivity of the cross-node geometry to stress changes; then subtract the included angle adjustment amount from the current flow channel included angle to obtain the corrected flow channel included angle. According to the thermodynamic empirical model, the temperature rise is approximately proportional to the flow resistance, and the flow resistance is inversely proportional to the bending radius R. Therefore, divide the oil temperature rise monitored by simulation by the allowable maximum temperature rise threshold and take the square root to obtain the temperature adjustment amount, and then multiply it by the current bending radius to obtain the corrected bending radius.

10. A check valve test device based on a hydraulic integrated valve block, operating a check valve test method based on a hydraulic integrated valve block according to any one of claims 1 to 9, characterized in that: A hydraulic schematic diagram generation module, configured to collect the operating parameters of the hydraulic system in real time through a fault perception sensor, map the sensor data to the initial parameters of the hydraulic schematic diagram, and output a hydraulic schematic diagram that conforms to the actual working conditions; A three-dimensional layout generation module, configured to generate the initial layout of the hydraulic integrated valve block from the hydraulic schematic diagram through a mapping rule to obtain the three-dimensional layout design of the hydraulic integrated valve block; An internal oil hole connection generation module, configured to perform the internal oil hole connection design of the hydraulic integrated valve block through an external cycle on the three-dimensional layout design of the hydraulic integrated valve block to obtain the internal oil hole connection design of the hydraulic integrated valve block; An output module, configured to perform software-assisted design analysis on the hydraulic integrated valve block according to the internal oil hole connection design of the hydraulic integrated valve block to obtain a simulation model of the hydraulic integrated valve block, and realize the check valve test based on the hydraulic integrated valve block.

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