A one-way valve test method and device based on a hydraulic integrated valve block

Abstract

The application 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 following steps: collecting hydraulic system operation parameters in real time through a fault sensing sensor, mapping the sensor data into initial parameters of a hydraulic principle diagram, and outputting a hydraulic principle diagram conforming to actual working conditions; generating an initial layout of the hydraulic integrated valve block through a mapping rule to obtain a three-dimensional layout design of the hydraulic integrated valve block; performing internal oil hole communication design of the hydraulic integrated valve block through external circulation to obtain the internal oil hole communication design of the hydraulic integrated valve block; performing software aided design analysis on the hydraulic integrated valve block to obtain a simulation model of the hydraulic integrated valve block, and realizing one-way valve test based on the hydraulic integrated valve block. The high-reliability one-way valve test device provided by the application can meet the requirements of standard one-way valve durability performance test, and the fault diagnosis accuracy is high.

Description

Technical Field

[0001] This invention belongs to the field of intelligent detection technology for coal mine support equipment, and more specifically, relates to a test method and device for a one-way valve based on a hydraulic integrated valve block. Background Technology

[0002] The hydraulic support system consists of five parts: power components, actuators, control components, auxiliary components, and working medium. Control components include various types of valves, commonly including directional valves, check valves, safety valves, and shut-off valves. The check valve for hydraulic supports is a crucial component of the system, serving two main functions: first, controlling the normal extension and retraction of the hydraulic support column and jacks to maintain their proper working positions; and second, locking the fluid within the working chamber to maintain the supporting external force.

[0003] Commonly used check valves for hydraulic supports include hydraulically piloted check valves, two-way locks, one-way locks, alternating check valves, double alternating check valves, return fluid shut-off valves, and differential pressure combination valves. Among these, hydraulically piloted check valves are particularly important because they are often used in columns.

[0004] The existing hydraulic support and component testing equipment has been in use for many years. First, the testing equipment has poor reliability, requires a large amount of maintenance, and a single piece of equipment has more than 50 failures per 100 hours, and the hardware foundation for intelligentization is poor. Second, the level of intelligence of the testing equipment is insufficient and cannot meet functions such as fault diagnosis. Third, there is a serious shortage of personnel and an aging workforce, making it difficult to meet the needs of a large number of equipment maintenance tasks.

[0005] The existing technical document (CN112213958A) discloses an electro-hydraulic control integrated simulation test platform. Its shortcomings are that it lacks in-depth consideration of the specific needs of check valve testing, and does not have specific settings for the test requirements and fault diagnosis of check valves. In terms of precision, its design and optimization of components in the hydraulic system are not in-depth enough, and it does not involve in detail the precise calculation and optimization of parameters such as the internal oil hole parameters of the hydraulic integrated valve block, which cannot meet the scenarios with high precision requirements for valve block performance. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a one-way valve testing method and apparatus based on a hydraulic integrated valve block. Through the design of the hydraulic integrated valve block and other methods, the hydraulic system for testing one-way valves achieves high integration and high reliability, and significantly reduces the failure rate.

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

[0008] The first aspect of this invention provides a test method for a one-way valve based on a hydraulic integrated valve block, specifically including:

[0009] The hydraulic system operating parameters are collected in real time by fault detection sensors, 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.

[0010] The hydraulic schematic diagram is used to generate the initial layout of the hydraulic integrated valve block through mapping rules, thus obtaining the three-dimensional layout design of the hydraulic integrated valve block.

[0011] The three-dimensional layout design of the hydraulic integrated valve block is carried out through external circulation to design the internal oil hole connection of the hydraulic integrated valve block, thus obtaining the internal oil hole connection design of the hydraulic integrated valve block.

[0012] Based on the internal oil hole connection design of the hydraulic integrated valve block, software-aided design analysis is performed on the hydraulic integrated valve block to obtain a simulation model of the hydraulic integrated valve block, and a one-way valve test based on the hydraulic integrated valve block is realized.

[0013] Preferably, the step of generating an initial layout of the hydraulic integrated valve block from the hydraulic schematic diagram using mapping rules, thereby obtaining a three-dimensional layout design of the hydraulic integrated valve block, specifically includes:

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

[0015] Based on the hydraulic schematic diagram, the component installation positions of the hydraulic integrated valve block are set according to mapping rules;

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

[0017] Preferably, the three-dimensional layout design of the hydraulic integrated valve block is achieved by using external circulation to design the internal oil hole connectivity of the hydraulic integrated valve block, specifically including:

[0018] Based on the main oil circuit interface position, branch oil circuit path and intersection node layout obtained from the hydraulic integrated valve block layout design, the main oil circuit and branch oil circuit paths, as well as the intersection node layout, are obtained through the internal oil hole connection design of the external circulation input hydraulic integrated valve block.

[0019] Verify whether the paths of the main oil circuit and branch oil circuits meet the standards. If they do not meet the standards, perform internal circulation iterative adjustments to the parameters of the main oil circuit and branch oil circuits until they meet the standards.

[0020] Preferably, the step of obtaining the main oil circuit interface position, branch oil circuit path, and intersection node layout from the hydraulic integrated valve block layout design, and obtaining the main oil circuit and branch oil circuit paths, as well as the intersection node layout, through the internal oil hole connection design of the external circulation input hydraulic integrated valve block, specifically includes:

[0021] Set the main oil circuit path, which adopts a straight-through layout. The main oil circuit runs straight from the oil inlet to the booster port and then extends to the oil outlet. Set the minimum flow channel diameter as the main oil circuit diameter.

[0022] Set up branch oil path, the branch oil path splits from the intersection node and finally merges into the oil tank, and solve the flow channel angle and bending radius between the branch oil paths;

[0023] The layout incorporates cross-nodes, with T-shaped connections between them, and the wall thickness is reinforced to 1.5 times that of the main oil passage wall thickness.

[0024] Preferably, the step of performing software-aided design analysis on the hydraulic integrated valve block based on the internal oil hole communication design to obtain a simulation model of the hydraulic integrated valve block specifically includes:

[0025] Based on the internal oil hole connectivity design model, a preliminary simulation model of the hydraulic integrated valve block is constructed;

[0026] Fault diagnosis was performed on the simulation model of the hydraulic integrated valve block, the layout design of the hydraulic integrated valve block was corrected, and the optimal simulation model of the hydraulic integrated valve block was obtained.

[0027] Preferably, the step of constructing a preliminary simulation model of the hydraulic integrated valve block based on the internal oil hole connectivity design model specifically includes:

[0028] The internal oil hole connection design model is combined with fluid continuity, thermodynamic conservation and PID control theory. A three-dimensional geometric model is constructed based on CAD, the main oil circuit interface and intersection node are marked, and a three-dimensional valve block model is generated.

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

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

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

[0032] The booster unit sets the piston area ratio, which is multiplied by the pressure received from the main oil circuit of the power unit to obtain the output pressure;

[0033] The test column unit obtains the load force by simulating the hydraulic cylinder load through mechanical library components based on the pressure fluctuation data received from the booster unit.

[0034] The servo control unit builds a three-position four-way servo valve by combining the signal library and the hydraulic library, sets 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 command, dynamically adjusts the valve core displacement, changes the branch oil circuit flow, and inputs the changed flow into the booster unit to adjust the inlet flow of the booster unit.

[0035] Preferably, the step of performing fault diagnosis on the simulation model of the hydraulic integrated valve block, correcting the layout design of the hydraulic integrated valve block, and obtaining the optimal simulation model of the hydraulic integrated valve block specifically includes:

[0036] Simulation parameters are obtained by simulating the pressure difference in the main oil circuit, the stress tensor at the intersection node, and the temperature gradient.

[0037] Fault diagnosis is performed based on simulation parameters;

[0038] Based on the fault diagnosis results, adjust the flow channel diameter, flow channel angle, and bending radius.

[0039] Preferably, the step of correcting the flow channel diameter, flow channel angle, and bending radius based on the fault diagnosis results specifically includes:

[0040] According to Poiseuille's law in fluid mechanics, the volumetric flow rate of the leaking main oil passage is proportional to the cube of the channel diameter. Therefore, the corrected channel diameter is obtained by taking the cube root of the ratio of the leakage rate threshold to the actual leakage rate and multiplying it by the current 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 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 intersection 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, while the flow resistance is inversely proportional to the bending radius R. Therefore, by dividing the oil temperature rise monitored by simulation by the maximum allowable temperature rise threshold and taking the square root, the temperature adjustment amount is obtained. Then, by multiplying it by the current bending radius, the corrected bending radius is obtained.

[0043] The second aspect of this invention provides a test device for a check valve based on a hydraulic integrated valve block, which operates the test method for a check valve based on a hydraulic integrated valve block described in the first aspect, including:

[0044] The hydraulic schematic diagram generation module is used to collect hydraulic system operating parameters in real time through fault detection sensors, 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.

[0045] The 3D layout generation module is used to generate the initial layout of the hydraulic integrated valve block from the hydraulic schematic diagram through mapping rules, and obtain the 3D layout design of the hydraulic integrated valve block.

[0046] The internal oil hole connection generation module is used to perform the internal oil hole connection design of the hydraulic integrated valve block through external circulation to obtain the internal oil hole connection design of the hydraulic integrated valve block.

[0047] The output module is used to perform software-aided design analysis on the hydraulic integrated valve block based on the internal oil hole connection design, obtain a 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 this invention are compared with those of the prior art:

[0049] This invention focuses on a one-way valve testing device and method. The device is designed around one-way valve testing, and from the design of the hydraulic integrated valve block to the construction of the testing device, it is closely related to the testing requirements of one-way valves. For example, it meets the durability performance testing requirements of one-way valves in standard GB25974.3-2010, and is more targeted for one-way valve testing in the field of coal mine support equipment.

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

[0051] The high-reliability check valve testing device provided by this invention has a rated pressure of 100MPa, a rated flow rate of 125L / min, and a pressure measurement accuracy of not less than 0.5%. It can meet the durability performance test requirements for check valves in standard GB25974.3-2010, with no more than one failure per 100 hours and a fault diagnosis accuracy of not less than 95%. It clearly proposes high reliability requirements, with the entire device having no more than one failure per 100 hours, ensuring safety and stability in high-pressure environments.

[0052] This invention is applicable to the field of intelligent detection of coal mine support equipment. Considering the coal mine working environment, the valve block design takes into account the characteristics of dust for solution. Attached Figure Description

[0053] Figure 1 Design block diagram for key module - hydraulic integrated valve block;

[0054] Figure 2This is a structural diagram of a hydraulic integrated valve block;

[0055] Figure 3 This is a detailed structural diagram of a hydraulic integrated valve block. Detailed Implementation

[0056] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of this invention. The embodiments described in this application are merely some embodiments of this invention, and not all embodiments. Based on the spirit of this invention, other embodiments obtained by those skilled in the art without creative effort are all within the protection scope of this invention.

[0057] The first embodiment of the present invention provides a test method for a one-way valve based on a hydraulic integrated valve block, such as... Figure 1 As shown, it includes:

[0058] Step 1: Collect hydraulic system operating parameters in real time through fault detection sensors, 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] The hydraulic system's operating parameters are collected in real time by fault detection sensors, which specifically include pressure sensors, flow sensors, temperature sensors, and vibration sensors.

[0061] According to the GB25974.3-2010 standard, the operating parameters of the hydraulic system are mapped to the initial parameters of the hydraulic schematic diagram. The hydraulic schematic diagram includes the interface positions and oil circuit directions of components such as hydraulic pumps, the type and location of fault detection sensors, the initial flow channel diameter of the oil hole connection, the flow channel angle and bending radius, as well as the theoretical parameters of pressure, flow rate, temperature and vibration.

[0062] Step 2: Generate the initial layout of the hydraulic integrated valve block from the hydraulic schematic diagram obtained in Step 1 using mapping rules, 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] More 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 coated with a nickel-based coating to adapt to the high dust environment of coal mines. A dust cover installation groove is reserved on the surface.

[0067] Step 2.2: Based on the hydraulic schematic diagram, set the component installation position of the hydraulic integrated valve block according to the mapping rules.

[0068] More preferably, step 2.2 includes:

[0069] Position the main oil circuit interface of the hydraulic integrated valve block, with the main oil circuit inlet / outlet vertically arranged on the top of the valve block.

[0070] The control unit is located on the top of the hydraulic integrated valve block, the servo valve group is centrally located, and the electrical control signal interface is separated from the hydraulic flow channel to avoid electromagnetic interference.

[0071] The bottom of the hydraulic integrated valve block is equipped with cross-hole nodes, which are set as horizontal cylinders with a wall thickness of 1.5 times that of the main oil circuit.

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

[0073] More preferably, step 2.3 includes:

[0074] A dust cover is designed on the surface of the hydraulic integrated valve block, and the main oil circuit interface is sealed with a double layer of rubber sealing ring and polytetrafluoroethylene sealing ring to prevent dust from entering the interior of the integrated valve block during coal mining operations.

[0075] The bottom base of the hydraulic integrated valve block has pre-drilled multi-directional bolt holes to meet the installation requirements of coal mine equipment.

[0076] Step 3: The three-dimensional layout design of the hydraulic integrated valve block is carried out through external circulation to design the internal oil hole connection of the hydraulic integrated valve block, thus obtaining 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. Through the internal oil hole connection design of the external circulation input hydraulic integrated valve block, obtain the path of the main oil circuit and branch oil circuit, as well as the layout of the cross node.

[0079] More preferably, step 3.1 includes:

[0080] Step 3.1.1: Set the main oil circuit path. The main oil circuit adopts a straight-through layout, running directly from the oil inlet to the booster port, and then extending to the oil outlet. Set the minimum flow channel diameter as the main oil circuit diameter. The calculation of the minimum flow channel diameter specifically includes:

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

[0082] In coal mine operating environments, a correction factor for the diameter of the main oil passage is constructed based on the mass concentration of suspended dust in the air of the operating area.

[0083] The minimum flow channel diameter is obtained by multiplying the ideal flow channel diameter without dust influence in the main oil circuit and the correction factor for the main oil circuit flow channel diameter, as expressed by the following formula:

[0084]

[0085] In the formula,

[0086] d min Indicates the minimum flow channel diameter.

[0087] Q represents flow rate.

[0088] C dust Indicates dust concentration.

[0089] v max Indicates the maximum permissible flow rate;

[0090] Step 3.1.2: Set the branch oil path. The branch oil path branches off from the intersection node and eventually merges into the oil tank. Solve for the flow channel angle and bending radius between the branch oil paths, expressed by the following formula:

[0091]

[0092] In the formula,

[0093] σ von The von Mises stress corresponds to the flow channel angle θ. Calculated by finite element analysis, it is minimized and exhibits optimal vibration suppression when θ = 60°.

[0094] E vib This indicates the vibration energy caused by fluid turbulence or pressure pulsation in a coal mine environment. The elbow radius is set 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] Vibrational energy is effectively suppressed.

[0098] Step 3.1.3: Arrange the intersection nodes, with the intersection nodes connected in a T-shape, and strengthen the wall thickness to 1.5 times the wall thickness of the main oil passage.

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

[0100] More preferably, step 3.2 includes:

[0101] Confirm the diameter of the main oil passage in step 3.1 to ensure it meets the flow rate requirements;

[0102] Confirm that the bending radius and wall thickness of the branch oil passage in step 3.1 meet the standards, as expressed by the following formula:

[0103]

[0104] In the formula,

[0105] R is the flow channel bending radius;

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

[0107] σ s This represents the yield strength of the material.

[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: Based on the internal oil hole connection design model in Step 3, perform software-aided design analysis on the hydraulic integrated valve block to obtain a 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: Based on the internal oil hole connection design model in Step 3, construct a preliminary simulation model of the hydraulic integrated valve block;

[0112] More preferably, step 4.1 includes:

[0113] Step 4.1.1: Connect the internal oil hole design model from Step 3, combine fluid continuity, thermodynamic conservation and PID control theory, construct a three-dimensional geometric model based on CAD, label the main oil circuit interface and intersection nodes, and generate a three-dimensional valve block model.

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

[0115] More preferably, step 4.1.2 includes:

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

[0117] The booster unit sets the piston area ratio, which is multiplied by the pressure received from the main oil circuit of the power unit to obtain the output pressure, thus achieving pressure multiplication;

[0118] The test column unit obtains the load force by simulating the hydraulic cylinder load through mechanical library components based on the pressure fluctuation data received from the booster unit.

[0119] The servo control unit builds a three-position four-way servo valve by combining the signal library and the hydraulic library, sets 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 command, dynamically adjusts the valve core displacement, changes the branch oil circuit flow, and inputs the changed flow into the booster unit to adjust the inlet flow of the booster unit.

[0120] Step 4.2: Perform fault diagnosis on the simulation model of the hydraulic integrated valve block, correct the hydraulic integrated valve block layout design in Step 2, obtain the optimal simulation model of the hydraulic integrated valve block, and realize the one-way valve test based on the hydraulic integrated valve block.

[0121] More preferably, step 4.2 includes:

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

[0123] More preferably, step 4.2.1 includes:

[0124] The pressure distribution in the main oil circuit is simulated to obtain the pressure difference in the main oil circuit;

[0125] Simulate the stress distribution at the intersection node and extract the von Mises stress as the stress tensor of the intersection node;

[0126] The simulation simulates the temperature rise of the oil, using a temperature gradient.

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

[0128] More preferably, step 4.2.2 includes:

[0129] The leakage rate is calculated based on the pressure difference in the main oil circuit, specifically including:

[0130] The volumetric flow rate of the main oil circuit is calculated using fluid dynamics formulas based on the pressure difference in the main oil circuit.

[0131] The leakage rate is obtained by multiplying the main oil circuit volumetric flow rate by the oil density and dividing by the effective area of ​​the sealing surface, as shown in the following formula:

[0132]

[0133] In the formula,

[0134] R leak Indicates the actual leakage rate.

[0135] ρ represents the density of the oil.

[0136] A represents the effective area of ​​the sealing surface.

[0137] Q leak The volumetric flow rate of the leaking main oil line is expressed by the following formula:

[0138]

[0139] In the formula,

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

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

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

[0143] μ represents the dynamic viscosity of the oil.

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

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

[0146] Step 4.2.3: Based on the fault diagnosis results of step 4.2.2, correct the flow channel diameter, flow channel angle, and bending radius.

[0147] More preferably, step 4.2.3 includes:

[0148] According to Poiseuille's law in fluid mechanics, the volumetric flow rate of the leaking main oil passage is proportional to the cube of the channel diameter. Therefore, the corrected channel diameter is obtained by taking the cube root of the ratio of the leakage rate threshold to the actual leakage rate and multiplying it by the current channel diameter.

[0149] Subtract the stress tensor monitored by simulation from the allowable stress threshold of the material, and then divide by the allowable stress threshold 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 intersection node geometry to stress changes; then subtract the angle adjustment amount from the current flow channel angle to obtain the corrected flow channel angle.

[0150] According to the thermodynamic empirical model, the temperature rise is approximately proportional to the flow resistance, while the flow resistance is inversely proportional to the bending radius R. Therefore, by dividing the oil temperature rise monitored by simulation by the maximum allowable temperature rise threshold and taking the square root, the temperature adjustment amount is obtained. Then, by multiplying it by the current bending radius, the corrected bending radius is obtained.

[0151] Repeat the above cyclic simulation, updating and correcting the flow channel diameter, flow channel angle, and bending radius until the final leakage rate, temperature rise, and tension meet the threshold.

[0152] The second embodiment of the present invention provides a one-way valve testing device based on a hydraulic integrated valve block, which operates the hydraulic integrated valve block according to the one-way valve testing method based on a hydraulic integrated valve block described in Embodiment 1, specifically including:

[0153] The data acquisition module is used to set the hydraulic schematic diagram based on the one-way valve life test, and to map the hydraulic schematic diagram onto the surface of the hydraulic integrated valve block to obtain the data from the fault detection sensor mapped onto the surface of the hydraulic integrated valve block.

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

[0155] The simulation model building module is used to build a simulation model of the hydraulic integrated valve block based on the internal oil hole parameters;

[0156] The test module is used to perform one-way valve tests on the simulation model of the hydraulic integrated valve block. The test results are used to optimize the internal oil hole parameters of the hydraulic integrated valve block until the reliability requirements are met, thus realizing the one-way valve test based on the hydraulic integrated valve block.

[0157] Embodiment 3 of the present invention provides a computer-readable storage medium storing a computer program that, when executed by a processor, 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 in the memory and executable on the processor. When the computer program is loaded onto the processor, it implements a hydraulic integrated valve block design method according to Embodiment 1.

[0159] The beneficial effects of this invention are compared with those of the prior art:

[0160] This invention focuses on a one-way valve testing device and method. The device is designed around one-way valve testing, and from the design of the hydraulic integrated valve block to the construction of the testing device, it is closely related to the testing requirements of one-way valves. For example, it meets the durability performance testing requirements of one-way valves in standard GB25974.3-2010, and is more targeted for one-way valve testing in the field of coal mine support equipment.

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

[0162] The high-reliability check valve testing device provided by this invention has a rated pressure of 100MPa, a rated flow rate of 125L / min, and a pressure measurement accuracy of not less than 0.5%. It can meet the durability performance test requirements for check valves in standard GB25974.3-2010, with no more than one failure per 100 hours and a fault diagnosis accuracy of not less than 95%. It clearly proposes high reliability requirements, with the entire device having no more than one failure per 100 hours, ensuring safety and stability in high-pressure environments.

[0163] This invention is applicable to the field of intelligent detection of coal mine support equipment. Considering the coal mine working environment, the valve block design takes into account the characteristics of dust for solution.

[0164] This disclosure can be a system, method, and / or computer program product. A computer program product may include a computer-readable storage medium having computer-readable program instructions loaded thereon for causing a processor to implement various aspects of this 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 it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart 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 test method for a one-way valve based on a hydraulic integrated valve block, characterized in that: The hydraulic system operating parameters are collected in real time by fault detection sensors, 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 hydraulic schematic diagram is used to generate the initial layout of the hydraulic integrated valve block through mapping rules, thus obtaining the three-dimensional layout design of the hydraulic integrated valve block. The three-dimensional layout design of the hydraulic integrated valve block is used to design the internal oil hole connectivity of the hydraulic integrated valve block through external circulation. This design includes: obtaining the main oil circuit interface position, branch oil circuit paths, and intersection node layout from the hydraulic integrated valve block layout design; inputting the internal oil hole connectivity design of the hydraulic integrated valve block through external circulation to obtain the paths of the main oil circuit and branch oil circuits, as well as the layout of the intersection nodes; specifically, setting the main oil circuit path, which adopts a straight-through layout, with the main oil circuit running directly from the inlet to the booster interface and then extending to the outlet, setting the minimum flow channel diameter as the main oil circuit diameter; setting the branch oil circuit paths, with branch oil circuits branching from the intersection nodes and finally converging into the oil tank, solving for the flow channel angle and bending radius between the branch oil circuits; and laying out the intersection nodes, with the intersections using T-shaped connections and the wall thickness reinforced to 1.5 times the wall thickness of the main oil circuit. Based on the internal oil hole connectivity design of the hydraulic integrated valve block, software-aided design analysis is performed on the hydraulic integrated valve block to obtain a simulation model. This includes: constructing a preliminary simulation model of the hydraulic integrated valve block based on the internal oil hole connectivity design model; performing fault diagnosis on the simulation model of the hydraulic integrated valve block, correcting the layout design of the hydraulic integrated valve block, and obtaining the optimal simulation model of the hydraulic integrated valve block; specifically, simulation parameters are obtained by simulating the pressure difference of the main oil circuit, the stress tensor of the intersection node, and the temperature gradient; fault diagnosis is performed based on the simulation parameters; and based on the fault diagnosis results, the flow channel diameter, flow channel angle, and bending radius are corrected to realize the one-way valve test based on the hydraulic integrated valve block.

2. The test method for a one-way valve based on a hydraulic integrated valve block according to claim 1, characterized in that: The process of generating an initial layout of the hydraulic integrated valve block from the hydraulic schematic diagram using mapping rules, and obtaining the three-dimensional layout design of the hydraulic integrated valve block, specifically includes: Determine the external dimensions of the hydraulic integrated valve block; Based on the hydraulic schematic diagram, the component installation positions of the hydraulic integrated valve block are set according to mapping rules; Set up external connection interfaces according to the hydraulic schematic diagram.

3. The test method for a one-way valve based on a hydraulic integrated valve block according to claim 1, characterized in that: The process of designing the three-dimensional layout of the hydraulic integrated valve block and then using external circulation to design the internal oil hole connectivity of the hydraulic integrated valve block, specifically includes: Verify whether the paths of the main oil circuit and branch oil circuits meet the standards. If they do not meet the standards, perform internal circulation iterative adjustments to the parameters of the main oil circuit and branch oil circuits until they meet the standards.

4. The test method for a one-way valve based on a hydraulic integrated valve block according to claim 1, characterized in that: The preliminary simulation model of the hydraulic integrated valve block, based on the internal oil hole connectivity design model, specifically includes: The internal oil hole connection design model is combined with fluid continuity, thermodynamic conservation and PID control theory. A three-dimensional geometric model is constructed based on CAD, the main oil circuit interface and intersection node are marked, and a three-dimensional valve block model is generated. The three-dimensional valve block model is divided into a power unit, a booster unit, a test column unit, and a servo control unit to obtain a preliminary simulation model of the hydraulic integrated valve block.

5. The test method for a one-way valve based on a hydraulic integrated valve block according to claim 4, characterized in that: The three-dimensional valve block model is divided into a power unit, a booster unit, a test column unit, and a servo control unit to obtain a preliminary simulation model of the hydraulic integrated valve block, specifically including: Define the pump's displacement-pressure relationship curve in the power unit, simulate the hydraulic pump's output characteristics, drive the system's flow and pressure, set the flow value, and obtain the pressure of the power unit's main oil circuit; The booster unit sets the piston area ratio, which is multiplied by the pressure received from the main oil circuit of the power unit to obtain the output pressure; The test column unit obtains the load force by simulating the hydraulic cylinder load through mechanical library components based on the pressure fluctuation data received from the booster unit. The servo control unit builds a three-position four-way servo valve by combining the signal library and the hydraulic library, sets 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 command, dynamically adjusts the valve core displacement, changes the branch oil circuit flow, and inputs the changed flow into the booster unit to adjust the inlet flow of the booster unit.

6. The test method for a one-way valve based on a hydraulic integrated valve block according to claim 1, characterized in that: Based on the fault diagnosis results, the flow channel diameter, flow channel angle, and bending radius are corrected, specifically including: According to Poiseuille's law in fluid mechanics, the volumetric flow rate of the leaking main oil passage is proportional to the cube of the channel diameter. Therefore, the corrected channel diameter is obtained by taking the cube root of the ratio of the leakage rate threshold to the actual leakage rate and multiplying it by the current channel diameter. Subtract the stress tensor monitored by simulation from the allowable stress threshold of the material, and then divide by the allowable stress threshold 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 intersection node geometry to stress changes; then subtract the angle adjustment amount from the current flow channel angle to obtain the corrected flow channel angle. According to the thermodynamic empirical model, the temperature rise is approximately proportional to the flow resistance, while the flow resistance is inversely proportional to the bending radius R. Therefore, by dividing the oil temperature rise monitored by simulation by the maximum allowable temperature rise threshold and taking the square root, the temperature adjustment amount is obtained. Then, by multiplying it by the current bending radius, the corrected bending radius is obtained.

7. A test apparatus for a check valve based on a hydraulic integrated valve block, wherein the test method for a check valve based on a hydraulic integrated valve block according to any one of claims 1 to 6 is characterized in that: The hydraulic schematic diagram generation module is used to collect hydraulic system operating parameters in real time through fault detection sensors, 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. The 3D layout generation module is used to generate the initial layout of the hydraulic integrated valve block from the hydraulic schematic diagram through mapping rules, and obtain the 3D layout design of the hydraulic integrated valve block. The internal oil hole connection generation module is used to perform the internal oil hole connection design of the hydraulic integrated valve block through external circulation to obtain the internal oil hole connection design of the hydraulic integrated valve block. The output module is used to perform software-aided design analysis on the hydraulic integrated valve block based on the internal oil hole connection design, obtain a simulation model of the hydraulic integrated valve block, and realize the one-way valve test based on the hydraulic integrated valve block.

Images