Electromagnetic force measurement system and method capable of controlling current value and duration

Abstract

The invention discloses an electromagnetic force measurement system and method capable of controlling current value and duration, a force sensor is arranged above a measured electromagnetic valve through an installation alignment structure, the measurement surface of the force sensor is opposite to the working surface of the measured electromagnetic valve, and the force sensor is used for detecting electromagnetic force data generated by the measured electromagnetic valve; the current sensor is installed in a circuit of the detected electromagnetic valve and used for detecting actual current data borne by the electromagnetic valve. The upper computer controls the electric control unit to provide a driving current with a set time length and a set value for the tested electromagnetic valve, and meanwhile, the upper computer communicates with the PLC through the control module and is used for starting or stopping electromagnetic force measurement; in the measurement process, the upper computer controls the data acquisition card to acquire the real-time measurement data of the current and the electromagnetic force, and forms a complete ascending, stable holding and descending curve of the current and the electromagnetic force. The device accurately measures the electromagnetic force of the electromagnetic valve, improves the detection efficiency, and can be perfectly applied to online detection of mass production of the electromagnetic valves.

Description

Technical Field

[0001] The present invention belongs to the technical field of electromagnetic force measurement, and in particular relates to an electromagnetic force measurement system with controllable current value and duration. Background Art

[0002] Electromagnetic force measurement technology is widely used in industry, particularly in electronics, electricity, and machinery. Electromagnetic force measurement provides reliable data support for engineering design and industrial production. However, in traditional solenoid valve testing devices, the solenoid current and measurement duration cannot be accurately controlled, resulting in significant electromagnetic force measurement errors and inaccurate measurement. If the solenoid valve is energized for too long under high load, the solenoid coil will overheat and damage the valve. This also affects the precision and accuracy of mechanical testing. These issues lead to inaccurate and inefficient test results, making it impossible to verify the electromagnetic force of the produced solenoid valves.

[0003] There are two common electromagnetic force measurement technologies. One uses electrical measurement to measure the electromagnetic force, calculating the electromagnetic force by measuring the voltage (or current) induced by an inductor. The other uses a magnetic variable electromagnetic force sensor to measure the electromagnetic force, calculating the electromagnetic force by measuring the magnetic resistance variable.

[0004] In the process of implementing the present invention, the inventors discovered that the prior art has at least the following problems:

[0005] Electrical measurement technology suffers from uncontrollable power-on duration, which can easily cause the solenoid valve to heat up, deform, and bulge due to prolonged power-on. Furthermore, it cannot accurately capture the force generated by the solenoid valve when it is energized. Magnetic variable electromagnetic force sensing technology has low sensitivity, and its measurement results are easily affected by external magnetic fields. Therefore, both technologies suffer from low measurement accuracy in practical applications and exhibit significant deviations. Summary of the Invention

[0006] In order to address the problems in traditional solenoid valve electromagnetic force testing, such as the inability to accurately control the current value and measurement time, low measurement efficiency, inability to achieve automatic detection in mass production, and inaccurate control of the solenoid valve power supply time, which leads to overheating, deformation and damage of the solenoid valve, the purpose of the embodiment of the present application is to provide an electromagnetic force measurement system and method with controllable current value and duration, which accurately measures the electromagnetic force of the solenoid valve and improves the detection efficiency, and can be perfectly applied to online detection of mass production of solenoid valves.

[0007] To achieve the above objectives, the technical solutions adopted are as follows:

[0008] An electromagnetic force measurement system with controllable current value and duration, comprising a host computer, a data acquisition card, a force sensor, a current sensor, an electronic control unit, a control module, a PLC and a solenoid valve to be measured;

[0009] The force sensor is installed above the electromagnetic valve under test through the installation alignment structure, and the measuring surface of the force sensor is opposite to the working surface of the electromagnetic valve under test, and is used to detect the electromagnetic force data generated by the electromagnetic valve under test;

[0010] The current sensor is used to detect the actual current data received by the solenoid valve under test;

[0011] After receiving the start acquisition signal from the host computer, the data acquisition card starts to acquire the electromagnetic force data and actual current data of the solenoid valve under test;

[0012] After receiving the instruction from the host computer, the electronic control unit provides a current with a controllable current value and duration to the solenoid valve under test, thereby stimulating the electromagnetic force of the solenoid valve under test;

[0013] The PLC communicates with the host computer through the control unit to start or stop electromagnetic force measurement.

[0014] Furthermore, a test bench is included, which is used to send identification information of the electromagnetic valve under test to the host computer and receive the electromagnetic force measurement result sent by the host computer.

[0015] Furthermore, an armature is fixed to the force sensor via an armature connecting rod. The armature is attracted by the electromagnetic force of the solenoid valve to be measured and generates a force on the force sensor via the armature connecting rod, so that the force sensor measures the electromagnetic force.

[0016] Furthermore, the installation and alignment structure of the force sensor may include:

[0017] A mounting base plate, which is used to mount the force sensor on the test bench and is provided with a calibration block and a locating pin hole. The calibration block is a groove on the mounting base plate and is used to align the mounting base plate and the test bench. The locating pin hole is used to position the mounting base plate.

[0018] The base is used to position the solenoid valve to ensure the gap and parallelism between the end face of the solenoid valve and the end face of the armature. The force sensor is installed between the base and the mounting base plate, wherein the base and the force sensor are adjusted for coaxiality and connected through the base connecting block; the armature is arranged at the lower part of the base and the lower end face of the base is flush with the end face of the armature. Several positioning columns of equal length are arranged under the base for guiding and positioning the feeding of the solenoid valve.

[0019] Furthermore, the PLC is also used to control the movement of the test bench to achieve loading and unloading.

[0020] A method for measuring electromagnetic force with controllable current value and duration, based on the above system implementation, includes:

[0021] Load the solenoid valve to be tested to the test station and connect it to the electronic control unit;

[0022] The PLC sends a start signal to the host computer through the control module;

[0023] The host computer sends a test signal to the PLC through the control module, so that the PLC controls the test bench and moves the force sensor to the top of the solenoid valve under test by installing the alignment structure;

[0024] The host computer sends a start acquisition signal to the data acquisition card and sends a drive current instruction to the electronic control unit to set the drive current size and duration;

[0025] The electronic control unit drives the solenoid valve under test according to the driving instruction;

[0026] The current sensor collects actual current data, the force sensor collects electromagnetic force data, and the data is fed back to the host computer through the data acquisition card to form current and electromagnetic force curves.

[0027] Furthermore, after the solenoid valve under test is connected to the system, the test bench sends identification information of the solenoid valve under test to the host computer;

[0028] Furthermore, after receiving the data transmitted by the data acquisition card, the host computer calculates and determines whether the solenoid valve under test is qualified, and sends an OK / NG signal to the PLC through the control module, so that the PLC controls the test bench and takes corresponding measures according to the qualification of the solenoid valve under test.

[0029] After the measurement is completed, the host computer sends the test results to the test bench and generates a report with the solenoid valve identification and the measurement results corresponding to each other.

[0030] The technical solutions provided by the embodiments of the present application may have the following beneficial effects:

[0031] First, the system's ingenious mechanical design ensures consistent and stable relative positioning between the solenoid valve and force sensor. This design also allows for zeroing and linear calibration of the force sensor anytime, anywhere. Furthermore, the inverted force sensor prevents interference from iron filings and foreign matter, achieving high-precision electromagnetic force measurement.

[0032] Secondly, the system utilizes a proprietary electronic control unit (ECU) with a unique circuit design. This ECU can be controlled by host computer software, enabling power supply at any voltage between 0 and 24V and precisely controlling the duration of the power supply. Combined with measurement feedback from current sensors, this enables closed-loop control, replacing costly programmable power supplies. The system also allows for adjustable current values and precisely adjustable measurement times, increasing the flexibility and scalability of the measurement system.

[0033] Finally, through the interaction between the host computer software and the PLC, the system achieves fully automated control and measurement, significantly improving production inspection efficiency. This system can be reliably used for electromagnetic force detection during mass production of solenoid valves. The electromagnetic force measurement results are aligned with the QR code on the workpiece, enabling accurate traceability of solenoid valve products. This online electromagnetic force inspection prevents the flow of defective products, improving both product quality and production efficiency.

[0034] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present application and, together with the description, serve to explain the principles of the present application.

[0036] Figure 1 Schematic diagram of an electromagnetic force measurement system with controllable current value and duration.

[0037] Figure 2 The mechanical structure diagram of the force sensor part, where (a) is a top view and (b) is a side view.

[0038] Figure 3 Schematic diagram of the calibration weight for electromagnetic force.

[0039] Figure numerals: 1-positioning column, 2-armature, 3-base, 4-armature connecting rod, 5-base connecting block, 6-force sensor, 7-calibration positioning block, 8-mounting base plate, 9-positioning pin hole. DETAILED DESCRIPTION

[0040] Exemplary embodiments are described in detail herein, with examples illustrated in the accompanying drawings. When the following description refers to the drawings, identical numerals in different drawings represent identical or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments are not intended to represent all embodiments consistent with this application.

[0041] The terms used in this application are for the purpose of describing specific embodiments only and are not intended to limit this application. As used in this application and the appended claims, the singular forms "a," "an," "the," and "the" are intended to include the plural forms, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items.

[0042] It should be understood that although the terms first, second, third, etc. may be used in this application to describe various information, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from each other. For example, without departing from the scope of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "at the time of" or "when" or "in response to determining".

[0043] This application proposes an electromagnetic force measurement system with controllable current value and duration, such as Figure 1 As shown, the system includes a host computer, a data acquisition card, a force sensor 6, a current sensor, an electronic control unit, a control module, a PLC (Programmable Logic Controller) and a solenoid valve under test; the force sensor 6 is arranged above the solenoid valve under test through an installation alignment structure, and the measuring surface of the force sensor 6 is opposite to the working surface of the solenoid valve under test, and is used to detect the electromagnetic force data generated by the solenoid valve under test. By having the measuring surface of the force sensor 6 facing downward, errors caused by impurities such as dust falling on the measuring surface of the force sensor 6 are avoided; the current sensor is used to detect the actual current data received by the solenoid valve under test; the data acquisition card is used to receive the start acquisition signal of the host computer and receive the electromagnetic force data and actual current data; the electronic control unit is used to receive the driving current and duration set by the host computer, and provide a timed driving current to the solenoid valve under test to enable the solenoid valve to generate electromagnetic force; the PLC communicates with the host computer through the control unit to start or stop electromagnetic force measurement.

[0044] In a specific implementation, the system may also include a test bench, which is used to send a unique identifier of the solenoid valve under test (which can be a QR code, barcode, etc.) to the host computer, and receive the electromagnetic force measurement results sent by the host computer to achieve one-to-one recording of the measurement results of the solenoid valve.

[0045] In one embodiment, an armature 2 is fixed to the force sensor 6 via an armature link 4. The armature 2 and the armature link 4 are made of magnetic conductive material. The armature 2 can be attracted by the electromagnetic force of the solenoid valve, and a force is generated on the force sensor 6 through the armature link 4, so that the force sensor 6 can measure the electromagnetic force.

[0046] like Figure 2 As shown, the installation and alignment structure of the force sensor 6 may include: a mounting base plate 8, the mounting base plate 8 is used to install the force sensor 6 on the test bench, and is provided with a calibration positioning block 7 and a positioning pin hole 9, the calibration positioning block 7 is a groove on the mounting base plate 8, which is used to align the mounting base plate 8 and the test bench, and the mounting base plate 8 is installed on the test bench through the positioning pin hole 9; a base 3, used to position the solenoid valve to ensure the gap and parallelism between the end face of the solenoid valve and the end face of the armature 2, the force sensor 6 is installed between the base 3 and the mounting base plate 8, wherein the base 3 and the force sensor 6 are adjusted for coaxiality and connected through the base connecting block 5; the armature 2 is provided at the lower part of the base 3 and the lower end face of the base 3 is flush with the end face of the armature 2, and a number of equal-length positioning columns 1 are provided below the base 3 for guiding and positioning the feeding of the solenoid valve.

[0047] In this embodiment, the number of the positioning posts 1 is three. During the alignment process between the force sensor 6 and the solenoid valve, the three positioning posts 1 (such as Figure 2 As shown in the figure, the force sensor 6, the armature 2 and the electromagnetic valve are first contacted and the electromagnetic valve is guided, so that the force sensor 6, the armature 2 and the electromagnetic valve are always concentric, thereby ensuring the accuracy of the electromagnetic force measurement.

[0048] In a specific implementation, the positioning structure may include several positioning posts 1, which limit the force sensor 6 and the solenoid valve. A fixed seat is provided around the force sensor 6, and the solenoid valve fits into the fixed seat, ensuring that the armature 2 maintains a predetermined distance from the working surface of the solenoid valve and that the measuring surface of the force sensor 6 is relatively parallel to the working surface of the solenoid valve. The predetermined distance is set to the actual clearance of the solenoid valve in the injector, which is 0.04 mm. This relative parallelism ensures accurate electromagnetic force measurement and is also a practical working condition.

[0049] This application also designs a jig and weight to match the calibration of the force sensor 6. Figure 3 The figure shows a 6kg weight. There are two such weights. The gravity generated by a single weight is below the lower limit of the electromagnetic force, while the combined gravity of the two weights is above the upper limit of the electromagnetic force (covering the electromagnetic force range of the solenoid valve). The weights are used to zero and calibrate the force sensor 6 at any time, ensuring the accuracy of electromagnetic force detection.

[0050] Based on the above system, this application also provides an electromagnetic force measurement system with controllable current value and duration, specifically:

[0051] Load the solenoid valve to be tested to the test station and connect it to the electronic control unit;

[0052] The PLC sends a start signal to the host computer through the control module;

[0053] The host computer sends a test signal to the PLC through the control module, so that the PLC controls the test bench and moves the force sensor 6 to the top of the solenoid valve under test by installing the alignment structure;

[0054] The host computer sends a start acquisition signal to the data acquisition card and sends a drive instruction to the electronic control unit to set the drive current size and duration;

[0055] The electronic control unit drives the solenoid valve under test according to the driving instruction;

[0056] The current sensor collects actual current data, and the force sensor 6 collects electromagnetic force data, which are fed back to the host computer through the data acquisition card to form current and electromagnetic force curves.

[0057] After the measurement is completed, the host computer sends the test results to the test bench and generates a report with the solenoid valve identification and the measurement results corresponding to each other.

[0058] Specifically, the solenoid valve is placed on the electromagnetic force test fixture of the test bench by the loading robot. After the proximity sensor installed on the electromagnetic force test fixture senses that the solenoid valve is in place, the PLC sends a start signal to the host computer through the control module. The host computer sends a test signal to the PLC through the control module, causing the PLC to control the servo motor of the test bench to drive the force sensor 6 and its installation alignment structure to descend. The force sensor 6 is fixed to the servo motor through the installation alignment structure. The position of the solenoid valve may deviate after loading. When the servo motor drives the force sensor 6 downward, the three positioning columns 1 (such as Figure 2 As shown in the figure, the electric contact first contacts the solenoid valve and guides the solenoid valve so that the force sensor 6 and the solenoid valve are always concentric, ensuring the accuracy of the electromagnetic force measurement, and then the electric contact automatically connects to the solenoid valve terminal.

[0059] The PLC sends a start signal to the host computer via the control module (communication relay). The host computer sends a start acquisition signal to the data acquisition card and sends instructions to the electronic control unit to set the current and duration. The electronic control unit accurately supplies power to the solenoid valve according to the instructions. The current sensor begins measuring the current value in the circuit (closed-loop confirmation of the DC power supply's operating status) and feeds the results back to the host computer software via the data acquisition card. Simultaneously, force sensor 6 begins measuring the electromagnetic force and feeds it back to the host computer software via the data acquisition card. The host computer records and displays the complete current and electromagnetic force rise, stable hold, and fall curves. It also calculates the average value of the current and electromagnetic force after stabilization, automatically determines whether the solenoid valve is qualified, and sends an OK / NG signal to the PLC via the control module.

[0060] The PLC receives the OK / NG signal sent by the host computer, controls the test bench according to the qualification of the solenoid valve under test, and places the qualified or unqualified parts on the corresponding conveyor belt. At this point, the solenoid valve completes the electromagnetic force detection.

[0061] Those skilled in the art will readily conceive of other embodiments of the present application after considering the specification and practicing the contents disclosed herein. This application is intended to cover any variations, uses, or adaptations of the present application that follow the general principles of this application and include common knowledge or customary techniques in the art that are not disclosed in this application.

[0062] It should be understood that the present application is not limited to the exact structures described above and shown in the drawings, and that various modifications and changes may be made without departing from the scope thereof. The scope of the present application is limited only by the appended claims.

Claims

1. An electromagnetic force measurement system with controllable current value and duration, characterized in that: Including host computer, data acquisition card, force sensor, current sensor, electronic control unit, control module, PLC and solenoid valve under test; The force sensor is installed above the electromagnetic valve under test through the installation alignment structure, and the measuring surface of the force sensor is opposite to the working surface of the electromagnetic valve under test, and is used to detect the electromagnetic force data generated by the electromagnetic valve under test; The current sensor is used to detect the actual current data received by the solenoid valve under test; The data acquisition card is used to collect electromagnetic force data and actual current data, and form electromagnetic force and current curves on the host computer; After receiving the instruction from the host computer, the electronic control unit provides a current with a controllable current value and duration to the solenoid valve under test, thereby stimulating the electromagnetic force of the solenoid valve under test; The PLC communicates with the host computer through the control unit to start or stop electromagnetic force measurement.

2. The system according to claim 1, wherein: The system also includes a test bench, which is used to send identification information of the electromagnetic valve under test to a host computer and receive electromagnetic force measurement results sent by the host computer.

3. The system according to claim 1, wherein: An armature is fixed to the force sensor via an armature connecting rod. The armature is attracted by the electromagnetic force of the electromagnetic valve to be measured and generates a force on the force sensor via the armature connecting rod, so that the force sensor measures the electromagnetic force.

4. The system according to claim 3, characterized in that The force sensor mounting and alignment structure may include: A mounting base plate, which is used to mount the force sensor on the test bench and is provided with a calibration block and a locating pin hole. The calibration block is a groove on the mounting base plate and is used to align the mounting base plate and the test bench. The locating pin hole is used to position the mounting base plate. The base is used to position the solenoid valve to ensure the gap and parallelism between the end face of the solenoid valve and the end face of the armature. The force sensor is installed between the base and the mounting base plate, wherein the base and the force sensor are adjusted for coaxiality and connected through the base connecting block; the armature is arranged at the lower part of the base and the lower end face of the base is flush with the end face of the armature. Several positioning columns of equal length are arranged under the base for guiding and positioning the feeding of the solenoid valve.

5. The system according to claim 1, wherein: The PLC is also used to control the test bench movements to enable loading and unloading.

6. A method for measuring electromagnetic force with controllable current value and duration, characterized in that: Based on the system implementation of any one of claims 1 to 5, the method includes: Load the solenoid valve to be tested to the test station and connect it to the electronic control unit; The PLC sends a start signal to the host computer through the control module; The host computer sends a test signal to the PLC through the control module, so that the PLC controls the test bench and moves the force sensor to the top of the solenoid valve under test by installing the alignment structure; The host computer sends a start acquisition signal to the data acquisition card and sends a drive current instruction to the electronic control unit to set the drive current size and duration; The electronic control unit provides a set current to drive the solenoid valve under test according to the driving current instruction; The current sensor collects actual current data, the force sensor collects electromagnetic force data, and the data is fed back to the host computer through the data acquisition card to form current and electromagnetic force curves.

7. The method according to claim 6, characterized in that After the solenoid valve under test is connected to the system, the test bench sends the identification information of the solenoid valve under test to the host computer; After the measurement is completed, the host computer sends the test results to the test bench and generates a report with the solenoid valve identification and the measurement results corresponding to each other.

8. The method according to claim 6, characterized in that After receiving the data transmitted by the data acquisition card, the host computer calculates and determines whether the solenoid valve under test is qualified, and sends an OK / NG signal to the PLC through the control module, so that the PLC controls the test bench and takes corresponding measures according to the qualified status of the solenoid valve under test.

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