Balance valve effectiveness simulation verification method and system

Abstract

The invention belongs to the technical field of hydraulic systems, and particularly relates to a balance valve effectiveness simulation verification method and system. The balance valve effectiveness simulation verification method is scientific and reasonable in design, and is realized through the following steps: constructing a hydraulic-mechanical coupling model containing a balance valve in AMESim, applying variable load force and periodic forcible entry force, performing real-time simulation in combination with Simulink, and comparing working conditions when the balance valve is installed and when the balance valve is not installed; and quantitatively analyzing the displacement tracking error, the pressure stabilization time and the oscillation amplitude. The system comprises a model building module, a load applying module, a joint simulation module and a result analysis module, and the stability of the balance valve in the hydraulic system can be verified efficiently at low cost. The method is suitable for engineering machinery such as forcible entry robots, and scientific basis is provided for design and optimization of the balance valve.

Description

Technical Field

[0001] The present invention belongs to the technical field of hydraulic systems, and specifically relates to a method and system for simulating and verifying the effectiveness of a balancing valve, which is particularly suitable for dynamic performance evaluation of balancing valves in hydraulic systems of engineering machinery such as demolition robots. Background Art

[0002] The balancing valve is a key component in hydraulic systems that prevents uncontrolled load sliding and stabilizes actuator movement. Its performance directly affects system safety and reliability. Traditional balancing valve effectiveness verification relies primarily on physical experiments, which have the following drawbacks:

[0003] 1) High cost: A dedicated test bench needs to be built, consuming a large amount of hydraulic oil and energy;

[0004] 2) Long cycle: Physical experiments require repeated parameter adjustments, making it difficult to cover complex working conditions;

[0005] 3) Working condition limitations: It is impossible to simulate actual working conditions such as extreme loads or high-frequency vibrations, resulting in incomplete verification.

[0006] Existing simulation methods are mostly based on single platforms such as AMESim or MATLAB / Simulink, which cannot achieve real-time interaction between the hydraulic system and the controller and lack a quantitative verification indicator system. Therefore, an efficient, low-cost, and comprehensive simulation verification method for balancing valves is urgently needed. Summary of the Invention

[0007] The purpose of the present invention is to overcome the above-mentioned problems existing in traditional technologies and provide a balancing valve effectiveness simulation verification method and system, which comprehensively evaluates the stability and reliability of the balancing valve in the hydraulic system through dynamic load simulation, real-time data interaction and quantitative index analysis.

[0008] In order to achieve the above technical objectives and the above technical effects, the present invention is implemented through the following technical solutions:

[0009] The present invention provides a method for simulating and verifying the effectiveness of a balancing valve, comprising the following steps:

[0010] S1. Build a hydraulic system simulation model;

[0011] S2, applying dynamic load;

[0012] S3, joint simulation and data comparison;

[0013] S4. Validity verification.

[0014] Furthermore, in step S1, a hydraulic-mechanical coupling model including a balancing valve is established in AMESim. The coupling model includes an asymmetric hydraulic cylinder, a servo proportional valve, a balancing valve structure in which a one-way valve and a sequence valve are connected in parallel, and a robotic arm load model.

[0015] Furthermore, the check valve of the balancing valve is used for free forward flow, and the sequence valve controls reverse flow by the difference between the pilot pressure and the system pressure. The relationship between the pilot pressure and the system pressure satisfies:

[0016] p3=k·(p1-p2)

[0017] Where p3 is the pilot pressure, p1 and p2 are the pressures in the rodless and rod chambers of the hydraulic cylinder, respectively, and k is the pressure adjustment coefficient.

[0018] Furthermore, the main valve core of the balancing valve adopts a cone valve sealing surface design, with a small flow cross-sectional area gradient and a large hydraulic radius to avoid blockage; the pilot control piston is provided with a damping hole to reduce the vibration of the valve core movement; the main valve chamber is integrated with a one-way throttle valve to prevent oil backflow.

[0019] Furthermore, in step S2, the applied dynamic load mainly includes a variable load force and a periodic demolition force; wherein, the variable load force is a resistance force that simulates the direction of the load when the robotic arm moves, and the value range is 7000~10000N; wherein, the periodic demolition force adopts a sine wave form to simulate the actual demolition working condition.

[0020] Furthermore, in step S3, a hydraulic manipulator solid model is constructed in AMESim, and the mass of the manipulator rods, the center of mass coordinates and the hydraulic cylinder parameters are set;

[0021] Design the controller in MATLAB / Simulink, implement data exchange between the two platforms through the S-Function interface, and transmit control signals and state parameters in real time;

[0022] By comparing the two working conditions with and without the balancing valve installed, the hydraulic cylinder displacement response curve, pressure fluctuation data and system oscillation amplitude were obtained.

[0023] Furthermore, in step S4, the validity verification criteria are as follows:

[0024] a) Displacement tracking error: After installing the balancing valve, the displacement error amplitude is reduced by more than 40%;

[0025] b) Pressure stabilization time: The time it takes for system pressure fluctuations to decay to a steady-state value is shortened by more than 30%;

[0026] c) Oscillation amplitude: The oscillation peak value during load mutation is reduced by more than 50%.

[0027] The present invention also provides a balancing valve effectiveness simulation verification system, which can implement the above-mentioned balancing valve effectiveness simulation verification method. The balancing valve effectiveness simulation verification system includes:

[0028] Hydraulic module, which includes a servo valve, an asymmetric hydraulic cylinder and a balancing valve. The balancing valve adopts a parallel structure of a one-way valve and a sequence valve;

[0029] Mechanical module, which builds the robot arm model based on the DH parameter method and defines the length, mass and moment of inertia of the rods;

[0030] A load application module, which can generate a variable load force and a periodic demolition force and load them to the end of the hydraulic cylinder;

[0031] Joint simulation module, which can drive AMESim and Simulink to run in coordination and compare simulation data under different working conditions in real time;

[0032] Result analysis module, which can calculate the displacement tracking error, pressure stabilization time and oscillation decay rate to verify the effectiveness of the balancing valve.

[0033] Furthermore, the hydraulic module, mechanical module and load application module together constitute a model construction module; the verification indicators of the result analysis module include:

[0034] a) Displacement tracking error: By comparing the simulation curve, the error amplitude is less than 0.5mm after installing the balancing valve;

[0035] b) Pressure stabilization time: The time it takes for the system pressure fluctuation to decay to ±2% of the steady-state value is less than 0.3 seconds;

[0036] c) Oscillation amplitude: The peak fluctuation of hydraulic cylinder pressure is less than ±5% when the load changes suddenly.

[0037] The present invention also provides a computer-readable storage medium having a computer program stored thereon. When the computer program is executed by a processor, the above-mentioned balancing valve effectiveness simulation verification method is implemented.

[0038] The beneficial effects of the present invention are:

[0039] 1. The present invention provides a method and system for simulating and verifying the effectiveness of a balancing valve. The method is implemented by the following steps: constructing a hydraulic-mechanical coupling model containing a balancing valve in AMESim, applying a variable load force (7000-10000N) and a periodic demolition force (amplitude 10000N, frequency 3Hz), and performing real-time simulation in conjunction with Simulink. Comparing the working conditions with and without the balancing valve installed, quantitatively analyzing the displacement tracking error (≤0.5mm), pressure stabilization time (≤0.3s), and oscillation amplitude (≤±5%). The system includes a model construction module, a load application module, a joint simulation module, and a result analysis module, which can verify the stability of the balancing valve in the hydraulic system efficiently and at low cost. The present invention is applicable to engineering machinery such as demolition robots, and provides a scientific basis for the design and optimization of balancing valves.

[0040] 2. The present invention is efficient and low-cost, does not require physical experiments, and shortens the simulation cycle by more than 50%. It covers all working conditions and can simulate extreme loads and high-frequency vibrations, making the verification results more reliable. It also provides quantitative evaluation and provides data support for balancing valve optimization through a clear indicator system.

[0041] Of course, any product implementing the present invention does not necessarily need to achieve all of the above advantages at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0043] Figure 1 Schematic diagram of hydraulic system simulation model;

[0044] Among them, 1-cylinder port P1, 2-valve port P2, 3-pilot port P3, 4-oil unloading port;

[0045] Figure 2 This is the flowchart of the joint simulation process;

[0046] Figure 3 is the displacement response comparison curve;

[0047] Figure 4 This is the pressure fluctuation spectrum analysis diagram. DETAILED DESCRIPTION

[0048] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0049] Example 1

[0050] This embodiment provides a method for simulating and verifying the effectiveness of a balancing valve, including the following steps:

[0051] S1. Build a hydraulic system simulation model

[0052] A hydraulic-mechanical coupling model including a balancing valve is established in AMESim, including:

[0053] 1) Asymmetric hydraulic cylinder: piston rod diameter 50mm, cylinder inner diameter 100mm, stroke 350~640mm;

[0054] 2) Servo proportional valve: adopts three-position four-way structure, response time ≤5ms;

[0055] 3) Balancing valve: The one-way valve and the sequence valve are designed in parallel, the gradient of the main valve core cone valve sealing surface is ≤0.02mm / °, and the diameter of the pilot control piston damping hole is 0.8mm;

[0056] 4) Robotic arm load model: Define the mass of the rod based on the DH parameter method, such as the coordinates of the center of mass of the upper arm (-132.9, 582.9) mm and the moment of inertia.

[0057] The parameters of the balancing valve verification simulation system are shown in Table 1:

[0058] Table 1

[0059] Serial number Parameter name Numerical 1 Equivalent load mass m(kg) 50 2 <![CDATA[Equivalent load damping B (N·s·m -1 )]]> 0 3 <![CDATA[Effective working area of the rodless cavity A1 (m 2 )]]> <![CDATA[7.854×10 -3 ]]> 4 <![CDATA[Effective working area of the rod chamber A2 (m 2 )]]> <![CDATA[5.89×10 -3 <!-- 3 -->]]> 5 <![CDATA[Dead volume of the rodless chamber V d1 (m 3 )]]> <![CDATA[5×10 -4 ]]> 6 <![CDATA[Dead volume V of the rod chamber d2 (m 3 )]]> <![CDATA[5×10 -4 ]]> 7 Valve port area gradient w <![CDATA[1.2×10 -2 ]]> 8 <![CDATA[Flow coefficient C d > 0.7 9 <![CDATA[Fuel supply pressure P s (MPa)]]> 25 10 <![CDATA[Volume elastic modulus β of oil e (MPa)]]> 1700 11 <![CDATA[The density of the oil ρ (kg·m -3 )]]> 850

[0060] S2. Apply dynamic load

[0061] The applied dynamic load mainly includes variable load force and periodic demolition force; among them, the variable load force simulates the resistance in the opposite direction of the load when the robotic arm moves, with a value range of 7000~10000N and a step size of 500N; among them, the periodic demolition force adopts a sinusoidal wave form with an amplitude of 10000N, a frequency of 3Hz (corresponding to 180bpm), and a duration of 5s to simulate actual demolition conditions.

[0062] S3. Joint simulation and data comparison

[0063] 1) Design an adaptive sliding mode controller based on the extended state disturbance observer in Simulink and implement data exchange between the two platforms through the S-Function interface;

[0064] 2) Real-time transmission of control signals (such as servo valve opening instructions) and state parameters (hydraulic cylinder pressure, displacement), with a communication frequency of 1kHz;

[0065] 3) Compare the working conditions with and without the balancing valve installed to obtain the following data:

[0066] Displacement response curve: sampling frequency 100Hz, recording overshoot and adjustment time;

[0067] Pressure fluctuation data: monitor rodless cavity pressure p1 and rod cavity pressure p2, with a resolution of 0.1MPa;

[0068] System oscillation amplitude: Analyze frequency components through Fast Fourier Transform (FFT).

[0069] S4. Validity Verification

[0070] Displacement tracking error: After installing the balancing valve, the error amplitude is reduced by more than 40% (e.g. from 1.2mm to 0.7mm);

[0071] Pressure stabilization time: The time for system pressure fluctuations to decay to ±2% of the steady-state value is shortened by more than 30% (e.g., from 0.5s to 0.35s);

[0072] Oscillation amplitude: When the load changes suddenly, the pressure peak fluctuation is less than ±5%, and the frequency components are concentrated below 5Hz.

[0073] In this embodiment, the structure of the balancing valve is as follows: Figure 1 As shown in the figure, it consists of a check valve and a sequence valve connected in parallel. The main function of this balancing valve is to overcome the influence of gravity on the reciprocating motion of the arm system, thereby effectively offsetting the adverse effects of the load. The operating principle of this valve can be summarized as a bidirectional pressure regulation mechanism: when oil flows into chamber P2, hydraulic oil flows smoothly into the hydraulic cylinder through the check valve. When oil flows into chamber P1 and the hydraulic cylinder is under negative load, the check valve closes. At this time, the system pressure p1, the return oil pressure p2, and the pilot pressure p3 jointly determine the opening and closing state of the valve core.

[0074] Specifically, the working characteristics of the balancing valve are manifested in three key stages: First, when the pilot pressure p3 is low, the valve core remains locked, effectively preventing the boom from sliding due to gravity and ensuring the static stability of the system; second, when the working pressure reaches the set threshold, the valve core opens on demand to achieve controllable motion adjustment; finally, in the event of a sudden overload condition, the balancing valve can quickly respond to pressure changes and protect the actuator safety through the automatic pressure relief function. This intelligent pressure-adaptive characteristic enables the balancing valve to play a dual role in heavy-duty equipment such as demolition robots: it not only ensures the smooth movement of the boom through precise backpressure control, but also significantly improves the reliability of the system through the overload protection mechanism.

[0075] In this embodiment, the check valve of the balancing valve is used for free forward flow, and the sequence valve controls reverse flow by the difference between the pilot pressure and the system pressure. The relationship between the pilot pressure and the system pressure satisfies:

[0076] p3=k·(p1-p2)

[0077] Where p3 is the pilot pressure, p1 and p2 are the pressures in the rodless and rod chambers of the hydraulic cylinder, respectively, and k is the pressure adjustment coefficient.

[0078] In this embodiment, the main valve core of the balancing valve adopts a cone valve sealing surface design, with a small flow cross-sectional area gradient and a large hydraulic radius to avoid blockage; the pilot control piston is provided with a damping hole to reduce the vibration of the valve core movement; the main valve chamber is integrated with a one-way throttle valve to prevent oil backflow.

[0079] The specific application of this embodiment is as follows:

[0080] The specific process of joint simulation includes:

[0081] In AMESim, set the DH parameters of each rod of the robotic arm, such as the coordinates of the center of mass of the upper arm (-132.9, 582.9) mm, and construct a four-degree-of-freedom linkage mechanism;

[0082] Design an adaptive sliding mode controller based on extended state disturbance observer in Simulink to improve system robustness;

[0083] The hydraulic cylinder pressure, flow and robotic arm joint angle are monitored in real time through the data interaction interface.

[0084] In model construction, the hydraulic library module is called in AMESim, a hydraulic circuit including a balancing valve is built, and the hydraulic cylinder parameters and the robot arm DH parameters are set; the controller is designed in Simulink, and the input and output variables (such as control voltage u and displacement \(x_p\)) are defined through the S-Function interface.

[0085] In the simulation parameter setting, the dynamic load module generates variable load force and periodic demolition force, which are loaded to the end of the hydraulic cylinder through the signal interface; the joint simulation step is set to 0.001s, the total duration is 10s, and all state parameters are recorded.

[0086] In data comparison and analysis, after running the simulation, the hydraulic cylinder displacement and pressure data were exported in AMESim, and the tracking error and stabilization time were calculated in Simulink; the FFT function of MATLAB was used to analyze the pressure fluctuation spectrum and identify the dominant frequency components.

[0087] In the result verification, if the displacement error amplitude is ≤0.5mm, the pressure stabilization time is ≤0.3s, and the oscillation frequency is <5Hz, the balancing valve is determined to be effective; if the indicators are not met, the balancing valve parameters (such as the pilot pressure coefficient k) or the controller parameters are adjusted and the simulation is repeated.

[0088] Example 2

[0089] This embodiment provides a balancing valve effectiveness simulation verification system, including:

[0090] Hydraulic module, which includes a servo valve, an asymmetric hydraulic cylinder and a balancing valve. The balancing valve adopts a parallel structure of a one-way valve and a sequence valve;

[0091] Mechanical module, which builds the robot arm model based on the DH parameter method and defines the length, mass and moment of inertia of the rods;

[0092] A load application module, which can generate a variable load force and a periodic demolition force and load them to the end of the hydraulic cylinder;

[0093] Joint simulation module, which can drive AMESim and Simulink to run in coordination and compare simulation data under different working conditions in real time;

[0094] Result analysis module, which can calculate the displacement tracking error, pressure stabilization time and oscillation decay rate to verify the effectiveness of the balancing valve.

[0095] Among them, the hydraulic module, mechanical module and load application module together constitute the model building module.

[0096] The verification indicators of the result analysis module include:

[0097] a) Displacement tracking error: By comparing the simulation curve, the error amplitude is less than 0.5mm after installing the balancing valve;

[0098] b) Pressure stabilization time: The time it takes for the system pressure fluctuation to decay to ±2% of the steady-state value is less than 0.3 seconds;

[0099] c) Oscillation amplitude: The peak fluctuation of hydraulic cylinder pressure is less than ±5% when the load changes suddenly.

[0100] Example 3

[0101] This embodiment provides a computer-readable storage medium having a computer program stored thereon. When the computer program is executed by a processor, the method for simulating and verifying the effectiveness of a balancing valve of embodiment 1 is implemented.

[0102] The preferred embodiments of the present invention disclosed above are intended only to help illustrate the present invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the present invention to specific embodiments. Obviously, many modifications and variations are possible based on the contents of this specification. These embodiments are selected and described in detail in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to better understand and utilize the present invention. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. The simulation verification method for the effectiveness of the balancing valve is characterized by: The steps include: S1. Build a hydraulic system simulation model; S2, applying dynamic load; S3, joint simulation and data comparison; S4. Validity verification.

2. The method for simulating and verifying the effectiveness of a balancing valve according to claim 1, characterized in that: In step S1, a hydraulic-mechanical coupling model including a balancing valve is established in AMESim. The coupling model includes an asymmetric hydraulic cylinder, a servo proportional valve, a balancing valve structure in which a one-way valve and a sequence valve are connected in parallel, and a robotic arm load model.

3. The method for balancing valve effectiveness simulation verification according to claim 2, characterized in that: The check valve of the balancing valve is used for free forward flow, and the sequence valve controls the reverse flow by the difference between the pilot pressure and the system pressure. The relationship between the pilot pressure and the system pressure satisfies: p3=k·(p1-p2) Where p3 is the pilot pressure, p1 and p2 are the pressures in the rodless and rod chambers of the hydraulic cylinder, respectively, and k is the pressure adjustment coefficient.

4. The method for simulating and verifying the effectiveness of a balancing valve according to claim 3, characterized in that: The main valve core of the balancing valve adopts a cone valve sealing surface design, with a small flow cross-sectional area gradient and a large hydraulic radius to avoid blockage; the pilot control piston is set with a damping hole to reduce the vibration of the valve core movement; the main valve chamber is integrated with a one-way throttle valve to prevent oil backflow.

5. The method for simulating and verifying the effectiveness of a balancing valve according to claim 1, characterized in that: In step S2, the applied dynamic load mainly includes a variable load force and a periodic demolition force; the variable load force simulates the resistance in the opposite direction of the load when the robotic arm moves, and the value range is 7000~10000N; the periodic demolition force adopts a sine wave form to simulate the actual demolition working condition.

6. The method for simulating and verifying the effectiveness of a balancing valve according to claim 1, characterized in that: In step S3, a hydraulic manipulator solid model is constructed in AMESim, and the mass of the manipulator rods, the center of mass coordinates, and the hydraulic cylinder parameters are set; Design the controller in MATLAB / Simulink, implement data exchange between the two platforms through the S-Function interface, and transmit control signals and state parameters in real time; By comparing the two working conditions with and without the balancing valve installed, the hydraulic cylinder displacement response curve, pressure fluctuation data and system oscillation amplitude were obtained.

7. The method for simulating and verifying the effectiveness of a balancing valve according to claim 1, characterized in that: In step S4, the validity verification criteria are as follows: a) Displacement tracking error: After installing the balancing valve, the displacement error amplitude is reduced by more than 40%; b) Pressure stabilization time: The time it takes for system pressure fluctuations to decay to a steady-state value is shortened by more than 30%; c) Oscillation amplitude: The oscillation peak value during load mutation is reduced by more than 50%.

8. A balancing valve effectiveness simulation verification system capable of implementing the balancing valve effectiveness simulation verification method according to any one of claims 1 to 7, characterized in that: The balancing valve effectiveness simulation verification system includes: Hydraulic module, which includes a servo valve, an asymmetric hydraulic cylinder and a balancing valve. The balancing valve adopts a parallel structure of a one-way valve and a sequence valve; Mechanical module, which builds the robot arm model based on the DH parameter method and defines the length, mass and moment of inertia of the rods; A load application module, which can generate a variable load force and a periodic demolition force and load them to the end of the hydraulic cylinder; Joint simulation module, which can drive AMESim and Simulink to run in coordination and compare simulation data under different working conditions in real time; Result analysis module, which can calculate the displacement tracking error, pressure stabilization time and oscillation decay rate to verify the effectiveness of the balancing valve.

9. The balancing valve effectiveness simulation verification system according to claim 8, characterized in that: The hydraulic module, mechanical module and load application module together constitute a model construction module; the verification indicators of the result analysis module include: a) Displacement tracking error: By comparing the simulation curve, the error amplitude is less than 0.5mm after installing the balancing valve; b) Pressure stabilization time: The time it takes for the system pressure fluctuation to decay to ±2% of the steady-state value is less than 0.3 seconds; c) Oscillation amplitude: The peak fluctuation of hydraulic cylinder pressure is less than ±5% when the load changes suddenly.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the method for simulating and verifying the effectiveness of a balancing valve as claimed in any one of claims 1 to 7 is implemented.

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