Hydraulic piston type structure interference monitoring system

Abstract

The invention discloses a hydraulic piston type structure interference monitoring system which comprises a to-be-monitored hydraulic actuator which comprises a static part, a piston part moving relative to the static part and a sealing part. The on-off state transmission device is used for transmitting the electric on-off state between the static part and the piston part, and the hydraulic actuator to be monitored is in an off state during normal work and is in an on state during interference; the signal processing device is connected with the power supply device and is used for receiving the on-off state signal, judging whether the static component and the piston component interfere with each other or not and integrating an alarm function; a power supply device; the state of the piston and the relative static part in the hydraulic actuator can be monitored in real time, whether interference occurs between the piston and the relative static part or not can be accurately judged through cooperative work of the contact device and the signal processing device, the timeliness and accuracy of detection can be improved, and the working efficiency is improved. And further damage to the equipment caused by incapability of finding interference problems in time is avoided.

Description

Technical Field

[0001] The present invention relates to the field of hydraulic actuator monitoring, and in particular to a hydraulic piston type structure interference monitoring system. Background Art

[0002] In modern industry, hydraulic actuators are widely used in a wide range of industries, including engineering machinery, mining, and construction, due to their high power and efficiency. Piston-based hydraulic actuators, such as hydraulic cylinders, hydraulic breakers, and rock drills, are key components in hydraulic systems. These piston-based actuators consist of three main components: the cylinder, piston, and seal. During normal operation, these two metal components must be separated by seals, supports, and a hydraulic oil film to ensure proper operation and performance.

[0003] However, in the actual working process, various abnormal situations are often encountered, such as premature aging and collapse of the seal due to high temperature, and the piston deviating from the track due to improper work, causing the cylinder and piston to move in contact, which will cause damage to the cylinder and piston.

[0004] General hydraulic piston actuators are characterized by high sealing, high pressure, and difficulty in disassembly. When parts are damaged due to interference inside the equipment, if they cannot be discovered and handled in time, they will usually continue to work, which will further damage the internal structure. In severe cases, the actuator will be scrapped. Currently, interference detection is carried out by stopping work and disassembling for inspection, or using special equipment for detection. Not only is the detection troublesome, it will also seriously delay the construction progress and seriously waste manpower and material resources. In addition, in order to ensure non-interference, hydraulic actuator equipment suppliers will recommend customers to replace oil seals and other wearing parts in advance, but this will increase unnecessary cost expenditures.

[0005] Therefore, designing a monitoring system that can monitor the internal situation of the hydraulic actuator in real time and accurately, issue warnings when necessary, and repair and stop losses in a timely manner is an issue that technical personnel in related fields urgently need to solve. Summary of the Invention

[0006] To solve the above technical problems, the present invention provides a technical solution: a hydraulic piston structure interference monitoring system, comprising:

[0007] A hydraulic actuator to be monitored, comprising a stationary component, a piston component moving relative to the stationary component, and a sealing component;

[0008] The on-off state transmission device is used to transmit the electrical on-off state between the stationary component and the piston component. The hydraulic actuator to be monitored is in the off state when it is working normally and in the on state when it is interfering.

[0009] A signal processing device, connected to the power supply device, for receiving the on / off status signal and determining whether interference occurs between the stationary component and the piston component, and integrating an alarm function;

[0010] The power supply device provides power to the on-off state transmission device and the signal processing device.

[0011] Preferably, the sealing component is arranged at the fitting gap between the stationary component and the piston component to seal the hydraulic medium; the sealing component does not affect the transmission of the electrical on / off state between the stationary component and the piston component; the sealing component includes a sealing ring, a support ring and a guide sleeve; if the sealing component is a conductive material, an isolation structure electrically isolated from the stationary component is provided on its surface.

[0012] Preferably, the on-off state transmission device includes a contact component and a conductive circuit for forming a continuous electrical connection with the hydraulic actuator to be monitored, the contact component is connected to the piston component, and the conductive circuit connects the signal processing device and the contact component.

[0013] Preferably, the contact component is a sliding contact structure, a fixed structure or a functional multiplexing structure;

[0014] When the contact assembly is a sliding contact structure, the contact assembly includes a conductive core, a spring for compressing the conductive core, and an insulating shell for wrapping the entire device; the contact assembly is mounted on the stationary component, the conductive core is tightly fitted with the piston component under the pressure of the spring, and the insulating shell ensures that only the conductive core and the piston component are electrically conductive in the entire device;

[0015] When the contact assembly is a fixed structure, the contact assembly is simplified to only have a conductive loop, which is directly connected to the piston component of the hydraulic actuator to be monitored;

[0016] When the contact assembly is a functional multiplexing structure, one of the seals in the sealing component is a composite structure, the inner circumferential surface of the seal in contact with the piston component is a conductive material, ensuring that a continuous electrical connection is formed only with the piston component, the outer circumferential surface and the axial end surface are wrapped with an insulating layer to ensure that the seal is not electrically connected to the stationary component; the inner circumferential surface of the seal is connected to the conductive circuit, and at the same time undertakes radial support or sealing auxiliary functions.

[0017] Preferably, one end of the signal processing device is connected to the conductive loop of the on-off state transmission device, and the other end is connected to one pole of the power supply device, and the other pole of the power supply device is connected to the stationary component to form a closed loop.

[0018] Preferably, the signal processing device is powered by a power supply device; the power supply device is a DC power supply; when the system detects interference, the signal processing device converts the interference signal into an acoustic and optical signal that can be perceived by humans.

[0019] Preferably, the interference refers to an unexpected contact, collision, jamming, friction abnormality between the stationary part and the piston part of the hydraulic actuator to be monitored; when the interference occurs, the electrical on-off state between the stationary part and the piston part is changed from off to on.

[0020] Preferably, the hydraulic actuator to be monitored is a hydraulic actuator to be monitored based on a piston system.

[0021] Preferably, whether the monitored actuator is interfered is judged by comparing the on frequency of the on-off state signal with the size relationship of the preset frequency threshold of the signal processing device. When the on frequency of the on-off state signal is greater than the preset frequency threshold, it is judged that the monitored actuator is interfered. The preset frequency threshold is not a fixed value, but is related to the type and model specification of the monitored actuator.

[0022] Preferably, the signal processing device can integrate an alarm function, or be connected with an independent communication module and an alarm module; when the independent module is connected, the signal processing device processes the interference signal, drives the alarm module to issue an alarm, and uploads the information to the cloud and the mobile client through the communication module.

[0023] Compared with the prior art, the present application has the following advantages:

[0024] (1) The present application can monitor the state of the piston and the relative stationary part inside the hydraulic actuator in real time, and through the cooperative work of the contact assembly and the signal processing device, it can accurately judge whether the piston and the relative stationary part are interfered, so as to improve the timeliness and accuracy of detection, and avoid further damage of the equipment due to the failure to find the interference problem in time.

[0025] (2) The contact assembly in the present application can be installed in the cooperation gap between the stationary part and the piston part of the hydraulic actuator, and can be installed on the stationary part or directly connected with the piston part, without changing the original structure of the equipment, and without affecting the normal sealing and pressure performance of the equipment, so as to ensure that the original function of the hydraulic actuator is not affected, and facilitate installation and maintenance.

[0026] (3) The present application can issue an alarm in time when the equipment is interfered, and the operator can repair according to the actual situation, so as to avoid excessive damage and early replacement of the vulnerable parts of the equipment, effectively reduce the maintenance cost and the risk of equipment scrapping, and improve the economic efficiency of the equipment use. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 is a schematic view of a hydraulic piston type structure interference monitoring system of the present application installed on a hydraulic breaking hammer.

[0028] Figure 2It is a schematic diagram of a hydraulic piston type structural interference monitoring system installed on a hydraulic cylinder according to the present invention.

[0029] Figure 3 It is a schematic diagram of an on-off state transmission device of a sliding contact structure in a hydraulic piston structure interference monitoring system of the present invention.

[0030] Figure 4 It is a schematic diagram of an on-off state transmission device of a function-multiplexing structure in a hydraulic piston-type structure interference monitoring system of the present invention.

[0031] Figure 5 It is a schematic diagram of an on-off state transmission device of a fixed structure in a hydraulic piston structure interference monitoring system of the present invention.

[0032] Figure 6 This is a schematic diagram of a hydraulic piston structure interference monitoring system of the present invention during interference. DETAILED DESCRIPTION

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0034] In the description of the embodiments of the present invention, it should be noted that if the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. appear, the orientation or position relationship indicated is based on the orientation or position relationship shown in the accompanying drawings, or the orientation or position relationship in which the product of the invention is usually placed when in use. It is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, it should not be understood as limiting the present invention. In addition, the terms "first", "second", "third", etc. are only used to distinguish the description and should not be understood as indicating or implying relative importance.

[0035] Furthermore, the use of terms such as "horizontal," "vertical," and "overhanging" does not necessarily imply that the component must be absolutely horizontal or overhanging, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," not that the structure must be completely horizontal, but rather that it can be slightly tilted.

[0036] In the description of the embodiments of the present invention, "a plurality of" means at least two.

[0037] In the description of the embodiments of the present application, it also needs to be explained that, unless explicitly defined and limited, if the terms "set", "install", "connect", "connect" appear, they should be understood in a broad sense, for example, they can be fixedly connected, or can be detachably connected, or integrally connected; can be mechanically connected, or can be electrically connected; can be directly connected, or can be indirectly connected through an intermediate medium, or can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0038] Embodiments:

[0039] In conjunction with the accompanying Figure 1-6 A hydraulic piston type structure interference monitoring system, comprising:

[0040] The hydraulic actuator 100 to be monitored comprises a stationary part 101, a piston part 102 moving relative to the stationary part 101, and a sealing part 103;

[0041] The on-off state transmission device 200 is used to transmit the electrical on-off state between the stationary part 101 and the piston part 102, and the hydraulic actuator 100 to be monitored is in the off state when it works normally, and in the on state when it interferes;

[0042] The signal processing device 300 is connected with the power supply device 400, used to receive the on-off state signal and judge whether the stationary part 101 and the piston part 102 interfere, and can integrate the alarm function;

[0043] The power supply device 400 provides power for the on-off state transmission device 200 and the signal processing device 300.

[0044] The sealing part 103 is arranged at the cooperation gap between the stationary part 101 and the piston part 102, and is used to seal the hydraulic medium; the sealing part 103 does not affect the electrical on-off state transmission between the stationary part 101 and the piston part 102; the sealing part 103 comprises a sealing ring, a support ring and a guide sleeve; if the sealing part 103 is a conductive material, its surface is provided with an isolation structure, such as an insulating layer, which is electrically isolated from the stationary part 101 or isolated from the stationary part 101 by structural design.

[0045] The on-off state transmission device 200 comprises a contact assembly for forming a continuous electrical connection with the hydraulic actuator 100 to be monitored and a conductive loop, the contact assembly is connected with the piston part 102, and the conductive loop is connected with the signal processing device 300 and the contact assembly.

[0046] The contact component is one of a sliding contact structure, a fixed structure or a functionally multiplexed structure; according to the working conditions of the hydraulic actuator 100 to be monitored, such as the piston movement mode and the installation space, the sliding contact structure, the fixed structure or the functionally multiplexed structure is reasonably selected. All three structures are suitable for hydraulic cylinders, hydraulic breakers and other piston-type hydraulic actuators 100 to be monitored.

[0047] When the contact assembly is a sliding contact structure, the contact assembly includes a conductive core 201, a spring 202 for compressing the conductive core 201, and an insulating shell 203 for wrapping the entire device; the contact assembly is mounted on the stationary component 101, the conductive core 201 is tightly fitted with the piston component 102 under the pressure of the spring 202, and the insulating shell 203 ensures that only the conductive core 201 and the piston component 102 are electrically connected in the entire device;

[0048] When the contact assembly is a fixed structure, the contact assembly is simplified, and only the conductive circuit 204 remains. The conductive circuit 204 is directly connected to the piston component 102 of the hydraulic actuator to be monitored;

[0049] When the contact assembly is a functional multiplexing structure, one of the seals in the sealing component 103 is a composite structure, and the inner circumference of the seal in contact with the piston component 102 is a conductive material, such as a polymer composite material containing copper powder, to ensure that a continuous electrical connection is formed only with the piston component 102; the outer circumference and the axial end face are wrapped with an insulating layer, such as a polytetrafluoroethylene coating, to ensure that the seal is not electrically connected to the stationary component 101; the inner circumference of the seal is connected to the conductive circuit 204, and at the same time undertakes radial support or sealing auxiliary functions.

[0050] One end of the signal processing device 300 is connected to the conductive loop 204 of the on / off state transmission device 200 , and the other end is connected to one pole of the power supply device 400 . The other pole of the power supply device 400 is connected to the stationary component 101 to form a closed loop.

[0051] The signal processing device 300 is powered by a power supply 400, which is a DC power supply. The signal processing device 300 can be an indicator light, a buzzer, or an integrated electronic system with certain computing capabilities. When the system detects interference, the signal processing device 300 converts the interference signal into perceptible audio and visual signals, such as a flashing indicator light, a sounding buzzer, and a screen display.

[0052] The interference refers to unexpected contact, collision, jamming, or friction abnormality between the stationary component 101 and the piston component 102 of the hydraulic actuator 100 to be monitored. When interference occurs, the electrical on / off state between the stationary component 101 and the piston component 102 changes from off to on.

[0053] The hydraulic actuator 100 to be monitored is a hydraulic actuator based on a piston system.

[0054] Interference with the monitored actuator is determined by comparing the on-off signal's frequency with a preset frequency threshold in the signal processing device. Interference with the monitored actuator is determined when the on-off signal's frequency exceeds the preset frequency threshold. This preset frequency threshold is not a fixed value but depends on the type and specifications of the monitored actuator.

[0055] The signal processing device 300 is also connected to a communication module and an alarm module; when connected to an independent module, the signal processing device 300 processes the interference signal, drives the alarm module to sound an alarm, and uploads the information to the cloud and mobile client through the communication module.

[0056] Specific case 1:

[0057] Combined with attachment Figure 1 、 3 The monitoring system is used on a hydraulic breaker. A hole is drilled in the lower cylinder of the breaker, and a contact assembly is inserted into the hole. The head of the contact assembly is a cylindrical carbon or copper brush, namely a conductive core 201. The tail is pressurized by a spring 202, which makes the conductive core 201 fit tightly against the piston component 102. The conductive core 201 is connected to a conductive circuit 204. The contact assembly has an insulating shell 203 to ensure that the conductive core 201 is only electrically connected to the piston component 102. The conductive circuit 204 is connected to the signal processing device 300. The excavator's 24V DC power supply serves as the power supply device 400. One pole of the power supply device 400 is connected to the signal processing device, and the other pole is connected to the cylinder, namely the stationary component 101. The signal processing device 300 can be an LED light, a buzzer, or a development board with certain computing capabilities. The signal processing device 300 is connected in series with the on-off state transmission device 200.

[0058] The working process of this monitoring system is as follows: when the hydraulic breaker is working normally, there is an oil film support between the breaker cylinder body (here the cylinder body specifically refers to the middle cylinder body) 101 and the piston component 102. At this time, the cylinder body 101 and the piston component 102 are electrically isolated, and the circuit is in a disconnected state; when the breaker is working, the piston component 102 moves downward and hits the drill rod connected to the lower cylinder body. During this process, the piston component 102 is always in contact with the carbon brush installed on the lower cylinder body. At the moment of impact, the piston component and the drill rod are electrically connected. At this time, "middle cylinder body-lower cylinder body-drill rod-piston-signal processing device-power supply-middle cylinder body" forms a complete circuit, and the signal processing device will receive a conduction signal, but this is a normal working state and needs to be eliminated; when abnormal contact occurs, that is, the piston component and the cylinder body are scratched, the circuit is connected, and the signal processing device in the system will receive a conduction signal. Under normal circumstances, each blow of the breaker hammer will impact the drill rod, and the signal processing device will receive a conduction signal. In other words, during normal operation, the frequency of the conduction signal received by the signal processing device is consistent with the hammer's striking frequency. When the frequency of the conduction signal received by the signal processing device is greater than the hammer's striking frequency, it can be determined to be interference. The signal processing device will have a preset frequency threshold. This threshold is related to the rated frequency of the monitored breaker hammer, and generally the two are consistent. The signal processing device will compare the frequency of the received conduction signal with the preset frequency threshold. When the frequency of the received conduction signal is greater than the preset frequency threshold, it is determined that there is interference with the monitored hydraulic breaker and an audible and visual alarm is issued to alert the operator.

[0059] Specific case 2:

[0060] Combined with attachment Figure 2 、 5The monitoring system is used on the hydraulic cylinder. The hydraulic cylinder is divided into a cylinder barrel (stationary component 101), a piston rod (piston component 102) and a sealing ring (sealing component 103). The support ring, sealing ring and guide sleeve in the sealing component are all made of non-conductive materials or have an insulating coating. Since the two ends of the hydraulic cylinder need to be installed on the equipment with the pin shaft, a "piston rod-pin shaft 1-equipment-pin shaft 2-cylinder barrel-power supply-signal processing device-piston rod" circuit will be formed by bypassing the inside of the cylinder. This will cause the signal processing device to always be judged as interference, resulting in monitoring failure. Therefore, this circuit needs to be disconnected at the electrical connectivity level. The specific method is to perform insulation treatment at the point where the cylinder and the pin shaft meet. For example, any one of the sleeves in the cylinder barrel and the piston rod is replaced with a non-conductive material (such as a ceramic bearing) or covered with an insulating coating on the surface, and the contact surface between the cylinder and the equipment is isolated with a gasket made of insulating material. After completing the above preparations, the monitoring system can be deployed. Operation is as follows: A wire 204 is directly connected to the rod end of the hydraulic cylinder's piston assembly 102. The other end of wire 204 is connected to a signal processing device 300. The signal processing device 300 is connected to one terminal of a power supply device 400, and the other terminal of the power supply device 400 is connected to the cylinder barrel of the hydraulic cylinder. During normal operation, the cylinder barrel and piston rod are electrically isolated due to the support of a sealing component, and the signal processing device 300 determines that the state is disconnected. However, due to heavy loads or compression and wear of the sealing component, the cylinder barrel and piston rod come into direct contact, and the two are connected. The signal processing device 300 determines that the state is connected, and it can be determined that the monitored hydraulic cylinder has an interference fault.

[0061] The present invention and its embodiments are described above. This description is not restrictive. The drawings show only one embodiment of the present invention, and the actual structure is not limited thereto. In short, if a person skilled in the art is inspired by this and, without departing from the purpose of the present invention, designs structures and embodiments similar to this technical solution without inventiveness, they shall fall within the scope of protection of the present invention.

Claims

1. A hydraulic piston type structure interference monitoring system, characterized in that: include: A hydraulic actuator to be monitored, comprising a stationary component, a piston component moving relative to the stationary component, and a sealing component; The on-off state transmission device is used to transmit the electrical on-off state between the stationary component and the piston component. The hydraulic actuator to be monitored is in the off state when it is working normally and in the on state when it is interfering. A signal processing device, connected to the power supply device, for receiving the on / off status signal and determining whether interference occurs between the stationary component and the piston component, and integrating an alarm function; The power supply device provides power to the on-off state transmission device and the signal processing device.

2. A hydraulic piston type structural interference monitoring system according to claim 1, characterized in that: The sealing component is arranged at the fitting gap between the stationary component and the piston component, and is used to seal the hydraulic medium; the sealing component includes a sealing ring, a support ring and a guide sleeve; the sealing component does not affect the transmission of the electrical on-off state between the stationary component and the piston component; if the sealing component is a conductive material, an isolation structure is provided on its surface to electrically isolate it from the stationary component.

3. The hydraulic piston type structural interference monitoring system according to claim 1, characterized in that: The on-off state transmission device includes a contact component and a conductive circuit for forming a continuous electrical connection with the hydraulic actuator to be monitored. The contact component is connected to the piston component, and the conductive circuit connects the signal processing device and the contact component.

4. A hydraulic piston type structural interference monitoring system according to claims 1 and 3, characterized in that: The contact component is one of a sliding contact structure, a fixed structure or a functional multiplexing structure; When the contact assembly is a sliding contact structure, the contact assembly includes a conductive core, a spring for compressing the conductive core, and an insulating shell for wrapping the entire device; the contact assembly is mounted on the stationary component, the conductive core is tightly fitted with the piston component under the pressure of the spring, and the insulating shell ensures that only the conductive core and the piston component are electrically conductive in the entire device; When the contact assembly is a fixed structure, the contact assembly is simplified to only have a conductive loop, which is directly connected to the piston component of the hydraulic actuator to be monitored; When the contact assembly is a functional multiplexing structure, one of the seals in the sealing component is a composite structure, the inner circumferential surface of the seal in contact with the piston component is a conductive material, ensuring that a continuous electrical connection is formed only with the piston component, the outer circumferential surface and the axial end surface are wrapped with an insulating layer to ensure that the seal is not electrically connected to the stationary component; the inner circumferential surface of the seal is connected to the conductive circuit, and at the same time undertakes radial support or sealing auxiliary functions.

5. The hydraulic piston type structural interference monitoring system according to claim 1, characterized in that: One end of the signal processing device is connected to the conductive loop of the on-off state transmission device, and the other end is connected to one pole of the power supply device, and the other pole of the power supply device is connected to the stationary component to form a closed loop.

6. The hydraulic piston type structural interference monitoring system according to claim 1, characterized in that: The signal processing device is powered by a power supply device; the power supply device is a DC power supply; when the system detects interference, the signal processing device converts the interference signal into an acoustic and optical signal that can be perceived by humans.

7. The hydraulic piston type structural interference monitoring system according to claim 1, characterized in that: The interference refers to unexpected contact, collision, jamming, or friction between the stationary component and the piston component of the hydraulic actuator to be monitored. When interference occurs, the electrical connection between the stationary component and the piston component changes from disconnection to conduction.

8. The hydraulic piston type structural interference monitoring system according to claim 1, characterized in that: The hydraulic actuator to be monitored is a hydraulic actuator to be monitored based on a piston system.

9. A hydraulic piston type structural interference monitoring system according to claim 1 or claim 7, characterized in that: Interference with the monitored actuator is determined by comparing the on-off signal's frequency with a preset frequency threshold in the signal processing device. Interference with the monitored actuator is determined when the on-off signal's frequency exceeds the preset frequency threshold. This preset frequency threshold is not a fixed value but depends on the type and specifications of the monitored actuator.

10. A hydraulic piston type structural interference monitoring system according to claim 1 or claim 8, characterized in that: The signal processing device can integrate an alarm function, or be connected to an independent communication module and an alarm module; when connected to an independent module, the signal processing device processes the interference signal, drives the alarm module to sound an alarm, and uploads the information to the cloud and mobile client through the communication module.

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