Pressure sensor body fault discrimination method and device

Abstract

The invention provides a pressure sensor body fault judgment method and device, and the method comprises the steps: starting the fault diagnosis of a pressure sensor body when a preset triggering condition is satisfied; the controller reads a measured value A1 of the pressure sensor; comparing the measured value A1 with a plurality of preset threshold values, and sending out corresponding alarm information according to a comparison result; when it is judged that the sensor body breaks down and the hydraulic station is started, the fixed value is automatically adopted to temporarily replace the measured value for control logic; and an alarm reset function is set, so that alarm reset can be automatically realized through manual operation or logic. Diagnosis is started through a preset triggering condition, the controller reads a measured value and compares the measured value with multiple threshold values, and a corresponding alarm is given out to quickly position the fault degree. And when the sensor is judged to fail and the hydraulic station is started, the fixed value is automatically used for replacing the measured value, so that the equipment is prevented from being mistakenly shut down. The method can achieve automatic diagnosis, does not need manual intervention, and has the advantages of being high in fault judgment efficiency and low in misjudgment rate.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of rolling steel, in particular to a pressure sensor body fault discrimination method and device. BACKGROUND

[0002] In the field of rolling steel production, the hydraulic cylinder is the core executive component of the rolling mill, and its running state is directly related to the quality precision and production efficiency of the rolling steel product. The oil pressure parameter of the hydraulic cylinder is a key indicator reflecting its working state. Through real-time monitoring of the oil pressure, it can be determined whether the hydraulic cylinder is in the normal working interval in time, thereby providing an important basis for the stable operation of the rolling mill.

[0003] At present, electronic sensors are commonly used in rolling steel production to measure the hydraulic pressure of the hydraulic cylinder. However, in the long-term high-intensity industrial environment, electronic sensors are easily affected by factors such as vibration, high temperature, and oil stains, and will inevitably deteriorate or fail, resulting in distorted pressure measurement data. After the hydraulic cylinder completes the emptying operation, its internal pressure should theoretically tend to zero, but in actual application, some faulty pressure sensors will still output non-zero pressure values, causing serious interference to the subsequent production process judgment, for example, misleading the operator to believe that the hydraulic cylinder is still in the pressure-bearing state, thereby delaying the normal production scheduling or maintenance work, and bringing great hidden dangers to the continuity and safety of rolling steel production. SUMMARY

[0004] The present application provides a pressure sensor body fault discrimination method and device to solve the problem that the pressure sensors used in existing rolling steel production are easily affected by factors such as vibration, high temperature, and oil stains, causing pressure sensor failure and interfering with the judgment of the production process state by the operator.

[0005] The present application provides a pressure sensor body fault discrimination method, comprising:

[0006] When the preset trigger condition is met, start the pressure sensor body fault diagnosis;

[0007] The controller reads the measurement value A1 of the pressure sensor;

[0008] Compare the measurement value A1 with the preset multiple threshold values, and issue corresponding alarm information according to the comparison result;

[0009] When the sensor body fault is determined and the hydraulic station is started, automatically use a fixed value to temporarily replace the measurement value for control logic;

[0010] Set the alarm reset function, which can be manually operated or automatically reset by logic.

[0011] In an embodiment of the present application, the preset trigger condition is that the hydraulic station is stopped and there is no pressure build-up in the hydraulic cylinder.

[0012] In an embodiment of the present application, in the step of comparing the measured value A1 with the preset threshold values and issuing corresponding alarm information according to the comparison result, the following steps are further included:

[0013] The preset threshold values include B1, B2 and B3.

[0014] If A1 is greater than B1 and less than or equal to B2, a yellow alarm is issued to prompt maintenance of the pressure sensor body.

[0015] If A1 is greater than B2 and less than or equal to B3, an orange alarm is issued to prompt removal of the sensor body for cleaning of the sensing end.

[0016] If A1 is greater than B3, a red alarm is issued to prompt replacement of the sensor.

[0017] In an embodiment of the present application, the following steps are further included:

[0018] The sensor value A11 at the time of triggering the fault diagnosis is recorded.

[0019] If the real-time detection value A1 of the sensor at the moment of starting the hydraulic station is less than A11 and less than B1, it is determined that the hydraulic station is running normally.

[0020] If the real-time detection value A1 of the sensor at the moment of starting the hydraulic station is greater than A11, a fixed value replacement operation is performed, and a red alarm is continuously issued.

[0021] A pressure sensor body fault discrimination device is applied to the pressure sensor body fault discrimination method as described above, and the device includes:

[0022] A triggering module for monitoring and determining whether a preset triggering condition is met to start the fault diagnosis.

[0023] A data acquisition module for reading the measured value of the pressure sensor after triggering the diagnosis.

[0024] A comparison and judgment module for comparing the measured value with the preset threshold values and generating a judgment result.

[0025] An alarm module for issuing corresponding alarm information according to the result of the comparison and judgment module.

[0026] A value replacement module for automatically using a fixed value to temporarily replace the measured value when it is determined that the sensor body is faulty and the hydraulic station is started.

[0027] A reset module for providing an alarm reset function of manual reset or logical automatic reset.

[0028] In an embodiment of the present application, the preset triggering condition monitored by the triggering module is that the hydraulic station is stopped and there is no pressure build-up in the hydraulic cylinder.

[0029] In an embodiment of the present application, the preset threshold in the comparison and judgment module includes B1, B2 and B3, and the alarm module can send yellow, orange and red alarms of different levels, which correspond to different fault degrees.

[0030] The present application has the following advantages: the pressure sensor body fault diagnosis method and device provided by the present application can start diagnosis by preset trigger conditions, issue corresponding alarm information by threshold comparison mechanism, quickly locate fault degree, shorten fault judgment and disposal time, reduce downtime loss caused by sensor fault, automatically use a fixed value to temporarily replace measurement value for control logic when sensor body fault is determined and the hydraulic station is started, avoid equipment mis-stop caused by abnormal pressure value output by sensor fault, and ensure the continuity of steel rolling production. The present application also has the function of manual or automatic alarm reset, which can quickly restore normal monitoring state after sensor fault is eliminated, improve the flexibility and convenience of fault handling, and further ensure the smooth operation of production process. The present application can realize automatic diagnosis of pressure sensor body fault, complete fault detection without manual intervention, solve the problems of low efficiency and high misjudgment rate caused by traditional manual judgment, and accurately identify false signals caused by sensor deterioration fault, avoiding misleading maintenance personnel. BRIEF DESCRIPTION OF DRAWINGS

[0031] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one embodiment consistent with the present application and, together with the description, serve to explain the principles of the application. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained from these drawings without creative labor for those skilled in the art.

[0032] In the drawings:

[0033] Figure 1 The flowchart of the pressure sensor body fault diagnosis method provided for an embodiment of the present application;

[0034] Figure 2 The schematic diagram of the pressure sensor body fault diagnosis device provided for an embodiment of the present application.

[0035] The reference signs are as follows:

[0036] Trigger module 1, data acquisition module 2, comparison and judgment module 3, alarm module 4, value replacement module 5, reset module 6. DETAILED DESCRIPTION

[0037] Following, the advantages and effects of the present application are easily understood by those skilled in the art from the description of the specific examples. The present application can also be implemented or applied by other different specific embodiments, and the details in the description can be modified or changed based on different views and applications without departing from the spirit of the present application. The following examples and features in the examples can be combined with each other without conflict.

[0038] It should be noted that the diagrams provided in the following examples only schematically illustrate the basic concept of the present application, and the components related to the present application are shown in the drawings, but not drawn according to the number, shape and size of the components in actual implementation. The shape, number and proportion of each component in actual implementation can be arbitrarily changed, and the layout pattern of the components can be more complex.

[0039] In the following description, a large number of details are discussed to provide a more thorough explanation of the embodiments of the present application. However, it is obvious to those skilled in the art that the embodiments of the present application can be implemented without these specific details, and in other embodiments, the known structures and devices are shown in the form of block diagrams rather than in the form of details to avoid making the embodiments of the present application difficult to understand.

[0040] Please refer to Figure 1 The present application provides a pressure sensor body fault discrimination method.

[0041] In an exemplary embodiment of the present application, the pressure sensor body fault discrimination method includes at least steps S110 to S150, which are described in detail as follows:

[0042] In step S110, when a preset triggering condition is met, the pressure sensor body fault diagnosis is started.

[0043] For example, the system detects the operating state parameters related to the pressure sensor in the steel rolling production in real time or at a fixed time through the built-in triggering monitoring mechanism to determine whether the preset fault diagnosis starting condition is met. The preset triggering condition is a specific state set based on the pressure sensor fault characteristics and the steel rolling production process characteristics. In this state, the hydraulic cylinder theoretically has no actual pressure, which can exclude the interference of normal working pressure on sensor detection. When the system monitors that the preset state is met, the triggering logic automatically takes effect, sends a starting instruction to the controller, and makes the pressure sensor body fault diagnosis process activated, so as to enter the subsequent measurement value collection and fault judgment stage.

[0044] In step S120, the controller reads the measurement value A1 of the pressure sensor.

[0045] Exemplarily, the controller establishes a communication connection with the pressure sensor through the data acquisition channel, after the fault diagnosis is started, triggers a data reading instruction, converts the pressure electric signal detected by the sensor in real time into a measurement value A1 and stores it, to provide original data for subsequent fault judgment.

[0046] In step S130, the measurement value A1 is compared with a plurality of preset threshold values, and corresponding alarm information is issued according to the comparison result.

[0047] Exemplarily, the controller compares the read measurement value A1 with a plurality of threshold values preset by the system, according to the threshold interval in which A1 is located, triggers and outputs an alarm signal of a corresponding level, and realizes the grading prompt of the fault degree.

[0048] In step S140, when it is determined that the sensor body is faulty and the hydraulic station is started, a fixed value is automatically used as a temporary measurement value for control logic.

[0049] Exemplarily, when the system determines that the sensor body is faulty and detects that the hydraulic station is started, a preset fixed value is automatically called to replace the measured value of the sensor, which is input into the control logic to maintain normal operation of the system.

[0050] In step S150, an alarm reset function is set, which can be realized by manual operation or logic.

[0051] Exemplarily, the system sets a reset mechanism, when the sensor fault is eliminated, a reset signal can be triggered by manual operation, or the system logic can automatically trigger when the sensor returns to normal, to clear the alarm state and make the system return to the normal monitoring mode.

[0052] In the embodiment, the diagnosis is started by a preset trigger condition, corresponding alarm information is issued by combining a threshold comparison mechanism, the fault degree can be quickly located, the fault judgment and disposal time is shortened, and the downtime loss caused by sensor failure is reduced; when it is determined that the sensor body is faulty and the hydraulic station is started, a fixed value is automatically used as a temporary measurement value for control logic, which can avoid the false shutdown of the equipment caused by the abnormal pressure value output by the sensor failure, and ensure the continuity of the steel rolling production; the application also has the functions of manual or automatic reset alarm, which can quickly restore the normal monitoring state after the sensor fault is eliminated, and improves the flexibility and convenience of fault handling, further ensuring the smooth operation of the production process. The application can realize the automatic diagnosis of the pressure sensor body fault, and can complete the fault detection without manual intervention, solve the problems of low efficiency and high misjudgment rate caused by traditional manual judgment, and especially can accurately identify the false signal caused by the deterioration of the sensor, and avoid misleading the maintenance personnel.

[0053] In an exemplary embodiment of the application, the preset trigger condition is that the hydraulic station is stopped and there is no pressure build-up in the hydraulic cylinder.

[0054] In the embodiment, the system monitors the running state of the hydraulic station and the pressure state of the hydraulic cylinder in real time. When it is detected that the hydraulic station stops running and the pressure in the hydraulic cylinder is zero, i.e., the preset triggering condition is met, the fault diagnosis is automatically started.

[0055] In an example embodiment of the present application, in the comparison of the measurement value A1 with the preset multiple threshold values and the issuance of the corresponding alarm information according to the comparison result, at least steps S210 to S240 are further included, which are described in detail as follows.

[0056] In step S210, the preset multiple threshold values include B1, B2 and B3.

[0057] For example, the system prestores three increasing threshold values B1, B2 and B3, which respectively correspond to the determination critical points of different fault degrees of the sensor, to provide a reference for the interval comparison of the measurement value A1.

[0058] In step S220, if A1 is greater than B1 and less than or equal to B2, a yellow alarm is issued to prompt the maintenance of the pressure sensor body.

[0059] For example, when the measurement value A1 is in the interval of B1 to B2, the system determines that the sensor has a slight abnormality, triggers a yellow alarm signal and prompts the execution of the maintenance operation.

[0060] In step S230, if A1 is greater than B2 and less than or equal to B3, an orange alarm is issued to prompt the removal of the sensor body for cleaning the sensing end.

[0061] For example, when the measurement value A1 is in the interval of B2 to B3, the system determines that the sensor is contaminated or slightly deteriorated, triggers an orange alarm and prompts the cleaning of the sensing end.

[0062] In step S240, if A1 is greater than B3, a red alarm is issued to prompt the replacement of the sensor.

[0063] For example, when the measurement value A1 exceeds B3, the system determines that the sensor has a serious fault, triggers a red alarm signal and prompts the immediate replacement of the sensor.

[0064] In the embodiment, when A1 is in the interval of B1 to B2, the yellow warning prompts maintenance, slight abnormalities can be handled in time to avoid deterioration of the fault; when A1 is in the interval of B2 to B3, the orange warning prompts cleaning of the sensing end, which can solve moderate faults caused by pollution and the like and reduce maintenance cost; when A1 exceeds B3, the red warning prompts replacement of the sensor, which can quickly dispose serious faults and reduce the risk of shutdown. Through the hierarchical alarm mechanism shown in the embodiment, maintenance personnel can quickly and clearly determine the fault degree and processing method, greatly shorten the judgment and disposal time, effectively avoid shutdown loss caused by fault misjudgment, and improve the continuity and stability of the rolling production.

[0065] In an example embodiment of the present application, at least steps S310 to S330 are further included, which are described in detail as follows.

[0066] In step S310, the sensor value A11 at the time of triggering fault diagnosis is recorded.

[0067] For example, when the fault diagnosis is started, the system automatically stores the measurement value A11 of the pressure sensor at this moment as the reference data for subsequent comparison and judgment at the start moment of the hydraulic station.

[0068] In step S320, if the real-time detection value A1 of the sensor at the start moment of the hydraulic station is less than A11 and less than B1, it is determined that the hydraulic station is normally running.

[0069] For example, at the start moment of the hydraulic station, the system compares the real-time value A1 of the sensor with the stored A11 and the threshold B1, and if A1 is less than both, it is determined that the hydraulic station is normally running.

[0070] In step S330, if the real-time detection value A1 of the sensor at the start moment of the hydraulic station is greater than A11, a fixed value replacement operation is performed, and a red alarm is continuously issued.

[0071] For example, at the start moment of the hydraulic station, if the real-time value A1 of the sensor is greater than the stored A11, the system determines that the sensor is faulty, and immediately enables the fixed value replacement and continuously issues a red alarm.

[0072] In the embodiment, when A1 is less than A11 and less than B1, it is determined that the hydraulic station is normally running, avoiding the influence of misjudgment on production; when A1 is greater than A11, the fixed value replacement is immediately performed and a red alarm is continuously issued, ensuring that the control logic is not disturbed by abnormal signals in the fault state, and the replacement of the sensor is promoted through intensified warning. Through the dynamic comparison at the start moment, the accuracy of fault judgment is effectively improved, production interruption or misoperation caused by sensor failure is prevented, and shutdown loss is reduced.

[0073] Please refer to Figure 2As shown, the application also provides a pressure sensor body fault discrimination device.

[0074] In an exemplary embodiment of the application, the pressure sensor body fault discrimination device comprises:

[0075] A triggering module 1 for monitoring and determining whether a preset triggering condition is met to start fault diagnosis;

[0076] A data acquisition module 2 for reading the measurement value of the pressure sensor after triggering diagnosis;

[0077] A comparison and judgment module 3 for comparing the measurement value with a preset threshold and generating a judgment result;

[0078] An alarm module 4 for issuing corresponding alarm information according to the result of the comparison and judgment module 3;

[0079] A numerical replacement module 5 for automatically using a fixed value to temporarily replace the measurement value when it is determined that the sensor body is faulty and the hydraulic station is started;

[0080] A reset module 6 for providing alarm reset functions of manual reset or logical automatic reset.

[0081] In this embodiment, the triggering module 1 monitors the system state in real time, and when it is determined that the preset triggering condition is met, it sends a start signal to other modules to activate the fault diagnosis process; the data acquisition module 2 immediately reads the measurement value of the pressure sensor after receiving the start signal to provide data support for subsequent judgment; the comparison and judgment module 3 receives the collected measurement value, compares and analyzes it with the preset threshold, and generates a judgment result of the fault degree; the alarm module 4 issues corresponding alarm information according to the result output by the comparison and judgment module 3, prompting relevant personnel to handle; if it is determined that the sensor body is faulty and the hydraulic station is started, the numerical replacement module 5 automatically calls a fixed value to temporarily replace the measurement value to ensure the normal operation of the control logic; the reset module 6 clears the alarm state after the fault is eliminated through manual operation or logical automatic triggering, so that the device returns to the normal monitoring mode. Each module has clear division of labor and cooperative work, forming a complete fault discrimination and response closed loop to realize automatic detection, judgment, alarm and handling of the pressure sensor body fault.

[0082] In an exemplary embodiment of the application, the preset triggering condition monitored by the triggering module 1 is that the hydraulic station stops and there is no pressure build-up in the hydraulic cylinder.

[0083] In this embodiment, the triggering module 1 collects the hydraulic station running state signal and the hydraulic cylinder pressure signal in real time, and when both of them meet the stop running and zero pressure, it is determined that the preset triggering condition is met, and the fault diagnosis process is started immediately.

[0084] In an example embodiment of the present application, the preset threshold values in the comparison and judgment module 3 include B1, B2, B3, and the alarm module 4 can issue three different levels of yellow, orange, and red alarms, corresponding to different degrees of failure.

[0085] In the present embodiment, the comparison and judgment module 3 pre-stores three threshold values B1, B2, and B3, and generates a failure degree result after comparing the sensor measurement value with the three threshold values; the alarm module 4 issues three alarms of yellow, orange, and red according to the generated failure degree result, corresponding to prompting maintenance, cleaning, and replacing the sensor.

[0086] The working principle is that the diagnosis is started by preset trigger conditions, and the corresponding alarm information is issued in combination with the threshold value comparison mechanism, which can quickly locate the failure degree, shorten the failure judgment and disposal time, and reduce the downtime loss caused by sensor failure; when the sensor body failure is determined and the hydraulic station is started, the fixed value is automatically used as a temporary measurement value for control logic, which can avoid the false shutdown of equipment caused by abnormal pressure values output by the sensor failure, and ensure the continuity of the rolling production; the present application also has the function of manual or automatic reset alarm, which can quickly restore the normal monitoring state after the sensor failure is eliminated, improving the flexibility and convenience of failure handling, and further ensuring the smooth operation of the production process. The present application can realize the automatic diagnosis of the pressure sensor body failure, and can complete the failure detection without manual intervention, solving the problems of low efficiency and high misjudgment rate caused by traditional manual judgment, and especially accurately identifying the false signals generated by the deterioration failure of the sensor, avoiding misleading the maintenance personnel.

[0087] The above embodiments only exemplarily illustrate the principles and effects of the present application, and are not used to limit the present application. Any person skilled in the art can modify or change the above embodiments without departing from the spirit and scope of the present application. Therefore, all equivalent modifications or changes completed by those skilled in the art without departing from the spirit and technical thought disclosed by the present application should be covered by the claims of the present application.

Claims

1. A method of discriminating a failure of a pressure sensor body, characterized by, include: When the preset trigger conditions are met, the pressure sensor body fault diagnosis is initiated. The controller reads the measured value A1 from the pressure sensor; The measured value A1 is compared with multiple preset thresholds, and corresponding alarm information is issued based on the comparison results. When a sensor malfunction is detected and the hydraulic station is started, a fixed value is automatically used to temporarily replace the measured value for the control logic. The alarm reset function can be set up to reset the alarm through manual operation or automatic logic.

2. The pressure sensor body failure determination method according to claim 1, characterized in that: The preset trigger condition is that the hydraulic station stops and there is no pressure buildup in the hydraulic cylinder.

3. The method of claim 1, wherein The process of comparing the measured value A1 with multiple preset thresholds and issuing corresponding alarm information based on the comparison results also includes: The preset thresholds include B1, B2, and B3; If A1 is greater than B1 and less than or equal to B2, a yellow alarm will be issued, prompting maintenance of the pressure sensor body. If A1 is greater than B2 and less than or equal to B3, an orange alarm will be issued, prompting the sensor body to be removed and the sensing terminal to be cleaned. If A1 is greater than B3, a red alarm will be issued, prompting the sensor to be replaced.

4. The method of claim 1, wherein Also includes: Record the sensor value A11 when fault diagnosis is triggered; If, at the moment the hydraulic station starts, the real-time detection value A1 of the sensor is less than A11 and less than B1, then the hydraulic station is determined to be operating normally. If the real-time sensor value A1 is greater than A11 at the moment the hydraulic station starts, a fixed value substitution operation will be performed, and a red alarm will be continuously issued.

5. A pressure sensor body failure determination device for use in the pressure sensor body failure determination method according to any one of claims 1 to 4, characterized by The device includes: The trigger module is used to monitor and determine whether preset trigger conditions are met in order to initiate fault diagnosis; The data acquisition module is used to read the measured values ​​of the pressure sensor after the diagnostic is triggered; The comparison and judgment module is used to compare the measured value with a preset threshold and generate a judgment result; The alarm module issues corresponding alarm information based on the result of the comparison and judgment module. The numerical substitution module automatically uses a fixed value to temporarily substitute the measured value when the sensor body is determined to be faulty and the hydraulic station is started. The reset module provides alarm reset functions, including manual reset or automatic logic reset.

6. The pressure sensor body failure determination device according to claim 5, characterized in that: The preset triggering condition monitored by the triggering module is that the hydraulic station stops and there is no pressure buildup in the hydraulic cylinder.

7. The pressure sensor body failure determination device according to claim 5, characterized in that: The preset thresholds in the comparison and judgment module include B1, B2, and B3. The alarm module can issue three different levels of alarms: yellow, orange, and red, each corresponding to a different degree of fault.

Images