Insulation detection method of cubic diamond press

Abstract

The invention relates to the technical field of cubic diamond presses, in particular to an insulation detection method of a cubic diamond press, which comprises the following steps: in response to an insulation detection request, acquiring a first voltage which is a voltage difference value between a first target and a second target; when the first voltage meets a preset condition, acquiring a second voltage and a third voltage; acquiring a fourth voltage, wherein the fourth voltage is a difference value between the second voltage and the third voltage; when it is determined that the ratio of the fourth voltage to the first voltage exceeds a preset value, the second voltage and the third voltage are compared, and first fault information is sent out; fifth voltage is obtained, the fifth voltage is the difference value between the first voltage and the sum of the second voltage and the third voltage, and when it is determined that the ratio of the fifth voltage to the first voltage exceeds a preset value, second fault information is sent out; and when it is determined that the fifth voltage exceeds the preset range, third fault information is sent out. The method can position faults, quantify degradation grades, shorten maintenance time, reduce misjudgment and waste block rate, and guarantee continuous production.

Description

Technical Field

[0001] This invention relates to the field of six-sided diamond press technology, and more specifically to an insulation testing method for a six-sided diamond press. Background Technology

[0002] The six-sided diamond press is the core equipment for the artificial synthesis of diamonds. It uses six hammers (two heated and four unheated) to simultaneously compress the synthesis block, creating a high-pressure environment of 5-7 GPa. The heating hammers' electric current heat effect raises the temperature of the synthesis block to 1300-1700℃, causing graphite powder to undergo a phase transformation to form diamond under the action of a metal catalyst. During this process, due to the conductivity of graphite and the metal catalyst, the heating hammers and the cylinder must maintain strict insulation. If the insulation deteriorates, some of the heating current will be diverted to the ground, resulting in insufficient heating power applied to the synthesis block, causing the synthesis temperature to deviate from the process requirements, ultimately producing a large number of defective blocks, severely impacting production efficiency and product yield.

[0003] Existing insulation testing methods for six-sided top presses mainly fall into two categories: one is the external resistance switching method (e.g., calculating the circuit insulation resistance by switching a measuring resistor with a known resistance value), and the other is the signal injection method (injecting a low-frequency signal into the heating circuit and judging the insulation status by signal attenuation). Both methods primarily test the overall circuit formed by the upper and lower heating hammers, only outputting a binary judgment result of insulation pass / fail, unable to further pinpoint the specific faulty heating hammer. For example, when the test result indicates insulation abnormality, workers must dismantle both heating hammers to check for insulation damage, wiring leakage, and other problems. A single heating hammer can weigh hundreds of kilograms, requiring specialized hoisting equipment for disassembly and reassembly. A single maintenance typically takes more than 4 hours. If multiple machines fail simultaneously, it can lead to production line downtime of more than 12 hours, resulting in reduced diamond production and significant economic losses.

[0004] When a tiny crack appears in the insulation layer of the heating hammer (leakage rate <5%), the actual heating power only decreases by 3%-5%, which can be compensated for by fine-tuning the output of the power regulator without stopping the machine. However, existing technology cannot quantify the level of insulation degradation, so it will directly determine that the insulation is unqualified and trigger a shutdown, causing production interruption; this failure mode can be addressed by timely maintenance after production is completed.

[0005] When the insulation layer of the heating hammer is locally carbonized, if it is not dealt with in time, the current shunting rate will continue to rise, and the temperature of the composite block will drop sharply by 50-100°C, eventually resulting in a waste block. However, existing technologies lack dynamic monitoring capabilities (they can only detect after the equipment is shut down) and cannot capture severe degradation under working conditions. Often, the insulation problem can only be traced back after a waste block is generated.

[0006] In summary, existing insulation testing methods for six-sided diamond presses can only make a binary judgment of the overall circuit of the upper and lower heating hammers as either qualified or unqualified. They cannot pinpoint the specific faulty heating hammer, leading to the need to disassemble hundreds of kilograms of dual hammers for individual inspection, resulting in long repair times. Furthermore, they cannot quantify the insulation degradation level based on the fault type, making it difficult to match the differentiated treatment requirements for different degrees of degradation, leading to a high scrap rate. Therefore, it is necessary to research an insulation testing method for six-sided diamond presses. Summary of the Invention

[0007] Therefore, the purpose of this invention is to provide an insulation testing method for a six-sided diamond press. Existing technology can only test the overall insulation performance of the heating hammers of the six-sided press. During maintenance, both heating hammers need to be completely disassembled for maintenance, which increases the workload of maintenance workers and makes maintenance time longer. At the same time, existing technology cannot accurately locate the fault location and fault level, thus leading to a reduction in diamond production.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is: an insulation testing method for a six-sided diamond press, comprising: In response to an insulation detection request, a first voltage is acquired, wherein the first voltage is the voltage difference between a first target and a second target; When the first voltage meets the preset conditions, the second voltage and the third voltage are acquired, where the second voltage and the third voltage are the ground voltages of the first target and the second target, respectively. A fourth voltage is obtained, which is the difference between the second voltage and the third voltage; when it is determined that the ratio of the fourth voltage to the first voltage exceeds a preset value, a first fault message is issued by comparing the magnitudes of the second voltage and the third voltage. A fifth voltage is obtained, which is the difference between the first voltage and the sum of the second and third voltages. When it is determined that the ratio of the fifth voltage to the first voltage exceeds a preset value, a second fault message is issued. When it is determined that the fifth voltage exceeds the preset range, a third fault message is issued.

[0009] Furthermore, after the first fault information is triggered, the triggering conditions for the second fault information are determined. If the second fault information meets the triggering conditions, the first warning information is issued; otherwise, the second warning information is triggered. The second warning information includes the first target warning information and the second target warning information.

[0010] Furthermore, after the first fault information or the second fault information is triggered, the triggering condition for the third fault information is determined. If the triggering condition is met, the third fault information is issued simultaneously with the first fault information or the second fault information.

[0011] Furthermore, the first target is an upper heating hammer, and the second target is a lower heating hammer. The upper and lower heating hammers are respectively connected to the upper and lower connection circuits of the sampling heating circuit, which is connected to the voltage and power regulation circuit. The first voltage sensor is connected between the upper and lower connection circuits to collect the first voltage. The upper and lower connection circuits are respectively connected to a ground circuit, and a resistor is provided in the ground circuit. The second and third voltage sensors are connected across the resistor and are respectively used to collect the second and third voltages.

[0012] Furthermore, the second voltage is the voltage of the upper heating hammer to ground, the third voltage is the voltage of the lower heating hammer to ground, and the fourth voltage is the absolute value of the difference between the second and third voltages. When the fourth voltage exceeds the threshold, a heating hammer insulation failure fault is sent to the controller. If the second voltage is greater than the third voltage, it indicates that the lower heating hammer insulation is unqualified. If the second voltage is less than the third voltage, it indicates that the upper heating hammer insulation is unqualified. The second fault information indicates that both the upper and lower heating hammers are unqualified in insulation. The third fault information indicates that the insulation detection system sensor is faulty.

[0013] Furthermore, corresponding detection logic is allocated based on the characteristics of different working stages. The detection logic includes sampling period, judgment range and sampling number. The first voltage is periodically collected based on the corresponding sampling period. Anomalies are determined according to the judgment range. When the anomaly is greater than the sampling number, the first voltage, second voltage and third voltage are collected at the same time, and corresponding fault information is triggered according to the corresponding judgment range.

[0014] Furthermore, the working stages include the pre-synthesis preparation stage, the synthesis heating stage, the synthesis isothermal and pressure stage, and the synthesis cooling and pressure relief stage; each stage is assigned a corresponding detection set, which includes the sampling period, judgment range, and number of samplings. The working state of the press is determined based on the working temperature and pressure of the press, and the corresponding detection set is called according to the working state.

[0015] The insulation detection method for the six-sided diamond press according to claim 1 determines the current working status based on the temperature and pressure data of the press synthesis chamber; Obtain the actual voltage to ground, and calculate the voltage deviation rate to ground based on the historical reference voltage under this operating condition; A sliding window filter is used to smooth the first voltage signal. Within each sliding window, the maximum value, minimum value, and average value within the window are extracted. The relative voltage fluctuation coefficient is obtained based on the maximum value, minimum value, and average value within the window. The heating voltage matching degree is obtained based on the ratio of the fifth voltage to the first voltage; Subsequently, the ground voltage deviation rate, voltage fluctuation coefficient and heating voltage matching degree were normalized to obtain normalized parameters for each working condition. The evaluation score is obtained by weighting the normalized parameters according to the preset weights. The corresponding insulation status level is generated based on the range in which the score is located.

[0016] Furthermore, when calculating the voltage deviation rate to ground, the historical reference voltages of the upper heating hammer and the lower heating hammer are obtained according to the operating conditions. The voltage deviation rates of the upper heating hammer and the lower heating hammer to ground are obtained according to the actual collected second and third voltages and the corresponding historical reference voltages. Then, the average value of the voltage deviation rates of the upper heating hammer and the lower heating hammer to ground is taken as the final voltage deviation rate to ground.

[0017] Furthermore, the insulation condition level includes excellent, slightly deteriorated, moderately deteriorated, and severely deteriorated; the indicator light flashing frequency is generated according to the corresponding insulation condition level, and the first fault information, the second fault information, and the third fault information generate corresponding indicator lights to light up. The combination of the flashing frequency and the lit indicator lights forms a comprehensive fault signal.

[0018] The beneficial effects of the above technical solution are as follows: This invention addresses the pain points in insulation testing of six-sided diamond presses, such as the inability to locate individual faulty heating hammers, difficulty in quantifying insulation degradation levels, low maintenance efficiency, and susceptibility to misjudgment. Using voltage signals as the core carrier, it constructs a detection logic that enables precise positioning, quantitative grading, and adaptability to operating conditions. By distinguishing the voltage to ground of the upper and lower heating hammers and the relative voltage between them, the specific faulty object is located through analysis of the difference and ratio. Furthermore, a multi-dimensional parameter system is introduced to construct an evaluation system, enabling the quantitative determination of insulation degradation levels.

[0019] To address the differences in electromagnetic interference and degradation risks at different stages of press operation (preparation, heating, constant temperature, and cooling), a dynamically adaptable detection strategy is employed to ultimately achieve precise fault location, optimized maintenance processes, and guaranteed production continuity.

[0020] Specifically, this invention, based on voltage conservation and circuit voltage division principles, transforms the abstract insulation state into quantifiable voltage signal characteristics. In practice, upon responding to a detection request, a configured voltage sensor collects the relative voltage between the upper and lower heating hammers. When the collected voltage meets the triggering conditions, the voltage to ground of both is simultaneously collected, providing basic data for subsequent analysis. By calculating the difference between the second and third voltages and their ratio to the first voltage, and comparing their magnitudes, a single faulty heating hammer is located. By calculating the difference between the first voltage and the sum of the second and third voltages, and their ratio to the first voltage, simultaneous faults in both heating hammers are determined. Sensor faults are identified by checking if the fifth voltage exceeds a reasonable range. Based on the press temperature and pressure, the working stage is determined, and the corresponding detection parameters are called. By calculating the voltage to ground deviation rate, relative voltage fluctuation coefficient, and heating voltage matching degree, a comprehensive score is obtained through normalization and weighted fusion operations, ultimately mapped to four insulation levels: excellent, slightly deteriorated, moderately deteriorated, and severely deteriorated. Based on the fault type and insulation level, a comprehensive fault signal is output through a combination of indicator light color, flashing frequency, and buzzer frequency, enabling targeted production intervention.

[0021] Therefore, by distinguishing the ground voltage characteristics of the upper and lower heating hammers, this invention can directly pinpoint a single faulty heating hammer, avoiding the blindness of traditional full-disassembly and repair, significantly shortening maintenance time, and reducing damage to non-faulty heating hammers caused by disassembly. Through multi-dimensional parameter fusion, it achieves graded determination of insulation status, avoiding ineffective shutdowns caused by misjudgments of minor degradation, ensuring timely handling of severe degradation, reducing the scrap rate of composite blocks, and guaranteeing production continuity. Simultaneously, this invention dynamically adjusts detection parameters to address differences in electromagnetic interference and degradation risk at different operating stages, effectively filtering transient interference, significantly reducing the misjudgment rate, and adapting to the detection needs of the entire synthesis cycle of the press. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the insulation detection method of the present invention; Figure 2 This is a fault logic block diagram of the present invention; Figure 3 This is a working condition detection diagram of the present invention; Figure 4 This is a logic block diagram for determining the interference level of the present invention; Figure 5 This is a circuit connection diagram for the present invention.

[0023] Reference numerals in the attached figures: 1. Voltage regulator; 2. Heating transformer; 3. Upper heating hammer; 4. Lower heating hammer; 5. Composite block; 6. Graphite column; 7. First voltage sensor; 8. Second voltage sensor; 9. Third voltage sensor. Detailed Implementation

[0024] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments: Example 1: This example aims to provide an insulation testing method for a six-sided diamond press. Existing technology is limited by the overall insulation judgment detection logic, which can only perform overall insulation performance testing on the two heating hammers of the six-sided press, and cannot further distinguish the insulation status of individual heating hammers. This directly leads to the need to completely disassemble and transport both heating hammers to a dedicated testing platform for inspection during maintenance. This not only greatly increases the physical labor intensity of maintenance personnel, but also makes it impossible to pinpoint the specific heating hammer with insulation abnormalities through test data. Furthermore, it cannot establish a grading judgment standard based on the degree of insulation degradation (such as mild leakage, moderate carbonization, and severe breakdown). This results in maintenance work relying entirely on blind disassembly and inspection, and inappropriate fault handling strategies. Mild insulation degradation that only requires minor adjustment and compensation may be misjudged as a serious fault, triggering a shutdown and causing unnecessary production interruptions. Alternatively, severe insulation degradation that requires emergency treatment may be missed, leading to continuous shunting of heating current, deviation of the temperature of the composite block 5 from the process window, and ultimately the generation of waste blocks.

[0025] In specific implementation, such as Figure 1 As shown in the figure, this embodiment provides an insulation testing method for a six-sided diamond press, which specifically includes the following steps: Step 1: In response to the insulation detection request, acquire the first voltage V1, which is the voltage difference between the first target and the second target. The triggering conditions for the detection request include automatic triggering when the press starts, automatic triggering during the synthesis process according to a preset cycle, and manual triggering via the control panel. After receiving the request, the control unit first determines the current working stage of the press: by collecting the temperature (thermocouple detection) and pressure (pressure sensor) of the synthesis chamber, match the following working stages: for example, the pre-synthesis preparation stage (temperature ≤ 500℃, pressure ≤ 1GPa); the synthesis heating stage (temperature 500-1300℃, pressure 1-5GPa); the synthesis isothermal and pressure isothermal stage (temperature 1300-1700℃, pressure 5-7GPa); and the post-synthesis cooling and pressure relief stage (temperature ≤ 1300℃, pressure ≤ 5GPa).

[0026] Step 2: When the first voltage V1 meets the preset conditions, acquire the second voltage and the third voltage V3. The second voltage and the third voltage V3 are the ground voltages of the first target and the second target, respectively. In practice, the acquisition of the second voltage and the third voltage V3 will only be triggered when the first voltage V1 exceeds the threshold. For example, the threshold of the first voltage V1 can be set to 1.5V. It serves as a prerequisite for triggering subsequent judgments. Subsequent judgments will only be performed when the first voltage V1 meets the triggering conditions.

[0027] In terms of specific implementation structure, such as Figure 5As shown, in this embodiment, the first target is the upper heating hammer 3, and the second target is the lower heating hammer 4. The upper heating hammer 3 and the lower heating hammer 4 are respectively connected to the upper connection circuit and the lower connection circuit of the sampling heating circuit. The sampling heating circuit is connected to the voltage and power regulation circuit. The voltage and power regulation circuit includes a voltage regulator 1 and a heating transformer 2. The voltage regulator 1 is a constant voltage source with adjustable voltage. After passing through the heating transformer 2, AC0-380V is converted into AC0-10V low voltage and high current. The high current is used to heat the graphite column 6 in the composite block 5.

[0028] In the specific structure, six top hammers are used to press the composite block 5 from six directions. Two of the top hammers are heating hammers, namely the upper heating hammer 3 and the lower heating hammer 4. Graphite pillars 6 are set inside the composite block 5. The upper heating transformer 2 leads out to the upper connection circuit and the lower connection circuit. The upper connection circuit is connected to the conductor post of the upper heating hammer 3, and the lower connection circuit is connected to the conductor post of the lower heating hammer 4. The first voltage sensor 7 is connected between the upper connection circuit and the lower connection circuit to collect the first voltage V1. The upper connection circuit and the lower connection circuit are respectively connected to the upper and lower pull-to-ground circuits and the lower pull-to-ground circuit. The upper and lower pull-to-ground circuits are equipped with upper resistors R and lower resistors R. In implementation, the upper resistors R and the lower resistors R are both 1200Ω resistors to improve the accuracy of voltage acquisition. The second voltage sensor 8 and the third voltage sensor 9 are respectively connected to the two ends of the upper resistors R and the lower resistors R to collect the second voltage V2 and the third voltage V3, and the collected data is connected to the six-sided press control system.

[0029] In the specific implementation steps, a corresponding first voltage V1 threshold can be configured according to different implementation objects. The PLC collects the first voltage V1 through the first voltage sensor 7. If the single collected value is greater than the first voltage V1 threshold of the current stage, continuous verification begins; if it is less than the threshold, it is determined that the heating circuit has not reached an effective working state, and subsequent collection is not triggered, returning to continue monitoring. Verification is performed according to the threshold requirements of the current stage. Continuous collection continues. If all sampled values ​​are greater than the threshold, it is determined that the first voltage V1 meets the preset conditions, and the collection of the second voltage V2 and the third voltage V3 is triggered; if any sampled value is less than the threshold, the verification count is reset, and the process is repeated.

[0030] Once the first voltage V1 passes the threshold verification, the PLC sends a synchronous acquisition command to the second voltage sensor 8 and the third voltage sensor 9 to ensure that the voltage of the upper heating hammer 3 to ground and the voltage of the lower heating hammer 4 to ground are consistent with the acquisition timestamp of the current first voltage V1, thus avoiding calculation errors caused by timing deviations.

[0031] Step 3: Obtain the fourth voltage, which is the difference between the second voltage V2 and the third voltage V3; when it is determined that the ratio of the fourth voltage to the first voltage V1 exceeds a preset value, the first fault information is issued by comparing the magnitudes of the second voltage V2 and the third voltage V3.

[0032] In specific implementation, the second voltage V2 is the voltage of the upper heating hammer 3 to ground, the third voltage V3 is the voltage of the lower heating hammer 4 to ground, and the fourth voltage is the absolute value of the difference between the second voltage V2 and the third voltage V3. When the fourth voltage exceeds the threshold, a fault for non-insulation of the heating hammer is sent to the controller. If the second voltage V2 is greater than the third voltage V3, it is displayed that the insulation of the lower heating hammer 4 is unqualified. If the second voltage V2 is less than the third voltage V3, it is displayed that the insulation of the upper heating hammer 3 is unqualified.

[0033] In the heating circuit of the six-sided top press, the upper and lower heating hammers 4 and the composite block 5 are connected in series to form a current path, which is ideally equal to +; when the insulation of a certain heating hammer deteriorates, current shunting will occur, resulting in abnormal voltage to ground of that heating hammer.

[0034] The principle is divided into insulation degradation of the upper heating hammer 3 and insulation degradation of the lower heating hammer 4. When the insulation of the lower heating hammer 4 is degraded, the current leaks through the lower heating hammer 4 and is shunt, the leakage voltage increases, which causes the measured third voltage V3 to decrease; when the insulation of the upper heating hammer 3 is degraded, the current leaks through the upper heating hammer 3 and is shunt, the leakage voltage increases, which causes the measured second voltage V3 to decrease.

[0035] If the ratio of the fourth voltage to the first voltage V1 exceeds the threshold, it indicates an insulation fault. To locate the fault, compare the magnitudes of the second voltage V2 and the third voltage V3. If V2 > V3, it indicates an abnormal decrease in the voltage to ground of the lower heating hammer 4, and the insulation of the lower heating hammer 4 is deemed unqualified. If V3 > V2, it indicates an abnormal decrease in the voltage to ground of the upper heating hammer 3, and the insulation of the upper heating hammer 3 is deemed unqualified.

[0036] Step 4: Obtain the fifth voltage, which is the difference between the first voltage V1 and the second voltage V2 and the third voltage V3. When it is determined that the ratio of the fifth voltage to the first voltage V1 exceeds a preset value, a second fault message is issued. The second fault message indicates that the insulation of both the upper and lower heating hammers 4 is unqualified. Step 5: When it is determined that the fifth voltage exceeds the preset range, a third fault message is issued, which is a sensor fault in the insulation detection system.

[0037] Based on the characteristics of different working stages, corresponding detection logic is allocated. The detection logic includes sampling period, judgment range and sampling number. The first voltage V1 is periodically collected based on the corresponding sampling period. Anomalies are determined according to the judgment range. When the number of anomalies exceeds the number of samplings, the first voltage V1, the second voltage V2 and the third voltage V3 are collected at the same time, and corresponding fault information is triggered according to the corresponding judgment range.

[0038] In specific implementation, such as Figure 3 As shown, the working stages include the pre-synthesis preparation stage, the synthesis heating stage, the synthesis isothermal and pressure stage, and the synthesis cooling and pressure relief stage. Each stage is assigned a corresponding detection set, which includes the sampling period, judgment range, and number of samplings. The working state of the press is determined based on the working temperature and pressure of the press, and the corresponding detection set is called according to the working state.

[0039] The detection set parameters for the corresponding working stage are called, including sampling period, judgment threshold, number of samplings, first threshold, second threshold and third threshold; where the first threshold is the fourth voltage / first voltage; the second threshold is the fifth voltage / first voltage; and the third threshold is the absolute value of the fifth voltage. The specific table content is as follows: During the implementation phase, the table is first invoked, and based on the real-time temperature T collected by the thermocouple built into the synthesis chamber and the real-time pressure P collected by the pressure sensor, the following operating conditions are matched. The corresponding detection set parameters are invoked according to the corresponding operating conditions, and the corresponding information collection and judgment logic is performed according to the agreed detection cycle, threshold and sampling number. For example, in the heating stage, the first voltage V1 is collected by the PLC. If the first voltage V1 is greater than the preset value, continuous collection is triggered. The sampling is continuously collected n times according to the current operating condition sampling cycle. If all sampled values ​​are greater than the threshold, it is determined that the preset condition is met. If any value is less than the threshold, the verification count is reset and the collection is repeated.

[0040] In this embodiment, in the heating circuit of the six-sided top press, the upper heating hammer 3, the composite block 5, and the lower heating hammer 4 are connected in series to form a closed circuit. Under ideal conditions (without insulation degradation), voltage conservation is satisfied. The composite block 5 has a stable resistance due to the graphite powder and metal catalyst, and its voltage division accounts for about 80%-90%. The upper heating hammer and the lower heating hammer 4 account for about 10%-20%, and the voltage division is balanced. Under ideal conditions, there is no current shunting between the upper heating hammer and the lower heating hammer 4, and all the heating power is applied to the composite block 5. When the insulation layer of the upper / lower heating hammer 4 is damaged / carbonized, the resistance decreases, and part of the heating current does not pass through the composite block 5, but directly leaks to the shunting through the heating hammer. According to the voltage division law of the circuit, the voltage division of the branch with decreased resistance increases. If the upper heating hammer 3 deteriorates, the second voltage V2 decreases. If the lower heating hammer 4 deteriorates, the third voltage V3 decreases. Thus, a single hammer fault leads to an increase in the fourth voltage. When it exceeds the threshold, the single hammer fault is located. If both the upper and lower heating hammers deteriorate, the second voltage V2 and the third voltage V3 decrease simultaneously, and the fifth voltage increases. After being compared with the first voltage V1, it exceeds the preset value, and the fault is a double hammer deterioration. If the sensor drifts / is damaged, it may cause data acquisition errors, resulting in abnormal changes in the fifth voltage. This may be a data acquisition error, and the further fault is a sensor fault.

[0041] This embodiment, based on the principle of voltage conservation, transforms insulation degradation into a quantifiable voltage deviation. By using a judgment logic that determines the proportion of the difference and compares its magnitude, it pinpoints the specific faulty hammer, solving the problem of complete disassembly and repair in existing technologies. It is precise down to the faulty hammer, avoiding accidental disassembly and significantly shortening repair time. Simultaneously, it reduces damage to non-faulty hammers, improving work efficiency and productivity. This completely breaks through the limitations of existing technologies that rely on overall judgment and complete disassembly for repair, accurately identifying one or both faulty hammers. It not only avoids unnecessary disassembly and reassembly of non-faulty hammers (traditional complete disassembly easily leads to wear on the insulation coating of non-faulty hammers), but also shortens the traditional 4-6 hour repair time to 1.5-2 hours. This significantly reduces the labor intensity of maintenance personnel while greatly improving equipment maintenance efficiency and production line uptime, indirectly reducing diamond production losses due to downtime.

[0042] This embodiment fully considers the differences in technical characteristics of the six-sided top diamond press at different working stages: Addressing the electromagnetic interference intensity (e.g., large voltage fluctuations during the heating stage, and strong high-voltage electromagnetic noise during the constant-temperature stage) and insulation degradation risk level (e.g., the highest risk of insulation material carbonization and degradation during the constant-temperature and constant-pressure synthesis stage due to high temperatures of 1300-1700℃ and high voltage of 5-7GPa), it provides an adaptive mechanism centered on working condition-adaptive dynamic thresholds and differentiated sampling periods. Under high-risk conditions, sensitive early warning of insulation degradation is achieved by lowering the judgment threshold and shortening the sampling period (e.g., 20% threshold and 300ms sampling period during the constant-temperature stage). Under low-risk conditions (e.g., the pre-synthesis preparation stage), transient interference signals are filtered by appropriately increasing the threshold and extending the sampling period (30% threshold and 1s sampling period), effectively avoiding invalid production interruptions caused by misjudgments. Ultimately, it provides a dedicated solution for insulation testing of the six-sided top diamond press, characterized by precise positioning, efficient maintenance, and adaptive adaptation.

[0043] Example 2 further illustrates the fault diagnosis method.

[0044] This implementation example Figure 2 As shown, after the first fault information is triggered, the triggering conditions for the second fault information are determined. If the second fault information meets the triggering conditions, a first warning information is issued; otherwise, a second warning information is triggered. The second warning information includes a first target warning information and a second target warning information. After the first or second fault information is triggered, the triggering conditions for the third fault information are determined. If the triggering conditions are met, the third fault information is issued simultaneously with the first or second fault information.

[0045] After the system completes the synchronous acquisition and validity verification of the first voltage V1, the second voltage V2, and the third voltage V3, the second fault information judgment process is triggered first. The reason is that insulation degradation in both heating hammers is a high-risk fault (it will cause a sharp drop in heating power, a sudden drop in the temperature of composite block 5, and a 100% scrap rate), and its urgency is far higher than that of a single heating hammer fault, requiring priority identification and intervention. The judgment logic is as follows: calculate the ratio of the fifth voltage to the first voltage V1. If the ratio exceeds the current operating condition threshold and passes the temperature deviation cross-verification, the second fault information is determined to meet the triggering conditions, and the first warning information output stage is directly entered without executing the subsequent single-hammer fault judgment.

[0046] If the second fault condition is not met, then the first fault information (single heating hammer fault, second highest priority) is determined. The specific judgment logic is as follows: If (V2-V3) / V1 > the set threshold, the fault is that the lower hammer is not insulated; If (V2-V3) / V1 > the set threshold, the fault is that the upper hammer is not insulated; If (V1-(V2+V3)) / V1>the set threshold, the fault is that the upper and lower hammers are not insulated. If V1-V2-V3>0.5V or V1-V2-V3<-0.5V, the fault is a monitoring system fault.

[0047] Theoretically, V1 = V2 + V3. The V1 voltage sensor can detect the voltage of the actual working block and can be used in conjunction with the current detection unit to calculate the electric heating power. It can also be used for system self-testing to prevent the detection system from failing due to the failure of a certain sensor.

[0048] Since the insulation performance of the heating hammer of the six-sided top press often deteriorates under high temperature and high pressure, it is necessary to detect it online in real time without affecting diamond synthesis. By collecting three voltages, V1, V2 and V3, and analyzing the voltage data in real time, the heating hammer with deteriorated insulation performance is identified and a warning is issued to protect the equipment, so as to achieve efficient and accurate detection of insulation performance.

[0049] Example 3: Based on Example 1, this example further determines the corresponding fault based on the degree of degradation.

[0050] This embodiment aims to achieve precise location of individual faulty heating hammers, quantitative judgment of insulation degradation level, and targeted optimization of maintenance process through innovative detection logic. This will fundamentally reduce maintenance workload and time loss, avoid diamond production reduction due to insulation detection defects, and ensure the stable operation of the six-sided top press under high temperature and high pressure conditions.

[0051] In specific implementation, such as Figure 4 As shown in the figure, this embodiment first determines the current working state based on the temperature and pressure data of the press synthesis chamber; obtains the actual voltage to ground, and calculates the voltage deviation rate to ground based on the historical reference voltage under this working condition; during implementation, for the upper heating hammer 3 and the lower heating hammer 4, the average effective voltage within the previous complete statistical period under the current working condition is retrieved as the historical reference voltage.

[0052] When calculating the voltage deviation rate to ground, the historical reference voltages of the upper heating hammer 3 and the lower heating hammer 4 are obtained according to the operating conditions. The voltage deviation rates of the upper heating hammer 3 and the lower heating hammer to ground are obtained according to the actual collected second voltage V2 and third voltage V3 and the corresponding historical reference voltages. Then, the average value of the voltage deviation rates of the upper heating hammer to ground and the lower heating hammer to ground is taken as the final voltage deviation rate to ground.

[0053] The formula for calculating the voltage deviation rate R to ground is as follows: In the formula , These are the voltage deviation rates of the upper heating hammer to ground and the lower heating hammer to ground, respectively. and These are the second voltage V2 and the third voltage V3, respectively, and their corresponding historical reference voltages; and These are the measured second voltage V2 and third voltage V3, respectively.

[0054] The average of the two values ​​is taken as the system-to-ground voltage deviation rate. The formula is: The first voltage V1 signal is smoothed by a sliding window filter. The maximum value, minimum value and average value within each sliding window are extracted. The relative voltage fluctuation coefficient is obtained based on the maximum value, minimum value and average value within each window.

[0055] In practical implementation, the specific content of the relative voltage fluctuation coefficient is as follows: For the first voltage V1 (relative voltage between the upper and lower heating hammers 4), filtering is performed using a working condition-adaptive window size. The window size is 3 cycles (sampling period 1s) for the preparation / cooling stage, 4 cycles (sampling period 500ms) for the heating stage, and 6 cycles (sampling period 300ms) for the isothermal stage, filtering out instantaneous electromagnetic interference. Within each sliding window, the extracted "maximum value within the window" is... Minimum value within the window Average value within the window "; Relative voltage fluctuation coefficient" The calculation formula is: The heating voltage matching degree is obtained based on the ratio of the fifth voltage to the first voltage V1; the fifth voltage is the absolute value of the difference between the first voltage V1 and the sum of the second and third voltages V3. The heating voltage matching degree M is the ratio of the fifth voltage to the theoretical voltage, reflecting the deviation between the actual heating voltage and the theoretical voltage division; the specific calculation formula is as follows: Subsequently, the ground voltage deviation rate, voltage fluctuation coefficient, and heating voltage matching degree are normalized to obtain normalized parameters for each operating condition. In specific implementation, due to the different fault thresholds of the three-dimensional characteristic parameters (such as a ground voltage deviation rate threshold of 25% in the constant temperature stage and a fluctuation coefficient threshold of 5%), R, C, and M need to be normalized to the [0, 1.5] interval. The formula has two cases: If the parameter value is less than or equal to the current operating condition threshold: Normalized value = Parameter value / Operating condition threshold If the parameter value is greater than the current operating condition threshold: normalized value = 1 + (parameter value - operating condition threshold) / operating condition threshold × 0.5 (the part exceeding the threshold is amplified by 50% to highlight severe degradation, with an upper limit of 1.5).

[0056] The threshold values ​​for various operating conditions are shown in the table below: Operating condition phase R threshold C threshold M threshold Pre-synthesis preparation stage 30% 3% 20% Synthesis heating stage 35% 8% 15% Synthesis isothermal and isobaric stage 25% 5% 10% Cooling stage after synthesis 30% 6% 20% During the isothermal phase, R = 20.4, normalized. =20.4% / 25%=0.816; C=4.95%, =4.95% / 5%=0.99; M=41.25%, =1+(41.25%-10%) / 10%×0.5=1+1.5625=2.5625 (take the upper limit of 1.5).

[0057] The evaluation score is obtained by weighting the normalized parameters according to the preset weights. During implementation, the weights are dynamically allocated (totaling 1) according to the differences in the importance of the parameters under each operating condition (electromagnetic interference intensity, insulation degradation risk), as follows: Operating condition phase <![CDATA[W R ]]> <![CDATA[W C ]]> <![CDATA[W M ]]> Pre-synthesis preparation stage 0.45 0.15 0.40 Synthesis heating stage 0.35 0.30 0.35 Synthesis isothermal and isobaric stage 0.55 0.15 0.30 Cooling stage after synthesis 0.45 0.15 0.40 in , , These are the weights for the voltage deviation rate to ground, the relative voltage fluctuation coefficient, and the heating voltage matching degree, respectively; the comprehensive insulation degradation score S is the weighted sum of the normalized parameters and their corresponding weights, as shown in the formula: For example , , Then S = 0.816 × 0.55 + 0.99 × 0.15 + 1.5 × 0.30 ≈ 0.449 + 0.148 + 0.45 = 1.047.

[0058] Finally, the corresponding insulation condition level is generated based on the score range. In specific implementation, the insulation condition levels include excellent, slightly deteriorated, moderately deteriorated, and severely deteriorated. The flashing frequency of the indicator lights is generated according to the corresponding insulation condition level. The first fault information, the second fault information, and the third fault information generate corresponding indicator lights to light up. The combination of the flashing frequency and the lit indicator lights forms a comprehensive fault signal.

[0059] The following strategies can be used for implementation: Excellent: 0≤S<0.3, the green light is always on in all 3 cycles within this range, there is no buzzer, the PLC outputs a normal insulation signal, and production is maintained; Slight degradation: 0.3≤S<0.6, all 3 cycles are in this range, yellow light flashes at 1Hz, buzzer beeps intermittently at 1Hz, display shows slight decrease in insulation, it is recommended to check after synthesis; Moderate degradation: 0.6≤S<1.0, both cycles are within this range, red light flashes at 1Hz, buzzer sounds intermittently at 2Hz, a shutdown suggestion signal is sent to the compressor control system, if not handled within 30 minutes, power is reduced to 80%; Severe degradation: S≥1.0, red light flashes at 2Hz for one cycle within this range, buzzer sounds continuously at 3Hz, interlocking shutdown is executed (pressure held for 5s → pressure reduced to 0V → pressure released to normal pressure), and control access is locked.

[0060] This embodiment addresses the challenges of insulation testing for a six-sided top-pressure press under combined operating conditions of 1300-1700℃ high temperature and 5-7GPa high pressure. It avoids the blind approach of complete disassembly and overhaul in existing technologies by calculating the voltage deviation rate to ground for both upper and lower heating hammers 4 and comparing it with historical reference voltages. Simultaneously, it constructs a three-dimensional evaluation system using the voltage deviation rate to ground (reflecting leakage), the relative voltage fluctuation coefficient (reflecting signal stability), and the heating voltage matching degree (reflecting circuit integrity). Based on the electromagnetic interference intensity and insulation degradation risk during the four stages of preparation, heating, isothermal control, and cooling, the parameter thresholds are dynamically adjusted. The system assigns weights and binds the overall score to the flashing frequency of indicator lights and the frequency of buzzers to form a hierarchical and signal-corresponding relationship, ensuring accurate fault response without interfering with production continuity. Ultimately, it achieves multiple optimization effects: precise location of individual faulty hammers reduces maintenance time from the traditional 4-6 hours to 1.5-2 hours, and avoids damage to the insulation layer of non-faulty hammers during disassembly; three-dimensional parameter quantification and grading allows for early warning without stopping the machine in cases of minor degradation, and rapid chain shutdown in cases of severe degradation, reducing the scrap rate of composite blocks; and the sliding window filtering and parameter thresholds adapted to the working conditions can filter electromagnetic interference under high temperature and high pressure, significantly reducing the misjudgment rate.

[0061] The embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention. The basic concept of the present invention is that by distinguishing the ground voltage characteristics of the upper and lower heating hammers, a single faulty heating hammer can be directly located, avoiding the blindness of complete disassembly and repair in traditional technologies. At the same time, by integrating multi-dimensional parameters, the insulation status can be graded, avoiding ineffective shutdowns caused by misjudgment of slight degradation. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. An insulation testing method for a six-sided diamond press, characterized in that: include In response to an insulation detection request, a first voltage is acquired, wherein the first voltage is the voltage difference between a first target and a second target; When the first voltage meets the preset conditions, the second voltage and the third voltage are acquired, where the second voltage and the third voltage are the ground voltages of the first target and the second target, respectively. A fourth voltage is obtained, which is the difference between the second voltage and the third voltage; when it is determined that the ratio of the fourth voltage to the first voltage exceeds a preset value, a first fault message is issued by comparing the magnitudes of the second voltage and the third voltage. A fifth voltage is obtained, which is the difference between the first voltage and the sum of the second and third voltages. When it is determined that the ratio of the fifth voltage to the first voltage exceeds a preset value, a second fault message is issued. When it is determined that the fifth voltage exceeds the preset range, a third fault message is issued.

2. The insulation testing method for a six-sided diamond press according to claim 1, characterized in that: After the first fault information is triggered, the triggering conditions for the second fault information are determined. If the second fault information meets the triggering conditions, the first warning information is issued; otherwise, the second warning information is triggered. The second warning information includes the first target warning information and the second target warning information.

3. The insulation testing method for a six-sided diamond press according to claim 2, characterized in that: After the first fault information or the second fault information is triggered, the triggering condition for the third fault information is determined. If the triggering condition is met, the third fault information is issued simultaneously with the first fault information or the second fault information.

4. The insulation testing method for a six-sided diamond press according to claim 1, characterized in that: The first target is an upper heating hammer, and the second target is a lower heating hammer. The upper and lower heating hammers are connected to the upper and lower connection circuits of the sampling heating circuit, respectively. The sampling heating circuit is connected to the voltage and power regulation circuit. The first voltage sensor is connected between the upper and lower connection circuits and is used to collect the first voltage. The upper and lower connection circuits are each connected to a ground circuit. A resistor is set in the ground circuit. The second and third voltage sensors are connected across the resistor and are used to collect the second and third voltages, respectively.

5. The insulation testing method for a six-sided diamond press according to claim 4, characterized in that: The second voltage is the voltage of the upper heating hammer to ground, the third voltage is the voltage of the lower heating hammer to ground, and the fourth voltage is the absolute value of the difference between the second and third voltages. When the fourth voltage exceeds the threshold, a heating hammer insulation failure fault is sent to the controller. If the second voltage is greater than the third voltage, it indicates that the lower heating hammer insulation is unqualified. If the second voltage is less than the third voltage, it indicates that the upper heating hammer insulation is unqualified. The second fault information indicates that both the upper and lower heating hammers are unqualified in insulation. The third fault information indicates that the insulation detection system sensor is faulty.

6. The insulation testing method for a six-sided diamond press according to claim 1, characterized in that: Based on the characteristics of different working stages, corresponding detection logic is allocated. The detection logic includes sampling period, judgment range and sampling number. The first voltage is periodically collected based on the corresponding sampling period. Anomalies are determined according to the judgment range. When the anomaly is greater than the sampling number, the first voltage, second voltage and third voltage are collected at the same time. According to the corresponding judgment range, the corresponding fault information is triggered.

7. The insulation testing method for a six-sided diamond press according to claim 6, characterized in that: The working stages include the pre-synthesis preparation stage, the synthesis heating stage, the synthesis isothermal and isobaric stage, and the synthesis cooling and depressurization stage. Each stage is assigned a corresponding detection set, which includes the sampling period, judgment range, and number of samplings. The working state of the press is determined based on the working temperature and pressure of the press, and the corresponding detection set is called according to the working state.

8. The insulation testing method for a six-sided diamond press according to claim 1, characterized in that: The current working status is determined based on the temperature and pressure data of the press synthesis chamber; Obtain the actual voltage to ground, and calculate the voltage deviation rate to ground based on the historical reference voltage under this operating condition; A sliding window filter is used to smooth the first voltage signal. Within each sliding window, the maximum value, minimum value, and average value within the window are extracted. The relative voltage fluctuation coefficient is obtained based on the maximum value, minimum value, and average value within the window. The heating voltage matching degree is obtained based on the ratio of the fifth voltage to the first voltage; Subsequently, the ground voltage deviation rate, voltage fluctuation coefficient and heating voltage matching degree were normalized to obtain normalized parameters for each working condition. The evaluation score is obtained by weighting the normalized parameters according to the preset weights. The corresponding insulation status level is generated based on the range in which the score is located.

9. The insulation testing method for a six-sided diamond press according to claim 8, characterized in that: When calculating the voltage deviation rate to ground, the historical reference voltages of the upper heating hammer and the lower heating hammer are obtained according to the operating conditions. The voltage deviation rates of the upper heating hammer and the lower heating hammer to ground are obtained according to the actual collected second and third voltages and the corresponding historical reference voltages. Then, the average value of the voltage deviation rates of the upper heating hammer and the lower heating hammer to ground is taken as the final voltage deviation rate to ground.

10. The insulation testing method for a six-sided diamond press according to claim 8, characterized in that: The insulation condition levels include excellent, slightly deteriorated, moderately deteriorated, and severely deteriorated. The flashing frequency of the indicator lights is generated according to the corresponding insulation condition level. The first fault information, the second fault information, and the third fault information generate corresponding indicator lights to light up. The combination of the flashing frequency and the lit indicator lights forms a comprehensive fault signal.

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