A reliability testing system and method for a hoisting balance valve

Abstract

This application provides a reliability testing system and method for a hoisting balance valve. The system includes: the outlet of a first hydraulic pump connected to the first port of a first tested balance valve; the second port of the first tested balance valve connected to the inlet of a first loading motor and then to an oil tank; the outlet of a second hydraulic pump connected to the control terminal of the second tested balance valve via a solenoid directional valve; the outlet of the second hydraulic pump connected to the inlet of the second loading motor; the outlet of the second loading motor connected to the second port of the second tested balance valve; the first port of the second tested balance valve connected to the inlet of the second loading motor via a proportional loading valve; the output shafts of the first and second loading motors connected via a flat coupling; safety valves are respectively installed at the outlets of the first and second hydraulic pumps; the first port of the second tested balance valve is unidirectionally connected to the first port of the first tested balance valve via a one-way throttle valve, used to inject the back pressure oil of the second loading motor into the first loading motor after throttling through the one-way throttle valve.

Description

Technical Field

[0001] This application relates to a reliability testing system and method for a hoisting balance valve, belonging to the field of engineering machinery. Background Technology

[0002] The winch balance valve is a crucial hydraulic safety control component in the winch mechanisms of engineering equipment such as truck cranes, rotary drilling rigs, crawler cranes, aerial work platforms, and ship deck machinery. Its core function is to reliably lock the hydraulic motor, preventing the load (such as hooks, drill rods, and work platforms) from accidentally falling under gravity; simultaneously, it allows the load to descend smoothly under controllable conditions and provides proportional control to the descent speed. Therefore, the reliability of the winch balance valve (i.e., its ability to maintain its design performance parameters and sealing integrity after long-term, repeated exposure to high pressure, impact loads, and frequent reversing operations) directly affects the safety and service life of the entire machine. Currently, there is no established testing method for the reliability of winch balance valves.

[0003] The existing testing method only requires a reverse reliability test on the winch balance valve. That is, the test bench pump outlet is connected to the one-way valve of the winch balance valve in the opposite direction. The overflow valve of the test bench pump outlet generates pressure to simulate the load. Then, the pilot pressure controls the valve core of the balance valve to switch to generate oil flow, so that the valve under test produces valve core movement and pressure pulsation from locking to opening. Each action is recorded as one. The test ends when the cumulative number of tests on the balance valve reaches the full life reliability cycle number.

[0004] Current experimental methods only cover the winch balance valve in the lock-up-open condition. During hoisting operations, the winch balance valve opens under high-pressure, high-flow hydraulic shock. A forward reliability test should be added to verify the full-life reliability of the check valve. This test should evaluate whether the valve core and sleeve can return to their normal position after the reciprocating motion during the cyclic opening process, and whether it still possesses unidirectional opening capability. However, the forward reliability test cannot generate the required pressure through the valve under test during bench testing; the test bench's relief valve needs to apply load, converting hydraulic energy into heat energy dissipation, resulting in significant energy consumption during the reliability test. Summary of the Invention

[0005] In view of at least one of the above technical problems, this application provides a reliability test system and test method for a hoisting balance valve, which can achieve simultaneous forward and reverse reliability tests through a scheme of two sets of hoisting balance valves and loading motors, and convert the back pressure energy of the loading motor into the drive motor through a throttling circuit in a closed system of two motor assemblies, thereby reducing external energy consumption.

[0006] To solve the above-mentioned technical problems, the technical solution adopted in this application is: According to a first aspect of this application, a reliability testing system for a hoisting balance valve is provided, comprising a first hydraulic pump, a second hydraulic pump, a first safety valve, a second safety valve, a solenoid directional valve, a proportional loading valve, a first test balance valve, a second test balance valve, a first loading motor, a second loading motor, a one-way throttle valve, and a coupling. The outlet of the first hydraulic pump is connected to the first port of the first tested balance valve, the second port of the first tested balance valve is connected to the inlet of the first loading motor, and the outlet of the first loading motor is connected to the oil tank. The outlet of the second hydraulic pump is connected to the control terminal of the second test balance valve through a solenoid directional valve. At the same time, the outlet of the second hydraulic pump is connected to the inlet of the second loading motor, the outlet of the second loading motor is connected to the second port of the second test balance valve, and the first port of the second test balance valve is connected to the inlet of the second loading motor through a proportional loading valve. The output shafts of the first loading motor and the second loading motor are connected by a flat coupling. A first safety valve is installed at the outlet of the first hydraulic pump, and a second safety valve is installed at the outlet of the second hydraulic pump. The first port of the second test balance valve is unidirectionally connected to the first port of the first test balance valve through a one-way throttle valve, which is used to inject the back pressure oil of the second loading motor into the first loading motor after throttling through the one-way throttle valve.

[0007] In some embodiments, the electromagnetic reversing valve is used to control the second test balance valve to switch between the first position and the second position; When the second test balance valve is in the first position, the second port cannot be connected to the first port due to the shut-off action of the check valve inside the second test balance valve. When the second test balance valve is in the second position, the second port of the second test balance valve is connected to the first port.

[0008] In some embodiments, the electromagnetic directional valve is provided with a first port connected to the outlet of the second hydraulic pump, a second port connected to the control end of the second tested balance valve, and a return port connected to the oil tank, and has at least a first position and a second position. When the solenoid of the solenoid directional valve is de-energized, it is in the first position, and the second port is connected to the return port. When the electromagnet of the solenoid directional valve is energized, it is in the second position, and the first port is connected to the second port.

[0009] In some embodiments, the solenoid directional valve is a two-position three-way solenoid directional valve.

[0010] In some embodiments, the reliability test system for the hoisting balance valve further includes a radiator, the oil inlet of which is connected to the outlet of the second safety valve, and the oil outlet of which is connected to the oil tank for circulating and cooling the oil in the tank.

[0011] In some embodiments, the reliability test system for the hoisting balance valve further includes a flow meter, which is installed between the outlet of the first loading motor and the oil tank, for monitoring the oil flow rate of the first tested balance valve.

[0012] In some embodiments, the reliability testing system for the hoisting balance valve further includes a pressure gauge installed at the first port of the first test balance valve to monitor the pressure at the first port of the first test balance valve.

[0013] In some embodiments, the reliability testing system for the hoisting balance valve further includes a drive device for driving the first hydraulic pump and the second hydraulic pump.

[0014] In some embodiments, the drive device includes a first motor and a second motor, wherein the first motor drives and is connected to a first hydraulic pump, and the second motor drives and is connected to a second hydraulic pump.

[0015] According to a second aspect of this application, a reliability testing method for a hoisting balance valve, based on the reliability testing system for the hoisting balance valve, includes: Start the first hydraulic pump and the second hydraulic pump to enter the working state; and set the outlet pressure of the first hydraulic pump to the rated pressure of the first tested balance valve through the first safety valve, and set the outlet pressure of the second hydraulic pump to the maximum control switching pressure of the second tested balance valve through the second safety valve. When the electromagnet controlling the solenoid directional valve is energized, the solenoid directional valve switches from the first position to the second position, the second test balance valve switches from the first position to the second position, the second loading motor rotates, and the pressure of the proportional loading valve is adjusted so that the second test balance valve reaches the rated pressure. Adjust the one-way throttle valve to its maximum opening and adjust the flow rate of the first hydraulic pump to bring the first tested balance valve to its rated flow rate; One cycle is defined as the de-energization and energization of the electromagnet of the electromagnetic reversing valve. The first tested balance valve is counted as one positive reliability test. Observe the test for any abnormal phenomena at set intervals and record the number of positive reliability tests. After the number of forward reliability tests of the first tested balance valve reaches the specified number, the installation positions of the first tested balance valve and the second tested balance valve are swapped, and the de-energization and energization of the solenoid of the electromagnetic reversing valve is continued as one cycle. The first tested balance valve is counted as one reverse reliability test. Observe the test for any abnormal phenomena at set intervals and record the number of reverse reliability tests. The test ends after the number of reverse reliability tests on the first tested balance valve reaches the specified number of reverse reliability tests.

[0016] In some embodiments, the number of forward reliability tests and the number of reverse reliability tests are equal, and the sum of the number of forward reliability tests and the number of reverse reliability tests equals the total number of motions throughout the lifetime.

[0017] In some embodiments, if the first test balance valve and / or the second test balance valve fail during the test, the test is stopped.

[0018] The beneficial effects achieved by this application are as follows: This application can achieve simultaneous forward and reverse reliability testing through a scheme of two sets of hoisting balance valves and loading motors. Furthermore, through a closed system of two motor assemblies, the back pressure energy of the second loading motor is converted into compensating power by entering the first loading motor through a throttling circuit, reducing external energy consumption. It has the following advantages: (1) Provide a dual-sample synchronous forward and reverse test architecture: Two sets of loading motors are rigidly connected by a coupling to realize the synchronous forward (lifting) and reverse (lowering) reliability tests of two sets of hoisting balance valves (first test balance valve and second test balance valve); traditional single-sample unidirectional test needs to be carried out step by step, which takes up to 50 days (based on 500,000 cycles); the synchronous dual-sample bidirectional test of this application improves efficiency by 200% and shortens the test cycle to 25 days (based on 500,000 cycles).

[0019] (2) Energy consumption optimization and energy recovery innovation: The back pressure oil of the second loading motor is injected into the first loading motor after being throttled by the one-way throttle valve, forming a closed-loop energy recovery hydraulic pump. Under the condition that the flow rate remains unchanged, the flow rate of the tested balance valve is increased by more than 30% by adjusting the one-way throttle valve, and the energy saving effect is ≥30%. Attached Figure Description

[0020] Figure 1 A schematic diagram of the hydraulic principle of a reliability testing system for a winch balance valve provided in this application embodiment; In the diagram: First motor 1, Second motor 2, First hydraulic pump 3, Second hydraulic pump 4, First safety valve 5, Second safety valve 6, Solenoid directional valve 7, Proportional loading valve 8, First test balance valve 9, Second test balance valve 10, First loading motor 11, Second loading motor 12, One-way throttle valve 13, Coupling 14, Radiator 15, Flow meter 16, Pressure gauge 17. Detailed Implementation

[0021] The present application will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present application, and should not be used to limit the scope of protection of the present application.

[0022] In the description of this invention, "several" means one or more, "multiple" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0023] In the description of this invention, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0024] The technical terms used in this application are explained as follows: Flow compensation: In a closed-loop motor system, the back pressure energy of the loaded motor is converted into compensation power by entering the drive motor through a throttling circuit, thereby reducing external energy consumption.

[0025] like Figure 1 As shown, this embodiment provides a reliability testing system for a hoist balance valve, including: a first hydraulic pump 3, a second hydraulic pump 4, a first safety valve 5, a second safety valve 6, a solenoid directional valve 7, a proportional loading valve 8, a first test balance valve 9, a second test balance valve 10, a first loading motor 11, a second loading motor 12, a one-way throttle valve 13, and a coupling 14. The outlet of the first hydraulic pump 3 is connected to the first port of the first tested balance valve 9, the second port of the first tested balance valve 9 is connected to the inlet of the first loading motor 11, and the outlet of the first loading motor 11 is connected to the oil tank. The outlet of the second hydraulic pump 4 is connected to the control terminal of the second test balance valve 10 through the electromagnetic reversing valve 7. At the same time, the outlet of the second hydraulic pump 4 is connected to the inlet of the second loading motor 12, the outlet of the second loading motor 12 is connected to the second port of the second test balance valve 10, and the first port of the second test balance valve 10 is connected to the inlet of the second loading motor 12 through the proportional loading valve 8. The output shafts of the first loading motor 11 and the second loading motor 12 are connected by a flat coupling 14. The outlet of the first hydraulic pump 3 is equipped with a first safety valve 5, and the outlet of the second hydraulic pump 4 is equipped with a second safety valve 6. The first port of the second test balance valve 10 is unidirectionally connected to the first port of the first test balance valve 9 through the one-way throttle valve 13, which is used to inject the back pressure oil of the second loading motor 12 into the first loading motor 11 after being throttled by the one-way throttle valve 13.

[0026] In some embodiments, the electromagnetic reversing valve 7 is used to control the second test balance valve 10 to switch between a first position (right position) and a second position (left position); When the second test balance valve 10 is in the first position (right position), the second port cannot be connected to the first port due to the shut-off action of the check valve inside the second test balance valve 10. When the second test balance valve 10 is in the second position (left position), the second port of the second test balance valve 10 is connected to the first port.

[0027] Furthermore, the electromagnetic reversing valve 7 is provided with a first port connected to the outlet of the second hydraulic pump 4, a second port connected to the control end of the second tested balance valve 10, and a return port connected to the oil tank, and has at least a first position (right position) and a second position (left position). When the solenoid YA1 of the solenoid directional valve 7 is de-energized, it is in the first position (right position), and the second port is connected to the return port; When the electromagnet YA1 of the solenoid directional valve 7 is energized, it is in the second position (left position), and the first port is connected to the second port.

[0028] In this embodiment, the electromagnetic reversing valve 7 is a two-position three-way electromagnetic reversing valve.

[0029] In some embodiments, the reliability testing system for the hoisting balance valve further includes a radiator 15, the oil inlet of which is connected to the outlet of the second safety valve 6, and the oil outlet of which is connected to an oil tank for circulating and cooling the oil in the tank to prevent the oil temperature from becoming too high during the test.

[0030] In some embodiments, the reliability test system for the hoisting balance valve further includes a flow meter 16, which is disposed between the outlet of the first loading motor 11 and the oil tank, for monitoring the oil flow rate of the first tested balance valve 9.

[0031] In some embodiments, the reliability test system for the hoisting balance valve further includes a pressure gauge 17, which is installed at the first port of the first test balance valve 9 to monitor the pressure at the first port of the first test balance valve 9.

[0032] In some embodiments, the reliability testing system for the hoisting balance valve further includes a drive device for driving the first hydraulic pump 3 and the second hydraulic pump 4.

[0033] It should be noted that the drive device can be an engine or an electric motor. In this embodiment, the drive device includes a first motor 1 and a second motor 2. The first motor 1 is connected to a first hydraulic pump 3, and the second motor 2 is connected to a second hydraulic pump 4.

[0034] This embodiment provides a reliability testing method for a hoisting balance valve. Based on the aforementioned reliability testing system for the hoisting balance valve, the method includes: Start the drive unit (first motor 1 and second motor 2) to put the first hydraulic pump 3 and the second hydraulic pump 4 into working state; and set the outlet pressure of the first hydraulic pump 3 to the rated pressure of the first tested balance valve 9 through the first safety valve 5, and set the outlet pressure of the second hydraulic pump 4 to the maximum control switching pressure of the second tested balance valve 10 through the second safety valve 6. When the electromagnet YA1 controlling the solenoid directional valve 7 is energized, the solenoid directional valve 7 switches from the first position (right position) to the second position (left position), the second test balance valve 10 switches from the first position (right position) to the second position (left position), the second loading motor 12 rotates, and the pressure of the proportional loading valve 8 is adjusted so that the second test balance valve 10 reaches the rated pressure (specifically, the pressure of the proportional loading valve 8 is adjusted by adjusting the electrical signal input to the electromagnet YA2 of the proportional loading valve 8). Adjust the one-way throttle valve 13 to its maximum opening and adjust the flow rate of the first hydraulic pump 3 to make the first tested balance valve 9 reach its rated flow rate; With the de-energization and energization of the electromagnet YA1 of the electromagnetic reversing valve 7 as one cycle, the number of positive reliability tests of the first tested balance valve 9 is recorded. Observe the test for any abnormal phenomena at set intervals (one hour) and record the number of positive reliability tests. After the number of positive reliability tests of the first test balance valve 9 reaches the specified number of positive reliability tests, the installation positions of the first test balance valve 9 and the second test balance valve 10 are swapped, and the de-energization and energization of the electromagnet YA1 of the electromagnetic reversing valve 7 is continued as one cycle, and the number of reverse reliability tests of the first test balance valve 9 is recorded. Observe the test for any abnormal phenomena at set intervals (one hour) and record the number of reverse reliability tests. The test ends after the number of reverse reliability tests of the first tested balance valve 9 reaches the specified number of reverse reliability tests.

[0035] It should be noted that the number of forward reliability tests and the number of reverse reliability tests are equal, and the sum of the number of forward reliability tests and the number of reverse reliability tests equals the total number of motions throughout the entire lifespan.

[0036] It should be noted that during the test, at set intervals (one hour), it is necessary to observe whether there are any abnormal phenomena (such as abnormal noise, leakage, jamming, etc.) during the test. At the same time, the test pressure, test temperature, number of positive reliability tests or number of negative reliability tests of the tested balance valve should also be recorded.

[0037] It should be noted that the reliability test method for the hoisting balance valve also includes: if the first test balance valve 9 and / or the second test balance valve 10 fail during the test, the test shall be stopped.

[0038] The methods for determining the failure of the balancing valve include: if abnormal phenomena occur during the test (such as abnormal noise, leakage, jamming, etc.), stop the reliability test, disassemble the balancing valve, inspect the main parts, and if the valve core plating is found to be peeling off or the sealing ring is aged and damaged, then the balancing valve is determined to be failed.

[0039] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0040] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0041] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0042] These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable apparatus for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0043] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A reliability testing system for a hoisting balance valve, characterized in that, It includes a first hydraulic pump, a second hydraulic pump, a first safety valve, a second safety valve, a solenoid directional valve, a proportional loading valve, a first test balance valve, a second test balance valve, a first loading motor, a second loading motor, a one-way throttle valve, and a coupling; The outlet of the first hydraulic pump is connected to the first port of the first tested balance valve, the second port of the first tested balance valve is connected to the inlet of the first loading motor, and the outlet of the first loading motor is connected to the oil tank. The outlet of the second hydraulic pump is connected to the control terminal of the second test balance valve through a solenoid directional valve. At the same time, the outlet of the second hydraulic pump is connected to the inlet of the second loading motor, the outlet of the second loading motor is connected to the second port of the second test balance valve, and the first port of the second test balance valve is connected to the inlet of the second loading motor through a proportional loading valve. The output shafts of the first loading motor and the second loading motor are connected by a flat coupling. A first safety valve is installed at the outlet of the first hydraulic pump, and a second safety valve is installed at the outlet of the second hydraulic pump. The first port of the second test balance valve is unidirectionally connected to the first port of the first test balance valve through a one-way throttle valve, which is used to inject the back pressure oil of the second loading motor into the first loading motor after throttling through the one-way throttle valve.

2. The reliability testing system for the hoisting balance valve according to claim 1, characterized in that, The electromagnetic reversing valve is used to control the second test balance valve to switch between the first position and the second position. When the second test balance valve is in the first position, the second port cannot be connected to the first port due to the shut-off action of the check valve inside the second test balance valve. When the second test balance valve is in the second position, the second port of the second test balance valve is connected to the first port.

3. The reliability testing system for the hoisting balance valve according to claim 1, characterized in that, The electromagnetic reversing valve is provided with a first port connected to the outlet of the second hydraulic pump, a second port connected to the control end of the second tested balance valve, and a return port connected to the oil tank, and has at least a first position and a second position. When the solenoid of the solenoid directional valve is de-energized, it is in the first position, and the second port is connected to the return port. When the electromagnet of the solenoid directional valve is energized, it is in the second position, and the first port is connected to the second port.

4. The reliability testing system for the hoisting balance valve according to claim 1, characterized in that, The solenoid directional valve is a two-position three-way solenoid directional valve.

5. The reliability testing system for the hoisting balance valve according to claim 1, characterized in that, It also includes a radiator, whose oil inlet is connected to the outlet of the second safety valve, and whose oil outlet is connected to the oil tank for circulating and cooling the oil in the tank. And / or, also includes a flow meter, disposed between the outlet of the first loading motor and the oil tank, for monitoring the oil flow rate of the first tested balance valve; And / or, also includes a pressure gauge, located at the first port of the first test balancing valve, for monitoring the pressure at the first port of the first test balancing valve.

6. The reliability testing system for the hoisting balance valve according to claim 1, characterized in that, It also includes a drive unit for driving the first hydraulic pump and the second hydraulic pump.

7. The reliability testing system for the hoisting balance valve according to claim 6, characterized in that, The drive device includes a first motor and a second motor. The first motor drives and is connected to a first hydraulic pump, and the second motor drives and is connected to a second hydraulic pump.

8. A reliability test method for a hoisting balance valve, characterized in that, The reliability testing system based on the hoisting balance valve according to any one of claims 1-7 includes the following method: Start the first hydraulic pump and the second hydraulic pump to enter the working state; and set the outlet pressure of the first hydraulic pump to the rated pressure of the first tested balance valve through the first safety valve, and set the outlet pressure of the second hydraulic pump to the maximum control switching pressure of the second tested balance valve through the second safety valve. When the electromagnet controlling the solenoid directional valve is energized, the solenoid directional valve switches from the first position to the second position, the second test balance valve switches from the first position to the second position, the second loading motor rotates, and the pressure of the proportional loading valve is adjusted so that the second test balance valve reaches the rated pressure. Adjust the one-way throttle valve to its maximum opening and adjust the flow rate of the first hydraulic pump to bring the first tested balance valve to its rated flow rate; One cycle is defined as the de-energization and energization of the electromagnet of the electromagnetic reversing valve. The first tested balance valve is counted as one positive reliability test. Observe the test for any abnormal phenomena at set intervals and record the number of positive reliability tests. After the number of forward reliability tests of the first tested balance valve reaches the specified number, the installation positions of the first tested balance valve and the second tested balance valve are swapped, and the de-energization and energization of the solenoid of the electromagnetic reversing valve is continued as one cycle. The first tested balance valve is counted as one reverse reliability test. Observe the test for any abnormal phenomena at set intervals and record the number of reverse reliability tests. The test ends after the number of reverse reliability tests on the first tested balance valve reaches the specified number of reverse reliability tests.

9. The reliability test method for the hoisting balance valve according to claim 8, characterized in that, The number of forward reliability tests and the number of reverse reliability tests are equal, and the sum of the number of forward reliability tests and the number of reverse reliability tests equals the total number of motions throughout the entire lifespan.

10. The reliability test method for the hoisting balance valve according to claim 8, characterized in that, If the first test balance valve and / or the second test balance valve fail during the test, the test shall be stopped.

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