An intelligent oil injection control method and intelligent oil injection vehicle for an electric actuator cylinder

Abstract

The present application belongs to the field of aviation equipment maintenance, and particularly relates to an intelligent oil injection control method and an intelligent oil injection vehicle for an electric actuator, aiming at solving the problem of insufficient oil injection precision and dependence on manual operation in the prior art. The method calculates the initial gas volume by pre-injection, divides the oil injection process into multiple stages based on real-time pressure changes, and realizes automatic switching of stages by real-time calculation of oil quantity combined with preset conditions. Meanwhile, the metal chip monitoring and alarm function is integrated, and the oil injection is finally stopped accurately through double confirmation of the capacitance proximity switch and pressure stability in the full oil determination stage. The intelligent oil injection vehicle implementing the method integrates an oil pump assembly, a tool management system with state monitoring, an oil drain valve assembly with built-in sensors, and a central control system. The present application realizes the precision, automation and intelligence of the oil injection process, effectively solving the problems of low oil injection precision and oil leakage.

Description

Technical Field

[0001] This invention belongs to the field of aviation equipment maintenance, and specifically relates to an intelligent oil injection control method and an intelligent oil injection vehicle for an electrically operated actuator. Background Technology

[0002] In the maintenance of flight simulators, the regular lubrication and oil change of electric actuators are crucial to ensuring their motion accuracy and service life. Currently, this operation mainly relies on manual or semi-automatic equipment, which suffers from problems such as low lubrication accuracy, cumbersome operation, easy oil leakage, and inefficient tool management.

[0003] In existing technologies, such as the utility model patent CN217350751U, a portable oil pump truck is provided. This truck uses an electric pump to replace manual oil filling, improving the filling speed to some extent and integrating tool storage functionality. However, this equipment still has significant drawbacks: oil filling control relies on manual judgment to start and stop, resulting in low filling accuracy (error of approximately ±5%); tool management still relies on physical storage, lacking intelligent identification and status monitoring functions; and the oil circuit system is not completely sealed, posing a risk of oil leakage during operation and threatening environmental and personnel safety.

[0004] Furthermore, in traditional operations, the oil injection control lacks a real-time sensing and compensation mechanism for factors such as gas compression, oil residue, and metal impurities inside the actuator, resulting in poor consistency in oil injection under different operating conditions and affecting the actuator's performance. At the same time, oil level monitoring after injection still relies on daily manual checks, which is inefficient and prone to omissions.

[0005] Based on this, the present invention proposes an intelligent oil injection control method and an intelligent oil injection vehicle for an electrically operated cylinder. Summary of the Invention

[0006] To address the aforementioned problems in the prior art, namely insufficient oil injection accuracy and reliance on manual operation, this invention provides an intelligent oil injection control method and an intelligent oil injection vehicle for an electrically operated cylinder.

[0007] In a first aspect, the present invention provides an intelligent oil injection control method for an electrically actuated cylinder, the method comprising:

[0008] A fixed amount of oil is injected into the actuator cylinder to establish the initial oil circuit pressure, and the initial gas volume inside the actuator cylinder is calculated based on the pressure value after pre-injection of oil.

[0009] Based on real-time monitoring of the pressure changes in the oil injection pipeline, the oil injection process is divided into multiple continuous pressure ranges, including initial filling, intermediate filling, and full oil determination.

[0010] Within the initial and medium filling pressure range, the actual oil volume inside the actuator cylinder is calculated in real time.

[0011] The condition for switching from the initial filling stage to the medium filling stage is that the actual oil volume reaches the first preset oil volume value, and the condition for switching from the medium filling stage to the full oil determination stage is that the actual oil volume reaches the second preset oil volume value.

[0012] Real-time monitoring of the metal shavings content in the oil; when the metal shavings signal exceeds the threshold, oil injection is terminated and an alarm is triggered.

[0013] When the pressure enters the full oil determination range and the actual oil volume reaches the third preset oil volume value, the oil injection volume per unit time is reduced, and the capacitive proximity switch signal at the oil injection port is monitored.

[0014] When the conditions of triggering the capacitive proximity switch and stabilizing the pipeline pressure are met simultaneously, it is determined that the oil is full and oil injection is stopped.

[0015] Furthermore, the initial gas volume inside the actuator cylinder is calculated based on the pressure value after pre-filling with oil, specifically including the following steps:

[0016] Obtain the amount of oil injected during the pre-oil injection stage and the amount of residual oil in the pipeline, and measure the stable pressure value inside the actuator cylinder after pre-oil injection;

[0017] Subtract the amount of residual oil in the pipeline from the amount of oil injected during the pre-oil injection stage to obtain the effective oil volume entering the actuator cylinder;

[0018] The initial gas volume is calculated by dividing the product of the effective oil volume and the atmospheric pressure by the difference between the stable pressure value and the atmospheric pressure.

[0019] Furthermore, the actual oil volume inside the actuator cylinder is calculated in real time, specifically including the following steps:

[0020] Obtain the initial gas volume and the real-time pressure value in the current oil injection pipeline;

[0021] Based on the ratio of the real-time pressure value to the atmospheric pressure, the current gas compression ratio is calculated.

[0022] The product of the initial gas volume and the gas compression ratio is determined as the equivalent oil volume occupied due to the gas compression effect.

[0023] The actual amount of oil inside the actuator cylinder is obtained by subtracting the residual oil in the pipeline and the equivalent oil volume from the cumulative oil injection amount.

[0024] Furthermore, the determination that the fuel level has been reached is specifically as follows:

[0025] When the capacitive proximity switch is triggered and the pressure change rate in the oil filling line is continuously lower than a preset threshold, it is determined that the oil filling state has been reached.

[0026] Furthermore, the method also includes:

[0027] After stopping the oil injection, allow the pressure to stand and hold. If the pressure drop exceeds the allowable range, perform compensatory oil injection.

[0028] Furthermore, compensatory injections are performed, the method of which is as follows:

[0029] Restart the oil pump and replenish the actuator cylinder with oil at a flow rate not exceeding a preset percentage of the rated flow rate;

[0030] Real-time monitoring of pressure changes in the oil injection pipeline;

[0031] When the pressure is detected to return to a preset percentage range of the full oil pressure threshold, the refilling process is stopped.

[0032] In a second aspect, the present invention provides an intelligent oil filling vehicle for implementing an intelligent oil filling control method for an electrically actuated cylinder, the oil filling vehicle comprising:

[0033] The vehicle body has a control system mounting layer on the upper part and a tool storage layer and an oil pump assembly mounting layer on the lower part.

[0034] The oil pump assembly includes an electrically driven pump and a gear flow meter connected to the pump outlet line for providing oil injection power and measuring the oil injection volume in real time.

[0035] The tool management system, located in the tool storage layer, is used to monitor the location and integrity of tools in real time.

[0036] The drain valve assembly is used to achieve a quick sealing connection between the drain port of the actuator cylinder and the oil injection pipeline, and can switch between gravity drain and pressure-driven oil injection states; the drain valve assembly integrates a pressure sensor for monitoring pipeline pressure and a metal detection sensor for detecting metal impurities in the oil.

[0037] The control system is used to receive sensor signals and control the start and stop of the oil pump to achieve quantitative or timed oil injection.

[0038] The oil pump assembly, tool management system, drain valve assembly, and control system are electrically connected.

[0039] Furthermore, the tool management system includes an RFID reader and RFID tags installed on the RFID reader, and / or includes an AI camera and an image recognition module for automatically identifying the presence and integrity of the tools.

[0040] Furthermore, the control system includes a programmable logic controller (PLC) and a human-machine interface touchscreen; the PLC is electrically connected to the human-machine interface touchscreen, the sensors in the oil pump assembly and the oil discharge valve assembly, and the tool management system.

[0041] Furthermore, the oil pump assembly also includes an oil moisture content sensor; the outlet pipeline of the electric drive pump is connected to the oil discharge valve assembly via the gear flow meter and the oil moisture content sensor through a rubber oil pipe.

[0042] The beneficial effects of this invention are:

[0043] This invention achieves precise control of the oil injection process by real-time monitoring of pressure changes in the oil injection pipeline and calculating the actual oil volume inside the actuator cylinder, avoiding errors caused by manual judgment and ensuring the accuracy and consistency of the oil injection volume.

[0044] This invention automatically divides the oiling stages and switches them automatically according to the oil volume, reducing manual intervention, simplifying the operation process, and improving work efficiency.

[0045] This invention employs a closed-loop oil circuit system and pressure stability monitoring to precisely stop oil injection when the oil level is full, thus avoiding excessive oil injection or leakage and ensuring a clean working environment and personnel safety.

[0046] This invention monitors the metal shavings content in the oil in real time. Once the threshold is exceeded, an alarm is immediately triggered and oil injection is terminated. This timely identification of potential equipment failures extends the service life of the actuator cylinder.

[0047] This invention calculates the initial gas volume and compensation factors to adapt to the oil injection requirements under different working conditions, ensuring the consistency and reliability of the oil injection results and improving the working performance of the actuator.

[0048] This invention replaces the traditional daily manual inspection, automatically determining the oil full status through capacitive proximity switches and pressure signals, reducing omissions and human error, and improving maintenance efficiency. Attached Figure Description

[0049] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0050] Figure 1 This is a flowchart illustrating an intelligent oil injection control method for an electrically driven actuator cylinder according to the present invention.

[0051] Figure 2 This is an overall schematic diagram of an intelligent oil filling vehicle according to the present invention;

[0052] Figure 3 This is a schematic diagram of the internal structure of an intelligent oil filling vehicle according to the present invention;

[0053] Figure 4 This is an enlarged view of the oil pump assembly of an intelligent oil filling vehicle according to the present invention;

[0054] Figure 5 This is an enlarged view of the control system of an intelligent oil filling vehicle according to the present invention;

[0055] Figure 6 This is a structural connection diagram of the oil drain valve assembly of an intelligent oil filling vehicle according to the present invention. Detailed Implementation

[0056] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0057] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0058] The first embodiment of the present invention proposes an intelligent oil injection control method for an electrically actuated cylinder, the method comprising:

[0059] Step S10: Inject a metered amount of oil into the actuator cylinder to establish the initial oil circuit pressure, and calculate the initial gas volume inside the actuator cylinder based on the pressure value after pre-injection of oil.

[0060] Step S20: Based on the real-time monitoring of the pressure changes in the oil injection pipeline, the oil injection process is divided into multiple continuous pressure ranges, including initial filling, intermediate filling, and full oil determination.

[0061] Step S30: Within the initial filling and medium filling pressure range, calculate the actual oil volume inside the actuator cylinder in real time.

[0062] Step S40: The actual oil quantity reaching the first preset oil quantity value is used as the condition for switching from the initial filling stage to the medium filling stage, and the actual oil quantity reaching the second preset oil quantity value is used as the condition for switching from the medium filling stage to the full oil determination stage.

[0063] Step S50: Monitor the content of metal shavings in the oil in real time. When the metal shavings signal exceeds the threshold, terminate the oil injection and trigger an alarm.

[0064] Step S60: When the pressure enters the full oil determination range and the actual oil quantity reaches the third preset oil quantity value, reduce the oil injection amount per unit time and monitor the capacitive proximity switch signal at the oil injection port.

[0065] Step S70: When the conditions of the capacitive proximity switch being triggered and the pipeline pressure stabilizing are met simultaneously, it is determined that the oil is full and oil injection is stopped.

[0066] To more clearly explain the intelligent oil injection control method for an electrically actuated cylinder according to the present invention, the following is in conjunction with... Figure 1 The steps in the embodiments of the present invention are described in detail below, including steps S10-S70:

[0067] Step S10: Inject a metered amount of oil into the actuator cylinder to establish the initial oil circuit pressure, and calculate the initial gas volume inside the actuator cylinder based on the pressure value after pre-injection of oil.

[0068] In this embodiment, a measured amount of oil is injected into the actuating cylinder to establish initial oil circuit pressure. During implementation, the main power supply of the oil injection trolley is first turned on. The PLC module automatically executes the initialization process, zeroing the gear flow meter and performing self-checks and zero-point calibrations on all sensors, including the miniature ceramic pressure sensor. After the touchscreen displays "Ready," the pre-oil injection stage begins. The PLC controls the oil pump to start, drawing approximately 10 ml of oil from the oil tank in a pulse manner. This process aims to initially establish oil circuit pressure and remove residual air from the pipeline. As the oil flows through the pipeline, the oil moisture content sensor collects the initial dielectric constant of the oil in real time. If detected If the oil content is >3.0 (corresponding to a moisture content greater than 1%), the PLC will immediately stop the oil pump and issue an "Oil Quality Abnormality" alarm on the touchscreen, prompting the operator to replace the oil; if If the pressure is ≤3.0, the PLC sends a continuous working signal to the oil pump, allowing the system to enter the subsequent phased oil injection process, thereby completing the reliable establishment of the initial oil circuit pressure and the preliminary judgment of the oil quality qualification.

[0069] In this embodiment, the initial gas volume inside the actuator cylinder is calculated based on the pressure value after pre-filling with oil, specifically including the following steps:

[0070] Step S11: Obtain the oil injection volume and residual oil volume in the pipeline during the pre-oil injection stage, and measure the stable pressure value in the actuator cylinder after pre-oil injection.

[0071] Step S12: Subtract the amount of residual oil in the pipeline from the amount of oil injected during the pre-oil injection stage to obtain the effective oil volume entering the actuator cylinder.

[0072] Step S13: Calculate the initial gas volume by dividing the product of the effective oil volume and atmospheric pressure by the difference between the stable pressure value and atmospheric pressure.

[0073] In the specific implementation process, the system first performs a pre-oil injection operation: the PLC controls the oil pump to inject a fixed amount of oil into the actuator cylinder with specific parameters (such as drawing 10mL of oil) to initially establish the oil circuit pressure and remove air from the pipeline. After the injection is completed, the system is allowed to stand for a short time until the pressure stabilizes. Then, the stable pressure value in the actuator cylinder after pre-oil injection is accurately measured by a miniature ceramic pressure sensor installed in the oil injection quick connector and recorded as P. 预注后 The unit is MPa. Simultaneously, the PLC automatically acquires the oil injection volume V for this pre-injection stage. 预注油 For example, 10 mL, and the residual oil volume V in the pipeline obtained through pre-calibration. 管路残留 , which is a fixed value, such as 0.5L.

[0074] Subsequently, the PLC's built-in calculation unit performs the calculation: First, it sets V... 预注油 Subtract V 管路残留 The actual effective oil volume V entering the actuator cylinder is obtained. 有效 Next, multiply V effectively by the standard atmospheric pressure P0 (usually taken as 0.1 MPa), and then divide by the difference between the measured stable pressure value Ppre-injected and the atmospheric pressure P0, which is P0. 预注后 -P0, based on which the initial gas volume V inside the actuator cylinder is calculated. 气初始 Its core calculation formula is: V 气初始 =(V 有效 ×P0) / (P 预注后 -P0). The calculation process is fully automated, requiring no human intervention, and the calculation results are used in real time for accurate oil quantity back-calculation in the subsequent "flow-pressure-gas" fusion model.

[0075] This invention achieves online, automatic, and high-precision calculation of the initial gas volume inside the actuator cylinder by embedding the aforementioned physical model and calculation formula into the control program. This method transforms the intangible gas volume parameter into a precise calculation of easily measurable parameters such as pressure and flow rate, providing a crucial initial benchmark for the precise control of the entire subsequent oil injection process. This fundamentally eliminates the measurement error in oil injection volume caused by gas compression effects, solves the industry problem of insufficient oil injection accuracy in irregularly shaped cavities, and elevates oil injection control from reliance on manual experience to a digital intelligent control level based on a deterministic physical model.

[0076] Step S20: Based on the real-time monitoring of the pressure changes in the oil injection pipeline, the oil injection process is divided into multiple continuous pressure ranges, including initial filling, intermediate filling, and full oil determination.

[0077] In practice, the system dynamically divides the filling process by acquiring signals from miniature ceramic pressure sensors installed on the oil injection pipeline in real time and continuously monitoring and analyzing the pressure data using a PLC. When the system detects that the pipeline pressure remains between 0 MPa and 0.2 MPa, it automatically determines that it has entered the initial filling stage. During this stage, the oil pump operates at a 5Hz pulse frequency to slowly build up the base pressure, ensuring that the oil smoothly fills the bottom space of the actuator cylinder and preferentially expels gas from the cavity. When the PLC detects that the pressure value exceeds 0.2 MPa and continues to rise to within the 0.5 MPa range, the system immediately and automatically switches to the medium filling stage. At this time, the oil pump pulse frequency increases to 8Hz to accelerate the oil injection speed. Simultaneously, the control algorithm within the PLC begins to verify the pressure rise rate. If the rate is lower than 0.02 MPa / s, an anomaly is detected and an alarm is triggered. When the pressure data further exceeds 0.5MPa and approaches the preset safety threshold of 0.8MPa, the system automatically enters the full oil determination stage. The oil pump pulse frequency drops to 3Hz for fine oil injection. At this time, the PLC synchronously monitors the capacitive proximity switch signal. When the pressure is ≥0.6MPa and the proximity switch is triggered, a stop command is immediately issued to accurately terminate the oil injection process.

[0078] This implementation method achieves automated stage identification and adaptive control of the entire oil injection process through precise definition and real-time judgment of pressure thresholds. Its core benefit lies in transforming the continuous physical oil injection process into discrete, precisely manageable control states. The system can automatically switch control strategies based on real-time pressure data without manual intervention. This not only significantly improves the reliability and safety of the oil injection process and effectively prevents overpressure risks, but more importantly, it matches optimal oil injection parameters for each stage, ensuring a smooth transition from rapid filling to precise full-oil determination, ultimately achieving high consistency, high precision, and full automation in cylinder oil injection.

[0079] Step S30: Within the initial filling and medium filling pressure range, calculate the actual oil volume inside the actuator cylinder in real time.

[0080] In this embodiment, the real-time calculation of the actual oil volume inside the actuator cylinder specifically includes the following steps:

[0081] Step S31: Obtain the initial gas volume and the real-time pressure value in the current oil injection pipeline;

[0082] Step S32: Calculate the current gas compression ratio based on the ratio of the real-time pressure value to the atmospheric pressure.

[0083] Step S33: The product of the initial gas volume and the gas compression ratio is determined as the equivalent oil volume occupied due to the gas compression effect.

[0084] Step S34: Subtract the residual oil in the pipeline and the equivalent oil volume from the cumulative oil injection amount to obtain the actual oil volume inside the actuator cylinder.

[0085] In practical implementation, the system accurately calculates the actual oil volume inside the actuator cylinder by combining real-time data acquisition with model calculation. The PLC controller continuously reads the real-time pressure value P from the miniature ceramic pressure sensor at a 10ms cycle. 当前 Unit: MPa, and calls the preset initial gas volume parameter V. 气初始 Unit: L.

[0086] Based on these real-time parameters, the PLC's built-in algorithm first calculates the gas compression ratio under the current pressure according to Boyle's Law. The calculation formula is as follows:

[0087] ;

[0088] in, The pressure is standard atmospheric pressure (0.1 MPa). The system then calculates the equivalent oil volume occupied by the compressed gas, i.e., the gas compression compensation ΔV. 气体压缩 The calculation formula is:

[0089] ΔV 气体压缩 =V 气初始 ×(1-P0 / P 当前 );

[0090] At the same time, the PLC obtains the cumulative oil injection volume V from the gear flow meter. 累计 Ultimately, the actual oil volume Q inside the actuator cylinder... 实际 The following calculation was performed using the model:

[0091] Q 实际 =V 累计- V 管路残留- ΔV 气体压缩 ;

[0092] Among them, V 管路残留 This is a pre-calibrated fixed value (e.g., 0.5L). The calculated result Q 实际 It is displayed in real time on the human-computer interaction touch screen and serves as one of the core judgment criteria for stage switching (such as from initial fill to medium fill).

[0093] This invention transforms the physical model of gas compression effect into an embedded control algorithm, enabling dynamic, non-invasive, and high-precision measurement of the actual oil volume within a sealed cavity. This method innovatively solves the problem of "false oil volume" readings caused by gas compression, transforming traditional indirect measurement relying on cumulative flow meters into direct oil volume estimation based on multi-parameter fusion, significantly improving the accuracy of oil injection control. The entire calculation process is fully automated, requiring no manual intervention, providing core data support for achieving adaptive and precise oil injection under different pressure ranges, fundamentally improving the reliability and intelligence level of electric actuator cylinder maintenance.

[0094] Step S40: The actual oil quantity reaching the first preset oil quantity value is used as the condition for switching from the initial filling stage to the medium filling stage, and the actual oil quantity reaching the second preset oil quantity value is used as the condition for switching from the medium filling stage to the full oil determination stage.

[0095] In practical implementation, the system uses the real-time calculated actual oil volume as the core criterion for switching between stages of the oil injection process, achieving fully automatic and precise control. During the initial filling stage (pressure range 0~0.2MPa), the PLC continuously calculates and monitors the actual oil volume Q inside the actuator cylinder. 实际 When Q 实际 When the first preset oil volume value (e.g., 1.8L) specifically set for this type of actuator cylinder is reached, and the system detects that the current pipeline pressure has stabilized at 0.2MPa, the PLC immediately and automatically issues a control command to switch the oil filling process from the initial filling stage to the medium filling stage. At this time, the system controls the oil pump to increase the pulse working frequency from 5Hz to 8Hz, and correspondingly adjusts its single oil injection volume from 0.5mL to 0.8mL to accelerate the filling speed.

[0096] Subsequently, during the medium filling stage (pressure range 0.2~0.5MPa), the PLC continued to calculate and monitor Q in real time. 实际 When Q 实际 When the second preset oil volume value (e.g., 5L) is reached, and the system confirms that the current pressure has stabilized at 0.5MPa, while the pressure rise rate meets the normal standard of ≥0.02MPa / s, the PLC automatically issues a control command again to switch the oil filling process to the full oil determination stage. The system then reduces the oil pump pulse frequency to 3Hz, adjusts the single oil filling volume to 0.3mL, and enters the fine oil filling mode to prepare for the final full oil determination.

[0097] By using the actual oil quantity calculated in real-time as the primary condition for stage switching and jointly verifying it with pressure parameters, a fundamental revolution in oil injection process control has been achieved. This method overcomes the shortcomings of traditional methods that rely solely on pressure or time parameters, resulting in low control accuracy and poor adaptability, making the determination of stage switching points more scientific, accurate, and reliable. This dual-parameter (oil quantity + pressure) collaborative judgment mechanism based on a physical model ensures that the system can automatically switch control strategies at the optimal time under different operating conditions and oil characteristics. This significantly improves the control accuracy at the injection endpoint and the efficiency of the entire process while ensuring oil injection safety, making it key to achieving intelligent and adaptive precision oil injection.

[0098] Step S50: Monitor the content of metal shavings in the oil in real time. When the metal shavings signal exceeds the threshold, terminate the oil injection and trigger an alarm.

[0099] In practical implementation, the system uses a capacitive metal detection sensor installed inside the oil filling quick connector to monitor the flowing oil in real time. This sensor operates based on the principle of electromagnetic induction, with its internal detection coil generating a stable high-frequency magnetic field. When oil containing metal fragments flows through the sensor's detection area, whether the metal particles are ferromagnetic or non-ferromagnetic, they will cause a change in the original magnetic field, resulting in a corresponding change in the voltage or frequency of the sensor's output signal.

[0100] The PLC reads and processes the sensor's output signal in real time, sampling every 10ms. The system has a preset critical action threshold: when the magnetic field change detected by the sensor exceeds 5%, it is considered excessive metal contamination. Once this threshold is reached or exceeded, the PLC immediately executes a hard-wired safety protection logic: first, it sends an emergency stop command to the oil pump driver to terminate the oil filling process; simultaneously, a prominent "Oil Contamination" alarm screen pops up on the human-machine interface touchscreen, and the audible and visual alarm (alarm volume ≥80dB) is activated to alert the operator. Furthermore, all relevant data for this alarm event (including trigger time, metal signal strength, cumulative oil filling volume, etc.) is automatically recorded and stored in the PLC's historical database, supporting subsequent queries and analysis, and providing data support for predictive maintenance.

[0101] This system enables millisecond-level real-time online monitoring and proactive safety protection of oil contamination during the refueling process. It transforms the traditional reactive monitoring model of "post-refueling disassembly and inspection" or "periodic oil sample analysis" into a proactive preventative model of "real-time process monitoring and immediate termination in case of abnormalities." It effectively intercepts oil containing worn metal fragments from entering the actuator cylinder, preventing secondary wear and scratches on precision components such as lead screws and gears caused by impurities. This significantly reduces the risk of malfunctions and high replacement costs due to oil contamination. This embedded online monitoring system is a core component in achieving high reliability and status awareness in intelligent refueling trucks.

[0102] The real-time monitoring of the metal shavings content in the oil specifically includes:

[0103] The pollution index is calculated based on a metal impurity pollution early warning model, which is expressed as follows:

[0104] C 污染指数 =(N 金属信号 (×0.5mL) / V 总注油 ×(1+α×ΔP 压力波动 )×K 频率系数

[0105] Among them, K 频率系数 =f 当前 / 5 is used to correct the monitoring sensitivity under different oil injection rates; α is the weighting coefficient for the influence of pressure fluctuation, with a value of 0.1; ΔP pressure fluctuation is the maximum pressure fluctuation value during the oil injection process.

[0106] When the pollution index C 污染指数 When the value is ≥0.1, an early warning will be issued; when the change in magnetic field detected by the capacitive metal detection sensor is >5%, the oil injection will be terminated immediately.

[0107] In this embodiment, during the initial and intermediate filling stages (pressure range 0~0.5MPa), the system simultaneously performs a metal impurity contamination early warning. The PLC collects the number of triggers N of the capacitive metal detection sensor in real time. 金属信号 The total oil injection volume V accumulated by the gear flow meter 总注油 Current oil pump pulse frequency f 当前 and pressure fluctuation value ΔP 压力波动 .

[0108] The system calculates the pollution index every 100ms based on a metal impurity pollution early warning model. This model comprehensively considers the metal particle density per unit of oil, the interference caused by pressure fluctuations, and the impact of oil injection flow rate on monitoring sensitivity, enabling earlier detection of abnormal wear trends.

[0109] When C 污染指数When the value is ≥0.1, the PLC displays a "Pollution Warning" message on the human-machine interface to alert the operator; this is a Level 1 warning. If the sensor directly detects an abnormal signal with a magnetic field change >5%, the PLC immediately triggers a Level 2 alarm, unconditionally stops the pump, and records all event data to prevent oil containing metal fragments from causing secondary damage to the precision components inside the actuator cylinder.

[0110] Step S60: When the pressure enters the full oil determination range and the actual oil quantity reaches the third preset oil quantity value, reduce the oil injection amount per unit time and monitor the capacitive proximity switch signal at the oil injection port.

[0111] In practical implementation, when the system detects that the oil injection pipeline pressure enters the full oil judgment range of 0.5 MPa to 0.8 MPa, and the actual oil volume Q inside the actuator cylinder, calculated in real time based on the "flow-pressure-gas" fusion model, actually reaches the third preset oil volume value (e.g., 7.8 L), the PLC immediately executes the refined oil injection control strategy. The system first sends a control command to the oil pump, switching its operating mode from a pulse frequency of 8Hz (single injection volume of 0.8 mL) to 3Hz (single injection volume of 0.3 mL). By reducing the injection volume per unit time, the oil flow rate is slowed down, creating stable conditions for accurate full oil judgment.

[0112] Simultaneously, the system activates the monitoring function of the capacitive proximity switch installed on the inner wall of the oil filler port. This switch is embedded, with its detection surface flush with the inner wall of the oil filler port. The detection distance is strictly calibrated to ≤5mm, ensuring that it only responds to the oil level within a 3-5mm range near the oil filler port. The PLC reads the proximity switch's status signal at a sampling frequency of 100 times per second, monitoring in real time whether the oil level has risen to the final position of the oil filler port. This "deceleration + dual monitoring" mechanism ensures that the system can provide dual data for the final determination of the full oil level while avoiding the risk of overpressure.

[0113] This invention controls the oil injection deceleration point by setting dual trigger conditions based on actual oil volume and pressure range, and combines this with a highly sensitive capacitive proximity switch for final liquid level verification, achieving intelligent and high-precision oil fullness determination. This method completely eliminates the risk of premature or late pump stoppage caused by traditional reliance on a single pressure parameter or timing control, ensuring accurate stopping of oil injection at the precise moment the actuating cylinder cavity is filled with oil. It not only improves injection accuracy but also effectively avoids the risks of overpressure and oil spillage caused by oil inertia through refined deceleration control, protecting the precision components inside the actuating cylinder. It is a key element in achieving intelligent, precise, and safe oil injection.

[0114] In this embodiment, reducing the amount of oil injected per unit time specifically includes:

[0115] The warning time for oil to reach the injection port is calculated based on the oil level-pressure nonlinear prediction model, which is expressed as:

[0116] t 预警 =(Q 目标 -Q 当前 ) / Q 流量速率 ×K 压力修正 ×K 频率修正 ;

[0117] Among them, K 压力修正 =1+0.05×(P 当前 / P 目标 ) 2 Used to compensate for flow resistance under high pressure; K 频率修正 =8 / f 当前 This is used to correct prediction lag caused by a decrease in pulse frequency; Q 流量速率 =f 当前 ×0.3mL / Hz represents the amount of oil injected per unit time.

[0118] Based on the aforementioned warning time, the oil pump is controlled in advance to reduce the pulse frequency from 8Hz to 3Hz.

[0119] For example, during the full oil determination phase (pressure range 0.5~0.8MPa), the system activates the oil level-pressure nonlinear prediction model to achieve precise control. The PLC first obtains the current model parameters: the actual current oil volume Q inside the actuator cylinder calculated through the "flow-pressure-gas" model. 当前 Target oil volume Q 目标 (7.8L), the current pressure P collected in real time by the pressure sensor 当前 Target pressure P 目标 (0.6MPa) and the current pulse frequency f of the oil pump 当前 (Initially 8Hz).

[0120] Subsequently, the PLC's built-in algorithm, based on formula K... 压力修正 =1+0.05×(P 当前 / P 目标 ) 2 A pressure correction factor is calculated, which increases as the pressure approaches the target value, effectively compensating for the increased viscous resistance of the oil under high pressure. Simultaneously, according to formula K... 频率修正 =8 / f 当前 The frequency correction factor is calculated. When the frequency drops from 8Hz to 3Hz, the factor increases from 1 to approximately 2.67 to correct the prediction time calculation deviation caused by the increased pulse interval.

[0121] Finally, the PLC calculates the predicted warning time based on the oil level-pressure nonlinear prediction model, and controls the oil pump to reduce the pulse frequency in advance to ensure that the system has sufficient response time, avoid overpressure, and smoothly complete the full oil determination before the capacitive proximity switch is triggered.

[0122] Step S70: When the conditions of the capacitive proximity switch being triggered and the pipeline pressure stabilizing are met simultaneously, it is determined that the oil is full and oil injection is stopped.

[0123] In this embodiment, determining that the fuel level has been reached is specifically as follows:

[0124] When the capacitive proximity switch is triggered and the pressure change rate in the oil filling line is continuously lower than a preset threshold, it is determined that the oil filling state has been reached.

[0125] In the specific implementation process, the system uses both capacitive proximity switch signals and pressure stability as dual criteria to accurately determine the oil full status. When the oil filling process enters the full oil determination stage, the PLC synchronously monitors two key signals at a sampling frequency of 100 times per second: one is the trigger status of the capacitive proximity switch embedded in the inner wall of the oil filling port (detection distance ≤5mm), and the other is the pipeline pressure data collected by the miniature ceramic pressure sensor.

[0126] The PLC calculates the pressure change rate (ΔP / Δt) in real time. When the system simultaneously detects that the following two conditions are met for 500 milliseconds: First, the capacitive proximity switch is reliably triggered, indicating that the oil level has reached the final position ≤3mm from the oil filling port; second, the calculated pressure change rate remains below the preset threshold of 0.01 MPa / s, indicating that the internal cavity of the actuator cylinder has been completely filled with oil and the pressure is stabilizing. Once both conditions are met, the PLC immediately determines that the system has reached the full oil state and sends an emergency stop command to the oil pump driver, immediately terminating all oil filling operations.

[0127] This invention constructs a redundant and reliable full-oil status determination logic by integrating direct evidence of physical liquid level arrival (proximity switch triggering) and indirect evidence of system pressure stability (pressure change rate below a threshold). This two-factor collaborative determination mechanism greatly overcomes the false alarm risks that may exist with a single sensor, such as a proximity switch falsely triggered by oil splashing, or a pressure sensor falsely judging stability due to slow system leakage, thus raising the accuracy and reliability of full-oil determination to a new level. It not only ensures that each oil injection precisely reaches the target oil volume, but also completely avoids the risk of overpressure due to over-filling or insufficient lubrication due to under-filling. It is the most critical link in realizing precise closed-loop control of oil injection, guaranteeing the long-term reliability and lifespan of the electric actuator.

[0128] In this embodiment, step S70 is followed by step S80, specifically:

[0129] Step S80: After stopping the oil injection, allow the pressure to stand and hold. If the pressure drop exceeds the allowable range, perform compensatory replenishment.

[0130] Compensatory supplementary injection, the method of which is as follows:

[0131] Step S81: Restart the oil pump and replenish the actuator cylinder with oil at a flow rate not exceeding a preset percentage of the rated flow rate;

[0132] Step S82: Monitor the pressure changes in the oil injection pipeline in real time;

[0133] Step S83: When the pressure is detected to have recovered to a preset percentage range of the full oil pressure threshold, the refilling is stopped.

[0134] In practice, after oil injection stops, the system automatically enters the pressure holding detection and compensatory replenishment stage. The PLC controls the oil pump to stop and starts timing, allowing the system to stand still for 2 minutes. During this period, the pressure change inside the actuator cylinder is continuously monitored by a miniature ceramic pressure sensor. After the standing period, the PLC calculates the pressure drop value ΔP, which is the difference between the pressure when the pump stops and the pressure after standing. If ΔP > 0.1 MPa, it is determined that "residual air" caused the abnormal pressure drop, and the system automatically starts the compensatory replenishment program.

[0135] The PLC first restarts the oil pump, but limits its output flow to less than 20% of the rated flow, i.e., low-flow mode, to slowly and precisely replenish the oil in the actuator cylinder. During the replenishment process, the PLC monitors the pressure changes in the pipeline in real time at a frequency of 50 times per second. When the pressure value is detected to rise and stabilize within the full oil pressure threshold, for example, 95% to 105% of 0.6 MPa, i.e., between 0.57 MPa and 0.63 MPa, the PLC immediately issues a stop command again to terminate the replenishment operation.

[0136] This invention creatively solves the industry-wide problem of insufficient oil injection caused by residual air inside the actuator cylinder through automated pressure holding detection and intelligent compensation procedures. This solution transforms the traditional "one-time oil injection + manual verification" model into a fully automated closed-loop control model of "oil injection-detection-compensation," ensuring that even under complex operating conditions with residual air, the final oil injection volume accurately reaches the target value. This self-verification and self-correction capability not only improves oil injection accuracy but also eliminates reliance on manual experience, significantly enhancing the standardization of operations and the reliability of equipment maintenance. It is a key guarantee for achieving high precision and robustness in intelligent oil injection vehicles.

[0137] After replenishment, record complete data of the oiling process, including the final oil volume, pressure-time curve, and metal shavings monitoring results.

[0138] In the specific implementation process, after the compensatory replenishment is completed and the system finally stops, the PLC automatically executes the data recording and archiving program. The system first integrates the full-cycle data of this oil injection operation: obtaining the final cumulative oil injection volume V through the gear flow meter. 总 Extract complete pressure-time curve data from the PLC's real-time database. This curve contains all pressure change information from the start of pre-oil injection, through each pressure stage, until the end of pressure holding. At the same time, retrieve all metal chip signal trigger events and their corresponding magnetic field changes recorded by the metal detection sensor throughout the process.

[0139] This data is automatically packaged by the PLC into a uniquely numbered data record package. In addition to the core data mentioned above, it also automatically includes a timestamp, actuator number, operator ID, and other information. This data package undergoes two storage operations simultaneously: first, it is stored in the PLC's local non-volatile memory, supporting offline retrieval; second, it is uploaded to the upper-level management system database via an onboard communication module (such as RS485 or Ethernet) for long-term traceability and analysis. Operators can query the complete data report of this oiling operation in various ways, such as by time and equipment number, on the "History" interface of the touchscreen.

[0140] This invention achieves fully automated, comprehensive, and traceable digital recording of oil injection process data. This function elevates each maintenance operation from an "operational" level to a "data-driven" management level. The resulting electronic data package not only provides tamper-proof proof of the operation's quality compliance but, more importantly, establishes a complete "health record" for each actuator. By long-term tracking and analysis of trend data such as pressure curve morphology and metal contamination index, potential wear and tear failures of components can be predicted in advance, achieving a leap from preventative maintenance to predictive maintenance. This significantly improves the refinement and intelligence of equipment lifecycle management and is a key data foundation for building a smart operation and maintenance system.

[0141] Although the steps in the above embodiments are described in the above order, those skilled in the art will understand that in order to achieve the effect of this embodiment, different steps do not need to be executed in such an order. They can be executed simultaneously (in parallel) or in a reverse order. These simple variations are all within the protection scope of this invention.

[0142] like Figures 2-6 As shown, in the second embodiment of the present invention, an intelligent oil filling vehicle is proposed to implement an intelligent oil filling control method for an electrically actuated cylinder. The oil filling vehicle includes:

[0143] The vehicle body 1 has a control system mounting layer 11 on its upper part and a tool storage layer 12 and an oil pump assembly mounting layer 13 on its lower part.

[0144] The oil pump assembly 2 includes an electrically driven pump 21 and a gear flow meter 22 connected to the pump outlet pipeline, which is used to provide oil injection power and measure the oil injection volume in real time.

[0145] The tool management system 3, located in the tool storage layer 12, is used to monitor the tool's location and integrity in real time.

[0146] The drain valve assembly is used to achieve a quick sealing connection between the drain port of the actuator cylinder and the oil injection pipeline, and can switch between gravity drain and pressure-driven oil injection states; the drain valve assembly integrates a pressure sensor for monitoring pipeline pressure and a metal detection sensor for detecting metal impurities in the oil.

[0147] Control system 4 is used to receive sensor signals and control the start and stop of the oil pump to achieve quantitative or timed oil injection;

[0148] The oil pump assembly 2, tool management system 3, oil drain valve assembly and control system 4 are electrically connected.

[0149] For further explanation of the present invention, see [link to relevant documentation]. Figure 2 and Figure 3 The tool management system 3 includes an RFID reader and RFID tags installed on the RFID reader, and / or includes an AI camera and an image recognition module for automatically identifying the presence and integrity of the tools.

[0150] See Figure 3 and Figure 5 The control system 4 includes a programmable logic controller (PLC) 41 and a human-machine interface touch screen 42; the PLC is electrically connected to the human-machine interface touch screen 42, the oil pump assembly 2, the sensors in the oil discharge valve assembly, and the tool management system 3.

[0151] See Figure 3 and Figure 4 The oil pump assembly 2 also includes an oil moisture content sensor; the outlet pipe of the electric drive pump 21 is connected to the oil discharge valve assembly via the gear flow meter 22 and the oil moisture content sensor through a rubber oil pipe.

[0152] In this embodiment, the vehicle body 1 is constructed with a high-strength stainless steel frame and a corrosion-resistant coated panel, and is equipped with doors. The upper part is a control system mounting layer 11, with an internal mounting base for fixing the PLC controller, power module, and circuit protection devices. The lower part is divided by a partition into a front tool storage layer 12 and a rear oil pump assembly mounting layer 13. The tool storage layer 12 is designed with custom-molded compartments for storing tools such as drain valve connectors and special wrenches. The oil pump assembly mounting layer 13 mounts the core pumping unit via a shock-absorbing base. The four corners of the vehicle body 1 are equipped with casters with brakes, and the front has a 900mm high handrail with an integrated emergency stop button, enable switch, and three-color power indicator light.

[0153] The oil pump assembly 2 is the power and metering core of the system. The electrically driven pump 21 is a DC brushless gear pump, and its outlet is connected to the inlet of the gear flow meter 22 via a high-pressure stainless steel rigid pipe. The gear flow meter 22 is a high-precision, low-flow model with a pulse equivalent of 0.1 mL / pulse. The flow meter outlet is connected via a tee connector, one path to a JWB2 oil moisture content sensor, and the other path through a 40 MPa pressure-resistant rubber hose 23, ultimately connecting to a quick-connect fitting. The entire oil circuit is enclosed in a metal compartment with an openable cover, ensuring both safety and aesthetics.

[0154] The tool management system 3 offers two optional implementation schemes. Scheme 1: An RFID reader / writer is embedded at the bottom of each compartment in the tool storage box, and an RFID tag is attached to the handle or a specific location on each tool. When a tool is placed in a compartment, the reader / writer automatically identifies it and reports its location. Scheme 2: An AI camera is installed at the top of the storage compartment. Using its built-in image recognition algorithm, it continuously monitors whether the tools are in place and whether there is any obvious damage, such as cracks, excessive oil stains, or whether the oil pipe joints are clean. The identification results from both schemes are uploaded to the control system 4 in real time.

[0155] like Figure 6 As shown, the drain valve assembly includes a drain valve body 51, a drain valve core 52, a drain valve core base 53, a drain valve connector 54, a drain valve connector nut 55, a double O-ring sealing structure 56, and a return spring 57.

[0156] The drain valve body 51 is fixedly installed at the drain port of the actuator cylinder, and the drain valve core 52 is provided inside. The drain valve core base 53 is fixedly installed inside the drain valve body 51 to support the drain valve core 52 and guide its axial movement.

[0157] The return spring 57 is housed between the drain valve core 52 and the valve core base 53, with one end acting on the drain valve core 52 and the other end acting on the valve core base 53, providing a continuous closing preload force for the drain valve core 52.

[0158] The drain valve connector 54 is detachably connected to the drain valve body 51 via the drain valve connector nut 55, forming a quick coupling mechanism.

[0159] A double O-ring sealing structure 56 is provided between the oil drain valve body 51 and the oil drain valve connector 54 to achieve a leak-free seal when connected and to isolate external contamination when disconnected.

[0160] When the drain valve connector 54 is connected and locked to the drain valve body 51, it pushes the drain valve core 52 to compress the return spring 57 to open the oil passage, realizing gravity-driven oil discharge or external oil pump pressure-driven oil injection; when the connection is disconnected, the drain valve core 52 moves under the reset action of the return spring 57 to seal the oil passage.

[0161] The pressure sensor and metal detection sensor are built into the drain valve connector 54.

[0162] The drain valve body 51 is permanently fixed to the drain port of the electrically actuated cylinder via threads, serving as a high-performance sealing plug during normal non-operational use. The drain valve core 52 is located inside the valve body, and this core remains normally closed under the action of the return spring 57, forming a one-way seal. The drain valve core base 53 is fixed inside the valve body, supporting the drain valve core 52 and precisely guiding its axial movement, while also providing a mounting base for the return spring 57.

[0163] The drain valve connector 54 is a key interface connecting the oil pipe of the oil filling vehicle and the drain valve body 51. It is detachably connected to the drain valve body 51 via the drain valve connector nut 55, forming a quick-couple mechanism. To achieve a comprehensive leak-free seal, this component employs a multi-seal design: First, a double O-ring seal structure 56 is provided at the junction of the drain valve body 51 and the drain valve connector 54; second, a double O-ring seal structure 56 is also provided at the threaded connection between the drain valve body 51 and the drain valve connector nut 55, ensuring no leakage risk at any mechanical connection interface; its outer surface is provided with a double O-ring seal structure 56 for static sealing with the actuating cylinder drain port; the mounting junction of the valve core base 53 and the drain valve body 51 is provided with a double O-ring seal structure 56 for internal static sealing, preventing oil leakage from this assembly gap.

[0164] Its working principle is as follows:

[0165] Connection and conduction: When performing oil draining or filling operations, insert the drain valve connector 54 into the drain valve body 51 and tighten the drain valve connector nut 55. During tightening, the inner end face of the drain valve connector 54 will push the drain valve core 52, overcoming the elastic force of the return spring 57 and causing it to move backward, thereby opening the oil passage.

[0166] Oil discharge and oil injection: After the oil circuit is opened, the waste oil in the actuator can be discharged by gravity; during the oil injection stage, the oil pump of the oil injection vehicle provides pressure to drive the oil injection.

[0167] Disconnection and sealing: After the operation is completed, loosen and remove the drain valve connector 54. The drain valve core 52 will quickly return to its original position under the action of the return spring 57, tightly fitting the valve seat and re-sealing the oil circuit.

[0168] Furthermore, to achieve intelligent monitoring, a miniature pressure sensor and a capacitive metal detection sensor are integrated into the drain valve connector 54. This integrated design allows the sensors to directly contact the flowing oil, thereby enabling real-time and accurate monitoring of pipeline pressure and metal shavings content.

[0169] The control system 4 acts as the brain, with its programmable logic controller (PLC) 41 being a modular medium-sized PLC. Its digital and analog input modules are responsible for acquiring all sensor signals, such as pressure, flow rate, metal signals, moisture content, and tool presence signals. The output modules control the oil pump's start / stop and pulse frequency. The human-machine interface touchscreen 42 communicates with the PLC via Ethernet, providing parameter setting, status display, historical data query, and audible / visual alarm functions. The PLC, touchscreen, sensors, and actuators are connected via shielded cables, forming a complete control loop.

[0170] The third embodiment of the present invention proposes an intelligent oil injection control system for an electrically actuated cylinder, based on an intelligent oil injection control method for an electrically actuated cylinder according to the first embodiment, the method comprising:

[0171] The initial gas volume calculation module is configured to inject a fixed amount of oil into the actuator cylinder to establish the initial oil circuit pressure, and calculate the initial gas volume inside the actuator cylinder based on the pressure value after pre-injection of oil.

[0172] The interval division module is configured to divide the oil injection process into multiple continuous pressure intervals, including initial filling, intermediate filling, and full oil determination, based on real-time monitoring of oil injection pipeline pressure changes.

[0173] The actual oil volume calculation module is configured to calculate the actual oil volume inside the actuator cylinder in real time within the initial filling and medium filling pressure range.

[0174] The determination module is configured to use the actual oil quantity reaching a first preset oil quantity value as a condition for switching from the initial filling stage to the medium filling stage, and to use the actual oil quantity reaching a second preset oil quantity value as a condition for switching from the medium filling stage to the full oil determination stage.

[0175] The metal shavings detection module is configured to monitor the metal shavings content in the oil in real time. When the metal shavings signal exceeds the threshold, the oil injection will be terminated and an alarm will be triggered.

[0176] The oil injection reduction module is configured to reduce the oil injection amount per unit time when the pressure enters the full oil determination range and the actual oil volume reaches the third preset oil volume value, and to monitor the capacitive proximity switch signal at the oil injection port.

[0177] The stop module is configured to determine that the oil level is full and stop oil injection when the conditions of the capacitive proximity switch being triggered and the pipeline pressure stabilizing are met simultaneously.

[0178] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working process and related descriptions of the system described above can be found in the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0179] It should be noted that the intelligent oil filling control system for an electrically actuated cylinder provided in the above embodiments is only an example of the division of the above functional modules. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the modules or steps in the embodiments of the present invention can be further decomposed or combined. For example, the modules in the above embodiments can be merged into one module, or further divided into multiple sub-modules to complete all or part of the functions described above. The names of the modules and steps involved in the embodiments of the present invention are only for distinguishing the various modules or steps and are not considered as an improper limitation of the present invention.

[0180] An electronic device according to a third embodiment of the present invention includes:

[0181] At least one processor; and

[0182] A memory communicatively connected to at least one of the processors; wherein,

[0183] The memory stores instructions that can be executed by the processor to implement the above-described intelligent oil filling control method for an electrically actuated cylinder.

[0184] A computer-readable storage medium according to a fourth embodiment of the present invention stores computer instructions, which are executed by the computer to implement the above-described intelligent oil filling control method for an electrically actuated cylinder.

[0185] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working process and related descriptions of the storage device and processing device described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0186] Those skilled in the art will recognize that the modules and method steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. The programs corresponding to the software modules and method steps can be placed in random access memory (RAM), main memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disks, removable disks, CD-ROMs, or any other form of storage medium known in the art. To clearly illustrate the interchangeability of electronic hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in electronic hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the invention.

[0187] The terms “first”, “second”, etc., are used to distinguish similar objects, not to describe or indicate a specific order or sequence.

[0188] The term "comprising" or any other similar term is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus / device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent in such process, method, article, or apparatus / device.

[0189] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A smart oil injection control method for an electrically actuated cylinder, characterized in that, The method includes: A fixed amount of oil is injected into the actuator cylinder to establish the initial oil circuit pressure, and the initial gas volume inside the actuator cylinder is calculated based on the pressure value after pre-injection of oil. Based on real-time monitoring of the pressure changes in the oil injection pipeline, the oil injection process is divided into multiple continuous pressure ranges, including initial filling, intermediate filling, and full oil determination. Within the initial and medium filling pressure range, the actual oil volume inside the actuator cylinder is calculated in real time: The real-time calculation of the actual oil volume inside the actuator cylinder includes the following steps: Obtain the initial gas volume and the real-time pressure value in the current oil injection pipeline; Based on the ratio of the real-time pressure value to atmospheric pressure, the current gas compression ratio is calculated. The product of the initial gas volume and the gas compression ratio is determined as the equivalent oil volume occupied due to the gas compression effect. The actual amount of oil inside the actuator cylinder is obtained by subtracting the residual oil in the pipeline and the equivalent oil volume from the cumulative oil injection volume. The condition for switching from the initial filling stage to the medium filling stage is that the actual oil volume reaches the first preset oil volume value, and the condition for switching from the medium filling stage to the full oil determination stage is that the actual oil volume reaches the second preset oil volume value. Real-time monitoring of the metal shavings content in the oil; when the metal shavings signal exceeds the threshold, oil injection is terminated and an alarm is triggered. When the pressure enters the full oil determination range and the actual oil volume reaches the third preset oil volume value, the oil injection volume per unit time is reduced, and the capacitive proximity switch signal at the oil injection port is monitored. When the conditions of triggering the capacitive proximity switch and stabilizing the pipeline pressure are met simultaneously, it is determined that the oil is full and oil injection is stopped.

2. The intelligent oil injection control method for an electrically actuated cylinder according to claim 1, characterized in that, The initial gas volume inside the actuator cylinder is calculated based on the pressure value after pre-filling with oil, specifically including the following steps: Obtain the amount of oil injected during the pre-oil injection stage and the amount of residual oil in the pipeline, and measure the stable pressure value inside the actuator cylinder after pre-oil injection; Subtract the amount of residual oil in the pipeline from the amount of oil injected during the pre-oil injection stage to obtain the effective oil volume entering the actuator cylinder; The initial gas volume is calculated by dividing the product of the effective oil volume and the atmospheric pressure by the difference between the stable pressure value and the atmospheric pressure.

3. The intelligent oil injection control method for an electrically actuated cylinder according to claim 1, characterized in that, The determination that the fuel level has been reached is specifically as follows: When the capacitive proximity switch is triggered and the pressure change rate in the oil filling line is continuously lower than a preset threshold, it is determined that the oil filling state has been reached.

4. The intelligent oil injection control method for an electrically actuated cylinder according to claim 1, characterized in that, The method also includes: After stopping the oil injection, allow the pressure to stand and hold. If the pressure drop exceeds the allowable range, perform compensatory oil injection.

5. The intelligent oil injection control method for an electrically actuated cylinder according to claim 4, characterized in that, The method for compensatory injection is as follows: Restart the oil pump and replenish the actuator cylinder with oil at a flow rate not exceeding a preset percentage of the rated flow rate; Real-time monitoring of pressure changes in the oil injection pipeline; When the pressure is detected to return to a preset percentage range of the full oil pressure threshold, the refilling process is stopped.

6. An intelligent oil filling vehicle, used to implement the intelligent oil filling control method for an electrically actuated cylinder as described in any one of claims 1-5, characterized in that, The oil filling vehicle includes: The vehicle body (1) has a control system mounting layer (11) on its upper part and a tool storage layer (12) and an oil pump assembly mounting layer (13) on its lower part. The oil pump assembly (2) includes an electrically driven pump (21) and a gear flow meter (22) connected to the pump outlet pipeline, for providing oil injection power and measuring the oil injection volume in real time; The tool management system (3) is located in the tool storage layer (12) and is used to monitor the tool's location and integrity in real time. The drain valve assembly is used to achieve a quick sealing connection between the drain port of the actuator cylinder and the oil injection pipeline, and can switch between gravity drain and pressure-driven oil injection states; the drain valve assembly integrates a pressure sensor for monitoring pipeline pressure and a metal detection sensor for detecting metal impurities in the oil. The control system (4) is used to receive sensor signals and control the start and stop of the oil pump to realize quantitative or timed oil injection; The oil pump assembly (2), tool management system (3), drain valve assembly and control system (4) are electrically connected.

7. The intelligent oil filling vehicle according to claim 6, characterized in that, The tool management system (3) includes an RFID reader and RFID tags installed on the RFID reader, and / or includes an AI camera and an image recognition module for automatically identifying the presence and integrity of the tools.

8. The intelligent oil filling vehicle according to claim 6, characterized in that, The control system (4) includes a programmable logic controller (PLC) (41) and a human-machine interface touch screen (42); the programmable logic controller (PLC) (41) is electrically connected to the human-machine interface touch screen (42), the oil pump assembly (2), the sensors in the oil discharge valve assembly, and the tool management system (3).

9. The intelligent oil filling vehicle according to claim 6, characterized in that, The oil pump assembly (2) also includes an oil moisture content sensor; the outlet pipeline of the electric drive pump (21) is connected to the oil discharge valve assembly via the gear flow meter (22) and the oil moisture content sensor through a rubber oil pipe.

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