Reliability rapid verification system and method for proportional direction control valve

Abstract

The invention provides a rapid reliability verification system and method for a proportional direction control valve, and belongs to the technical field of reliability verification of proportional direction control valves. Judging whether a preset target is reached or not according to data input by the test data acquisition interface and the key parameters of the trial production link; according to the rapid reliability verification system and method for the proportional direction control valve, after unfavorable factors are recognized and optimized in real time in the design and sample trial-manufacture process, overall design and sample trial-manufacture of the proportional direction control valve are completed, and then systematic reliability verification and analysis are conducted; whether the proportional direction control valve has reliability in multiple environments or not is determined; the method has higher accuracy, risk factors can be completely and efficiently eliminated in the design and development process of the proportional directional control valve, and the development time is greatly shortened.

Description

Technical Field

[0001] This invention belongs to the field of reliability verification technology for proportional directional control valves, and more specifically relates to a rapid reliability verification system and method for proportional directional control valves. Background Technology

[0002] Hydraulic proportional directional control valves are key control components in hydraulic systems. With complex internal structures, they face stringent challenges in various industries due to different environmental conditions and performance requirements. Therefore, the reliability of proportional directional control valves is of paramount importance.

[0003] Currently, most methods for rapid reliability verification of hydraulic components involve collecting a small amount of input data and then performing simulation and probabilistic analysis. Due to the relatively small sample size and simulation analysis model errors, the reliability characteristics (such as mean time to failure) range is large when considering confidence intervals. Moreover, for proportional directional control valves with complex structures and high control precision, their failure modes are particularly diverse. Existing simulation and calculation verification methods are not very accurate and cannot completely and efficiently eliminate risk factors during the design and development of proportional directional control valves.

[0004] Traditional reliability verification requirements for hydraulic proportional directional control valves, based on US SAE standards and Chinese GJB standards, require a significant investment of manpower and resources for each reliability test during product development. Furthermore, the efficiency of rapidly iterating product electromechanical modules during development is reduced due to the need for actual reliability testing, further impacting efficiency and increasing costs. In addition, testing under different environmental conditions requires highly specialized equipment.

[0005] Reliability verification methods based on extensive simulation and probabilistic analysis are not suitable for complex and precise hydraulic components, namely proportional directional control valves. Furthermore, reliability verification methods based on numerous rigorous tests are no longer suitable for the efficiency and cost requirements of rapid iteration of electromechanical systems in the design process of modern new proportional directional control valves. Therefore, a new method for rapid reliability verification suitable for proportional directional control valves is needed. Summary of the Invention

[0006] To overcome the above problems, one object of the present invention is to provide a rapid reliability verification system for a proportional directional control valve, comprising: A functional unit database, which stores information on functional groups involved in the entire process of designing and pilot-producing proportional directional control valves; and, Performance test database: The performance test database is used to store performance parameter information of proportional directional control valves; and, Environmental adaptability test database: The environmental adaptability test database is used to store environmental adaptability parameter information of proportional directional control valves; and, A reliability database, which stores reliability parameter information of proportional directional control valves; A trial production stage database is used to store information on each trial production stage of the proportional directional control valve, and key parameter information for each trial production stage. Each trial production stage information is associated with performance parameters and / or reliability parameters and / or environmental adaptability parameters related to that stage, serving as key parameter information for that stage. The decision module includes a test data acquisition interface. At the end of each trial production stage, the decision module determines whether the preset target has been achieved based on the data input from the test data acquisition interface and the key parameters of the trial production stage. It performs key parameter determination and identifies adverse factors affecting the reliability of the proportional directional control valve. If the key parameters of the trial production stage do not meet the preset target, it returns to the previous trial production stage or the trial production stage that caused the adverse factor.

[0007] Preferably, the functional unit includes a material processing unit, a structural unit, a system unit, a simulation unit, a performance testing unit, an environmental adaptability testing unit, and a reliability analysis unit; Among them, in each functional unit: The goal of the materials and processes unit is to achieve the selection of materials, selection of material forming processes, formulation of process specifications, and processing and manufacturing of main components for each component of the proportional directional control valve product. The goal of the structural unit is to realize the design of the flow channel of the valve body, the design of the main structure, and the design of the overall structure of the proportional directional control valve. In the process of design and trial production combined with rapid reliability verification, it is also necessary to participate in the identification of adverse structural factors and structural optimization in a timely manner. The goal of the system unit is to achieve valve core control of the proportional directional control valve through motor controller hardware and algorithms. In addition, it is necessary to implement the software and hardware testing, function adjustment and calibration functions of the proportional directional control valve through the host computer. The goal of the simulation unit is to establish a mathematical and physical model and calculate and verify the feasibility of the design scheme. The goal of the performance testing unit is to verify the performance compliance of certain components, parts, or the whole of the proportional directional control valve product using conventional testing methods that meet industry standards. The goal of the environmental adaptability test unit is to verify the performance reliability of proportional directional control valve products under extreme and harsh environments by conducting environmental adaptability tests on proportional directional control valve products under single or a few combined environmental conditions. The purpose of the reliability analysis unit is to complete the formulation of reliability-related evaluation indicators, test design, obtain reliability-related data, and complete the analysis.

[0008] Another objective of this invention is to provide a rapid reliability verification method for a proportional directional control valve, comprising the following steps: S1. Divide the entire process of designing and pilot production of the proportional directional control valve into different functional units according to the design content, analyze the design and pilot production goals that different functional units need to achieve, and break down the goal achievement process into specific steps. S2. Based on the design and trial production stages of different functional units, identify the characteristics and important evaluation indicators of each trial production stage, and then decompose the elements required for reliability verification and insert them into each trial production stage of each function in the design and trial production. S3. After each trial production stage is completed, analyze the results of the corresponding stage, determine the key parameters, and identify the adverse factors affecting the reliability of the proportional directional control valve. S4. If a non-conformity is found in the trial production stage, after analysis, return to the previous trial production stage or the trial production stage that caused the adverse factor, and redesign or re-produce the trial production. S5. After identifying and optimizing adverse factors in real time during the process, complete the overall design and sample production of the proportional directional control valve, and then conduct systematic reliability verification and analysis to confirm whether the proportional directional control valve has reliability in multiple environments.

[0009] Preferably, in step S1, the different functional units are divided according to the characteristics of the proportional directional control valve product, including: material processing unit, structural unit, system unit, simulation unit, performance testing unit, environmental adaptability testing unit, and reliability analysis unit. Among them, in each functional unit: The main objective of the materials and processes unit is to achieve the selection of materials, selection of material forming processes, formulation of process specifications, and processing and manufacturing of main components for each component of the proportional directional control valve product. The main objective of the structural unit is to realize the design of the flow channel of the valve body, the design of the main structure, and the design of the overall structure of the proportional directional control valve. In the process of design and trial production combined with rapid reliability verification, it is also necessary to participate in the identification of adverse factors in the structure and the structural optimization process in a timely manner. The main objective of the system unit is to achieve valve core control of the proportional directional control valve through motor controller hardware and algorithms. In addition, it is necessary to implement the software and hardware testing, function adjustment and calibration functions of the proportional directional control valve through the host computer. The goal of the simulation unit is to establish a mathematical and physical model and calculate and verify the feasibility of the design scheme. The goal of the performance testing unit is to verify the performance compliance of certain components, parts, or the whole of the proportional directional control valve product using conventional testing methods that meet industry standards. The goal of the environmental adaptability test unit is to verify the performance reliability of proportional directional control valve products under extreme and harsh environments by conducting environmental adaptability tests on proportional directional control valve products under single or a few combined environmental conditions. The purpose of the reliability analysis unit is to complete the formulation of reliability-related evaluation indicators, test design, obtain reliability-related data, and complete the analysis.

[0010] Preferably, in step S2, the characteristics and important evaluation indicators of different trial production stages belong to the key parameters, performance, or performance stability of the proportional directional control valve product under different environmental conditions. Includes one or more of the following key parameters, performance characteristics, or requirements: core material hardness, corrosion resistance, density, tensile strength, elongation, stability in reaction with oil, product envelope, weight, mounting surface, electrical connectors, appearance quality, markings and designations, insulation resistance, electrical strength, leakage current, stator resistance, stator inductance, accidental overcurrent, power input, electrical safety protection, withstand pressure, external leakage, internal leakage, rated flow rate, flow gain, linearity, hysteresis, symmetry, polarity, coverage, threshold, zero bias, pressure gain, zero drift, step response time, frequency response, temperature rise, electromagnetic compatibility, and height loop. Performance under ambient conditions, performance after high-temperature storage, performance during high-temperature operation, performance after extreme low-temperature storage, performance during low-temperature operation, performance during rapid temperature changes at a specified transition time, performance during temperature changes at a specified rate of change, performance after acceleration, performance after random vibration, performance after sinusoidal vibration, performance after sinusoidal superimposed random vibration, performance after random vibration during transportation, performance after impact, performance after free fall, performance under constant humid and hot conditions, performance under alternating humid and hot conditions, influence of mold environment, influence of salt spray environment, influence of sand and dust environment, fluid sensitivity, enclosure protection rating, performance after pressure pulse, lifespan, burst pressure.

[0011] Preferably, in steps S2 and S3, the elements required for reliability verification and the method for identifying verification results have the following characteristics: The elements required for reliability verification are generally the key parameters, performance, or targeted verification methods for the performance stability of proportional directional control valve products under different environmental conditions, mainly including simulation, testing, and experimentation. Based on the parameters obtained from the verification, adverse factors affecting reliability can be identified. Adverse factors refer to factors that affect the normal operation of proportional directional control valve products under normal conditions and possible abnormal conditions, without unacceptable performance degradation or failure.

[0012] Preferably, in step S4, the degree of adverse factors is analyzed. If the adverse factor occurs by chance, retesting or further experiments are required. If it is confirmed that the adverse factor is a common factor and will appear in more than 1% of the product batch, then the non-conformity is determined, and the link in which the non-conformity initially occurred is analyzed, and the pilot production link in which the initial adverse factor was identified is returned.

[0013] Preferably, in step S5, after the reliability analysis and optimization of the process are completed, step S5 performs a systematic reliability verification of the proportional directional control valve product as a whole. The method for systematic reliability verification is as follows: First, we need to confirm the core performance of the product, including the confirmation of hydraulic static and dynamic performance. We will conduct tests using a hydraulic servo test bench, following the test method for a four-way flow valve. After the hydraulic static and dynamic performance meets the requirements, the most stringent random vibration and sinusoidal vibration tests are carried out to test the overall mechanical integrity of the proportional directional control valve product. After the vibration test, the hydraulic static and dynamic performance is retested. Then, accelerated life testing is conducted to test the long-term operational stability of the proportional directional control valve under harsh conditions, and to quickly expose any material, structural, and control system problems that still exist after process reliability verification. For the problems exposed at this stage, it is analyzed whether they are due to errors in process reliability verification or are caused by a combination of factors that will only be exposed during the overall proportional directional control valve product testing. If it is the latter, then after problem analysis and optimization, the accelerated life test is repeated. The pressure pulse test, the remaining mechanical environmental adaptability test, the climate environmental adaptability test, and the life test are carried out in sequence, and then a reliability analysis is performed to draw conclusions.

[0014] Preferably, the reliability analysis includes qualitative and quantitative methods, and the methods used include one or more of the following: failure mode and effects analysis, fault tree analysis, hazard and operability analysis, reliability prediction, reliability block diagram, Markov analysis method and Weibull analysis.

[0015] As described above, the proportional directional control valve reliability rapid verification system and method of the present invention, after real-time identification and optimization of adverse factors during the design and sample production process, completes the overall design and sample production of the proportional directional control valve, and then conducts systematic reliability verification and analysis to confirm whether the proportional directional control valve has reliability under multiple environments; this method has higher accuracy and can completely and efficiently eliminate risk factors in the design and development process of proportional directional control valve, significantly shortening the development time. Attached Figure Description

[0016] The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, wherein similar elements are numbered in a similar manner, wherein: Figure 1 This is a schematic diagram of a rapid reliability verification method for a proportional directional control valve; Figure 2 This is a schematic diagram of a rapid reliability verification system and method for a proportional directional control valve. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0018] It should be noted that if directional indicators (such as up, down, left, right, front, back, etc.) are involved in the embodiments of this invention, these directional indicators are only used to explain the relative positional relationships and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly. Unless otherwise explicitly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0019] Furthermore, if the embodiments of the present invention involve descriptions using terms such as "first," "second," etc., these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Moreover, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0020] The technical solution of the present invention will be further described in detail below through embodiments and in conjunction with the accompanying drawings, but the present invention is not limited to the following embodiments.

[0021] Hydraulic proportional directional control valves are key control components in hydraulic systems. With complex internal structures, they face stringent challenges in various industries due to different environmental conditions and performance requirements. Therefore, the reliability of proportional directional control valves is of paramount importance.

[0022] Currently, most methods for rapid reliability verification of hydraulic components involve collecting a small amount of input data and then performing simulation and probabilistic analysis. Due to the relatively small sample size and simulation analysis model errors, the reliability characteristics (such as mean time to failure) range is large when considering confidence intervals. Moreover, for proportional directional control valves with complex structures and high control precision, their failure modes are particularly diverse. Existing simulation and calculation verification methods are not very accurate and cannot completely and efficiently eliminate risk factors during the design and development of proportional directional control valves.

[0023] Traditional reliability verification requirements for hydraulic proportional directional control valves, based on US SAE standards and Chinese GJB standards, require a significant investment of manpower and resources for each reliability test during product development. Furthermore, the efficiency of rapidly iterating product electromechanical modules during development is reduced due to the need for actual reliability testing, further impacting efficiency and increasing costs. In addition, testing under different environmental conditions requires highly specialized equipment.

[0024] Reliability verification methods based on extensive simulation and probabilistic analysis are not suitable for complex and precise hydraulic components, namely proportional directional control valves. Furthermore, reliability verification methods based on numerous rigorous tests are no longer suitable for the efficiency and cost requirements of rapid iteration of electromechanical systems in the design process of modern new proportional directional control valves. Therefore, a new method for rapid reliability verification suitable for proportional directional control valves is needed.

[0025] To overcome the above problems, one object of the present invention is to provide a rapid reliability verification system for a proportional directional control valve, comprising: A functional unit database, which stores information on functional groups involved in the entire process of designing and pilot-producing proportional directional control valves; and, Performance test database: The performance test database is used to store performance parameter information of proportional directional control valves; and, Environmental adaptability test database: The environmental adaptability test database is used to store environmental adaptability parameter information of proportional directional control valves; and, A reliability database, which stores reliability parameter information of proportional directional control valves; A trial production stage database is used to store information on each trial production stage of the proportional directional control valve, and key parameter information for each trial production stage. Each trial production stage information is associated with performance parameters and / or reliability parameters and / or environmental adaptability parameters related to that stage, serving as key parameter information for that stage. The decision module includes a test data acquisition interface. At the end of each trial production stage, the decision module determines whether the preset target has been achieved based on the data input from the test data acquisition interface and the key parameters of the trial production stage. It performs key parameter determination and identifies adverse factors affecting the reliability of the proportional directional control valve. If the key parameters of the trial production stage do not meet the preset target, it returns to the previous trial production stage or the trial production stage that caused the adverse factor.

[0026] In this embodiment, as Figure 1 , Figure 2 As shown, a rapid reliability verification system for proportional directional control valves is used to quickly verify the reliability of proportional directional control valves. The functional unit database refers to dividing the entire process of proportional directional control valve design and reliability verification into multiple functional units, each of which completes different modules. The functional units include a materials processing unit, a structural unit, a system unit, a simulation unit, a performance testing unit, an environmental adaptability testing unit, and a reliability analysis unit. Among them, in each functional unit: The goal of the materials and processes unit is to achieve the selection of materials, selection of material forming processes, formulation of process specifications, and processing and manufacturing of main components for each component of the proportional directional control valve product. The goal of the structural unit is to realize the design of the flow channel of the valve body, the design of the main structure, and the design of the overall structure of the proportional directional control valve. In the process of design and trial production combined with rapid reliability verification, it is also necessary to participate in the identification of adverse structural factors and structural optimization in a timely manner. The goal of the system unit is to achieve valve core control of the proportional directional control valve through motor controller hardware and algorithms. In addition, it is necessary to implement the software and hardware testing, function adjustment and calibration functions of the proportional directional control valve through the host computer. The goal of the simulation unit is to establish a mathematical and physical model and calculate and verify the feasibility of the design scheme. The goal of the performance testing unit is to verify the performance compliance of certain components, parts, or the whole of the proportional directional control valve product using conventional testing methods that meet industry standards. The goal of the environmental adaptability test unit is to verify the performance reliability of proportional directional control valve products under extreme and harsh environments by conducting environmental adaptability tests on proportional directional control valve products under single or a few combined environmental conditions. The purpose of the reliability analysis unit is to complete the formulation of reliability-related evaluation indicators, test design, obtain reliability-related data, and complete the analysis.

[0027] The performance test database, reliability database, and environmental adaptability test database can be the system's knowledge base or standard library, storing the performance parameter information of the proportional directional control valve, specifically including parameter name, standard value range, test method standard, pass / fail criteria, and historical records.

[0028] For example, for the performance parameter of rated flow rate, the standard value range is 5±0.25 L / min, the test method standard is GBT 35023-2018 Reliability Assessment Method for Hydraulic Components, and the pass / fail criteria record the range of pass / fail judgment for this performance parameter.

[0029] The database for the trial production phase is the core of the system, used to store specific steps in the design and reliability verification process of proportional directional control valves.

[0030] Specific reference Figure 2 The trial production stage is divided into: SP1: Material performance verification stage. In this stage, the material process unit completes the material and process selection for the proportional directional control valve body, valve sleeve, valve core, end cap, bushing, bracket, and outer shell; the performance testing unit completes the physical and chemical performance testing of the formed material; and then determines whether the material performance meets the requirements.

[0031] In practical implementation, the valve body, valve sleeve, end cap, bracket, and outer shell are typically made of high-strength aluminum alloy (such as 2A12-T4) or martensitic stainless steel (such as 1Cr17Ni2). Performance requirements are: tensile strength ≥ 450 MPa, yield strength ≥ 290 MPa, and hardness ≥ HB 120. Corrosion resistance is required to pass a 48-hour neutral salt spray test (NSS) with a rating ≥ 9 (no corrosion of the base metal).

[0032] Valve core and bushing: As critical friction pairs, they require extremely high hardness, wear resistance, and dimensional stability. They are typically made of 17-4PH (05Cr17Ni4Cu4Nb) precipitation-hardening stainless steel. Performance requirements are: hardness HRC 40-45 after heat treatment; radial dimensional accuracy IT5 grade; roundness ≤ 2μm; surface roughness Ra ≤ 0.2μm. Cryogenic treatment is required to stabilize dimensions and eliminate retained austenite.

[0033] SP2: Flow verification stage. In this stage, the structural unit completes the valve body flow channel design, and the simulation unit completes the flow simulation; then it is determined whether the flow rate meets the design requirements.

[0034] In the specific implementation process, the flow simulation uses computational fluid dynamics software, such as ANSYS Fluent or Siemens Star-CCM+, to perform three-dimensional transient flow field simulation.

[0035] Specifically, it includes: Geometric modeling and mesh generation: Obtain accurate 3D models of the valve core and sleeve from structural elements, especially the geometry of the throttling window. Perform high-precision polyhedral mesh generation on the fluid domain, and locally refine the mesh in key areas such as the throttling orifice to ensure that the *y+* value is within the range required by the turbulence model.

[0036] Physical model settings: Fluid medium: defined as hydraulic oil conforming to ISO 4401, with density and viscosity set as temperature-dependent parameters. Turbulence model: Realizable k-ε model or SST k-ω model is selected to accurately capture internal flow and eddies at high Reynolds numbers. Boundary conditions: inlet is set as pressure inlet, outlet as pressure outlet. Dynamic meshing or overlapping meshing is used to simulate valve spool motion.

[0037] Solution and Post-processing: Calculate the flow rate under different valve core displacements (e.g., 0%, 25%, 50%, 75%, 100% opening), generating flow-pressure drop curves and flow gain curves. Post-processing allows observation of cavitation phenomena, velocity distribution, and pressure contour maps in the flow field to optimize flow channel design and avoid localized eddies and energy losses.

[0038] SP3: Pressure resistance simulation verification stage. In this stage, the structural unit completes the design of the main body of the proportional directional control valve, including the valve body, valve core, valve sleeve, end cover, bushing, motor stator, and bracket; the simulation unit completes the pressure resistance simulation of the main structure; and then the simulation results are used to determine whether the pressure resistance meets the design requirements.

[0039] In the actual implementation process, the pressure resistance simulation uses finite element analysis software, such as ANSYS Mechanical or Abaqus, to perform static structural simulation.

[0040] SP4: Pressure resistance test verification stage. In this stage, the main components are manufactured by the materials and processes unit, and then the main structure is tested for pressure resistance by the performance testing unit. In the actual implementation process, the pressure test uses a hydraulic test bench to immerse the specimen in transparent oil to observe the leakage, and slowly applies pressure to 1.5 times the rated pressure and holds the pressure for at least 3 minutes.

[0041] During the pressure holding period, the pressure gauge reading must not show a continuous decrease, and there must be no oil leakage, permanent deformation, or cracking sound on any external surface of the specimen.

[0042] SP5: Environmental adaptability verification stage. In this stage, the structural unit completes the overall structural design of the proportional directional control valve; then the simulation unit performs environmental adaptability simulation; and finally, it is determined whether the environmental adaptability meets the design requirements.

[0043] Each of the SP1-SP5 steps proceeds to the next step only after the preset performance indicators of the previous step have been met. If the preset performance indicators are not met, the cause of the non-compliance is analyzed, the step in which the cause of the non-compliance is identified, and the process returns to the step in which the cause of the non-compliance occurred.

[0044] SP6: Control System Verification Phase. In this phase, the system unit completes the hardware and software design of the control system, the simulation unit performs functional simulation of the hardware and software algorithms, and then determines whether the hardware and software control functions are implemented; then the system unit completes the test bench debugging of the control system; and finally, it determines whether the control system functions normally.

[0045] SP7 will be performed after SP5 and SP6 reach the preset performance targets.

[0046] SP7: Overall Reliability Analysis. In this stage, the materials and processes unit completes the overall component manufacturing, the structural unit completes the overall structural assembly of the control system and proportional directional control valve, and the performance testing unit completes the hydraulic static and dynamic tests. Then, random vibration and sinusoidal vibration tests, accelerated life tests, pressure pulse tests, shock and acceleration tests, high and low temperature storage-operation-high temperature and damp heat tests and rapid temperature change tests, and life tests are carried out in sequence. Finally, the reliability analysis is completed and a conclusion is drawn.

[0047] If the preset performance indicators are not met in steps SP6 and SP7, analyze the reasons for the non-compliance, identify the factors that caused the non-compliance, and return to the point where the non-compliance factors were generated.

[0048] Another objective of this invention is to provide a rapid reliability verification method for a proportional directional control valve, comprising the following steps: S1. Divide the entire process of designing and pilot production of the proportional directional control valve into different functional units according to the design content, analyze the design and pilot production goals that different functional units need to achieve, and break down the goal achievement process into specific steps. S2. Based on the design and trial production stages of different functional units, identify the characteristics and important evaluation indicators of each trial production stage, and then decompose the elements required for reliability verification and insert them into each trial production stage of each function in the design and trial production. S3. After each trial production stage is completed, analyze the results of the corresponding stage, determine the key parameters, and identify the adverse factors affecting the reliability of the proportional directional control valve. S4. If a non-conformity is found in the trial production stage, after analysis, return to the previous trial production stage or the trial production stage that caused the adverse factor, and redesign or re-produce the trial production. S5. After identifying and optimizing adverse factors in real time during the process, complete the overall design and sample production of the proportional directional control valve, and then conduct systematic reliability verification and analysis to confirm whether the proportional directional control valve has reliability in multiple environments.

[0049] Furthermore, in step S1, different functional units are divided according to the characteristics of the proportional directional control valve product, including: material processing unit, structural unit, system unit, simulation unit, performance testing unit, environmental adaptability testing unit, and reliability analysis unit. Among them, in each functional unit: The main objective of the materials and processes unit is to achieve the selection of materials, selection of material forming processes, formulation of process specifications, and processing and manufacturing of main components for each component of the proportional directional control valve product. The main objective of the structural unit is to realize the design of the flow channel of the valve body, the design of the main structure, and the design of the overall structure of the proportional directional control valve. In the process of design and trial production combined with rapid reliability verification, it is also necessary to participate in the identification of adverse factors in the structure and the structural optimization process in a timely manner. The main objective of the system unit is to achieve valve core control of the proportional directional control valve through motor controller hardware and algorithms. In addition, it is necessary to implement the software and hardware testing, function adjustment and calibration functions of the proportional directional control valve through the host computer. The goal of the simulation unit is to establish a mathematical and physical model and calculate and verify the feasibility of the design scheme. The goal of the performance testing unit is to verify the performance compliance of certain components, parts, or the whole of the proportional directional control valve product using conventional testing methods that meet industry standards. The goal of the environmental adaptability test unit is to verify the performance reliability of proportional directional control valve products under extreme and harsh environments by conducting environmental adaptability tests on proportional directional control valve products under single or a few combined environmental conditions. The purpose of the reliability analysis unit is to complete the formulation of reliability-related evaluation indicators, test design, obtain reliability-related data, and complete the analysis.

[0050] Furthermore, in step S2, the characteristics and important evaluation indicators of different trial production stages belong to the key parameters, performance, or performance stability of the proportional directional control valve product under different environmental conditions. Includes one or more of the following key parameters, performance characteristics, or requirements: core material hardness, corrosion resistance, density, tensile strength, elongation, stability in reaction with oil, product envelope, weight, mounting surface, electrical connectors, appearance quality, markings and designations, insulation resistance, electrical strength, leakage current, stator resistance, stator inductance, accidental overcurrent, power input, electrical safety protection, withstand pressure, external leakage, internal leakage, rated flow rate, flow gain, linearity, hysteresis, symmetry, polarity, coverage, threshold, zero bias, pressure gain, zero drift, step response time, frequency response, temperature rise, electromagnetic compatibility, and height loop. Performance under ambient conditions, performance after high-temperature storage, performance during high-temperature operation, performance after extreme low-temperature storage, performance during low-temperature operation, performance during rapid temperature changes at a specified transition time, performance during temperature changes at a specified rate of change, performance after acceleration, performance after random vibration, performance after sinusoidal vibration, performance after sinusoidal superimposed random vibration, performance after random vibration during transportation, performance after impact, performance after free fall, performance under constant humid and hot conditions, performance under alternating humid and hot conditions, influence of mold environment, influence of salt spray environment, influence of sand and dust environment, fluid sensitivity, enclosure protection rating, performance after pressure pulse, lifespan, burst pressure.

[0051] Furthermore, in steps S2 and S3, the elements required for reliability verification and the method for identifying verification results have the following characteristics: The elements required for reliability verification are generally the key parameters, performance, or targeted verification methods for the performance stability of proportional directional control valve products under different environmental conditions, mainly including simulation, testing, and experimentation. Based on the parameters obtained from the verification, adverse factors affecting reliability can be identified. Adverse factors refer to factors that affect the normal operation of proportional directional control valve products under normal conditions and possible abnormal conditions, without unacceptable performance degradation or failure.

[0052] Furthermore, in step S4, the degree of adverse factors is analyzed. If the adverse factor occurs by chance, retesting or further experiments are required. If it is confirmed that the adverse factor is a common factor and will appear in a product batch at a rate higher than 1%, then a non-conformity is determined, and the initial stage of the non-conformity is analyzed. The process is then returned to the trial production stage where the initial adverse factor was identified.

[0053] Furthermore, in step S5, after the reliability analysis and optimization of the process are completed, step S5 performs a systematic reliability verification of the proportional directional control valve product as a whole. The method for systematic reliability verification is as follows: First, we need to confirm the core performance of the product, including the confirmation of hydraulic static and dynamic performance. We will conduct tests using a hydraulic servo test bench, following the test method for a four-way flow valve. After the hydraulic static and dynamic performance meets the requirements, the most stringent random vibration and sinusoidal vibration tests are carried out to test the overall mechanical integrity of the proportional directional control valve product. After the vibration test, the hydraulic static and dynamic performance is retested. Then, accelerated life testing is conducted to test the long-term operational stability of the proportional directional control valve under harsh conditions, and to quickly expose any material, structural, and control system problems that still exist after process reliability verification. For the problems exposed at this stage, it is analyzed whether they are due to errors in process reliability verification or are caused by a combination of factors that will only be exposed during the overall proportional directional control valve product testing. If it is the latter, then after problem analysis and optimization, the accelerated life test is repeated. The pressure pulse test, the remaining mechanical environmental adaptability test, the climate environmental adaptability test, and the life test are carried out in sequence, and then a reliability analysis is performed to draw conclusions.

[0054] Furthermore, the reliability analysis includes qualitative and quantitative methods, and the methods used include one or more of the following: failure mode and effects analysis, fault tree analysis, hazard and operability analysis, reliability prediction, reliability block diagram, Markov analysis method, and Weibull analysis.

[0055] In various embodiments of the present invention, it should be understood that the sequence number of each process does not necessarily imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0056] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutively indicated blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It is particularly important to note that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, can be implemented using a dedicated hardware-based system that performs the specified function or operation, or using a combination of dedicated hardware and computer instructions.

[0057] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

[0058] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A rapid reliability verification system for a proportional directional control valve, characterized in that, include: A functional unit database, which stores information about functional groups involved in the entire process of designing and pilot-producing proportional directional control valves; as well as, Performance test database: The performance test database is used to store performance parameter information of proportional directional control valves; as well as, Environmental adaptability test database: The environmental adaptability test database is used to store environmental adaptability parameter information of proportional directional control valves; and, A reliability database, which stores reliability parameter information of proportional directional control valves; The trial production stage database is used to store information on each trial production stage of the proportional directional control valve and key parameter information for each trial production stage. The information on each trial production stage is associated with the performance parameter information and / or reliability parameter information and / or environmental adaptability parameter information involved in that trial production stage, which serves as the key parameter information for that trial production stage. as well as, Decision module, which includes a test data acquisition interface; The decision module is used to determine whether the preset target has been achieved at the end of each trial production stage, based on the data input from the test data acquisition interface and the key parameters of that trial production stage. It performs key parameter determination and identifies adverse factors affecting the reliability of the proportional directional control valve. If the key parameters of the trial production stage do not meet the preset target, it returns to the previous trial production stage or the trial production stage that caused the adverse factor.

2. The rapid reliability verification system for a proportional directional control valve according to claim 1, characterized in that, The functional units include a materials processing unit, a structural unit, a system unit, a simulation unit, a performance testing unit, an environmental adaptability testing unit, and a reliability analysis unit. Among them, in each functional unit: The goal of the materials and processes unit is to achieve the selection of materials, selection of material forming processes, formulation of process specifications, and processing and manufacturing of main components for each component of the proportional directional control valve product. The goal of the structural unit is to realize the design of the flow channel of the valve body, the design of the main structure, and the design of the overall structure of the proportional directional control valve. In the process of design and trial production combined with rapid reliability verification, it is also necessary to participate in the identification of adverse structural factors and structural optimization in a timely manner. The goal of the system unit is to achieve valve core control of the proportional directional control valve through motor controller hardware and algorithms. In addition, it is necessary to implement the software and hardware testing, function adjustment and calibration functions of the proportional directional control valve through the host computer. The goal of the simulation unit is to establish a mathematical and physical model and calculate and verify the feasibility of the design scheme. The goal of the performance testing unit is to verify the performance compliance of certain components, parts, or the whole of the proportional directional control valve product using conventional testing methods that meet industry standards. The goal of the environmental adaptability test unit is to verify the performance reliability of proportional directional control valve products under extreme and harsh environments by conducting environmental adaptability tests on proportional directional control valve products under single or a few combined environmental conditions. The purpose of the reliability analysis unit is to complete the formulation of reliability-related evaluation indicators, test design, obtain reliability-related data, and complete the analysis.

3. A rapid reliability verification method for a proportional directional control valve, characterized in that, Includes the following steps: S1. Divide the entire process of designing and pilot production of the proportional directional control valve into different functional units according to the design content, analyze the design and pilot production goals that different functional units need to achieve, and break down the goal achievement process into specific steps. S2. Based on the design and trial production stages of different functional units, identify the characteristics and important evaluation indicators of each trial production stage, and then decompose the elements required for reliability verification and insert them into each trial production stage of each function in the design and trial production. S3. After each trial production stage is completed, analyze the results of the corresponding stage, determine the key parameters, and identify the adverse factors affecting the reliability of the proportional directional control valve. S4. If a non-conformity is found in the trial production stage, after analysis, return to the previous trial production stage or the trial production stage that caused the adverse factor, and redesign or re-produce the trial production. S5. After identifying and optimizing adverse factors in real time during the process, complete the overall design and sample production of the proportional directional control valve, and then conduct systematic reliability verification and analysis to confirm whether the proportional directional control valve has reliability in multiple environments.

4. The rapid reliability verification method for a proportional directional control valve according to claim 3, characterized in that: In step S1, different functional units are divided according to the characteristics of the proportional directional control valve product, including: material processing unit, structural unit, system unit, simulation unit, performance testing unit, environmental adaptability testing unit, and reliability analysis unit. Among them, in each functional unit: The main objective of the materials and processes unit is to achieve the selection of materials, selection of material forming processes, formulation of process specifications, and processing and manufacturing of main components for each component of the proportional directional control valve product. The main objective of the structural unit is to realize the design of the flow channel of the valve body, the design of the main structure, and the design of the overall structure of the proportional directional control valve. In the process of design and trial production combined with rapid reliability verification, it is also necessary to participate in the identification of adverse factors in the structure and the structural optimization process in a timely manner. The main objective of the system unit is to achieve valve core control of the proportional directional control valve through motor controller hardware and algorithms. In addition, it is necessary to implement the software and hardware testing, function adjustment and calibration functions of the proportional directional control valve through the host computer. The goal of the simulation unit is to establish a mathematical and physical model and calculate and verify the feasibility of the design scheme. The goal of the performance testing unit is to verify the performance compliance of certain components, parts, or the whole of the proportional directional control valve product using conventional testing methods that meet industry standards. The goal of the environmental adaptability test unit is to verify the performance reliability of proportional directional control valve products under extreme and harsh environments by conducting environmental adaptability tests on proportional directional control valve products under single or a few combined environmental conditions. The purpose of the reliability analysis unit is to complete the formulation of reliability-related evaluation indicators, test design, obtain reliability-related data, and complete the analysis.

5. The rapid reliability verification method for a proportional directional control valve according to claim 3, characterized in that: In step S2, the characteristics and important evaluation indicators of different trial production stages are key parameters, performance, or performance stability of proportional directional control valve products under different environmental conditions. Includes one or more of the following key parameters, performance characteristics, or requirements: core material hardness, corrosion resistance, density, tensile strength, elongation, stability in reaction with oil, product envelope, weight, mounting surface, electrical connectors, appearance quality, markings and designations, insulation resistance, electrical strength, leakage current, stator resistance, stator inductance, accidental overcurrent, power input, electrical safety protection, withstand pressure, external leakage, internal leakage, rated flow rate, flow gain, linearity, hysteresis, symmetry, polarity, coverage, threshold, zero bias, pressure gain, zero drift, step response time, frequency response, temperature rise, electromagnetic compatibility, and height loop. Performance under ambient conditions, performance after high-temperature storage, performance during high-temperature operation, performance after extreme low-temperature storage, performance during low-temperature operation, performance during rapid temperature changes at a specified transition time, performance during temperature changes at a specified rate of change, performance after acceleration, performance after random vibration, performance after sinusoidal vibration, performance after sinusoidal superimposed random vibration, performance after random vibration during transportation, performance after impact, performance after free fall, performance under constant humid and hot conditions, performance under alternating humid and hot conditions, influence of mold environment, influence of salt spray environment, influence of sand and dust environment, fluid sensitivity, enclosure protection rating, performance after pressure pulse, lifespan, burst pressure.

6. The rapid reliability verification method for a proportional directional control valve according to claim 3, characterized in that: In steps S2 and S3, the elements required for reliability verification and the method for identifying verification results have the following characteristics: The elements required for reliability verification are generally the key parameters, performance, or targeted verification methods for the performance stability of proportional directional control valve products under different environmental conditions, mainly including simulation, testing, and experimentation. Based on the parameters obtained from the verification, adverse factors affecting reliability can be identified. Adverse factors refer to factors that affect the normal operation of proportional directional control valve products under normal conditions and possible abnormal conditions, without unacceptable performance degradation or failure.

7. The rapid reliability verification method for a proportional directional control valve according to claim 3, characterized in that: In step S4, the degree of adverse factors is analyzed. If the adverse factor occurs by chance, retesting or further experiments are required. If the adverse factor is confirmed to be a common factor and will appear in a product batch at a rate higher than 1%, then a non-conformity is determined, and the initial stage of the non-conformity is analyzed. The process is then returned to the trial production stage where the initial adverse factor was identified.

8. The rapid reliability verification method for a proportional directional control valve according to claim 3, characterized in that: In step S5, after the reliability analysis and optimization of the process are completed, step S5 performs a systematic reliability verification of the proportional directional control valve product as a whole. The method for systematic reliability verification is as follows: First, we need to confirm the core performance of the product, including the confirmation of hydraulic static and dynamic performance. We will conduct tests using a hydraulic servo test bench, following the test method for a four-way flow valve. After the hydraulic static and dynamic performance meets the requirements, the most stringent random vibration and sinusoidal vibration tests are carried out to test the overall mechanical integrity of the proportional directional control valve product. After the vibration test, the hydraulic static and dynamic performance is retested. Then, accelerated life testing is conducted to test the long-term operational stability of the proportional directional control valve under harsh conditions, and to quickly expose any material, structural, and control system problems that still exist after process reliability verification. For the problems exposed at this stage, it is analyzed whether they are due to errors in process reliability verification or are caused by a combination of factors that will only be exposed during the overall proportional directional control valve product testing. If it is the latter, then after problem analysis and optimization, the accelerated life test is repeated. The pressure pulse test, the remaining mechanical environmental adaptability test, the climate environmental adaptability test, and the life test are carried out in sequence, and then a reliability analysis is performed to draw conclusions.

9. The rapid reliability verification method for a proportional directional control valve according to claim 8, characterized in that: The reliability analysis includes qualitative and quantitative methods, and the methods used include one or more of the following: failure mode and effects analysis, fault tree analysis, hazard and operability analysis, reliability prediction, reliability block diagram, Markov analysis method and Weibull analysis.

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