Main pump fault diagnosis method and system based on pressure detection

Abstract

The invention discloses a main pump fault diagnosis method and system based on pressure detection, and belongs to the technical field of hydraulic system fault diagnos.The method comprises the steps that under multiple preset rotating speeds of a main pump, real-time pressure data of a hydraulic system under different working modes and different load conditions are collected; comparing the collected real-time pressure data with pre-stored factory reference data, wherein the factory reference data is a system pressure value or a main pump pressure value measured under the same rotating speed, the same electromagnetic valve control current and the same working mode; and the difference percentage between the real-time pressure data and the factory standard data is calculated, and if the difference percentage exceeds a preset fault judgment threshold value, it is judged that the performance of the main pump is abnormal. According to the method, performance degradation of the main pump caused by abrasion, clamping stagnation or internal leakage can be effectively recognized, early warning and accurate positioning of faults are achieved, and the automation level and reliability of fault diagnosis of the hydraulic system are remarkably improved.

Description

Technical Field

[0001] This invention relates to a method and system for diagnosing main pump faults based on pressure detection, belonging to the field of hydraulic system fault diagnosis technology. Background Technology

[0002] The hydraulic main pump is the core power component of a hydraulic system, and its health directly affects the reliability of the entire system. Traditional fault diagnosis methods often rely on experience-based judgment, which suffers from low accuracy and inability to provide early warnings. This is especially challenging in dual-pump systems where accurately locating the fault source is even more difficult. Therefore, a quantitative diagnostic method based on comparing multi-condition test data with factory baseline data is needed. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a main pump fault diagnosis method and system based on pressure detection. This method and system can effectively identify the performance degradation of the main pump caused by wear, jamming or internal leakage, realize early warning and accurate location of faults, and significantly improve the automation level and reliability of hydraulic system fault diagnosis.

[0004] To achieve the above objectives, the present invention is implemented using the following technical solution: In a first aspect, the present invention provides a main pump fault diagnosis method based on pressure detection, comprising: At multiple preset speeds of the main pump, real-time pressure data of the hydraulic system under different working modes and different load conditions are collected. The real-time pressure data includes system pressure values ​​or main pump pressure values ​​corresponding to different solenoid valve current values. The collected real-time pressure data is compared with the pre-stored factory reference data, which is the system pressure value or main pump pressure value measured under the same speed, the same solenoid valve control current and the same working mode. Calculate the percentage difference between the real-time pressure data and the factory baseline data. If the percentage difference exceeds a preset fault determination threshold, the main pump is determined to have a performance abnormality.

[0005] Furthermore, the operating mode includes at least one of the following: dual-pump combined operating mode, front pump independent operating mode, and rear pump independent operating mode.

[0006] Furthermore, the acquisition of real-time pressure data of the hydraulic system under different operating modes and load conditions includes: Control the solenoid valve to raise the system pressure to its maximum, and record the maximum control current of the solenoid valve and the corresponding system pressure value. During the system pressurization process, record the system pressure value or main pump pressure value corresponding to different solenoid valve control current values; Under different load conditions of the system, record the system pressure value or the main pump pressure value corresponding to the set solenoid valve control current.

[0007] Furthermore, when determining whether there is a performance abnormality in the main pump, a main pump performance decay threshold A% and a main pump performance abnormality threshold B% are set, where A < B; when the difference percentage exceeds A% but does not exceed B%, it is determined that the main pump performance decays and a warning is given; when the difference percentage exceeds B%, it is determined that the main pump performance is abnormal and a fault alarm is given.

[0008] Furthermore, the comparison of the collected real-time pressure data with the pre-stored factory reference data includes: At each rotational speed, put the dual-pump system in a pressure-holding state, obtain the system pressure value corresponding to the maximum solenoid valve current, and compare it with the factory main pump pressure reference value; At each rotational speed, put the dual-pump system in a pressure-holding state, obtain the main pump pressure values corresponding to different solenoid valve current values, and compare them with the factory main pump pressure reference value; At each rotational speed and under different loads, obtain the main pump pressure values corresponding to the dual-pump solenoid valve current, and compare them with the factory main pump pressure reference value; For the front pump system, at each rotational speed, obtain the system pressure value corresponding to the maximum solenoid valve current of the front pump, and compare it with the factory main pump pressure reference value; For the front pump system, at each rotational speed, obtain the main pump pressure values corresponding to different solenoid valve current values of the front pump, and compare them with the factory main pump pressure reference value; For the front pump system, at each rotational speed, obtain the main pump pressure values corresponding to the dual-pump solenoid valve current, and compare them with the factory main pump pressure reference value; For the rear pump system, at each rotational speed, obtain the system pressure value corresponding to the maximum solenoid valve current of the rear pump, and compare it with the factory main pump pressure reference value; For the rear pump system, at each rotational speed, obtain the main pump pressure values corresponding to different solenoid valve current values of the rear pump, and compare them with the factory main pump pressure reference value; For the rear pump system, at each rotational speed, obtain the main pump pressure values corresponding to the dual-pump solenoid valve current, and compare them with the factory main pump pressure reference value; At each rotational speed and under different loads, obtain the pressure difference corresponding to each solenoid valve current of the front and rear pumps, and compare the pressure difference with the factory pressure difference reference value.

[0009] In a second aspect, the present invention provides a main pump fault diagnosis system based on pressure detection for implementing any one of the前述 based on pressure detection main pump fault diagnosis methods, and the system includes: The data acquisition module is used to acquire real-time pressure data of the hydraulic system under different working modes and different load conditions at multiple preset speeds of the main pump. The real-time pressure data includes system pressure values ​​or main pump pressure values ​​corresponding to different solenoid valve current values. The comparison module is used to compare the collected real-time pressure data with the pre-stored factory reference data, which is the system pressure value or main pump pressure value measured under the same speed, the same solenoid valve control current and the same working mode. The data processing and fault diagnosis module is used to calculate the percentage difference between the real-time pressure data and the factory reference data. If the percentage difference exceeds a preset fault judgment threshold, the main pump is determined to have a performance abnormality.

[0010] Furthermore, the data acquisition module is used to perform at least one of the following test modes: voltage saturation test, variable current test, and variable load test.

[0011] Furthermore, the data processing and fault diagnosis module is configured to perform graded alarms based on the main pump performance degradation threshold A% and the performance abnormality threshold B%.

[0012] Furthermore, it also includes a human-computer interaction module, used to receive user commands to initiate diagnosis and display the diagnostic results generated by the fault diagnosis module.

[0013] Furthermore, the human-machine interaction module is integrated into the control instrument of the hydraulic equipment, providing a main pump performance detection function option for users to choose to enable after power-on.

[0014] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: This invention provides a main pump fault diagnosis method and system based on pressure detection. By systematically collecting pressure data under multiple operating conditions and comparing it with high-precision factory reference data, it can effectively identify the performance degradation of the main pump caused by wear, jamming or internal leakage, realize early warning and accurate location of faults (specifically to the front pump or the rear pump), and significantly improve the automation level and reliability of hydraulic system fault diagnosis. Attached Figure Description

[0015] Figure 1 This is a flowchart of a main pump fault diagnosis method based on pressure detection provided in an embodiment of the present invention. Detailed Implementation

[0016] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0017] Example 1: This example introduces a main pump fault diagnosis method based on pressure detection, including: At multiple preset speeds of the main pump, real-time pressure data of the hydraulic system under different working modes and different load conditions are collected. The real-time pressure data includes system pressure values ​​or main pump pressure values ​​corresponding to different solenoid valve current values. The collected real-time pressure data is compared with the pre-stored factory reference data, which is the system pressure value or main pump pressure value measured under the same speed, the same solenoid valve control current and the same working mode. Calculate the percentage difference between the real-time pressure data and the factory baseline data. If the percentage difference exceeds a preset fault determination threshold, the main pump is determined to have a performance abnormality.

[0018] like Figure 1 As shown in the figure, the main pump fault diagnosis method based on pressure detection provided in this embodiment involves the following steps in its application process: 1. Data acquisition steps: Under multiple preset speeds, acquire system pressure values ​​and solenoid valve control current values ​​of the hydraulic system under different working modes (including dual pumps working together, front pump working alone, and rear pump working alone) and different load conditions. 2. Benchmark Comparison Step: Compare the real-time pressure data collected in step 1 with the pre-stored corresponding factory benchmark data; the factory benchmark data includes system pressure values ​​or main pump pressure values ​​measured under the same rotational speed, the same solenoid valve current, and the same operating mode. 3. Fault determination steps: Calculate the percentage difference between real-time data and factory baseline data. If the percentage exceeds the preset threshold, it is determined that the main pump has a jamming or leakage fault.

[0019] In a further embodiment, the operating modes include: Pressure hold test mode: Control the solenoid valve to raise the system pressure to the maximum, and record the maximum current and the corresponding system pressure; Variable current test mode: During the system pressure build-up process, record the system pressure or main pump pressure corresponding to different solenoid valve current values; Variable load test mode: Record the system pressure or main pump pressure corresponding to a specific solenoid valve current under different system load conditions.

[0020] The safety threshold for main pump deviation is set as A%, and the main pump performance degradation threshold is set as B%. Fault diagnosis is specifically performed using one or more of the following methods in combination: Method 1: At each speed, put the dual-pump system in a pressurized state, obtain the system pressure value corresponding to the maximum current of the solenoid valve, compare the pressure value with the factory-set main pump pressure reference value, if the difference exceeds the threshold A%, it indicates that the main pump performance has degraded, and if it exceeds B%, it indicates that the main pump performance is abnormal. Method 2: At various speeds, the dual-pump system is put into a pressurized state, and the main pump pressure value corresponding to different solenoid valve current values ​​is obtained. The pressure value is compared with the factory main pump pressure reference value. If the difference exceeds the threshold A%, it indicates that the main pump performance has degraded. If it exceeds B%, it indicates that the main pump performance is abnormal. Method 3: Under different speeds and loads, obtain the main pump pressure value corresponding to the dual-pump solenoid valve current, compare the pressure value with the factory-set main pump pressure reference value, and if the difference exceeds the threshold A%, it indicates that the main pump performance has degraded, and if it exceeds B%, it indicates that the main pump performance is abnormal. Method 4: For the front pump system, at each speed, obtain the system pressure value corresponding to the maximum current of the front pump solenoid valve, compare the pressure value with the factory main pump pressure reference value, if the difference exceeds the threshold A%, it indicates that the main pump performance has degraded, and if it exceeds B%, it indicates that the main pump performance is abnormal. Method 5: For the front pump system, at each speed, obtain the main pump pressure value corresponding to different solenoid valve current values ​​of the front pump, compare the pressure value with the factory main pump pressure reference value, and if the difference exceeds the threshold A%, it indicates that the main pump performance has degraded, and if it exceeds B%, it indicates that the main pump performance is abnormal. Method 6: For the front pump system, at each speed, obtain the main pump pressure value corresponding to the dual pump solenoid valve current, compare the pressure value with the factory main pump pressure reference value, if the difference exceeds the threshold A%, it indicates that the main pump performance has degraded, and if it exceeds B%, it indicates that the main pump performance is abnormal. Method 7: For the rear pump system, at each speed, obtain the system pressure value corresponding to the maximum current of the front pump solenoid valve, compare the pressure value with the factory main pump pressure reference value, if the difference exceeds the threshold A%, it indicates that the main pump performance has degraded, and if it exceeds B%, it indicates that the main pump performance is abnormal. Method 8: For the rear pump system, at each speed, obtain the main pump pressure value corresponding to different solenoid valve current values ​​of the front pump, compare the pressure value with the factory main pump pressure reference value, and if the difference exceeds the threshold A%, it indicates that the main pump performance has degraded, and if it exceeds B%, it indicates that the main pump performance is abnormal. Method 9: For the rear pump system, at each speed, obtain the main pump pressure value corresponding to the current of the dual pump solenoid valve, compare the pressure value with the factory main pump pressure reference value, if the difference exceeds the threshold A%, it indicates that the main pump performance has degraded, and if it exceeds B%, it indicates that the main pump performance is abnormal. Method 10: Under various speeds and loads, obtain the pressure difference between the front and rear pumps at each solenoid valve current. Compare this difference with the factory pressure difference benchmark value. If the difference exceeds the threshold A%, it indicates that the main pump performance has degraded; if it exceeds B%, it indicates that the main pump performance is abnormal.

[0021] If the main pump exhibits one or a combination of the above phenomena, it is determined that the main pump is faulty.

[0022] This embodiment systematically collects pressure data under multiple operating conditions and compares it with high-precision factory reference data. It can effectively identify the performance degradation of the main pump caused by wear, jamming or internal leakage, realize early warning and accurate location of faults (specifically the front pump or the rear pump), and significantly improve the automation level and reliability of hydraulic system fault diagnosis.

[0023] Example 2: This example provides a main pump fault diagnosis system based on pressure detection, used to implement any of the main pump fault diagnosis methods based on pressure detection described in Example 1. The system includes: The data acquisition module is used to acquire real-time pressure data of the hydraulic system under different working modes and different load conditions at multiple preset speeds of the main pump. The real-time pressure data includes system pressure values ​​or main pump pressure values ​​corresponding to different solenoid valve current values. The comparison module is used to compare the collected real-time pressure data with the pre-stored factory reference data, which is the system pressure value or main pump pressure value measured under the same speed, the same solenoid valve control current and the same working mode. The data processing and fault diagnosis module is used to calculate the percentage difference between the real-time pressure data and the factory reference data. If the percentage difference exceeds a preset fault judgment threshold, the main pump is determined to have a performance abnormality.

[0024] The data acquisition module is used to perform at least one of the following test modes: voltage saturation test, variable current test, and variable load test.

[0025] The data processing and fault diagnosis module is configured to perform graded alarms based on the main pump performance degradation threshold A% and the performance abnormality threshold B%.

[0026] It also includes a human-computer interaction module, which is used to receive user commands to initiate diagnosis and display the diagnostic results generated by the fault diagnosis module.

[0027] The human-machine interface module is integrated into the control instrument of the hydraulic equipment, providing a main pump performance detection function option for users to choose to enable after power-on.

[0028] The specific functions of each module described above are explained in the relevant content of the method in Embodiment 1, and will not be repeated here.

[0029] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

[0030] Those skilled in the art will understand that embodiments of this disclosure can be provided as methods, systems, or computer program products. Therefore, this disclosure can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this disclosure can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0031] This disclosure is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this disclosure. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create a machine for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0032] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0033] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0034] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this disclosure and not to limit its protection scope. Although this disclosure has been described in detail with reference to the above embodiments, those skilled in the art should understand that after reading this disclosure, they can still make various changes, modifications or equivalent substitutions to the specific implementation of the invention, but these changes, modifications or equivalent substitutions are all within the protection scope of the pending claims.

Claims

1. A method for diagnosing main pump faults based on pressure detection, characterized in that, Including: Collect real-time pressure data of the hydraulic system under different working modes and different load conditions at multiple preset speeds of the main pump. The real-time pressure data includes the system pressure value or the main pump pressure value corresponding to different solenoid valve current values; Compare the collected real-time pressure data with the pre-stored factory reference data, where the factory reference data is the system pressure value or the main pump pressure value measured under the same speed, the same solenoid valve control current, and the same working mode; Calculate the percentage difference between the real-time pressure data and the factory reference data. If the percentage difference exceeds the preset fault determination threshold, it is determined that the main pump has performance anomalies.

2. The main pump fault diagnosis method based on pressure detection according to claim 1, characterized in that, The working mode includes at least one of the dual-pump combined working mode, the front pump single working mode, and the rear pump single working mode.

3. The main pump fault diagnosis method based on pressure detection according to claim 1, characterized in that, The collection of real-time pressure data of the hydraulic system under different working modes and different load conditions includes: Control the solenoid valve to raise the system pressure to the maximum, record the maximum control current of the solenoid valve and the corresponding system pressure value; During the system pressure holding process, record the system pressure value or the main pump pressure value corresponding to different solenoid valve control current values; Under different load states of the system, record the system pressure value or the main pump pressure value corresponding to the set solenoid valve control current.

4. The main pump fault diagnosis method based on pressure detection according to claim 1, characterized in that, When determining whether the main pump has performance anomalies, a main pump performance decay threshold A% and a main pump performance anomaly threshold B% are set, where A < B; when the percentage difference exceeds A% but does not exceed B%, it is determined that the main pump performance decays and a warning is given; when the percentage difference exceeds B%, it is determined that the main pump has performance anomalies and a fault alarm is given.

5. The main pump fault diagnosis method based on pressure detection according to claim 2, characterized in that, The comparison of the collected real-time pressure data with the pre-stored factory reference data includes: At each speed, make the dual-pump system in a pressure holding state, obtain the system pressure value corresponding to the maximum current of the solenoid valve, and compare it with the factory main pump pressure reference value; At each speed, make the dual-pump system in a pressure holding state, obtain the main pump pressure values corresponding to different solenoid valve current values, and compare them with the factory main pump pressure reference value; At each speed and under different loads, obtain the main pump pressure values corresponding to the dual-pump solenoid valve current, and compare them with the factory main pump pressure reference value; For the front pump system, at each speed, obtain the system pressure value corresponding to the maximum current of the front pump solenoid valve, and compare it with the factory main pump pressure reference value; For the front pump system, at each speed, obtain the main pump pressure values corresponding to different solenoid valve current values of the front pump, and compare them with the factory main pump pressure reference value; For the front pump system, at each speed, obtain the main pump pressure values corresponding to the dual-pump solenoid valve current, and compare them with the factory main pump pressure reference value; For the rear pump system, at each speed, obtain the system pressure value corresponding to the maximum current of the rear pump solenoid valve, and compare it with the factory main pump pressure reference value; For the rear pump system, at each speed, obtain the main pump pressure values corresponding to different solenoid valve current values of the rear pump, and compare them with the factory main pump pressure reference value; For the rear pump system, at each speed, obtain the main pump pressure values corresponding to the dual-pump solenoid valve current, and compare them with the factory main pump pressure reference value; Under various speeds and loads, the pressure difference between the front and rear pumps at each solenoid valve current is obtained, and the pressure difference is compared with the factory pressure difference benchmark value.

6. A main pump fault diagnosis system based on pressure detection, used to implement the main pump fault diagnosis method based on pressure detection as described in any one of claims 1-5, characterized in that, The system includes: The data acquisition module is used to acquire real-time pressure data of the hydraulic system under different working modes and different load conditions at multiple preset speeds of the main pump. The real-time pressure data includes system pressure values ​​or main pump pressure values ​​corresponding to different solenoid valve current values. The comparison module is used to compare the collected real-time pressure data with the pre-stored factory reference data, which is the system pressure value or main pump pressure value measured under the same speed, the same solenoid valve control current and the same working mode. The data processing and fault diagnosis module is used to calculate the percentage difference between the real-time pressure data and the factory reference data. If the percentage difference exceeds a preset fault judgment threshold, the main pump is determined to have a performance abnormality.

7. The main pump fault diagnosis system based on pressure detection according to claim 6, characterized in that, The data acquisition module is used to perform at least one of the following test modes: voltage saturation test, variable current test, and variable load test.

8. The main pump fault diagnosis system based on pressure detection according to claim 6, characterized in that, The data processing and fault diagnosis module is configured to perform graded alarms based on the main pump performance degradation threshold A% and the performance abnormality threshold B%.

9. The main pump fault diagnosis system based on pressure detection according to claim 6, characterized in that, It also includes a human-computer interaction module, which is used to receive user commands to initiate diagnosis and display the diagnostic results generated by the fault diagnosis module.

10. The main pump fault diagnosis system based on pressure detection according to claim 9, characterized in that, The human-machine interface module is integrated into the control instrument of the hydraulic equipment, providing a main pump performance detection function option for users to choose to enable after power-on.

Images