Dual-redundancy servo system capable of automatically switching and control method

Abstract

The invention is suitable for the field of servo control equipment, and provides a dual-redundancy servo system capable of automatically switching and a control method. In the embodiment of the invention, a control center monitors a valve core position feedback signal of a servo valve in a main servo assembly in a connected state in real time, compares the signal with a received control instruction, and adjusts a sub-servo assembly in a cut-off state to be in a connected state when determining that a comparison result of the signal and the received control instruction triggers a servo assembly switching condition; and the main servo assembly is adjusted to be in a cut-off state, so that logic switching between the main servo assembly and the sub-servo assemblies is realized. And then the switched main servo assembly is monitored in real time, and switching is performed again when the switching condition is determined to be triggered again, so that automatic switching among the servo assemblies is realized, and maintenance can be performed without shutdown when a certain servo assembly fails. The problem that shutdown loss and maintenance cost are increased due to the fact that a host needs to be shut down during fault maintenance of an existing servo control system is solved.

Description

Technical Field

[0001] This application relates to the field of servo control equipment technology, and in particular to an automatically switching dual-redundant servo system and control method. Background Technology

[0002] Traditional servo control systems typically employ a single servo valve structure, with dual parallel servo valve architectures used only in critical application scenarios. During operation, such systems rely on manual fault detection and switching operations. Failure to detect faults in a timely manner will directly lead to the shutdown of the host machine for troubleshooting and handling.

[0003] In a typical single-system setup, continuous operation of the host cannot be guaranteed when the servo valve becomes blocked or experiences abnormal feedback. Traditional redundant systems require manual judgment and switching, which can lead to hydraulic fluctuations, causing the host to trip or become unstable. Furthermore, traditional redundant systems typically lack the maintenance capability to replace faulty valves without shutting down the system. Fault repair requires the host to be shut down, significantly increasing downtime losses and maintenance costs. Moreover, they usually do not support the removal and repair of faulty valves without shutting down the system. Summary of the Invention

[0004] In view of this, this application provides an automatically switchable dual-redundant servo system and control method to solve the problem that the host machine needs to be shut down when the existing servo control system is repaired due to failure, thereby increasing downtime losses and maintenance costs.

[0005] The first aspect of this application provides an automatically switchable dual-redundant servo control method applied to the control center of a dual-redundant servo control system. The system includes several servo components composed of servo valves and isolation valves. Each servo component includes a main servo component in a connected state and several sub-servo components in a disconnected state. The method includes: Receive control commands sent by the host computer and monitor the valve core position feedback signal of the servo valve in the main servo component in real time; When the switching conditions for the servo component are determined by the control command and the valve core position feedback signal, the target sub-servo component is identified from the sub-servo components, the main servo component is disconnected, and the target sub-servo component is connected to switch the target sub-servo component to the main servo component. The valve core position feedback signal of the servo valve in the switched main servo component is compared with the control command in real time until the servo valve switching condition is triggered, at which point the servo component is switched again.

[0006] Optionally, the servo component further includes manual valves, respectively disposed on both sides of the servo valve and the isolation valve, and the method further includes: When a maintenance isolation command is received, the target servo valve or target isolation valve that needs to be maintained is determined through the maintenance isolation command. After determination, the target servo valve or target isolation valve is isolated through the manual valves on both sides.

[0007] Optionally, determining the switching conditions for the servo component through the control command and valve core position feedback signal includes: The deviation between the position indicated in the control command and the valve core position in the valve core position feedback signal is determined by the control command and the valve core position feedback signal. The deviation value is compared with a preset deviation threshold, and the servo component switching condition is determined when the deviation value is greater than the deviation threshold.

[0008] Optionally, a pressure sensor or flow meter is also installed at the output of the servo valve, and the determination of the switching conditions for the servo component through the control command and the valve core position feedback signal includes: The deviation between the position indicated in the control command and the valve core position in the valve core position feedback signal is determined by the control command and the valve core position feedback signal, and the corresponding pressure value or flow value is determined by the pressure sensor or flow meter. When the deviation value is greater than a preset deviation threshold, or the pressure value is greater than a preset pressure threshold, or the flow rate value is greater than a preset flow rate threshold, the servo component switching condition is determined to be triggered.

[0009] A second aspect of this application provides an automatically switching dual-redundant servo system, comprising: Servo valve (1), the servo valve (1) includes a first servo valve (11) and a second servo valve (12), which are connected in parallel and receive synchronous control command signals from the control system (4); The isolation valve (2) is located in the downstream circuit of the servo valve (1) and is used to receive the system power-on control signal to realize opening and closing regulation; Manual valve (3) is used for maintenance isolation; The control system (4) is equipped with a signal acquisition and processing module (41) for generating real-time synchronous control command signals and for acquiring and analyzing the valve core position feedback signal of the servo valve (1) to realize fault monitoring and alarm and automatic switching.

[0010] Optionally, the isolation valve (2) includes a first isolation valve (21) and a second isolation valve (22); the downstream circuit of the first servo valve (11) is provided with the first isolation valve (21), and the downstream circuit of the second servo valve (12) is provided with the second isolation valve (22).

[0011] Optionally, the manual valves (3) are respectively arranged in front of and behind the first servo valve (11) and behind the first isolation valve (21).

[0012] Optionally, the control system (4) is controlled by the first servo valve (11), and the second servo valve (12) moves synchronously. The fault detection and alarm process of the control system (4) is as follows: The control system (4) compares the valve core position feedback signal of the first servo valve (11) with the control command signal in real time; when the deviation between the two exceeds the set threshold, the system immediately determines that the first servo valve (11) is abnormal and issues an alarm signal and performs automatic switching. The control system (4) compares the valve core position feedback signal of the second servo valve (12) with the control command signal in real time; when the deviation between the two exceeds the set threshold, the system immediately determines that the second servo valve (12) is abnormal and issues an alarm signal.

[0013] Optionally, the deviation value can be obtained by calculating the absolute value of the difference between the control command signal and the valve core position feedback signal as the deviation value.

[0014] Optionally, the execution logic for the automatic switching is as follows: When the alarm signal is triggered, the control system (4) simultaneously energizes the first isolation valve and the second isolation valve: The first isolation valve is closed, and the second isolation valve is open; The system control is smoothly transferred from the first servo valve (11) to the second servo valve (12).

[0015] In the embodiments provided in this application, the control center monitors the valve core position feedback signal of the servo valve in the main servo component in the connected state in real time, compares this signal with the received control command, and when the comparison result triggers the servo component switching condition, it adjusts the sub-servo component in the cut-off state to the connected state and adjusts the main servo component to the cut-off state, thereby realizing the logical switching between the main servo component and the sub-servo component. Then, it monitors the main servo component after the switch in real time, and switches again when the switching condition is triggered again, thereby realizing automatic switching between the various servo components, so that maintenance can be carried out without stopping the system when a servo component fails. This solves the problem that the existing servo control system requires the main unit to be shut down when a fault occurs, thereby increasing downtime losses and maintenance costs. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall layout structure of the isolation component provided in the embodiments of this application; Figure 2 A flowchart illustrating the method provided in this application embodiment; Figure 3 This is a schematic diagram of the system structure provided in the embodiments of this application; Figure 4This is another structural schematic diagram provided for an embodiment of this application. Detailed Implementation

[0017] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0018] The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. In this application and the appended claims, the singular forms “a,” “the,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to any and all possible combinations comprising one or more of the associated listed items.

[0019] It should be understood that although the terms first, second, third, etc., may be used in this application to describe various information, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to determination."

[0020] This application provides an automatically switching dual-redundant servo system and control method to reduce downtime losses and maintenance costs of the servo control system.

[0021] The technical solutions of this application will be described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments.

[0022] This application provides an automatically switchable dual-redundant servo system and control method. The method is applied to the control center of a dual-redundant servo control system. The system includes several servo components composed of servo valves and isolation valves. Each servo component includes a main servo component in a connected state and several sub-servo components in a disconnected state.

[0023] In this embodiment, each servo component is connected in parallel to the control circuit, such as... Figure 1As shown in the diagram, this figure includes two parallel servo components. Servo component 1 consists of a first servo valve 11 and a first isolation valve 21, while servo component 2 consists of a second servo valve 12 and a second isolation valve 22. Initially, the first isolation valve 21 is set to open, so the oil path of servo component 1 is not interrupted, making it the main servo component in a connected state. Initially, the second isolation valve 22 is set to close, so the oil path of servo component 2 is interrupted, making it the sub-servo component in a disconnected state.

[0024] The flowchart of this method is as follows Figure 2 As shown, the method includes: Step S201: Receive control commands sent by the host computer and monitor the valve core position feedback signal of the servo valve in the main servo component in real time.

[0025] In this embodiment, the host computer or controller first sends a control command to the control center. This control command can be a desired valve core target position or a desired valve core region. Simultaneously, the actual valve core position of the servo valve is monitored in real time using high-precision sensors, such as LVDTs or magnetostrictive displacement sensors, and continuous valve core position feedback signals are generated.

[0026] Furthermore, this embodiment can also simultaneously monitor the valve core position feedback signal of the servo valve in each sub-servo component, thereby identifying the faulty sub-servo component. This allows the faulty sub-servo component to be removed from the candidate list when determining the trigger condition for servo component switching and executing the step of identifying the target sub-servo component.

[0027] In step S202, when the switching condition of the servo component is determined by the control command and the valve core position feedback signal, the target sub-servo component is identified from the sub-servo components, the main servo component is disconnected, and the target sub-servo component is connected to switch the target sub-servo component to the main servo component.

[0028] In this embodiment, the control center can pre-set a switching condition for a servo component. For example, if the control command carries a desired valve core position area, and the actual valve core position indicated by the valve core position feedback signal falls within this area, the servo component switching condition is not triggered. However, if the actual valve core position is outside this area, the servo component switching condition is triggered. At this point, a target sub-servo component is identified from among several sub-servo components. The connection switch of the isolation valve in this target sub-servo component is opened, and the connection switch of the isolation valve in the main servo component is closed. This adjusts the target sub-servo component to a connected state, while the original main servo component is adjusted to a cut-off state, thereby achieving the switching between the target sub-servo component and the main servo component.

[0029] In this embodiment, there are many methods for determining the target sub-servo component, such as selecting sequentially after numbering, random selection, and selection based on the performance and service life of each sub-servo component, etc. This application does not impose any limitations on these methods. Furthermore, the actual valve core position of each sub-servo component can be detected before determining the target sub-servo component to avoid malfunctions in the determined target sub-servo component.

[0030] In another embodiment, determining the switching conditions for the servo component via the control command and the valve core position feedback signal includes: The deviation between the position indicated in the control command and the valve core position in the valve core position feedback signal is determined by the control command and the valve core position feedback signal. The deviation value is compared with a preset deviation threshold, and the servo component switching condition is determined when the deviation value is greater than the deviation threshold.

[0031] In this embodiment, the control command carries a desired target valve core position. The actual valve core position is compared with the desired target position, and the difference between the two is taken as the comparison result. This comparison result directly reflects the degree and direction of deviation between the current valve core position and the position required by the command. At this time, the deviation value can be sent to the subsequent control algorithm. After amplification and correction, a drive current is generated, which acts on the torque motor of the servo valve to push the valve core to move in the direction of reducing error.

[0032] When the deviation between the actual valve core position and the desired target valve core position continues to increase until the deviation exceeds a preset deviation threshold, the servo component switching condition is triggered. Then, the steps of determining the target sub-servo component and switching it with the main servo component are executed.

[0033] In another embodiment, a pressure sensor or flow meter is also installed at the output of the servo valve, and the determination of the switching conditions for the servo component through the control command and the valve core position feedback signal includes: The deviation between the position indicated in the control command and the valve core position in the valve core position feedback signal is determined by the control command and the valve core position feedback signal, and the corresponding pressure value or flow value is determined by the pressure sensor or flow meter. When the deviation value is greater than a preset deviation threshold, or the pressure value is greater than a preset pressure threshold, or the flow rate value is greater than a preset flow rate threshold, the servo component switching condition is determined to be triggered.

[0034] In this embodiment, the control command still carries a desired target valve core position. Besides comparing this desired target position with the actual valve core position to determine the deviation, this embodiment also adds two additional parameters: pressure and flow rate, and sets corresponding thresholds for each. In this embodiment, if any one of the deviation, pressure, or flow rate exceeds its corresponding threshold, the servo component switching condition is triggered.

[0035] This embodiment provides a multi-parameter, multi-dimensional collaborative monitoring method for safety and performance. It not only focuses on the positional deviation parameter, which characterizes execution accuracy, but also evaluates in real-time the pressure parameter, which characterizes dynamic load conditions, and the flow parameter, which characterizes energy supply status. When any parameter exceeds its limit, whether due to excessive positional deviation caused by mechanical jamming, a sudden pressure surge caused by abnormal load, or insufficient flow due to oil source failure, a timely switchover can be triggered to prevent a single fault point from escalating into system failure. This greatly enhances the reliability and adaptability of the equipment.

[0036] In another embodiment, the servo component further includes manual valves disposed on both sides of the servo valve and the isolation valve, and the method further includes: When a maintenance isolation command is received, the target servo valve or target isolation valve that needs to be maintained is determined through the maintenance isolation command. After determination, the target servo valve or target isolation valve is isolated through the manual valves on both sides.

[0037] In this embodiment, manual valves are installed on both sides of each servo valve and isolation valve. This allows operators to manually close the manual valves before and after the servo component when a servo valve or isolation valve malfunctions. The servo valve or isolation valve in the servo component can then be removed for cleaning or replacement without shutting down the main unit. After troubleshooting, the servo component can be switched back into operation.

[0038] Step S203: In real time, the valve core position feedback signal of the servo valve in the switched main servo component is compared with the control command until the servo valve switching condition is triggered, and then the servo component is switched again.

[0039] In this embodiment, after the target sub-servo component is switched to the main servo component, it is necessary to process the main servo component according to the method in steps S201-202 until it triggers the servo valve switching condition, and then switch the servo component again, so as to realize the automatic switching of each servo component.

[0040] This concludes the process. Figure 1 The process is shown below.

[0041] In this embodiment, the control center monitors the valve core position feedback signal of the servo valve in the main servo component in the connected state in real time, compares this signal with the received control command, and when the comparison result triggers the servo component switching condition, it adjusts the sub-servo component in the cut-off state to the connected state and adjusts the main servo component to the cut-off state, thereby realizing the logical switching between the main servo component and the sub-servo component. Then, it monitors the switched main servo component in real time, and switches again when the switching condition is triggered again, thereby achieving automatic switching between the various servo components, allowing for maintenance without shutting down the system when a servo component fails. This solves the problem that existing servo control systems require the main unit to be shut down for fault repair, thus increasing downtime losses and maintenance costs.

[0042] like Figure 1 , 3 As shown in Figure 4, this application also provides an automatically switching dual-redundant servo system, including: Servo valve 1 includes a first servo valve (11) and a second servo valve (12), which are connected in parallel and receive synchronous control command signals from the control system (4); Isolation valve 2 is located in the downstream circuit of servo valve 1 and is used to receive the system power-on control signal to realize opening and closing regulation; Manual valve 3 is used for maintenance isolation; The control system 4 is equipped with a signal acquisition and processing module 41, which is used to generate real-time synchronous control command signals and to acquire and analyze the valve core position feedback signal of the servo valve 1, so as to realize fault monitoring and alarm and automatic switching.

[0043] The above technical solution utilizes an automatically switchable dual-redundant servo system to achieve rapid automatic switching in fault conditions, while supporting online maintenance of faulty valves and ensuring continuous and stable operation of the main unit. The system's hardware consists of: a servo valve 1, an isolation valve 2, a manual valve 3, and a control system 4. The system is configured with two identical DDV servo valves 1 connected in parallel (first servo valve 11 and second servo valve 12), both of which are direct-acting electro-hydraulic servo valves 1 with valve core position feedback (such as the Moog D633 or D634 series). An isolation valve 2 (first isolation valve 21) is provided in the downstream circuit of the first servo valve 11. The downstream circuit of the second servo valve 12 is equipped with an isolation valve 2 (second isolation valve 22); and manual valves 3 are provided before and after the first servo valve 11 and after the first isolation valve 21. These are generally manual switching / shut-off valves used to isolate the circuit during maintenance operations, reducing downtime for maintenance and repair costs. By using a signal acquisition and processing module 41, the control command signal and valve core position feedback signal of the servo valve 1 are acquired and analyzed in real time to realize fault monitoring, alarm and automatic switching control operations. This provides the maintenance conditions for replacing faulty valves without stopping the machine during the operation of the software, and supports the timely removal and maintenance of faulty valves during shutdown.

[0044] In another embodiment, such as Figure 1 As shown, the isolation valve (2) includes a first isolation valve (21) and a second isolation valve (22); the downstream circuit of the first servo valve (11) is provided with the first isolation valve (21), and the downstream circuit of the second servo valve (12) is provided with the second isolation valve (22).

[0045] In the above technical solution, the isolation valve 2 is a two-position two-way solenoid valve; the isolation valve 2 is installed in series on the downstream output oil line of the first servo valve 11. This valve is a normally open (NO) type solenoid valve, which remains open under normal conditions without power to ensure the smooth flow of the main working oil line; the second isolation valve 22 is installed in series on the downstream output oil line of the second servo valve 12. This valve is a normally closed (NC) type solenoid valve, which remains closed under normal conditions without power to isolate the backup oil line from the system; the electromagnet drive coils of the first isolation valve 21 and the second isolation valve 22 are both connected to the switching control output port of the control system 4, and receive the same power signal to control their state switching; this combination of "one normally open and one normally closed" ensures that the system can automatically recover to the initial safe state controlled by the first servo valve 11 under extreme conditions such as power failure, and has the ability to protect against power failure.

[0046] In another embodiment, such as Figure 3 As shown, the manual valve (3) is respectively located before and after the first servo valve (11) and after the first isolation valve (21).

[0047] In another embodiment, the control system (4) is controlled by a first servo valve (11), with a second servo valve (12) acting synchronously. The fault detection and alarm process of the control system (4) is as follows: The control system (4) compares the valve core position feedback signal of the first servo valve (11) with the control command signal in real time; when the deviation between the two exceeds the set threshold, the system immediately determines that the first servo valve (11) is abnormal and issues an alarm signal and performs automatic switching. The control system (4) compares the valve core position feedback signal of the second servo valve (12) with the control command signal in real time; when the deviation between the two exceeds the set threshold, the system immediately determines that the second servo valve (12) is abnormal and issues an alarm signal.

[0048] In another embodiment, the execution logic for the automatic switching is as follows: When the alarm signal is triggered, the control system (4) simultaneously energizes the first isolation valve and the second isolation valve: The first isolation valve is closed, and the second isolation valve is open; The system control is smoothly transferred from the first servo valve (11) to the second servo valve (12).

[0049] The above embodiments of the present invention provide an automatically switchable dual-redundant servo control system, and based on the system, an automatically switchable dual-redundant servo control method is provided. Through the above method and system, the downtime loss and maintenance cost of the servo control system can be reduced.

[0050] This embodiment also discloses a computer device, which includes a processor and a memory. The memory stores at least one instruction, which is loaded and executed by the processor to implement any of the above-described automatically switching dual-redundant servo control methods.

[0051] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A dual-redundant servo control method with automatic switching capability, characterized in that, A control center for a dual-redundant servo control system, the system comprising several servo components consisting of servo valves and isolation valves, each servo component including a main servo component in a connected state and several sub-servo components in a disconnected state, the method comprising: Receive control commands sent by the host computer and monitor the valve core position feedback signal of the servo valve in the main servo component in real time; When the switching conditions for the servo component are determined by the control command and the valve core position feedback signal, the target sub-servo component is identified from the sub-servo components, the main servo component is disconnected, and the target sub-servo component is connected to switch the target sub-servo component to the main servo component. The valve core position feedback signal of the servo valve in the switched main servo component is compared with the control command in real time until the servo valve switching condition is triggered, at which point the servo component is switched again.

2. The method according to claim 1, characterized in that, The servo component also includes manual valves, respectively disposed on both sides of the servo valve and the isolation valve, and the method further includes: When a maintenance isolation command is received, the target servo valve or target isolation valve that needs to be maintained is determined through the maintenance isolation command. After determination, the target servo valve or target isolation valve is isolated through the manual valves on both sides.

3. The method according to claim 1, characterized in that, The process of determining the switching conditions for the servo component through the control command and valve core position feedback signal includes: The deviation between the position indicated in the control command and the valve core position in the valve core position feedback signal is determined by the control command and the valve core position feedback signal. The deviation value is compared with a preset deviation threshold, and the servo component switching condition is determined when the deviation value is greater than the deviation threshold.

4. The method according to claim 1, characterized in that, The output end of the servo valve is also equipped with a pressure sensor or flow meter. The determination of the switching conditions for the servo component through the control command and the valve core position feedback signal includes: The deviation between the position indicated in the control command and the valve core position in the valve core position feedback signal is determined by the control command and the valve core position feedback signal, and the corresponding pressure value or flow value is determined by the pressure sensor or flow meter. When the deviation value is greater than a preset deviation threshold, or the pressure value is greater than a preset pressure threshold, or the flow rate value is greater than a preset flow rate threshold, the servo component switching condition is determined to be triggered.

5. A dual-redundant servo system with automatic switching capability, characterized in that, include: The servo valve (1) includes a first servo valve (11) and a second servo valve (12), which are connected in parallel and receive synchronous control command signals from the control system (4); The isolation valve (2) is located in the downstream circuit of the servo valve (1) and is used to receive the system power-on control signal to realize opening and closing regulation; Manual valve (3) is used for maintenance isolation; The control system (4) is equipped with a signal acquisition and processing module (41) for generating real-time synchronous control command signals and for acquiring and analyzing the valve core position feedback signal of the servo valve (1) to realize fault monitoring and alarm and automatic switching.

6. The automatically switching dual-redundant servo system according to claim 6, characterized in that, The isolation valve (2) includes a first isolation valve (21) and a second isolation valve (22); the downstream circuit of the first servo valve (11) is provided with the first isolation valve (21), and the downstream circuit of the second servo valve (12) is provided with the second isolation valve (22).

7. The automatically switching dual-redundant servo system according to claim 7, characterized in that, The manual valves (3) are respectively located before and after the first servo valve (11) and after the first isolation valve (21).

8. The automatically switching dual-redundant servo system according to claim 1, characterized in that, The control system (4) is controlled by the first servo valve (11), and the second servo valve (12) moves synchronously. The fault detection and alarm process of the control system (4) is as follows: The control system (4) compares the valve core position feedback signal of the first servo valve (11) with the control command signal in real time; when the deviation between the two exceeds the set threshold, the system immediately determines that the first servo valve (11) is abnormal and issues an alarm signal and performs automatic switching. The control system (4) compares the valve core position feedback signal of the second servo valve (12) with the control command signal in real time; when the deviation between the two exceeds the set threshold, the system immediately determines that the second servo valve (12) is abnormal and issues an alarm signal.

9. A dual-redundant servo system with automatic switching capability according to claim 5, characterized in that, The deviation value is obtained by calculating the absolute value of the difference between the control command signal and the valve core position feedback signal.

10. A dual-redundant servo system with automatic switching capability according to claim 6, characterized in that, The execution logic for the automatic switching is as follows: When the alarm signal is triggered, the control system (4) simultaneously energizes the first isolation valve and the second isolation valve: The first isolation valve is closed, and the second isolation valve is open; The system control is smoothly transferred from the first servo valve (11) to the second servo valve (12).

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