Hydraulic element test system integrating data acquisition and automatic data analysis functions

Abstract

The invention belongs to the technical field of hydraulic test and intelligent control, and particularly discloses a hydraulic component test system integrating data acquisition and automatic data analysis functions, which comprises a physical hardware test platform, a test control software platform and a digital twinborn model of a tested component, and realizes real-time interaction through an OPC UA protocol. Model parameters are corrected on line by means of measured data, and steady state, transient state and disturbance working condition tests are automatically executed based on a working condition library; and dynamically optimizing a test sequence in a test process, skipping a redundant working condition or encrypting a critical region, and synchronously generating a structured performance report. The accuracy and consistency of test results are improved, working condition simulation signals are automatically generated, performance data are collected in real time, a comprehensive performance report is generated, manual operation is reduced, the test process optimization unit can skip redundant working conditions and refine failure boundary positioning, and the test time and cost are effectively saved.

Description

Technical Field

[0001] This invention belongs to the field of hydraulic testing and intelligent control technology, specifically relating to a hydraulic component testing system that integrates data acquisition and automatic data analysis functions. Background Technology

[0002] Hydraulic components, as key power transmission and control parts in modern industrial equipment, directly affect the operating efficiency and safety of the entire system due to their performance stability and reliability. In high-end equipment manufacturing, aerospace, and engineering machinery fields, higher demands are placed on the testing accuracy, operating condition coverage, and intelligent data processing level of hydraulic components. Traditional hydraulic component testing systems typically consist of a physical test bench, independent data acquisition devices, and offline analysis software. The testing process relies on a preset fixed operating condition sequence, and manual intervention is required to switch between different testing stages and evaluate results.

[0003] In existing hydraulic component testing practices, test conditions are generally constructed using combinations of pressure, flow, and temperature parameters set based on experience, and the hydraulic power source is controlled by a PLC or industrial computer to output corresponding excitation signals. Some systems have introduced basic data logging functions, allowing the export of raw sensor data after testing for subsequent manual analysis. To improve testing efficiency, some solutions attempt to use digital simulation models for preliminary test condition simulations; however, these models are usually decoupled from the physical testing platform, lack real-time interactive capabilities, and do not establish a dynamic feedback mechanism between model parameters and measured data.

[0004] However, the above-mentioned existing technologies still have several limitations when facing complex and ever-changing real-world application scenarios: (1) The generation of test conditions depends on static libraries or manual configuration, lacks the ability to adaptively adjust according to the characteristics of the tested object, and is difficult to fully cover boundary conditions and transient response characteristics.

[0005] (2) The separation of data collection and analysis leads to a delay in performance evaluation and makes it impossible to support online decision-making and optimization during the testing process.

[0006] (3) There is a lack of closed-loop linkage between the digital model and the physical platform. Once the model parameters are set, they remain fixed and cannot be continuously corrected using measured data, which limits the predictability and consistency of the test results. Summary of the Invention

[0007] In view of this, in order to solve the problems mentioned in the background technology, a hydraulic component testing system integrating data acquisition and automatic data analysis functions is proposed.

[0008] The objective of this invention can be achieved through the following technical solution: This invention provides a hydraulic component testing system with integrated data acquisition and automatic data analysis functions, including: a test integration unit construction module, a simulation control signal generation module, a test environment physical reproduction module, a data feedback and model correction module, and a performance test report generation module.

[0009] The test integration unit construction module is connected to the analog control signal generation module, the analog control signal generation module is connected to the test environment physical reproduction module, the test environment physical reproduction module is connected to the data feedback and model correction module, and the data feedback and model correction module is connected to the performance test report generation module.

[0010] The test integration unit construction module builds a test integration unit that integrates a physical hardware test platform, a test control software platform, and a digital twin model of the hydraulic component under test.

[0011] The analog control signal generation module is used by the test control software platform to select the target test condition parameters and drive the digital twin model to calculate based on these parameters to generate the operating condition analog control signals for controlling the physical hardware test platform.

[0012] The physical reproduction module of the test environment is a physical hardware test platform that receives and executes the working condition simulation control signal to reproduce the hydraulic environment corresponding to the target test working condition at its output end, and tests the hydraulic components under test installed on it.

[0013] The data feedback and model correction module collects the performance data of the tested hydraulic components in real time during the test and feeds it back to the digital twin model simultaneously; the digital twin model corrects its internal parameters online based on the performance data.

[0014] The performance test report generation module repeatedly executes the operations from the simulation control signal generation module to the data feedback and model correction module to complete the testing of multiple target test conditions; the test control software platform analyzes the performance data under each target test condition and generates a comprehensive performance test report of the tested hydraulic component.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The present invention constructs a three-in-one test unit consisting of a physical hardware test platform, a test control software platform, and a digital twin model, and establishes an online feedback correction mechanism for model parameters based on measured performance data during the test process. This enables the digital twin model to dynamically approximate the real physical behavior of the tested hydraulic component as the test progresses, solving the problems of model-physical disconnect and inaccurate prediction in traditional testing, and improving the consistency and repeatability of test results.

[0016] 2. This invention uses a graded hydraulic power source unit in conjunction with a proportional relief valve group for pressure-flow coordinated regulation. An auxiliary pump is introduced on the basis of the main pump to cope with transient high flow demand. The relief valve current is dynamically adjusted by real-time monitoring of multi-channel pressure difference, so that the system maintains pressure balance in a wide operating range and avoids test excitation distortion caused by pump source response lag.

[0017] 3. This invention is based on a circulating cooling filter unit that achieves rapid oil temperature stabilization through a variable frequency cooling pump and multi-stage temperature control logic. It uses a signal generator to accurately reproduce complex interference waveforms with a high-frequency servo proportional valve and pressure closed-loop control, thereby reproducing a complete test environment covering steady-state, transient, and disturbance conditions on a single platform.

[0018] 4. This invention integrates a test process optimization unit into the test control software platform, dynamically adjusts the subsequent test sequence, reduces redundant tests in areas with sufficient performance margin, and densifies test points in critical performance areas, which not only shortens the average test time but also improves the accuracy of failure boundary identification. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the system module connections of the present invention. Detailed Implementation

[0021] 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 some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figure 1 As shown, this invention provides a hydraulic component testing system that integrates data acquisition and automatic data analysis functions. The specific modules are distributed as follows: a test integration unit construction module, a simulation control signal generation module, a test environment physical reproduction module, a data feedback and model correction module, and a performance test report generation module.

[0023] The test integration unit construction module is connected to the analog control signal generation module, the analog control signal generation module is connected to the test environment physical reproduction module, the test environment physical reproduction module is connected to the data feedback and model correction module, and the data feedback and model correction module is connected to the performance test report generation module.

[0024] The test integration unit construction module builds a test integration unit that integrates a physical hardware test platform, a test control software platform, and a digital twin model of the hydraulic component under test.

[0025] It should be noted that the hardware testing platform is equipped with a graded hydraulic power source, a circulating cooling and filtration system, and a signal generator, possessing the ability to dynamically adjust system pressure and flow rate, as well as a closed-loop control function for oil temperature. Specifically, it includes a hydraulic power unit capable of dynamically adjusting system pressure and flow rate, a circulating cooling and filtration system capable of closed-loop control of oil temperature, and a signal generator capable of injecting pressure interference signals.

[0026] The test control software platform has a built-in working condition library containing multiple preset typical working conditions.

[0027] The preset typical working conditions include, but are not limited to, working conditions in various fields such as engineering machinery, aerospace, and industrial automation.

[0028] The digital twin model integrates at least one sub-model reflecting the hydrodynamic characteristics, electrical drive characteristics, and mechanical friction characteristics of the hydraulic component under test, and establishes a bidirectional data connection with the physical hardware test platform through a real-time communication interface.

[0029] As an exemplary embodiment of the present invention, the physical hardware testing platform is specifically a modular hardware architecture, which is formed by integrating a graded hydraulic power source unit, a circulating cooling and filtration unit and a signal generator on the same mounting base through hydraulic pipelines and electrical control lines.

[0030] The graded hydraulic power source unit uses a combination of a variable pump and a proportional relief valve to achieve wide-range, highly dynamic flow and pressure regulation; the circulating cooling and filtration unit integrates a heater, cooler, and temperature sensor, and achieves oil temperature regulation through closed-loop control; the signal generator uses a high-frequency response proportional valve to inject controllable pressure pulsation interference.

[0031] For example, the signal generator uses a high-frequency response proportional valve with a response frequency ≥1kHz to inject controllable pressure pulsation interference with an amplitude range of 0.5MPa-10MPa and a frequency range of 0.1Hz-200Hz.

[0032] The test control software platform is developed based on LabVIEW, MATLAB, or industrial control software such as WinCC. Its core is to build a structured operating condition library and integrate four major functional sub-modules: operating condition selection, signal generation, data acquisition, and analysis and processing. It achieves real-time communication compatibility with physical hardware test platforms and digital twin models through the OPC UA protocol.

[0033] The digital twin model integrates sub-models reflecting the hydraulic fluid dynamic characteristics, electrical drive response characteristics, and mechanical friction loss characteristics of the tested hydraulic components. Its data interface is adapted to the OPC UA protocol, realizing a one-to-one mapping between model input and output variables and sensor / actuator signals of the physical hardware test platform.

[0034] As an exemplary embodiment of the present invention, the specific construction process of the digital twin model of the hydraulic component under test includes: acquiring the geometric structural parameters, material property parameters, factory performance calibration data and kinematic pair fit clearance data of the hydraulic component under test.

[0035] In one specific example, the geometric parameters include, but are not limited to, flow channel diameter, length, bending angle, valve core stroke, and valve port opening range; the material property parameters include, but are not limited to, density, elastic modulus, and coefficient of friction of the housing and valve core materials, and viscosity, density, and compressibility of the hydraulic oil; the factory performance calibration data include, but are not limited to, flow output value under rated pressure, step response time, leakage, and control current-output flow corresponding curve; the kinematic pair fit clearance data include, but are not limited to, fit clearance between valve core and valve sleeve, and between piston and cylinder.

[0036] A three-dimensional flow channel topology model is established based on geometric structural parameters, and a hydraulic fluid dynamics sub-model is constructed by combining the Navier-Stokes equations to simulate the dynamic characteristics of pressure and flow rate of hydraulic oil in the component flow channel.

[0037] Based on material property parameters and kinematic pair clearance data, a mechanical friction loss sub-model is established, which includes Coulomb friction, viscous damping, and Stribeck effect, to calculate friction loss during component movement.

[0038] Based on the drive circuit topology and electromagnetic force-current nonlinear relationship of the tested hydraulic component, an electrical drive response sub-model is constructed. The electrical drive response sub-model outputs control current to the hydraulic fluid dynamics sub-model to realize cross-domain linkage between electrical and hydraulic systems.

[0039] The hydraulic fluid dynamics sub-model, mechanical friction loss sub-model, and electrical drive response sub-model are coupled and integrated through a unified state-space expression, and a data interface consistent with the communication protocol of the hardware test platform is configured to realize a one-to-one mapping between the model input and output variables and the signals of the physical platform sensors / actuators.

[0040] It should be noted that the state-space expression uses valve core displacement, hydraulic oil pressure, and control current as state variables, operating parameters as input variables, and component output flow and outlet pressure as output variables.

[0041] It should also be added that the coupling and linkage logic of each sub-model in the state space expression is as follows: the control current output by the electrical drive response sub-model is used as the input of the hydraulic fluid dynamics sub-model. The driving force output by the hydraulic fluid dynamics sub-model and the friction force output by the mechanical friction loss sub-model form a counterforce, which together determine the motion state of the component, such as the valve core displacement.

[0042] The analog control signal generation module is used by the test control software platform to select the target test condition parameters and drive the digital twin model to calculate based on these parameters to generate the operating condition analog control signals for controlling the physical hardware test platform.

[0043] As an exemplary embodiment of the present invention, the specific calculation process of the operating condition simulation control signal includes: retrieving target test operating condition parameters from the operating condition library, wherein the target test operating condition parameters include target pressure curve, target flow curve, target oil temperature value and interference signal waveform.

[0044] It should be noted that the waveform of the interference signal is selected from sine wave, square wave or random noise wave, with an amplitude range of 0.5MPa-10MPa and a frequency range of 0.1Hz-200Hz.

[0045] The target pressure curve and target flow curve are input into the hydraulic fluid dynamics sub-model of the digital twin model, and the load simulation signal is calculated through the dynamic response simulation of the hydraulic system under load. The target oil temperature value is input into the thermodynamic sub-model of the digital twin model, and the oil temperature setting signal is generated through temperature regulation simulation.

[0046] It should be noted that the thermodynamic sub-model corresponds to the circulating cooling and filtration system of the physical hardware test platform.

[0047] The interference signal waveform is input into the dynamic response sub-model in the digital twin model to generate the interference pressure signal.

[0048] It should be noted that the dynamic response sub-model corresponds to the signal generator of the physical hardware test platform.

[0049] The load simulation signal, oil temperature setting signal, and interference pressure signal are collectively referred to as the operating condition simulation control signal.

[0050] It should be noted that the timing alignment of each signal in the operating condition simulation control signal is performed, such as a trigger time difference of ≤1ms, to ensure that each signal is triggered synchronously on the time axis; and the operating condition simulation control signal is sent to the physical hardware test platform through the real-time communication interface of the OPC UA protocol, with a transmission delay of ≤5ms, so as to accurately reproduce the dynamic characteristics of the target test condition.

[0051] This invention constructs a three-in-one testing unit consisting of a physical hardware testing platform, a testing control software platform, and a digital twin model. During the testing process, it establishes an online feedback correction mechanism for model parameters based on measured performance data. This enables the digital twin model to dynamically approximate the real physical behavior of the tested hydraulic component as the testing progresses. This solves the problems of model-physical disconnect and inaccurate prediction in traditional testing, and improves the consistency and repeatability of test results.

[0052] The physical reproduction module of the test environment is a physical hardware test platform that receives and executes the working condition simulation control signal to reproduce the hydraulic environment corresponding to the target test working condition at its output end, and tests the hydraulic components under test installed on it.

[0053] As an exemplary embodiment of the present invention, the test environment physical reproduction module includes outputting pressure and flow through a graded hydraulic power source unit. The specific process includes: the graded hydraulic power source unit includes a main pump group, an auxiliary pump group, and a proportional relief valve group.

[0054] It should be noted that the main pump set is a variable displacement piston pump with a rated working pressure of 21MPa-31.5MPa and a rated flow rate of 50L / min-200L / min, used to provide the basic working pressure; the auxiliary pump set is a fixed displacement vane pump with a rated working pressure consistent with the main pump set and a rated flow rate of 50L / min-150L / min, used to start in parallel for supplementary power during transient high flow demand; the proportional relief valve set has an adjustment accuracy of ±0.1MPa and a response frequency ≥100Hz, used to dynamically distribute the output pressure of the main pump and the auxiliary pump.

[0055] Based on the pressure and flow setpoints output by the digital twin model, calculate the total power requirement for the current operating conditions.

[0056] It should be noted that the total power requirement required under the current operating conditions = pressure setpoint × flow setpoint / system efficiency parameter.

[0057] The system efficiency parameter is set at 0.85-0.9, which is determined based on the typical working efficiency of the hydraulic pump, ensuring that the power calculation results are consistent with the actual requirements.

[0058] If the total power demand exceeds the set percentage of the rated output power of the main pump group, such as 90%, the auxiliary pump group is started, and the output pressure of the main pump and the auxiliary pump is dynamically distributed through the proportional overflow valve group.

[0059] The system monitors the main pump outlet pressure, auxiliary pump outlet pressure, and system return oil pressure in real time. When the pressure difference between any two lines exceeds the preset tolerance threshold, the control current of the proportional relief valve is adjusted to balance the pressure output.

[0060] Specifically, the main pump outlet pressure, auxiliary pump outlet pressure, and system return oil pressure are monitored in real time at a sampling frequency of 100Hz-200Hz. When the pressure difference between any two lines exceeds the preset tolerance threshold of ±0.3MPa-±0.5MPa, the control current of the proportional relief valve is adjusted to balance the pressure output.

[0061] It should be noted that during the switching of operating conditions, a time constant is used to smooth the start and stop commands of the pump unit to avoid pressure over-limit caused by hydraulic shock.

[0062] The time constant can be a ramp function of 0.5s to 2s, and can be adaptively adjusted according to the severity of the change in operating conditions. When the difference in operating conditions is large, such as from low pressure to high pressure, a time constant of 2s is used, and when the difference in operating conditions is small, a time constant of 0.5s is used to ensure a smooth transition of pressure and flow.

[0063] This invention employs a graded hydraulic power source unit in conjunction with a proportional relief valve assembly for pressure-flow coordinated regulation. An auxiliary pump is introduced on the basis of the main pump to cope with transient high flow demand. The relief valve current is dynamically adjusted by real-time monitoring of multi-channel pressure difference, so that the system maintains pressure balance within a wide operating range and avoids test excitation distortion caused by pump source response lag.

[0064] As an exemplary embodiment of the present invention, the test environment physical reproduction module includes adjusting the hydraulic oil temperature to a set value through a circulating cooling filter unit. The specific process includes: the circulating cooling filter unit includes a heat exchanger, a variable frequency cooling pump, a temperature sensor, and a multi-stage filter.

[0065] It should be noted that the multi-stage filter uses a stainless steel filter element and combines deep filtration with surface filtration. The filtration accuracies are 25 microns, 10 microns and 3 microns respectively, which are intended to ensure that the cleanliness of the test medium meets the requirements of levels 18 / 16 / 13 in the ISO 4406 standard.

[0066] The 25-micron filter removes large particles, the 10-micron filter removes medium-sized particles, and the 3-micron filter removes fine particles. The filter element is removable, washable, and replaceable.

[0067] After receiving the oil temperature setting signal output by the digital twin model, the current oil temperature is compared with the set value, and the absolute value of the temperature difference is calculated.

[0068] If the absolute value of the temperature difference is greater than the upper limit of the absolute value, such as 2℃, then the variable frequency cooling pump is started, and the pump speed gear is set according to the preset mapping relationship.

[0069] In one specific example, the preset mapping relationship is as follows: a temperature difference of 2℃-5℃ corresponds to 50% of the rated speed; a temperature difference of 5℃-8℃ corresponds to 75% of the rated speed; and a temperature difference greater than 8℃ corresponds to 100% of the rated speed.

[0070] During the cooling process, the hydraulic oil temperature is collected at fixed intervals, such as every 500 milliseconds. If the absolute value of the temperature difference between three consecutive sampled values ​​and the set value is less than the lower limit of the absolute value, such as 0.5℃, it is determined that the hydraulic oil temperature has reached a steady state, and the cooling pump stops running.

[0071] It should be noted that the hydraulic oil flows through multiple filters simultaneously.

[0072] As an exemplary embodiment of the present invention, the test environment physical reproduction module includes injecting an interference pressure signal with a preset amplitude and frequency through a signal generator. The specific process includes: the signal generator is configured with a programmable waveform generation submodule, a high-frequency servo proportional valve, and a pressure feedback closed-loop controller.

[0073] The system receives interference pressure signal parameters output by the digital twin model. These parameters include the waveform type (sine wave, square wave, or random noise) and the corresponding amplitude and frequency ranges.

[0074] It should be noted that the amplitude range is specifically 0.5MPa to 10MPa; the frequency range is specifically 0.1Hz to 200Hz.

[0075] Based on the waveform type and parameters, a corresponding control voltage signal is generated, and a high-frequency servo proportional valve is driven to superimpose dynamic pressure disturbances in the main test circuit.

[0076] The actual superimposed pressure value is collected in real time by a high-frequency pressure sensor installed at the inlet of the hydraulic component under test, and the value is fed back to the pressure feedback closed-loop controller.

[0077] The pressure feedback closed-loop controller dynamically adjusts the drive current of the high-frequency servo proportional valve based on the deviation between the actual superimposed pressure value and the target interference pressure signal using a PID control algorithm.

[0078] Specifically, the pressure feedback closed-loop controller uses a proportional coefficient based on the deviation between the actual superimposed pressure value and the target interference pressure signal. The integral time is 0.8-1.2. The time interval is 0.1s–0.3s, and the derivative time is... A PID control algorithm with a time range of 0.01s to 0.05s is used to dynamically adjust the drive current of the high-frequency servo proportional valve, ensuring that the amplitude error of the actual disturbance pressure signal does not exceed ±2% and the phase error does not exceed ±3°, thereby ensuring the accuracy of disturbance condition reproduction.

[0079] This invention achieves rapid oil temperature stabilization through a circulating cooling filter unit, a variable frequency cooling pump, and multi-stage temperature control logic. It also uses a signal generator, a high-frequency servo proportional valve, and pressure closed-loop control to accurately reproduce complex interference waveforms, thereby reproducing a complete test environment covering steady-state, transient, and disturbance conditions on a single platform.

[0080] The data feedback and model correction module collects the performance data of the tested hydraulic components in real time during the test and feeds it back to the digital twin model simultaneously; the digital twin model corrects its internal parameters online based on the performance data.

[0081] As an exemplary embodiment of the present invention, the specific implementation process of the data feedback and model correction module includes: using pressure sensors, flow meters, temperature sensors and displacement / speed sensors installed at the inlet and outlet of the hydraulic component under test, the pressure difference, flow rate, oil temperature and motion state data of the hydraulic component under test collected in real time during the test are used as performance data.

[0082] The performance data is packaged according to the sampling period and uploaded to the digital twin model through a real-time communication interface.

[0083] Specifically, the performance data is packaged with a sampling period of 500 microseconds and uploaded to the digital twin model through a real-time communication interface of the OPC UA protocol.

[0084] The parameter identification unit in the digital twin model updates the leakage coefficient in the hydrodynamic characteristic sub-model, the response delay parameter in the electric drive characteristic sub-model, and the friction torque parameter in the mechanical friction characteristic sub-model based on the residual between the performance data and the model prediction output using the least squares method or Kalman filter algorithm.

[0085] It should be noted that the use of least squares method or Kalman filter algorithm to update the specific rotation includes: using least squares method under steady-state conditions such as continuous operation under rated pressure, and using Kalman filter algorithm under dynamic conditions such as pressure or flow change conditions.

[0086] After each parameter update, the corrected model parameters are stored in the local database, and the version number of the corresponding test condition is marked.

[0087] Specifically, after each parameter update, the corrected model parameters are stored in local data according to the version number rule of working condition number - test timestamp - parameter update number.

[0088] For example, the version number of a certain modified model parameter is: Gongkuang01-202405201430-001.

[0089] It should be noted that when the same hydraulic component under test uses the same digital twin model again in subsequent tests, the latest version of the model parameters will be automatically loaded to improve the simulation accuracy.

[0090] The performance test report generation module repeatedly executes the operations from the simulation control signal generation module to the data feedback and model correction module to complete the testing of multiple target test conditions; the test control software platform analyzes the performance data under each target test condition and generates a comprehensive performance test report of the tested hydraulic component.

[0091] As an exemplary embodiment of the present invention, the specific implementation process of the performance test report generation module includes: after completing the test of a target test condition, determining whether there are any unexecuted target test conditions; if so, returning to the simulation control signal generation module to select the parameters of the next target test condition.

[0092] Specifically, if there are still unexecuted target test conditions, the system returns to the simulation control signal generation module to select the parameters for the next target test condition, and repeats the operations of the simulation control signal generation module, the test environment physical reproduction module, and the data feedback and model correction module.

[0093] If not, then summarize the performance data of all completed target test conditions, including steady-state performance indicators and dynamic response indicators.

[0094] The steady-state performance indicators include volumetric efficiency, leakage, and temperature rise rate under rated pressure, while the dynamic response indicators include step response time, overshoot, and frequency response bandwidth.

[0095] Based on the performance data, the performance level of the tested hydraulic component under each target test condition is quantitatively scored according to the preset evaluation rules.

[0096] Specifically, based on the preset evaluation rules set by the ISO 4406 standard and the manufacturer's technical specifications of the tested component, the performance level of the tested hydraulic component under various target test conditions is quantitatively scored. For example, assuming a total score of 100 points, a score of 85 or above is rated as excellent, 70-84 points is rated as good, 55-69 points is rated as medium, and <55 points is rated as poor.

[0097] An exemplary preset evaluation rule: (1) Volumetric efficiency ≥ 95% gets 10 points, 90%-95% gets 8 points, 85%-90% gets 6 points, < 85% gets 0 points; (2) Leakage ≤ 5 mL / min gets 10 points, 5-10 mL / min gets 8 points, 10-15 mL / min gets 6 points, > 15 mL / min gets 0 points; (3) Step response time ≤ 0.5s gets 10 points, 0.5-1s gets 8 points, 1-2s gets 6 points, > 2s gets 0 points.

[0098] The scoring results of each target test condition, the original performance data curves, and the model correction records are integrated to generate a structured comprehensive performance test report.

[0099] It should be noted that the report is output in PDF or XML format and includes traceable information such as test timestamp, operating condition parameter version number, sensor calibration date and calibration error, component model, and test operator.

[0100] It should also be added that after generating the structured comprehensive performance test report, a working condition adaptability report is further generated. The specific process includes: extracting the steady-state flow error, step response rise time and 90% response time of the tested hydraulic component under each target test condition as core performance indicators.

[0101] The acceptable range for the steady-state flow error is ±3%, the acceptable range for the step response rise time is 0.1s-1s, and the acceptable range for the 90% response time is 0.2s-1.5s.

[0102] After normalizing the core performance indicators of each target test condition, a multi-dimensional performance vector is constructed.

[0103] Specifically, the normalization process can be performed using the min-max normalization method, i.e., normalized value = (original value - minimum index value) / (maximum index value - minimum index value).

[0104] Calculate the Euclidean distance between the performance vectors corresponding to any two operating conditions. If the distance is less than the preset similarity threshold, the tested component is determined to perform consistently under the two operating conditions.

[0105] In one specific example, the preset similarity threshold can be set to 0.3 in the same field and 0.5 in the cross-field field.

[0106] For each performance index, its maximum value, minimum value, and standard deviation are calculated across all target test conditions to assess the performance fluctuation range of the tested component.

[0107] Based on the relationship between the performance fluctuation range and the preset qualified range, a working condition adaptability conclusion with four levels of evaluation (excellent, good, medium, and poor) is generated, and the specific working condition number and the out-of-standard index item that exceeds the qualified range are marked.

[0108] As an exemplary embodiment of the present invention, the performance test report generation module is configured with a test process optimization unit, the specific implementation process of which includes: real-time analysis of the relationship between the performance data of the completed target test conditions and the preset qualified boundary.

[0109] If the performance margin of the tested hydraulic component is better than the acceptable boundary in multiple consecutive target test conditions, then the unexecuted conditions that are less than the set threshold in similarity to the tested conditions are skipped.

[0110] Specifically, if the performance margin of the hydraulic component under test is ≥20% in three or more consecutive target test conditions, and the similarity between the unexecuted condition and the tested condition is less than a set threshold such as ≤0.2, and the severity of the unexecuted condition is determined to be lower than that of the tested condition according to the priority of pressure level, interference signal, temperature range, and flow requirement, then the unexecuted redundant condition is skipped.

[0111] If the performance index of the hydraulic component under test exceeds the failure threshold in a certain target test condition, several intermediate transition conditions will be automatically inserted to refine the failure boundary location.

[0112] Specifically, if the core performance indicators of the hydraulic component under test exceed the failure threshold under a certain target test condition, such as flow control error ≥20%, response time drift ≥0.5s, or leakage flow increment ≥50% of the initial leakage, then no more than 3 intermediate transition conditions will be automatically inserted, such as core parameters designed with a 10% step size, to refine the failure boundary location.

[0113] All process adjustments are recorded in the test execution log, and the basis for optimization and its impact are explained in the comprehensive performance test report.

[0114] It should be noted that the test process optimization unit is used to dynamically adjust the execution order of the remaining conditions or terminate redundant tests during the execution of a multi-condition test sequence.

[0115] This invention integrates a test process optimization unit into the test control software platform, dynamically adjusts subsequent test sequences, reduces redundant tests in areas with sufficient performance margin, and densifies test points in critical performance areas, thereby shortening the average test time and improving the accuracy of failure boundary identification.

[0116] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, in the form of a computer program product.

[0117] Those skilled in the art will recognize that the algorithmic steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this application.

[0118] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0119] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0120] Finally, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A hydraulic component testing system integrating data acquisition and automatic data analysis functions, characterized in that: include: The test integration unit construction module builds a test integration unit that integrates a physical hardware test platform, a test control software platform, and a digital twin model of the hydraulic component under test; The analog control signal generation module selects the target test condition parameters from the test control software platform and drives the digital twin model to calculate based on these parameters, generating the operating condition analog control signal used to control the physical hardware test platform. The physical reproduction module of the test environment is a physical hardware test platform that receives and executes the working condition simulation control signal to reproduce the hydraulic environment corresponding to the target test working condition at its output end, and tests the hydraulic components under test installed on it. The data feedback and model correction module collects the performance data of the tested hydraulic components in real time during the test and feeds it back to the digital twin model simultaneously. The digital twin model adjusts its internal parameters online based on performance data; The performance test report generation module repeatedly executes the operations from the simulation control signal generation module to the data feedback and model correction module to complete the testing of multiple target test conditions; The test control software platform analyzes the performance data under each target test condition and generates a comprehensive performance test report for the tested hydraulic component.

2. The hydraulic component testing system with integrated data acquisition and automatic data analysis functions according to claim 1, characterized in that: The physical hardware testing platform is specifically a modular hardware architecture, consisting of a graded hydraulic power source unit, a circulating cooling and filtration unit, and a signal generator integrated into the same mounting base via hydraulic pipelines and electrical control lines. The test control software platform is developed based on LabVIEW, MATLAB, or industrial control software. The digital twin model integrates sub-models reflecting the hydraulic fluid dynamic characteristics, electrical drive response characteristics, and mechanical friction loss characteristics of the tested hydraulic component.

3. The hydraulic component testing system with integrated data acquisition and automatic data analysis functions according to claim 1, characterized in that: The specific construction process of the digital twin model of the tested hydraulic component includes: Obtain the geometric parameters, material properties, factory performance calibration data, and kinematic pair clearance data of the hydraulic component under test; A three-dimensional flow channel topology model is established based on geometric structural parameters, and a hydraulic fluid dynamics sub-model is constructed by combining the Navier-Stokes equations. Based on material property parameters and kinematic pair clearance data, a mechanical friction loss sub-model including Coulomb friction, viscous damping, and Stribeck effect is established. Based on the drive circuit topology and electromagnetic force-current nonlinear relationship of the tested hydraulic component, an electrical drive response sub-model is constructed, and the electrical drive response sub-model outputs control current to the hydraulic fluid dynamics sub-model. The hydraulic fluid dynamics sub-model, mechanical friction loss sub-model, and electrical drive response sub-model are coupled and integrated through a unified state-space expression, and a data interface consistent with the communication protocol of the hardware test platform is configured.

4. The hydraulic component testing system with integrated data acquisition and automatic data analysis functions according to claim 1, characterized in that: The specific calculation process for the operating condition simulation control signal includes: Retrieve target test condition parameters from the operating condition database. The target test condition parameters include target pressure curve, target flow curve, target oil temperature value, and interference signal waveform. The target pressure curve and target flow curve are input into the hydraulic fluid dynamics sub-model of the digital twin model, and the load simulation signal is calculated through the dynamic response simulation of the hydraulic system under load. The target oil temperature value is input into the thermodynamic sub-model of the digital twin model, and the oil temperature setting signal is generated through temperature regulation simulation. The interference signal waveform is input into the dynamic response sub-model in the digital twin model to generate an interference pressure signal; The load simulation signal, oil temperature setting signal, and interference pressure signal are collectively referred to as the operating condition simulation control signal.

5. The hydraulic component testing system with integrated data acquisition and automatic data analysis functions according to claim 2, characterized in that: The physical reproduction module of the test environment includes outputting pressure and flow through a graded hydraulic power source unit, the specific process of which includes: The graded hydraulic power source unit includes a main pump group, an auxiliary pump group, and a proportional relief valve group. Calculate the total power requirement for the current operating condition based on the pressure and flow setpoints output by the digital twin model; If the total power demand exceeds the set percentage of the rated output power of the main pump group, the auxiliary pump group is started, and the output pressure of the main pump and the auxiliary pump is dynamically distributed through the proportional relief valve group. The system monitors the main pump outlet pressure, auxiliary pump outlet pressure, and system return oil pressure in real time. When the pressure difference between any two lines exceeds the preset tolerance threshold, the control current of the proportional relief valve is adjusted to balance the pressure output.

6. The hydraulic component testing system with integrated data acquisition and automatic data analysis functions according to claim 2, characterized in that: The physical reproduction module of the test environment includes adjusting the hydraulic oil temperature to a set value through a circulating cooling and filtering unit. The specific process includes: The circulating cooling filtration unit includes a heat exchanger, a variable frequency cooling pump, a temperature sensor, and a multi-stage filter. After receiving the oil temperature setting signal output by the digital twin model, the current oil temperature is compared with the set value, and the absolute value of the temperature difference is calculated. If the absolute value of the temperature difference is greater than the upper limit of the absolute value, the variable frequency cooling pump is started, and the pump speed gear is set according to the preset mapping relationship; During the cooling process, the hydraulic oil temperature is collected at fixed intervals. If the absolute value of the temperature difference between three consecutive sampled values ​​and the set value is less than the lower limit of the absolute value, it is determined that the hydraulic oil temperature has reached a steady state, and the cooling pump stops running.

7. The hydraulic component testing system with integrated data acquisition and automatic data analysis functions according to claim 2, characterized in that: The physical reproduction module of the test environment includes injecting an interference pressure signal with a preset amplitude and frequency through a signal generator. The specific process includes: The signal generator is equipped with a programmable waveform generation submodule, a high-frequency servo proportional valve, and a pressure feedback closed-loop controller. The system receives interference pressure signal parameters output by the digital twin model, the parameters including sine wave, square wave or random noise waveform type and corresponding amplitude range and frequency range; Based on the waveform type and parameters, a corresponding control voltage signal is generated, and a high-frequency servo proportional valve is driven to superimpose dynamic pressure disturbance in the main test circuit. The actual superimposed pressure value is collected in real time by a high-frequency pressure sensor installed at the inlet of the hydraulic component under test, and the value is fed back to the pressure feedback closed-loop controller. The pressure feedback closed-loop controller dynamically adjusts the drive current of the high-frequency servo proportional valve based on the deviation between the actual superimposed pressure value and the target interference pressure signal using a PID control algorithm.

8. The hydraulic component testing system with integrated data acquisition and automatic data analysis functions according to claim 1, characterized in that: The specific implementation process of the data feedback and model correction module includes: The pressure difference, flow rate, oil temperature, and motion status data of the tested hydraulic components collected in real time during the test are used as performance data. The performance data is packaged according to the sampling period and uploaded to the digital twin model through a real-time communication interface; The parameter identification unit in the digital twin model updates the leakage coefficient in the hydrodynamic characteristic sub-model, the response delay parameter in the electric drive characteristic sub-model, and the friction torque parameter in the mechanical friction characteristic sub-model based on the residual between the performance data and the model prediction output using the least squares method or Kalman filter algorithm. After each parameter update, the corrected model parameters are stored in the local database, and the version number of the corresponding test condition is marked.

9. The hydraulic component testing system with integrated data acquisition and automatic data analysis functions according to claim 1, characterized in that: The specific implementation process of the performance test report generation module includes: After completing the test of a target test condition, determine whether there are any unexecuted target test conditions. If so, return to the simulation control signal generation module to select the parameters of the next target test condition. If not, then summarize all performance data under the completed target test conditions, including steady-state performance indicators and dynamic response indicators; Based on the performance data, the performance level of the tested hydraulic component under each target test condition is quantitatively scored according to the preset evaluation rules. The scoring results of each target test condition, the original performance data curves, and the model correction records are integrated to generate a structured comprehensive performance test report.

10. The hydraulic component testing system with integrated data acquisition and automatic data analysis functions according to claim 9, characterized in that: The performance test report generation module is configured with a test process optimization unit, the specific implementation process of which includes: Real-time analysis of the relationship between performance data of completed target test conditions and preset pass / fail boundaries; If the performance margin of the tested hydraulic component is better than the acceptable boundary in multiple consecutive target test conditions, then skip the unexecuted conditions that are less than the set threshold in similarity to the tested conditions. If the performance index of the hydraulic component under test exceeds the failure threshold in a certain target test condition, several intermediate transition conditions will be automatically inserted to refine the failure boundary location. All process adjustments are recorded in the test execution log, and the basis for optimization and its impact are explained in the comprehensive performance test report.

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