Rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and control method

Abstract

The application relates to the technical field of electro-hydraulic servo control, in particular to a rotary direct-drive electro-hydraulic servo valve and a control method based on self-sensing remote operation and maintenance, which comprises the following steps: a servo valve drives a valve core to move linearly along the inner wall of a valve sleeve through a rotary direct-drive driving module; a state sensing module collects analog electric signals representing physical parameters in real time and outputs operation state data after analog-digital conversion; a digital control module receives the operation state data and generates driving control electric signals, and the driving control electric signals are transmitted to a motor stator; meanwhile, a remote operation and maintenance module modulates the operation state data into wireless radio frequency signals and transmits the signals to a cloud platform, then receives and analyzes external diagnosis instructions, and changes the output values of the driving control electric signals according to the external diagnosis instructions. The application eliminates transmission clearance by interference press-fitting rolling bearings, and prevents mechanical overtravel by using mechanical limiting surfaces at the end of eccentric elliptical holes, so that high-precision closed-loop control and fault predictive operation and maintenance are finally realized.

Description

Technical Field

[0001] This invention relates to the field of electro-hydraulic servo control technology, and in particular to a rotary direct-drive electro-hydraulic servo valve and control method based on self-sensing remote operation and maintenance. Background Technology

[0002] In precision hydraulic control fields such as aerospace, shipbuilding, metallurgy, and engineering machinery, the operational stability of electro-hydraulic servo valves is highly dependent. These valves play a crucial role in flow regulation and directional control within hydraulic systems. Current hydraulic control systems primarily rely on single position feedback signals for closed-loop regulation, lacking integrated multi-dimensional state sensing modules within the servo valve's internal components. This lack of sensing modules results in incomplete coverage of critical state variables such as temperature fluctuations, pressure transients, and shell vibrations during operation, leading to incomplete information acquisition within the system. Furthermore, the lack of remote monitoring and diagnostic capabilities prevents maintenance centers from real-time tracking of remote equipment operation status; and inefficient data exchange channels hinder the development of intelligent fault analysis algorithms that lack the necessary input foundation.

[0003] Insufficient existing sensing methods and a lack of monitoring and diagnostic capabilities prevent the system from accurately predicting sudden failures, making equipment prone to unexpected shutdowns during operation. After a sudden shutdown, significant time is required for on-site troubleshooting, and the disassembly and repair process is complex, resulting in frequent spare parts replacements. These technical deficiencies lead to high workloads for maintenance personnel, ultimately resulting in substantial equipment maintenance costs, comprised of both direct expenses and indirect losses. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a rotary direct-drive electro-hydraulic servo valve and control method based on self-sensing remote operation and maintenance. This invention solves the technical problem that the lack of multi-dimensional operating status perception and remote monitoring and diagnostic capabilities of servo valves makes it difficult to prevent sudden failures and results in extremely high equipment operation and maintenance costs.

[0005] To solve the above-mentioned technical problems, the specific contents of the present invention are as follows: In a first aspect, the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance provided by the present invention includes equipment components and a control component for communication connection equipment components; The equipment components include a valve body, a valve sleeve fixedly assembled inside the valve body, a valve core slidably passing through the valve sleeve, a motor stator fixedly connected to the valve body, a motor rotor core passing through the motor stator, an eccentric shaft segment fixedly connected to one end of the motor rotor core, and a rolling bearing sleeved outside the eccentric shaft segment. The valve sleeve has an inner wall, and the rolling bearing is in transmission cooperation with the valve core. When the motor rotor core rotates, the rolling bearing drives the valve core to move linearly along the inner wall. The control components include: The status sensing module is deployed on the equipment components to collect analog electrical signals that characterize the physical parameters of the equipment components and perform analog-to-digital conversion to output operating status data. The digital control module, the electrical connection status sensing module, and the motor stator receive operating status data and generate drive control electrical signals, which are then transmitted to the motor stator. The remote operation and maintenance module is electrically connected to the digital control module. It extracts the operating status data and modulates it into a wireless radio frequency signal for transmission to a cloud platform. It receives external diagnostic commands from the cloud platform, parses the external diagnostic commands and inputs them into the digital control module. The digital control module changes the output value of the drive control electrical signal according to the external diagnostic commands.

[0006] Furthermore, the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance described in this invention includes a bushing, a first bearing, and a second bearing. The upper surface of the valve body is machined with a mounting part, and the bushing is fixedly connected to the mounting part. The motor stator is fixedly fitted onto the outer circumferential surface of the bushing, and the bushing forms a physical isolation layer between the motor stator and the hydraulic oil flowing inside the valve body. The motor rotor core passes through the inner hole of the bushing. The upper end of the motor rotor core away from the eccentric shaft section is fitted with the first bearing and rotatably supported inside the bushing. The lower end of the motor rotor core near the eccentric shaft section is fitted with the second bearing and rotatably supported inside the valve body. The first bearing and the second bearing convert the rotational sliding friction of the motor rotor core into rolling friction. The equipment components also include a connecting rod. A connecting rod section extends integrally from the end of the motor rotor core. The connecting rod section is constructed as a connecting rod. The end of the connecting rod away from the motor rotor core is fixedly connected to an eccentric shaft section. An eccentric elliptical hole with an elliptical cross-section is opened inside the end of the valve core near the eccentric shaft section. The eccentric elliptical hole has an inner sidewall. The rolling bearing is housed inside the eccentric elliptical hole, and the outer surface of the rolling bearing contacts the inner sidewall.

[0007] Furthermore, the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance described in this invention has an eccentric elliptical hole with an internal bottom surface. The internal bottom surface is constructed as a mechanical limiting surface. The digital control module generates a limit deflection electrical signal and sends the limit deflection electrical signal to the motor stator. The motor stator receives the limit deflection electrical signal and generates a magnetic field to drive the motor rotor core to rotate to the maximum set angle value. The motor rotor core drives the rolling bearing to rotate synchronously. The outer surface of the rolling bearing directly abuts against the mechanical limiting surface, restricting the valve core from continuing to move in the same direction.

[0008] Furthermore, in the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance described in this invention, the rolling bearing has an outer contour cross-sectional dimension, and the eccentric elliptical hole has an inner cross-sectional dimension when not under stress. The outer contour cross-sectional dimension is larger than the inner cross-sectional dimension. The rolling bearing is pressed into the eccentric elliptical hole by interference, so that the outer surface of the rolling bearing and the inner sidewall are elastically deformed and fitted together.

[0009] Furthermore, the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance described in this invention includes a status sensing module comprising a temperature sensor, a pressure sensor, and a rotation angle sensor. Physical parameters include valve body surface temperature, fluid pressure, and rotor rotation angle. Analog electrical signals include temperature analog signals, pressure analog signals, and rotation angle analog signals. The temperature sensor is attached to the valve body surface, collects the temperature analog signal representing the valve body surface temperature, and converts it into a temperature value. A fluid pipeline is provided inside the valve body, and the pressure sensor is assembled inside the fluid pipeline, collects the pressure analog signal representing the fluid pressure, and converts it into a fluid pressure value. The rotation angle sensor is aligned with the motor rotor core, collects the rotation angle analog signal representing the rotor rotation angle, and converts it into a rotation angle value. The fluid pressure value and the rotation angle value are combined to generate operating status data. This operating status data is continuously transmitted to the digital control module. The digital control module has an embedded displacement calculation algorithm. The digital control module extracts the rotation angle value from the operating status data, performs trigonometric function calculations in conjunction with a preset eccentricity parameter, calculates the displacement estimation data representing the linear movement distance of the valve core, and uses this to construct a position closed-loop control.

[0010] Furthermore, the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance described in this invention includes a digital control module comprising a microprocessor chip and an electric drive component. The microprocessor chip internally stores a fault determination rule model, which includes a historical normal reference dataset. The microprocessor chip receives operating status data and inputs it into the fault determination rule model. The fault determination rule model calculates the numerical difference between the operating status data and the historical normal reference dataset, outputs the deviation result value, and uses a preset mapping relationship to convert the deviation result value into an equipment health score value. The microprocessor chip receives the equipment health score value and an external input control command, summarizes the equipment health score value and the external input control command to calculate the target drive current value, and sends a weak current control signal corresponding to the target drive current value to the electric drive component. The electric drive component receives the weak current control signal and supplies a drive current corresponding to the target drive current value to the motor stator. The drive current constitutes a drive control electrical signal, and the motor stator receives the drive current and generates an electromagnetic field.

[0011] Furthermore, the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance described in this invention includes a remote operation and maintenance module comprising a wireless communication component and a life assessment component. The wireless communication component is electrically connected to a microprocessor chip and extracts equipment health score values. The wireless communication component modulates the equipment health score values ​​into wireless radio frequency signals and transmits them to a cloud platform. The life assessment component internally stores equipment failure thresholds. The life assessment component retrieves multiple equipment health score values ​​within a continuous time period in chronological order, constructs a two-dimensional coordinate system data point with the time values ​​and multiple equipment health score values, and fits and generates an analytical expression for the performance degradation curve. The life assessment component calculates the coordinates of the intersection point of the performance degradation curve analytical expression and the equipment failure threshold, and extracts the time span value corresponding to the intersection coordinates as the remaining usage time value for output.

[0012] Furthermore, the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance described in this invention includes a remote operation and maintenance module comprising an early warning triggering component. The early warning triggering component internally stores multiple warning limit values. The early warning triggering component receives the equipment health score value and compares the equipment health score value with the multiple warning limit values ​​one by one. When the calculated equipment health score value exceeds a specific warning limit value, a graded alarm signal matching the specific warning limit value is generated. The early warning triggering component inputs the graded alarm signal to the wireless communication component, and the wireless communication component converts the graded alarm signal into a wireless radio frequency signal and transmits it to the cloud platform.

[0013] Furthermore, in the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance described in this invention, the microprocessor chip pre-stores the initial drive current configuration parameters. The cloud platform receives the graded alarm signal and sends a parameter correction data packet as an external diagnostic instruction to the wireless communication component. The wireless communication component receives the parameter correction data packet and decodes the communication protocol, outputting local update parameters to the microprocessor chip. The microprocessor chip receives and uses the local update parameters to overwrite and replace the initial drive current configuration parameters. The microprocessor chip calculates the corrected weak current control signal based on the replaced local update parameters and sends it to the electric drive component. The electric drive component receives the corrected weak current control signal and changes the drive current supplied to the motor stator. The motor stator changes the deflection angle of the motor rotor core according to the changed drive current, driving the valve core to change the linear movement stroke coordinate.

[0014] Secondly, the rotary direct-drive electro-hydraulic servo valve control method based on self-sensing remote operation and maintenance provided by the present invention is applied to the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance as described above, including: Step 1: Collect analog electrical signals that characterize the physical parameters of the equipment components through status sensing modules deployed on the equipment components, and output the operating status data after analog-to-digital conversion processing; Step 2: The digital control module receives the operating status data and generates a drive control electrical signal, which is then sent to the motor stator to drive the motor rotor core to rotate and cause the valve core to move linearly along the inner wall of the valve sleeve. Step 3: The remote operation and maintenance module extracts the operating status data and modulates it into a wireless radio frequency signal to transmit to the cloud platform. At the same time, it receives external diagnostic commands from the cloud platform and inputs the parsed external diagnostic commands into the digital control module. The digital control module then changes the output value of the drive control electrical signal according to the external diagnostic commands.

[0015] Beneficial effects of this invention: The core power transmission of the rotary direct-drive electro-hydraulic servo valve relies on the direct mechanical connection between the motor rotor core and the valve core. An eccentric shaft section connected to the end of the motor rotor core is fitted with a rolling bearing, and the valve core has an eccentric elliptical hole with an elliptical cross-section. The rolling bearing is press-fitted into the eccentric elliptical hole, and this interference fit causes elastic deformation between the outer surface of the rolling bearing and the inner wall of the eccentric elliptical hole, thus directly eliminating mechanical backlash during the mechanical transmission process. When the motor stator is energized, it generates a magnetic field and drives the motor rotor core to rotate. The rolling bearing rotates accordingly and rolls inside the eccentric elliptical hole. This rolling motion converts the circumferential displacement into linear displacement of the valve core along the inner wall of the valve sleeve, replacing traditional sliding friction with rolling friction and reducing the rate of mechanical wear. Simultaneously, the bottom surface inside the eccentric elliptical hole is constructed as a mechanical limiting surface. When the motor rotor core reaches its maximum set angle, the outer surface of the rolling bearing directly abuts against the mechanical limiting surface, using rigid physical impact to block the valve core from continuing to move in the same direction. Ultimately, this mechanical linkage mechanism physically cuts off the control lag caused by transmission backlash at the fundamental level.

[0016] Traditional hydraulic control systems rely on single position signals for closed-loop regulation. The rotary direct-drive electro-hydraulic servo valve control method, based on self-sensing remote operation and maintenance, constructs multi-dimensional data acquisition nodes by deploying temperature, pressure, and rotation angle sensors. Temperature sensors acquire simulated electrical signals of temperature from the valve body surface, pressure sensors acquire simulated electrical signals of pressure from inside the fluid pipeline, and rotation angle sensors acquire simulated electrical signals of rotor rotation angle. These various simulated electrical signals are processed through analog-to-digital conversion to generate operating status data. The microprocessor chip retrieves a fault determination rule model containing historical normal reference datasets from its internal storage. This model receives the operating status data and calculates the difference between the operating status data and the historical normal reference dataset, then converts the difference into a quantified equipment health score. The microprocessor chip aggregates the equipment health score and external input control commands to calculate the target drive current value. The electric drive component then delivers the drive current corresponding to the target drive current value to the motor stator. The electromagnetic field intensity generated by the drive current is adjusted in real-time based on the equipment health score value. This multi-dimensional data fusion computation mechanism overcomes the limitation of a single feedback mechanism in capturing sudden disturbances.

[0017] Data silos caused by remote equipment operation increase maintenance costs. Status data collected during the control process is synchronously integrated into the remote data interaction link. The wireless communication component modulates the equipment health score values ​​into radio frequency signals and transmits them to the cloud platform. The lifespan assessment component extracts multiple equipment health score values ​​over a continuous time period, constructing data points in a two-dimensional coordinate system using the time values ​​and multiple health score values. These data points are fitted to generate an analytical expression for a performance degradation curve. The intersection coordinates of this performance degradation curve with a preset equipment failure threshold are directly output as the remaining usage time. When the equipment health score value exceeds the warning limit, the warning trigger component generates a tiered alarm signal and pushes it to the cloud platform. The cloud platform receives the tiered alarm signal and sends a parameter correction data packet. The wireless communication component receives and parses the parameter correction data packet to generate local update parameters. The microprocessor chip uses these local update parameters to overwrite and replace the initial drive current configuration parameters, causing the changed drive current to readjust the deflection angle of the motor rotor core. The closed-loop diagnostic and dynamic parameter correction mechanism compensates for potential zero-point drift errors in the hydraulic system in advance, transforming sudden downtime into a planable predictive maintenance process, and ultimately reducing the overall operation and maintenance costs of equipment in precision hydraulic control scenarios. Attached Figure Description

[0018] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on the drawings without creative effort.

[0019] Figure 1 This is a three-dimensional exploded structural diagram of the rotary direct-drive electro-hydraulic servo valve provided in an embodiment of the present invention.

[0020] Figure 2 yes Figure 1 A partially enlarged schematic diagram of the core components of the medium-speed rotary direct drive transmission module.

[0021] Figure 3 This is a cross-sectional schematic diagram of the rotary direct-drive electro-hydraulic servo valve provided in an embodiment of the present invention.

[0022] Explanation of reference numerals in the attached drawings: 1-valve body, 2-valve sleeve, 3-valve core, 31-eccentric elliptical hole, 311-mechanical limiting surface, 4-left end cover, 5-right end cover, 6-top cover, 7-motor stator, 8-motor rotor core, 81-connecting rod, 82-eccentric shaft section, 9-rolling bearing, 10-shield, 11-first bearing, 12-second bearing. Detailed Implementation

[0023] To make the technical solution of the present invention clearer, the present invention will be clearly and completely described below with reference to specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. 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. The various embodiments of the present invention will be described in detail below with reference to the accompanying drawings. To better understand the purpose of the present invention, the present invention will be described in further detail below.

[0024] Firstly, please refer to Figures 1 to 3 The rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance provided by the present invention includes equipment components and control components for communication connection equipment components; The equipment components include a valve body 1, a valve sleeve 2 fixedly assembled inside the valve body 1, a valve core 3 slidably passing through the valve sleeve 2, a motor stator 7 fixedly connected to the valve body 1, a motor rotor core 8 passing through the motor stator 7, an eccentric shaft section 82 fixedly connected to one end of the motor rotor core 8, and a rolling bearing 9 sleeved on the outside of the eccentric shaft section 82. The valve sleeve 2 has an inner wall inside, and the rolling bearing 9 is in transmission cooperation with the valve core 3. When the motor rotor core 8 rotates, the rolling bearing 9 drives the valve core 3 to move linearly along the inner wall. The control components include: The status sensing module is deployed on the equipment components to collect analog electrical signals that characterize the physical parameters of the equipment components and perform analog-to-digital conversion to output operating status data. The digital control module, the electrical connection status sensing module, and the motor stator 7 receive operating status data and generate drive control electrical signals, which are then transmitted to the motor stator 7. The remote operation and maintenance module is electrically connected to the digital control module. It extracts the operating status data and modulates it into a wireless radio frequency signal for transmission to a cloud platform. It receives external diagnostic commands from the cloud platform, parses the external diagnostic commands and inputs them into the digital control module. The digital control module changes the output value of the drive control electrical signal according to the external diagnostic commands.

[0025] The underlying hardware architecture of the self-sensing remote operation and maintenance rotary direct-drive electro-hydraulic servo valve relies on a precision mechanical transmission chain to achieve kinetic energy transmission; a valve sleeve 2 is fixedly assembled inside the valve body 1, and a valve core 3 slides through the valve sleeve 2. One end of the valve body 1 is connected to a motor stator 7, and a motor rotor core 8 is arranged inside the motor stator 7.

[0026] To meet the mechanical stability requirements under high-frequency reciprocating regulation conditions, a cylindrical bushing 10 is fixedly mounted on the upper surface of the valve body 1. The motor stator 7 is interference-fitted onto the outer circumference of the bushing 10. The bushing 10 itself forms a physical water barrier, completely isolating the electromagnetic winding of the motor stator 7 from the hydraulic oil flowing through the high-pressure chamber inside the valve body 1, eliminating the potential for coil insulation failure caused by hydraulic oil erosion. The motor rotor core 8 is longitudinally inserted into the internal through hole of the bushing 10. A first bearing 11 is press-fitted at the top of the motor rotor core 8 away from the eccentric shaft section 82, and the outer ring of the first bearing 11 is fixedly fitted into the bearing hole inside the bushing 10; a second bearing 12 is press-fitted at the bottom of the motor rotor core 8 near the eccentric shaft section 82, and the outer ring of the second bearing 12 is fixedly connected to the inner wall support surface of the valve body 1. The first bearing 11 and the second bearing 12 form a stable double-end support mechanical structure, ensuring that the geometric center axis of the motor rotor core 8 is closely aligned with the center axis of the motor stator 7, thus physically suppressing the radial runout amplitude of the motor rotor core 8 during high-frequency commutation.

[0027] To convert rotational motion into linear displacement, a connecting rod section extends integrally from the end of the motor rotor core 8 to form a connecting rod 81. The end of the connecting rod 81 away from the motor rotor core 8 is fixedly connected to an eccentric shaft section 82. An eccentric elliptical hole 31 with an elliptical cross-section is opened inside the end face of the valve core 3 near the eccentric shaft section 82; the rolling bearing 9 is sleeved on the outside of the eccentric shaft section 82 and housed inside the eccentric elliptical hole 31.

[0028] To eliminate the mechanical dead zone during reversing, the outer profile cross-sectional dimension of the rolling bearing 9 is designed to be larger than the internal cross-sectional dimension of the eccentric elliptical bore 31 under no-stress conditions. During assembly, a press-fit process is used to press the rolling bearing 9 into the eccentric elliptical bore 31, forcing a microscopic elastic deformation fit between the outer surface of the rolling bearing 9 and the inner wall of the eccentric elliptical bore 31. When the servo valve is in the aircraft flight control actuation surface adjustment mode, the motor rotor core 8 generates rotational torque, causing the eccentric shaft section 82 to deflect. The rolling bearing 9 rotates accordingly and rolls inside the eccentric elliptical bore 31. The change in the trajectory of the rolling outer circle applies a lateral thrust to the inner wall of the eccentric elliptical bore 31, thereby driving the valve core 3 to move linearly along the inner wall of the valve sleeve 2 without sliding friction.

[0029] Continuous high-frequency reciprocating motion scenarios require the setting of rigid limits to prevent mechanical damage caused by exceeding the physical stroke. An internal bottom surface is machined into the eccentric elliptical hole 31, which directly constitutes a mechanical limiting surface 311 in three-dimensional space. When the digital control module receives a full-stroke start command or detects a risk of uncontrolled deflection, it inputs a limit deflection electrical signal to the winding port of the motor stator 7, indicating that the motor has reached electrical saturation.

[0030] The motor stator 7 uses the limit deflection electrical signal to excite the maximum intensity electromagnetic field, driving the motor rotor core 8 to rotate to the maximum set angle value allowed by the mechanical structure; at the same time, the rolling bearing 9 deflects synchronously to the limit spatial coordinate position, and the outer surface of the rolling bearing 9 directly abuts against the mechanical limit surface 311, using the rigid collision of the metal parts to block the spatial passage of the valve core 3 to continue moving in the same direction.

[0031] The execution of underlying mechanical actions is accompanied by changes in multidimensional environment and state variables. The state perception module is responsible for the continuous quantitative acquisition of physical parameters. The state perception module includes a temperature sensor attached to the surface of valve body 1, a pressure sensor arranged in the fluid pipeline inside valve body 1, and a rotation angle sensor aligned with the end face of valve core 3. The temperature sensor uses a thermistor material to acquire a temperature analog electrical signal representing the surface temperature of the valve body, the pressure sensor uses a piezoelectric crystal to acquire a pressure analog electrical signal representing the fluid pressure, and the rotation angle sensor uses a differential transformer structure to acquire a rotation angle analog electrical signal representing the rotor rotation angle.

[0032] The analog front-end hardware circuit performs low-pass filtering and signal amplification on the analog temperature, pressure, and angle signals. Then, the analog-to-digital converter (ADC) converts the amplified analog voltages into discrete digital codes at a fixed sampling frequency, outputting temperature values ​​in °C, fluid pressure values ​​in MPa, and angle values ​​in mm, respectively. The microprocessor chip concatenates the temperature, fluid pressure, and angle values ​​at the same timestamp according to a preset data frame format, generating operational status data containing a multi-dimensional variable matrix. Finally, the operational status data is continuously transmitted to the digital control module at a fixed baud rate via the internal data bus.

[0033] The digital control module undertakes the core computing power tasks of local closed-loop regulation and equipment health assessment. The microprocessor chip internally stores a fault determination rule model pre-trained using a large number of experimental samples, and the storage unit also carries a historical normal reference dataset. After the operating status data is input into the fault determination rule model, the mathematical algorithm reads the multidimensional variable matrix in the operating status data and retrieves the benchmark feature vector of the corresponding operating condition dimension from the historical normal reference dataset.

[0034] The fault determination rule model uses Mahalanobis distance mathematical logic to calculate the spatial geometric distance between the matrix vector composed of the current operating status data and the baseline feature vector, defining the calculated spatial geometric distance as the numerical difference. The conversion algorithm retrieves a preset mapping relationship and uses an inverse proportional function expression to map the numerical difference to a percentage-based equipment health score value between 0 and 100; an increase in the numerical difference will cause a non-linear decay in the equipment health score value.

[0035] When executing position closed-loop adjustment commands, the digital control module abandons the existing direct displacement measurement mechanism. The angle detection element inside the state sensing module captures the high-frequency rotation of the motor rotor core 8 in real time, outputting high-resolution angle values. The microprocessor chip retrieves the angle value and calls the geometric eccentricity parameters of the eccentric shaft segment 82 stored in its internal read-only memory. The arithmetic logic unit of the microprocessor chip uses a trigonometric function mapping matrix to multiply the angle value in circular motion with the geometric eccentricity parameters, calculating in real time the displacement estimate of the valve core 3 sliding along the inner wall of the valve sleeve 2. The digital control module compares the displacement estimate with the target position command issued by the external diagnostic command, generating a dynamic compensation signal for adjusting the deflection angle of the motor rotor core 8. This indirect calculation mechanism effectively avoids interference from hydraulic oil contaminants on the direct displacement sensor, improving the position closed-loop control link's resistance to harsh environments.

[0036] The microprocessor chip receives an external input control command from an external industrial control bus, and combines the equipment health score value with the external input control command. It then superimposes a gain compensation coefficient representing wear characteristics into the position closed-loop PID algorithm to calculate the target drive current value required to maintain the target valve opening. The microprocessor chip's pulse width modulation port sends a weak current control signal with a duty cycle corresponding to the target drive current value to the electric drive component. The power semiconductor switch inside the electric drive component performs high-frequency chopping based on the weak current control signal, supplying a drive current corresponding to the target drive current value to the motor stator 7 winding. This continuously changing drive current serves as the core drive control electrical signal, exciting the motor stator 7 to generate a rotating electromagnetic field.

[0037] While the local hardware nodes are operating, the remote maintenance module simultaneously conducts long-term lifecycle tracking. The wireless communication component is electrically connected to the microprocessor chip through an internal serial interface to extract the equipment health score value representing the current mechanical wear level. The wireless communication component converts the equipment health score value into a wireless radio frequency signal with a specific carrier frequency using a radio frequency transceiver chip, and transmits it to a cloud platform through an antenna for distributed recording.

[0038] The lifespan assessment component internally includes a non-volatile storage area to store constant-valued device failure thresholds. Following a chronological order based on system time, the component retrieves thousands of device health scores from a cloud database for consecutive time periods. The assessment engine defines the time values ​​as the horizontal axis and the device health score values ​​as the vertical axis, constructing a large number of two-dimensional coordinate data points in a virtual two-dimensional space. The mathematical fitting module uses the least squares method to perform exponential descent trajectory fitting on the two-dimensional coordinate data points, generating an analytical expression for a performance degradation curve that fully characterizes the aging trend of the component. The equation solving unit calculates the mathematical intersection coordinates of the performance degradation curve and the constant-term device failure threshold. The microprocessor extracts the time span value pointed to by the horizontal axis of the intersection coordinates and defines the time span value as the remaining usage time value, outputting it to the maintenance display terminal window.

[0039] Abnormal operating conditions are usually accompanied by parameter exceeding limits, and the early warning triggering component is responsible for identifying sudden parameter changes. The read-only memory of the early warning triggering component contains multiple warning threshold values ​​representing different hazard levels. The component receives the device health score value output by the microprocessor chip and performs difference comparisons between the device health score value and each of the multiple warning threshold values ​​in the comparator hardware unit. When the logic processing module detects a rapid decrease in the device health score value and its exceeding a specific warning threshold value, the circuit automatically activates the internal alarm execution stack, generating a graded alarm signal that matches the specific warning threshold value.

[0040] The early warning triggering component converts the graded alarm signal into high and low level data packets and inputs them to the wireless communication component. The wireless communication component encapsulates the graded alarm signal into a radio frequency signal according to the TCP / IP protocol stack specification and transmits it to the cloud platform. Upon receiving the graded alarm signal, the cloud platform allocates computing power to run a diagnostic algorithm, searching for the optimal electronic control parameters to compensate for the static error caused by current mechanical wear, and sends parameter correction data packets as external diagnostic instructions to the wireless communication component. The wireless communication component receives the parameter correction data packets and invokes the communication protocol decoding program to remove the checksum and additional information from the frame header and trailer, outputting the payload as local update parameters for transmission to the microprocessor chip.

[0041] The microprocessor chip has a pre-allocated flash memory sector to store the initial drive current configuration parameters. Upon receiving the local update parameters, the microprocessor chip triggers a low-level erase / write command, replacing the original initial drive current configuration parameters with the updated local parameters. Subsequently, the microprocessor chip re-substitutes the replaced local update parameters into the drive equation calculation model to calculate a corrected weak current control signal with drift compensation attributes, which is then sent to the electric drive component. The electric drive component receives the corrected weak current control signal, adjusts the duty cycle amplification factor of its internal isolated drive circuit, and changes the final drive current value delivered to the motor stator 7 winding. The motor stator 7, based on the changed drive current value, excites a new magnetic field strength after correction, thereby changing the actual deflection angle of the motor rotor core 8, which in turn drives the valve core 3 to change its linear travel coordinate.

[0042] Secondly, the rotary direct-drive electro-hydraulic servo valve control method based on self-sensing remote operation and maintenance provided by the present invention is applied to the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance as described above, including: Step 1: Collect analog electrical signals that characterize the physical parameters of the equipment components through status sensing modules deployed on the equipment components, and output the operating status data after analog-to-digital conversion processing; Step 2: The digital control module receives the operating status data and generates a drive control electrical signal, which is then sent to the motor stator 7 to drive the motor rotor core 8 to rotate and cause the valve core 3 to move linearly along the inner wall of the valve sleeve 2. Step 3: The remote operation and maintenance module extracts the operating status data and modulates it into a wireless radio frequency signal to transmit to the cloud platform. At the same time, it receives external diagnostic commands from the cloud platform and inputs the parsed external diagnostic commands into the digital control module. The digital control module then changes the output value of the drive control electrical signal according to the external diagnostic commands.

[0043] The status sensing module deployed on the equipment components includes a temperature sensor integrated on the outside of the valve body 1, a pressure sensor located at the hydraulic port, and a speed sensor located at the end of the motor. The multi-channel sensor array captures physical parameters reflecting the mechanical operating conditions in real time, and the physical parameters are converted into continuously changing analog electrical signals. The analog front-end circuit performs low-pass filtering and signal conditioning on the analog electrical signals, and the analog-to-digital converter converts the conditioned signals into quantized values ​​according to the preset sampling frequency and outputs the operating status data.

[0044] The operating status data, as a digital set reflecting the real-time operating conditions of the servo valve, specifically includes temperature values ​​representing environmental conditions, pressure values ​​representing hydraulic circuit load pressure, coordinate values ​​representing valve core axial displacement, and frequency values ​​representing motor rotation position. The digital control module encapsulates the above discrete values ​​to form a feature vector sequence with timestamp information. The feature vector sequence can fully present the pressure fluctuation and structural vibration characteristics of the servo valve when the actuator is subjected to aerodynamic load impact in aerospace precision hydraulic control scenarios.

[0045] After acquiring the operating status data, the digital control module runs a deviation closed-loop control algorithm through its internal processor, comparing the position command with the feedback displacement of the valve core 3. The calculation result is converted into a specific pulse width modulation signal through a preset control gain mapping logic, and then converted by the power drive circuit to generate a drive control electrical signal. The drive control electrical signal is sent to the motor stator 7, and the electromagnetic coil inside the motor stator 7 generates a rotating magnetic field under current excitation, which drives the motor rotor core 8 located inside the magnetic field to generate a rotational torque.

[0046] Rotational power is transmitted to the eccentric shaft section 82 at the motor shaft end via the integrally formed connecting rod 81; the eccentric shaft section 82 drives the rolling bearing 9 sleeved on the outside to roll within the eccentric elliptical hole 31 at the driving end of the valve core 3; by utilizing the geometric constraints of the eccentric elliptical hole 31, the circumferential rolling displacement of the rolling bearing 9 is converted into the axial linear displacement of the valve core 3 along the inner wall of the valve sleeve 2; the mechanical limiting surface 311 at the end of the eccentric elliptical hole 31 limits the maximum operating boundary of the rolling bearing 9, preventing the valve core 3 from overtravel.

[0047] The wireless communication chip integrated into the remote operation and maintenance module extracts the operating status data from the digital control module. Through frequency modulation technology, the operating status data is loaded onto a carrier signal of a specific band, forming a wireless radio frequency signal, which is then transmitted to the cloud platform. The wireless radio frequency signal is received by the cloud platform across the spatial link. The cloud platform uses the stored health assessment model to perform in-depth analysis on the feature vector sequence to identify potential risks such as hydraulic oil deterioration, valve wear, or motor degradation. The technical judgment results generated by the analysis are converted into external diagnostic instructions containing control parameter adjustment amounts or maintenance warning information.

[0048] The remote operation and maintenance module receives external diagnostic commands from the cloud platform through a two-way communication link. The communication protocol processor performs noise reduction and frame de-framing on the received data stream to extract the parsed external diagnostic commands. The parsed external diagnostic commands are input to the digital control module. The digital control module modifies the proportional, integral, or derivative parameters inside the control algorithm according to the external diagnostic commands, thereby changing the current amplitude or frequency of the drive control electrical signal output to the motor stator 7.

[0049] Through the above dynamic closed-loop adjustment process, the servo valve can compensate for zero-position drift or response hysteresis caused by long-term wear based on the remote diagnostic results, realizing a data closed loop from sensor-level perception to cloud-based intelligent decision-making and then to precise control of the actuator. In business scenarios such as ship steering gear control or precision operation of engineering machinery, the above data flow process can transform the static passive maintenance mode into predictive maintenance logic based on operating status data.

[0050] As a further extension of the technical solution of the present invention, the following is a specific embodiment focusing on the underlying hardware collaborative scheduling and instruction execution physical link: The self-sensing remote operation and maintenance rotary direct-drive electro-hydraulic servo valve is deployed within the aircraft flight control actuation surface adjustment system. The hardware architecture of the status sensing module relies on a high-precision analog-to-digital conversion channel. Temperature, pressure, and angle sensors output continuously changing analog electrical signals. These signals are fed into an independent operational amplifier at the front end of the microprocessor chip for impedance matching and high-frequency noise filtering. The microprocessor chip integrates a 16-bit resolution analog-to-digital converter peripheral. An internal timer peripheral generates an overflow event according to a fixed clock division factor, triggering the analog-to-digital converter peripheral to initiate a hardware sampling sequence. The analog-to-digital converter peripheral stores the converted operating status data into an internal result register. The direct memory access controller within the microprocessor chip responds to the status flag bit of the result register, automatically transferring the operating status data to a consecutive address range in static random access memory without occupying a CPU core clock cycle.

[0051] The completion of data transfer triggers an internal hardware interrupt signal in the microprocessor chip. The CPU core suspends the currently processing background task and jumps the program pointer to the pre-allocated interrupt service routine. Inside the interrupt service routine, the arithmetic logic unit (ALU) reads the operating status data from the static random access memory (SRAM) via the internal high-speed data bus. The microprocessor chip's multiply-accumulate instruction module performs matrix operations on the operating status data and the factory calibration coefficients stored in the read-only memory sector, outputting a device health score value that eliminates zero-bit bias. The microprocessor chip receives external input control commands from the aircraft's master control bus node. The microprocessor chip uses the ALU to summarize the device health score value and the external input control commands, calculating and outputting the target drive current value required to maintain the target throttling area of ​​the valve orifice.

[0052] The target drive current value is directly written into the capture-compare register of the advanced control timer inside the microprocessor chip. The advanced control timer dynamically updates the duty cycle width of the pulse width modulation waveform based on the overload value of the capture-compare register, generating a weak current control signal with a specific duty cycle. This weak current control signal is transmitted to the internal gate drive circuit of the power drive assembly via a high-speed opto-isolation chip. The gate drive circuit controls the on / off state of the power switch transistor, injecting a high-frequency chopped drive current into the coil windings of the motor stator 7. The coils inside the motor stator 7 generate a rotating electromagnetic field under the excitation of the drive current. This rotating electromagnetic field drives the motor rotor core 8 to overcome static friction torque and rotate. The motor rotor core 8 drives the eccentric shaft section 82 to rotate synchronously via the connecting rod 81. The rolling bearing 9, sleeved outside the eccentric shaft section 82, rolls inside the eccentric elliptical hole 31. The outer surface of the rolling bearing 9 applies a normal thrust to the inner wall of the eccentric elliptical hole 31, driving the valve core 3 to overcome the hydraulic flow force and move axially in a straight line along the inner wall of the valve sleeve 2, thereby changing the flow area of ​​the fluid pipeline inside the valve body 1.

[0053] For the cloud data interaction link, the microprocessor chip is equipped with an independent high-speed serial peripheral interface bus. The microprocessor chip writes the device health score value into the transmit data register of the serial peripheral interface bus. The wireless communication component receives the clock synchronization signal and data bit stream from the data bus, and pushes the underlying data bit stream into the on-chip transmit FIFO buffer. The RF baseband processing core reads the byte sequence in the transmit FIFO buffer, uses quadrature amplitude modulation technology to generate a high-frequency carrier wireless RF signal, and transmits it to the cloud platform through an external antenna. After the antenna end of the wireless communication component receives the wireless RF signal sent from the cloud platform, the internal baseband demodulation circuit stores the demodulated parameter correction data packet into the receive FIFO buffer and sends a level toggling pulse to the external interrupt pin of the microprocessor chip.

[0054] The microprocessor chip responds to external hardware interrupts and retrieves local update parameters from the serial bus. It writes a specific unlock sequence to the key register of the internal flash memory controller, releasing the programming protection state of the built-in flash memory sector and overwriting the local update parameters into the specified flash memory page address range. The microprocessor chip resets the protection bits of the flash memory controller, and the control logic reloads the local update parameters from the flash memory page address. Based on the compensation factor included in the local update parameters, the microprocessor chip adjusts the value written to the capture-compare register, correcting the amplitude of the drive current output to the motor stator 7. The motor stator 7 generates a compensating magnetic field based on the corrected drive current, driving the motor rotor core 8 to rotate the eccentric shaft segment 82, fine-tuning the dwell position of the rolling bearing 9 within the eccentric elliptical hole 31, and compensating for the actual stroke deviation of the valve core 3 caused by mechanical wear.

Claims

1. A rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance, characterized in that, Control components, including equipment parts and communication connection equipment parts; The equipment components include a valve body (1), a valve sleeve (2) fixedly assembled inside the valve body (1), a valve core (3) slidably passing through the valve sleeve (2), a motor stator (7) fixedly connected to the valve body (1), a motor rotor core (8) passing through the motor stator (7), an eccentric shaft section (82) fixedly connected to one end of the motor rotor core (8), and a rolling bearing (9) sleeved outside the eccentric shaft section (82). The valve sleeve (2) has an inner wall inside. The rolling bearing (9) is in transmission cooperation with the valve core (3). When the motor rotor core (8) rotates, the rolling bearing (9) drives the valve core (3) to move linearly along the inner wall. The control components include: The status sensing module is deployed on the equipment components to collect analog electrical signals that characterize the physical parameters of the equipment components and perform analog-to-digital conversion to output operating status data. The digital control module, the electrical connection status sensing module and the motor stator (7) receive the operating status data and generate the drive control electrical signal, and send the drive control electrical signal to the motor stator (7). The remote operation and maintenance module is electrically connected to the digital control module. It extracts the operating status data and modulates it into a wireless radio frequency signal for transmission to a cloud platform. It receives external diagnostic commands from the cloud platform, parses the external diagnostic commands and inputs them into the digital control module. The digital control module changes the output value of the drive control electrical signal according to the external diagnostic commands.

2. The rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance according to claim 1, characterized in that, The equipment components include a bushing (10), a first bearing (11), and a second bearing (12). The upper surface of the valve body (1) is machined with a mounting part, and the bushing (10) is fixedly connected to the mounting part. The motor stator (7) is fixedly fitted on the outer circumferential surface of the bushing (10). The bushing (10) forms a physical isolation layer between the motor stator (7) and the hydraulic oil flowing inside the valve body (1). The motor rotor core (8) passes through the inner hole of the bushing (10). The upper end of the motor rotor core (8) away from the eccentric shaft section (82) is fitted with the first bearing (11) and rotated and supported inside the bushing (10). The lower end of the motor rotor core (8) near the eccentric shaft section (82) is fitted with the second bearing (12) and rotated and supported inside the valve body (1). The first bearing (11) and the second bearing (12) convert the rotational sliding friction of the motor rotor core (8) into rolling friction. The equipment components also include a connecting rod (81). A connecting rod section extends integrally from the end of the motor rotor core (8). The connecting rod section is constructed as a connecting rod (81). The end of the connecting rod (81) away from the motor rotor core (8) is fixedly connected to an eccentric shaft section (82). The valve core (3) has an eccentric elliptical hole (31) with an elliptical cross-section at the end near the eccentric shaft section (82). The eccentric elliptical hole (31) has an inner sidewall. The rolling bearing (9) is housed inside the eccentric elliptical hole (31). The outer surface of the rolling bearing (9) contacts the inner sidewall.

3. The rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance according to claim 2, characterized in that, The eccentric elliptical hole (31) has an inner bottom surface, which is constructed as a mechanical limiting surface (311). The digital control module generates a limit deflection electrical signal and sends the limit deflection electrical signal to the motor stator (7). The motor stator (7) receives the limit deflection electrical signal and generates a magnetic field to drive the motor rotor core (8) to rotate to the maximum set angle value. The motor rotor core (8) drives the rolling bearing (9) to rotate synchronously. The outer surface of the rolling bearing (9) directly abuts against the mechanical limiting surface (311), limiting the valve core (3) to continue moving in the same direction.

4. The rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance according to claim 3, characterized in that, The rolling bearing (9) has an outer contour cross-sectional dimension, and the eccentric elliptical hole (31) has an inner cross-sectional dimension when it is not under stress. The outer contour cross-sectional dimension is larger than the inner cross-sectional dimension. The rolling bearing (9) is pressed into the eccentric elliptical hole (31) by interference, so that the outer surface of the rolling bearing (9) and the inner sidewall are elastically deformed and fitted together.

5. The rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance according to claim 4, characterized in that, The state sensing module includes a temperature sensor, a pressure sensor, and a rotation angle sensor. The physical parameters include the valve body surface temperature, fluid pressure, and rotor rotation angle. The analog electrical signals include temperature analog electrical signals, pressure analog electrical signals, and rotation angle analog electrical signals. The temperature sensor is attached to the surface of the valve body (1), collects the temperature analog electrical signal representing the valve body surface temperature, and converts it into a temperature value. A fluid pipeline is provided inside the valve body (1). The pressure sensor is installed inside the fluid pipeline, collects the pressure analog electrical signal representing the fluid pressure, and converts it into a fluid pressure value. The rotation angle sensor is aligned with the motor rotor core (8), collects the rotation angle analog electrical signal representing the rotor rotation angle, and converts it into a rotation angle value. The fluid pressure value and the rotation angle value are combined to generate operating state data. The operating state data is continuously transmitted to the digital control module. The digital control module has a displacement calculation algorithm embedded in it. The digital control module extracts the rotation angle value from the operating state data, performs trigonometric function calculations in combination with the preset eccentricity parameter, calculates the displacement estimation data representing the linear movement distance of the valve core (3), and constructs a position closed-loop control based on this.

6. The rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance according to claim 5, characterized in that, The digital control module includes a microprocessor chip and a power drive component. The microprocessor chip stores a fault determination rule model, which includes a historical normal reference dataset. The microprocessor chip receives the operating status data and inputs it into the fault determination rule model. The fault determination rule model calculates the difference between the operating status data and the historical normal reference dataset, outputs the deviation result value, and uses a preset mapping relationship to convert the deviation result value into a device health score value. The microprocessor chip receives the device health score value and an external input control command, summarizes the device health score value and the external input control command to calculate the target drive current value, and sends a weak current control signal corresponding to the target drive current value to the power drive component. The power drive component receives the weak current control signal and supplies the drive current corresponding to the target drive current value to the motor stator (7). The drive current constitutes the drive control electrical signal, and the motor stator (7) receives the drive current and generates an electromagnetic field.

7. The rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance according to claim 6, characterized in that, The remote operation and maintenance module includes a wireless communication component and a life assessment component. The wireless communication component is electrically connected to the microprocessor chip, extracts the device health score value, and modulates the device health score value into a wireless radio frequency signal to be transmitted to the cloud platform. The life assessment component stores the device failure threshold internally. The life assessment component retrieves multiple device health score values ​​in chronological order within a continuous time period, constructs a two-dimensional coordinate system data points with the time values ​​and multiple device health score values, and fits them to generate an analytical expression for the performance degradation curve. The life assessment component calculates the coordinates of the intersection point of the performance degradation curve analytical expression and the device failure threshold, and extracts the time span value corresponding to the intersection point coordinates as the remaining usage time value for output.

8. The rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance according to claim 7, characterized in that, The remote operation and maintenance module includes an early warning triggering component, which stores multiple warning threshold values. The early warning triggering component receives the device health score value and compares it with each of the multiple warning threshold values. When the calculated device health score value exceeds a specific warning threshold value, it generates a graded alarm signal that matches the specific warning threshold value. The early warning triggering component inputs the graded alarm signal to the wireless communication component, which converts the graded alarm signal into a wireless radio frequency signal and transmits it to the cloud platform.

9. The rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance according to claim 8, characterized in that, The microprocessor chip has pre-stored the initial drive current configuration parameters. The cloud platform receives the graded alarm signal and sends the parameter correction data packet as an external diagnostic instruction to the wireless communication component. The wireless communication component receives the parameter correction data packet and decodes the communication protocol, outputting the local update parameters to the microprocessor chip. The microprocessor chip receives and uses the local update parameters to overwrite and replace the initial drive current configuration parameters. The microprocessor chip calculates the corrected weak current control signal based on the replaced local update parameters and sends it to the power drive component. The power drive component receives the corrected weak current control signal and changes the drive current supplied to the motor stator (7). The motor stator (7) changes the deflection angle of the motor rotor core (8) according to the changed drive current, driving the valve core (3) to change the linear travel coordinate.

10. A control method for a rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance, applied to the rotary direct-drive electro-hydraulic servo valve based on self-sensing remote operation and maintenance as described in any one of claims 1 to 9, characterized in that, include: Step 1: Collect analog electrical signals that characterize the physical parameters of the equipment components through status sensing modules deployed on the equipment components, and output the operating status data after analog-to-digital conversion processing; Step 2: The digital control module receives the operating status data and generates a drive control electrical signal, which is then sent to the motor stator (7) to drive the motor rotor core (8) to rotate and cause the valve core (3) to move linearly along the inner wall of the valve sleeve (2). Step 3: The remote operation and maintenance module extracts the operating status data and modulates it into a wireless radio frequency signal to transmit to the cloud platform. At the same time, it receives external diagnostic commands from the cloud platform and inputs the parsed external diagnostic commands into the digital control module. The digital control module then changes the output value of the drive control electrical signal according to the external diagnostic commands.

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