Dynamic loading control optimization method in explosion-proof integrated machine torque test process

Abstract

The present application relates to a dynamic loading control optimization method in the process of explosion-proof integrated machine torque testing, belonging to the technical field of torque testing control, comprising: obtaining a target test torque and an actual torque, outputting a first loading instruction to a loading mechanism according to the torque difference between the two, maintaining the loading output after outputting and stopping the superposition of the same direction loading instruction, continuously collecting the actual torque and calculating the torque increment of adjacent sampling intervals; when the absolute value of the torque increment decreases successively and the last time does not exceed the set threshold, the remaining torque difference is recalculated with the last actual torque, and the next loading instruction is determined according to the position relationship between the actual torque and the target torque allowable range; when the actual torque enters the target torque allowable range in advance, the loading output is maintained, and after the recalculating condition is met, the remaining torque difference is implemented to increase or decrease the load, thereby reducing the torque overshoot and repeated adjustment caused by continuous superposition of the load, improving the loading control stability, control accuracy and test result consistency.

Description

Technical Field

[0001] This invention relates to the field of torque test control technology, specifically to a dynamic loading control optimization method for torque testing of an explosion-proof integrated machine. Background Technology

[0002] In existing technologies for torque testing of power or transmission equipment such as explosion-proof integrated machines, the actual torque is typically acquired in real time using a torque sensor. This actual torque is then compared with the target torque, and the difference is used to control the loading mechanism to increase or decrease the load, gradually bringing the test torque closer to the set value. While this closed-loop method achieves basic automatic loading, in actual testing, factors such as response hysteresis, mechanical inertia, elastic deformation recovery, and sampling period exist in the loading mechanism, transmission connections, the tested component, and the torque sensing link. After the loading command is output, the actual torque does not stop changing synchronously but may continue to increase or decrease along the original loading direction. If the controller continuously superimposes loading commands in the same direction based solely on the current instantaneous torque difference before the previous loading effect has fully manifested, it can easily cause repeated compensation of the loading amount. This can lead to the torque continuing to drift even after entering the target allowable range, resulting in overshoot, reverse correction, and reciprocating oscillations, affecting test stability and result repeatability.

[0003] Patent publication CN115051622A discloses a torque closed-loop control system and method for a motor test bench. It uses a torque sensor to collect the actual torque in real time, calculates the difference between the target value and the real-time collected value, and adjusts the torque command sent to the loading inverter in each execution cycle when the difference exceeds the control accuracy. The command size is determined based on the difference between the target value and the real-time collected value. While this scheme can form real-time closed-loop control, its control logic mainly revolves around continuously adjusting the current difference according to the execution cycle. It lacks a mechanism to determine whether the actual torque continues to change after the loading command is output, allowing the loading effect to decay before recalculating the remaining difference. Therefore, in torque-loaded objects with significant inertia or hysteresis, the overlapping effects of preceding and following commands may still occur. Another patent publication, CN117007306B, proposes a device and control method for reducing vibrations during loading tests of high-ratio gearboxes. By detecting the speed difference between the loading motor and the driving motor and using a torque adjustment component to transmit torque, the speeds of the two motors are made to be consistent, thereby improving the accuracy and safety of the loading test. Its key solution is to address the vibrations caused by inconsistent speeds during the loading process of high-ratio gearboxes. However, it does not specifically address transients within or outside the allowable range of the target torque, the trend of torque increment decay, or the timing of recalculating the remaining torque difference.

[0004] Therefore, existing torque test control still needs to address the following issues: when the actual torque exhibits continuous variation characteristics after the loading command is executed, how to avoid adding commands in the same direction before the previous loading action has stabilized, and how to distinguish when the actual torque temporarily enters the target allowable range and reaches a point where it is basically stable with the loading action, so as to determine the timing for recalculating the remaining torque difference based on the torque change trend, and to subsequently implement load increase or decrease control to reduce overshoot and repeated corrections, thereby improving the dynamic loading control accuracy and stability during the torque test process of the explosion-proof integrated machine. Summary of the Invention

[0005] The purpose of this invention is to provide a dynamic loading control optimization method for the torque testing process of an explosion-proof integrated machine, thereby solving some of the drawbacks and shortcomings pointed out in the background art.

[0006] The present invention adopts the following technical solution to solve the above-mentioned technical problems:

[0007] The system acquires the target test torque and the actual torque. Based on the torque difference between the target test torque and the actual torque, it outputs a first loading command to the loading mechanism. After outputting the command, it maintains the loading output and stops adding loading commands in the same direction as the first loading command. It continuously collects the actual torque and calculates the torque increment between adjacent sampling intervals. While the actual torque changes in the direction that reduces the torque difference, it maintains the loading output. When the absolute value of the torque increment obtained from continuous sampling decreases sequentially and the absolute value of the last torque increment does not exceed a set threshold, it recalculates the remaining torque difference based on the actual torque of the last sample. When the actual torque is outside the allowable range of the target torque, it outputs the next loading command based on the remaining torque difference. When the actual torque enters the allowable range of the target torque before the condition for recalculating the remaining torque difference is met, it maintains the loading output. After the condition for recalculating the remaining torque difference is met, it implements load increase or decrease based on the remaining torque difference.

[0008] Furthermore, after the absolute value of the torque increment decreases sequentially and the absolute value of the last torque increment does not exceed the set threshold, the loading output is maintained; after the next loading command is output, if the absolute value of the torque increment in the subsequent sampling interval exceeds the set threshold, the loading output is paused until the subsequent torque increment again meets the condition for recalculating the remaining torque difference.

[0009] Furthermore, when the actual torque enters the target torque allowable range before satisfying the condition for recalculating the remaining torque difference, the loading output is maintained, and the torque increment generated along the loading direction of the first loading command after entering the target torque allowable range is accumulated; the boundary torque margin between when the actual torque enters the target torque allowable range and the allowable range boundary along the loading direction is determined; after satisfying the condition for recalculating the remaining torque difference, the load reduction amount is determined based on the portion of the accumulated result that exceeds the boundary torque margin.

[0010] Furthermore, before outputting the next loading command, the actual torque change formed along the direction of decreasing torque difference during the action of the previous loading command is determined as the first realized torque amount; when the remaining torque difference is less than the first realized torque amount, the loading output change of the next loading command is made lower than the loading output change of the previous loading command, and after the torque increment during the action of the next loading command satisfies the condition of recalculating the remaining torque difference, the subsequent loading output change is adjusted according to the remaining torque difference.

[0011] Furthermore, the accumulated result is accumulated according to the sampling order to accumulate the torque increment that is consistent with the loading direction after entering the target torque allowable range; when the reverse torque increment opposite to the loading direction is obtained by sampling, the absolute value of the reverse torque increment is subtracted from the accumulated result, so that the accumulated result represents the same-direction loading effect that has not dissipated during the loading output.

[0012] Furthermore, when the accumulated result reaches the boundary torque margin, the loading output is maintained and the loading command consistent with the loading direction is stopped; when the subsequent torque increment causes the actual torque to exceed the target torque allowable range, the amount of actual torque exceeding the allowable range boundary is included in the load reduction.

[0013] Furthermore, after determining the load reduction amount based on the portion of the accumulated result exceeding the boundary torque margin, a first load reduction amount is determined based on the load reduction amount and output, maintaining the load output after load reduction; when the actual torque generates a torque increment opposite to the loading direction, the amount of actual torque exceeding the allowable range boundary is re-determined, and subsequent load reduction amounts are output based on the re-determined torque amount.

[0014] Furthermore, after the next loading command is output, the actual torque change formed along the direction of reducing the remaining torque difference during the period when the next loading command is in effect is accumulated; when the accumulated actual torque change reaches the remaining torque difference, the loading output is stopped and the loading output at the stop time is maintained until the torque increment collected during the period when the next loading command is in effect meets the condition for recalculating the remaining torque difference, and then the remaining torque difference is recalculated.

[0015] Furthermore, after the torque increment during the next loading command satisfies the condition for recalculating the remaining torque difference, the actual torque change amount formed by the next loading command along the direction of decreasing torque difference is determined as the second realized torque amount; when the second realized torque amount is less than the recalculated remaining torque difference, the subsequent loading output change amount is increased; when the two values ​​are the same, the subsequent loading output change amount is maintained; when the second realized torque amount exceeds the recalculated remaining torque difference, the subsequent loading output change amount is decreased.

[0016] Furthermore, the second realized torque is compared with the first realized torque; when the load output change of the next load instruction is lower than the load output change of the previous load instruction, and the second realized torque reaches or exceeds the first realized torque, it is prohibited to increase the subsequent load output change and the load output after the completion of the next load instruction is maintained; when the recalculated remaining torque difference is less than the second realized torque, the subsequent load output change is reduced.

[0017] This invention, after outputting a first loading command based on the torque difference between the target test torque and the actual torque, maintains the loading output and stops further superimposing loading commands in the same direction. Simultaneously, it continuously collects the actual torque and calculates the torque increment between adjacent sampling intervals. During the period when the actual torque changes along the direction of decreasing torque difference, the condition for recalculating the remaining torque difference is that the absolute value of the continuous torque increment decreases sequentially, with the last increment not exceeding a threshold. This allows the dynamic attenuation trend of the actual torque to determine whether the previous loading action has been largely released, reducing repeated loading caused by mechanical inertia and transmission lag, lowering the probability of torque overshoot and reciprocating corrections, and improving the stability of the dynamic loading process.

[0018] Furthermore, when the actual torque enters the target torque allowable range before meeting the recalculation conditions, this invention does not immediately add or remove load, but maintains the current load output. Loading or unloading is then implemented based on the recalculated remaining torque difference after the torque increment meets the stated conditions. This control method avoids misjudging a short-term entry into the allowable range as a stable attainment of the target torque, ensuring that subsequent adjustments are based on the stable actual torque state. This improves the accuracy of target torque control, the consistency of test results, and the reliability of torque testing for the explosion-proof integrated machine. Attached Figure Description

[0019] Figure 1 This is a flowchart illustrating the dynamic loading control optimization process during the torque testing of the explosion-proof integrated machine of the present invention.

[0020] Figure 2 This is a diagram showing the actual torque dynamic response and attenuation determination in Embodiment 1 of the present invention.

[0021] Figure 3This is a comparison chart of the accumulated results and the boundary torque margin in Embodiment 1 of the present invention.

[0022] Figure 4 This is a dynamic adjustment diagram of the first load reduction amount and subsequent load reduction amounts in Embodiment 1 of the present invention.

[0023] Figure 5 This is a graph showing the actual torque response and incremental attenuation during the first and second rounds of loading in Embodiment 2 of the present invention.

[0024] Figure 6 This is a diagram showing the adaptive adjustment of torque and load output changes in Embodiment 2 of the present invention.

[0025] Figure 7 This is a diagram showing the output limitation under the enhanced torque response condition in Embodiment 2 of the present invention. Detailed Implementation

[0026] As attached Figure 1 As shown, in this embodiment, the target test torque corresponding to the torque test is first obtained, and the allowable range of the target test torque is predetermined according to the test requirements. The allowable range of the target test torque includes the upper boundary corresponding to the direction of increasing torque and the lower boundary corresponding to the direction of decreasing torque. When the actual torque is between the upper and lower boundaries, it is considered that the actual torque has entered the allowable range of the target test torque. The actual torque is continuously obtained during the loading process. The target test torque and the actual torque are compared to obtain the torque difference between the two, and the loading direction is determined according to the direction of the torque difference. The first loading command is determined according to the magnitude of the torque difference. The first loading command corresponds to one adjustment of the loading output of the loading mechanism. When the torque difference is larger, a relatively larger change in loading output can be used, and when the torque difference is smaller, a relatively smaller change in loading output can be used. The specific change in loading output is determined according to the adjustable output range of the loading mechanism and the loading gear preset in the current test state. After the first loading command is output to the loading mechanism, the loading mechanism changes the loading output according to the first loading command. After completing this loading output adjustment, the current loading output is maintained, and no more loading commands with the same direction as the first loading command are added. Simultaneously, the actual torque is acquired through continuous sampling, and the actual torque obtained at two adjacent sampling times is compared. The change between the two is used as the torque increment for the corresponding sampling interval. The sampling period is predetermined based on the sampling capability of the torque sensor and the dynamic response speed of the loading mechanism, and remains constant throughout the same torque test. By continuously obtaining the torque increments for multiple sampling intervals, the process of the actual torque continuing to change and gradually stabilizing after the first loading command is output can be reflected.

[0027] During the current load output, the direction of actual torque change is determined. When the actual torque continues to change in the direction that reduces the torque difference between the target test torque and the actual torque, it indicates that the loading effect generated by the first loading command is still being transmitted. At this time, the current load output is maintained, and no new loading commands in the same direction are added. The absolute value of the torque increment obtained from continuous sampling is taken, and the changes in the absolute values ​​of each torque increment are compared in the order of sampling time. When the absolute values ​​of multiple consecutively obtained torque increments decrease sequentially in the order of sampling time, and the absolute value of the last obtained torque increment does not exceed the set threshold, it indicates that the subsequent torque change caused by the current loading effect has decayed to a state that meets the requirements for re-judging the loading. The set threshold is set before the test starts based on the measurement resolution of the torque sensor, the torque fluctuation level during the test, and the allowable control stability, so that the torque increment less than or equal to the set threshold can indicate that the actual torque change between adjacent sampling times has reached a predetermined stable level; the same set threshold is used in the same test. To avoid the influence of random fluctuations in a single sampling interval on the judgment, sequential decrease means that the absolute values ​​of torque increments in at least multiple consecutive sampling intervals generally decrease sequentially, and whether the absolute value of the last torque increment does not exceed the set threshold is used as the final judgment condition. At this point, the actual torque obtained from the last sampling is used as the new actual torque benchmark, and the remaining torque difference between the actual torque and the target test torque is calculated again. This avoids the situation where the actual torque exceeds the expected range due to the continued addition of load before the previous loading effect has been fully realized.

[0028] After recalculating the remaining torque difference, the positional relationship between the current actual torque and the target test torque allowable range is determined. If the actual torque is still outside the target test torque allowable range, the next loading command is determined based on the recalculated remaining torque difference. The loading output is then adjusted using the next loading command to bring the actual torque closer to the target test torque allowable range. The direction of the next loading command is determined based on the adjustment direction corresponding to the remaining torque difference, and the change in loading output corresponding to the next loading command is determined based on the magnitude of the remaining torque difference and the actual torque response after the previous loading. If the actual torque has entered the target test torque allowable range before the torque increment meets the condition for recalculating the remaining torque difference, the loading output is not immediately changed based on this state of entering the allowable range. Instead, the current loading output is maintained, allowing the dynamic loading effect generated by the previous loading command to continue to be released. Once the torque increments obtained from continuous sampling meet the conditions for recalculating the remaining torque difference, the remaining torque difference is re-determined based on the actual torque at this point. Loading or unloading is then implemented according to the direction and magnitude represented by the remaining torque difference. Specifically, loading is implemented when the actual torque is below the target test torque's allowable range and adjustment towards increasing torque is required; unloading is implemented when the actual torque is above the target test torque's allowable range and adjustment towards decreasing torque is required. This control method coordinates the output of the loading command with the dynamic response of the actual torque, allowing for gradual stabilization after each loading action before the next loading adjustment. This reduces the possibility of torque overshoot or repeated adjustments due to continuous superimposed loading and improves the stability of the torque loading control process.

[0029] In this embodiment, when the absolute values ​​of the torque increments obtained from continuous sampling gradually decrease according to the sampling time sequence, and the absolute value of the torque increment corresponding to the last sampling does not exceed a set threshold, it indicates that the dynamic torque change caused by the previous loading command has decayed to a state that meets the re-judgment of loading requirements. At this time, the current loading output is maintained, keeping the loading mechanism at the current output level, and the remaining torque difference between the target test torque and the actual torque is recalculated based on the actual torque obtained at this time. After determining the next loading command based on the recalculated remaining torque difference, the next loading command is output to the loading mechanism, and the loading output is further adjusted through the next loading command. The amount of load output change corresponding to the next loading command can be selected from multiple load output change levels pre-divided by the loading mechanism, or it can be determined within the continuous adjustment range allowed by the loading mechanism, and the determined amount of load output change does not exceed the single adjustment range allowed by the loading mechanism under the current test conditions, thereby ensuring that each loading adjustment can be actually executed by the loading mechanism.

[0030] After the next loading command is output, the actual torque continues to be collected according to the established sampling method, and the torque increment corresponding to the adjacent sampling interval is calculated. If the absolute value of the torque increment obtained in any subsequent sampling interval exceeds the set threshold again, it indicates that the actual torque is still under the continuous influence of the aforementioned loading action or the current loading action, and the torque change has not yet entered a stable stage suitable for continuing to increase the loading output. At this time, the increase in loading output is paused, and the loading output state corresponding to the pause time is maintained, while the actual torque continues to be collected and the torque increment of the subsequent sampling interval is calculated. Pausing the increase in loading output means no longer outputting new loading commands that further increase the loading output along the current loading direction, rather than canceling the already applied loading output. When the absolute value of the subsequently obtained torque increment decreases again, and the absolute value of the last torque increment does not exceed the set threshold again, the remaining torque difference is recalculated based on the current actual torque, and the subsequent loading adjustment is determined based on the recalculated remaining torque difference. Through this control method, the loading output can be prevented from continuing to increase when the torque response increases again, so that the next loading adjustment is based on the dynamic change of torque decaying again, thereby reducing the loading superposition caused by the dynamic response not yet ending during continuous loading.

[0031] In this embodiment, when the actual torque has not yet met the conditions for recalculating the remaining torque difference, but has already entered the target test torque allowable range, the loading output is not immediately reduced, nor is a loading command in the same direction as the first loading command continued to be added. Instead, the current loading output is maintained, and the actual torque continues to be collected according to the predetermined sampling period. The moment when the actual torque enters the target test torque allowable range is used as the accumulation starting point. The torque increment of each subsequent adjacent sampling interval is calculated according to the sampling time sequence, and the torque increment generated along the loading direction of the first loading command is accumulated. Simultaneously, based on the actual torque value corresponding to when the actual torque enters the target test torque allowable range, and the boundary of the target test torque allowable range corresponding to the current loading direction, the torque difference between the two is determined, and this torque difference is defined as the boundary torque margin. Specifically, when the current loading direction is the direction that increases the actual torque, the upper boundary of the target test torque allowable range is used to determine the boundary torque margin; when the current loading direction is the direction that decreases the actual torque, the lower boundary of the target test torque allowable range is used to determine the boundary torque margin. The boundary torque margin is used to represent the amount of torque change that the actual torque can accommodate from the position where it enters the target test torque allowable range to the corresponding allowable range boundary along the current loading direction. In subsequent sampling, if the torque increment is still generated along the loading direction of the first loading command, this torque increment is continued to be included in the accumulated result. If the direction of the sampled torque increment is opposite to the loading direction of the first loading command, the absolute value of this reverse torque increment is subtracted from the existing accumulated result; when the accumulated result after subtraction is lower than zero, the accumulated result is treated as zero to avoid the reverse torque change causing the accumulated result to represent the undissipated loading effect opposite to the current loading direction. Thus, the accumulated result increases with the enhancement of the same-direction dynamic loading effect and decreases with the appearance of the reverse falling effect, so that the accumulated result can reflect the same-direction loading effect that has not dissipated during the maintenance of loading output.

[0032] As the actual torque continues to change, when the accumulated result reaches the boundary torque margin, it indicates that the actual torque has consumed the available torque margin between the point of entering the target test torque allowable range and the corresponding allowable range boundary. At this point, the current loading output is maintained, and the addition of new loading commands in the same direction as the current loading direction is stopped, while subsequent actual torque is continuously collected. If subsequent torque increments continue to develop in the current loading direction, causing the actual torque to cross the target test torque allowable range, the amount of actual torque exceeding the corresponding allowable range boundary is determined, and this excess portion is used as the basis for forming the load reduction amount. The load reduction amount is used to determine the loading output that the loading mechanism needs to reduce in the opposite direction to the current loading direction. Its magnitude is determined based on the amount of torque exceeding the allowable range boundary and the actual torque response of the loading mechanism during the previous loading process. Therefore, the load reduction basis does not directly use all the same-direction torque increments after entering the target test torque allowable range, but first uses the boundary torque margin to absorb the dynamic torque changes that can still be accommodated within the allowable range. Only when the dynamic torque change exceeds the boundary torque margin and causes the actual torque to cross the allowable range boundary is a load reduction requirement formed based on the excess portion.

[0033] After meeting the condition for recalculating the remaining torque difference, the accumulated result is compared with the boundary torque margin, and the load reduction is determined based on the portion of the accumulated result exceeding the boundary torque margin. When the accumulated result does not exceed the boundary torque margin, no load reduction is generated due to exceeding the boundary of the target test torque allowable range; when the accumulated result exceeds the boundary torque margin, the load reduction is determined based on the degree of actual torque exceeding the boundary reflected by the excess portion. After determining the load reduction, a first load reduction is first determined based on this load reduction, and a load reduction command corresponding to the first load reduction is output to the loading mechanism, reducing the loading output from the current level to the output level after the first load reduction is applied. The first load reduction is less than or equal to the load reduction determined this time, and a smaller load reduction amplitude that can produce a recognizable load reduction response from the loading mechanism is preferred to avoid applying the entire load reduction to the loading mechanism at once. After the first load reduction is output, the loading output after load reduction is maintained, and the actual torque continues to be collected. When the actual torque increases in the opposite direction to the original loading direction, it indicates that the load reduction has begun to bring the actual torque back towards the target test torque's allowable range. At this point, the positional relationship between the actual torque and the corresponding allowable range boundary is reassessed. If the actual torque is still outside the target test torque's allowable range, the amount by which the actual torque exceeds the allowable range boundary is redefined, and the subsequent load reduction is formed based on this redefined excess torque. The loading output is then adjusted further based on this subsequent load reduction. If the actual torque has already entered the target test torque's allowable range, the load reduction is stopped, the current loading output is maintained, and the dynamic response is assessed for stability according to the aforementioned torque increment decay condition. By determining the first and subsequent load reductions in stages, the load reduction process can be gradually adjusted based on the actual torque's dynamic response to the load reduction operation. This avoids implementing excessive load reduction all at once before the dynamic loading effect has completely dissipated, thereby reducing the possibility that the actual torque will rapidly fall from the side exceeding the allowable range and cross the other side of the allowable range.

[0034] In this embodiment, before outputting the next loading command, the actual torque change during the period of the previous loading command is statistically analyzed. Specifically, the actual torque at the start of the previous loading command is used as the starting point of the change. The actual torque change generated during the period of the loading command along the direction of reducing the torque difference between the target test torque and the actual torque is accumulated, and the accumulated actual torque change is determined as the first realized torque amount. When the direction of actual torque change within the sampling interval is consistent with the direction of reducing the torque difference, the torque change corresponding to that sampling interval is included in the first realized torque amount; when the direction of change is opposite to the direction of reducing the torque difference, this reverse change is not included in the first realized torque amount as a realized positive adjustment effect. The first realized torque amount is used to characterize the actual torque adjustment effect generated by the previous loading command in the current test state. After recalculating the remaining torque difference, the absolute magnitude of the remaining torque difference is compared with the first realized torque amount. When the absolute magnitude of the remaining torque difference is less than the first realized torque amount, it indicates that the amount of torque that needs to be adjusted further is less than the amount of torque change that the previous loading command could achieve. To reduce the possibility of torque overshoot caused by continuing to adjust based on the previous load output change, the load output change corresponding to the next load command is lower than that corresponding to the previous load command, thereby reducing the magnitude of the current load adjustment. Specifically, the reduced load output change can be achieved by using an adjacent load setting lower than the previous load output change, or, under continuously adjustable conditions, by using an output value lower than the previous load output change. After the next load command is executed, the dynamic changes in actual torque continue to be monitored. Once the torque increment meets the condition for recalculating the remaining torque difference, the subsequent load output change is adjusted based on the newly obtained remaining torque difference, ensuring that the subsequent load output change changes with the actual remaining adjustment requirements.

[0035] After the next loading command is output, the actual torque during the period of the next loading command's action is continuously collected, and the actual torque change generated along the direction of reducing the remaining torque difference is accumulated. During the accumulation process, the actual torque at the start of the next loading command is used as the statistical benchmark, and the torque adjustment amount already achieved by the current loading is determined based on the actual torque changes obtained from subsequent sampling. When the direction of the sampled torque change is consistent with the direction of reducing the remaining torque difference, the corresponding torque change is included in the torque adjustment amount already achieved by the current loading; reverse changes are not added as the already achieved positive torque adjustment amount. When the accumulated actual torque change reaches the absolute size of the remaining torque difference determined before the next loading command is output, it indicates that the current loading action has achieved the torque change corresponding to the remaining adjustment requirement. At this point, the loading output is stopped, but the loading output corresponding to the moment of cessation is maintained, allowing the applied loading action to continue to be transmitted to the measured object. During the period of maintaining the loading output, the actual torque continues to be collected, and the torque increment between adjacent sampling intervals is calculated. Once the torque increment acquired during the next loading command meets the conditions for recalculating the remaining torque difference, the remaining torque difference is recalculated based on the current actual torque, thus establishing the next round of loading adjustment on the basis that the dynamic response of this loading has been fully reflected.

[0036] When the torque increment during the next loading command meets the condition for recalculating the remaining torque difference, the actual torque change during the next loading command, formed along the direction of decreasing torque difference, is determined as the second realized torque amount. The second realized torque amount represents the actual torque adjustment effect achieved by the current loading command after reducing the load output change. Subsequently, the second realized torque amount is compared with the absolute magnitude of the recalculated remaining torque difference. If the second realized torque amount is less than the absolute magnitude of the recalculated remaining torque difference, it indicates that the torque adjustment effect produced by the current load output change is insufficient to meet subsequent adjustment requirements. Therefore, the subsequent load output change amount is increased. The increased load output change amount does not exceed the aforementioned allowable single adjustment range and can be a larger output change amount from an adjacent loading gear or a continuously adjustable range than the current load output change amount. When the second realized torque amount is the same as the absolute magnitude of the recalculated remaining torque difference, the current subsequent load output change amount is maintained. When the second realized torque exceeds the absolute value of the recalculated remaining torque difference, it indicates that the torque adjustment capability corresponding to the current load output change has exceeded the subsequent required adjustment. Therefore, the subsequent load output change is reduced by using an output change smaller than the adjacent load setting or within the continuously adjustable range. Further, the second realized torque is compared with the first realized torque. When the load output change of the next load command is lower than the load output change of the previous load command, but the second realized torque still reaches or exceeds the first realized torque, it indicates that although the load output change has been reduced, the actual torque change has not been correspondingly weakened. At this point, increasing the subsequent load output change is prohibited, and the load output after the next load command is completed is maintained, allowing the actual torque to continue releasing the dynamic response generated by the current load action. When the absolute value of the recalculated remaining torque difference is less than the second realized torque, the subsequent load output change is further reduced to decrease the adjustment effect of subsequent loading on the actual torque. By dynamically adjusting the load output variation based on the relationship between the first realized torque, the second realized torque, and the remaining torque difference, the load amplitude can be matched with the actual torque response capability, and the possibility of torque overshoot caused by excessively large continuous load amplitude settings due to changes in the response characteristics of the loading mechanism can be reduced.

[0037] Example 1:

[0038] In this embodiment, the explosion-proof integrated torque testing system includes a torque sensor, a controller, a loading mechanism, and the object under test. The controller acquires the target test torque corresponding to this test and determines the allowable range of the target torque according to the test requirements. Simultaneously, it continuously acquires the actual torque detected by the torque sensor according to a predetermined sampling period. The controller determines the loading direction based on the torque difference between the target test torque and the actual torque and outputs a first loading command to the loading mechanism. After the first loading command is executed, the controller maintains the current loading output and does not continue to add loading commands in the same direction as the first loading command, allowing the loading effect already generated by the first loading command to continue to be transmitted to the object under test.

[0039] In a specific test process, the target test torque is set to 200 N·m, the allowable range of the target torque is set to 198 N·m to 202 N·m, the sampling period is set to 100 ms, and the threshold for torque increment is set to 0.15 N·m. Before the first loading command is output, the actual torque is 193.2 N·m, and the current load output of the loading mechanism is 42% of the rated controllable output range. The controller outputs the first loading command based on the current torque difference, increasing the load output to 48% of the rated controllable output range. After this adjustment, the load output remains at 48%, the controller stops outputting load increase commands in the same direction, and continues to obtain subsequent actual torque. The difference between the actual torque at two adjacent sampling moments is used as the torque increment of the corresponding sampling interval. When the actual torque continues to change in a direction close to the target test torque, the controller maintains the current load output and continues to sample and judge, without repeatedly increasing the load output because the actual torque has not yet stabilized.

[0040] Figure 2 The continuous dynamic response process after the actual torque enters the target torque allowable range and the decay process of the absolute value of the torque increment are shown. The actual torque starts at 198.4 N·m and continues to increase while maintaining a 48% load output. The target test torque of 200 N·m and the target torque allowable range of 198 N·m to 202 N·m are used to represent the positional relationship of the actual torque relative to the test target. Meanwhile, Figure 2 The absolute value of the torque increment corresponding to each sampling interval is displayed in relation to a set threshold of 0.15 N·m. Figure 2 It is evident that the actual torque continues to increase even after it has entered the target torque allowable range. This indicates that the dynamic loading effect generated by the first loading command does not immediately disappear when the torque enters the allowable range. Therefore, the controller does not immediately reduce the load based on the single state of the actual torque entering the allowable range, but continues to maintain the load output and monitor subsequent dynamic changes.

[0041] When the actual torque enters the target torque allowable range from outside the target torque allowable range, the controller uses the moment of entering the target torque allowable range as the starting point for accumulation. It then accumulates the torque increments generated along the loading direction of the first loading command. When a torque increment occurs in the opposite direction to the loading direction of the first loading command, the absolute value of the reverse torque increment is subtracted from the existing accumulated result. This embodiment uses the following formula to determine the accumulation result:

[0042]

[0043] in, This indicates the period from when the actual torque enters the target torque allowable range until the [number]th [time period]. The cumulative result obtained at the end of each sampling interval is in N·m; This indicates the total number of sampling intervals participating in the current statistics; Indicates the sequential number of the sampling interval; Indicates the first The torque increment corresponding to each sampling interval is expressed in N·m. This represents the absolute value of the torque increment; Indicates the first The torque increment is a dimensionless directional coefficient relative to the loading direction of the first loading command. When this torque increment is aligned with the loading direction of the first loading command... Take 1, when the torque increment is opposite to the loading direction of the first loading command. Take the negative 1. Thus, the increase in torque in the same direction increases the cumulative result, while the increase in torque in the opposite direction decreases the cumulative result, so that the cumulative result can characterize the effect of the same direction loading that has not dissipated during the period of maintaining the loading output.

[0044] As a specific data example, the target torque range is first entered when the actual torque reaches 198.4 N·m, and the load output remains at 48% thereafter. The subsequent eight sampling intervals yield 0.90 N·m, 0.72 N·m, and 0.58 N·m along the current loading direction, followed by 0.08 N·m in the opposite direction, and then 0.48 N·m, 0.40 N·m, 0.34 N·m, and 0.30 N·m along the current loading direction. According to the above calculation formula, the cumulative result is 0.90 N·m + 0.72 N·m + 0.58 N·m - 0.08 N·m + 0.48 N·m + 0.40 N·m + 0.34 N·m + 0.30 N·m, resulting in... The actual torque is 3.64 N·m. Since the actual torque is 198.4 N·m when it enters the target torque allowable range, the actual torque after the above 8 sampling intervals is 202.04 N·m, which is consistent with the net same-direction torque change corresponding to the cumulative result.

[0045] To determine the amount of torque change that can be accommodated within the allowable range when the actual torque continues to change along the current loading direction after entering the target torque allowable range, this embodiment further determines the boundary torque margin:

[0046]

[0047] in, This indicates the boundary torque margin, expressed in N·m. This indicates the allowable range boundary of the target torque along the current loading direction, in N·m. This represents the actual torque when the actual torque falls within the target torque's allowable range, expressed in N·m. When the current loading direction is the direction that increases the actual torque... Take the upper boundary of the target torque allowable range; when the current loading direction is the direction that reduces the actual torque, Take the lower boundary of the target torque's allowable range. In the example above, the current loading direction is the direction that increases the actual torque. It is 202 N·m. It is 198.4 N·m, from which we obtain It is 3.6 N·m.

[0048] Figure 3 The changes in the accumulated result during the sampling process and the positional relationship between the accumulated result and the boundary torque margin are further illustrated. When the actual torque enters the target torque allowable range, the accumulated result starts from 0 and then gradually increases with the increase of the same-direction torque. When a reverse torque increment of 0.08 N·m occurs in the 4th sampling interval, the accumulated result drops from 2.20 N·m to 2.12 N·m, indicating that the reverse change has been subtracted from the still-dissipated same-direction loading effect. The accumulated result continues to increase thereafter, reaching 3.64 N·m in the 8th sampling interval, exceeding the boundary torque margin of 3.60 N·m by 0.04 N·m. After maintaining the loading output, the accumulated result finally increases to 4.16 N·m, exceeding the boundary torque margin by 0.56 N·m. Figure 3 The "exceeding" region is used to indicate that the dynamic torque change has exceeded the torque margin that can be accommodated within the allowable range of the target torque, thereby distinguishing between dynamic changes that are still acceptable within the allowable range and dynamic changes that actually pose a risk of exceeding the limit.

[0049] At the end of the 8th sampling interval, the actual torque was 202.04 N·m, exceeding the upper limit of the target torque allowable range by 0.04 N·m. The controller maintained the current 48% load output and stopped adding new load commands in the same direction as the current load, while continuing to collect the actual torque to determine whether the applied load was still being released. The subsequent three sampling intervals obtained torque increments of 0.22 N·m, 0.17 N·m, and 0.13 N·m in the same direction, respectively. At this point, the accumulated result increased from 3.64 N·m to 4.16 N·m, and the actual torque increased from 202.04 N·m to 202.56 N·m. Correspondingly, the portion of the accumulated result exceeding the 3.6 N·m boundary torque margin was 0.56 N·m, and the amount of actual torque exceeding the upper limit of the 202 N·m allowable range was also 0.56 N·m. Figure 2 As shown in the torque increment change diagram, the subsequent torque increments in the same direction decreased sequentially from 0.30 N·m to 0.22 N·m, 0.17 N·m, and 0.13 N·m. The final increment of 0.13 N·m did not exceed the set threshold of 0.15 N·m, thus satisfying the condition for recalculating the remaining torque difference. At this point, the controller confirms that the current dynamic loading effect has decayed to a state suitable for reassessing the loading requirements and generates a load reduction demand based on the 0.56 N·m exceedance threshold.

[0050] The load reduction operation of the loading mechanism is performed using pre-calibrated discrete load reduction gears. The controller establishes a pre-defined correspondence between different levels of exceedance and different load reduction gears based on the loading mechanism's rated controllable output range, the minimum identifiable output adjustment range, and the actual torque response corresponding to changes in load output. In this embodiment, when the actual torque exceeds the target torque allowable range boundary by no more than 0.5 N·m, a load reduction gear that lowers the rated controllable output range by 1% is used; when the exceedance is greater than 0.5 N·m but not exceeding 1.0 N·m, a load reduction gear that lowers the rated controllable output range by 2% is used. The actual torque currently exceeds the upper boundary by 0.56 N·m, therefore the controller selects a 2% reduction gear, determines it as the first load reduction amount, and outputs a corresponding load reduction command to the loading mechanism, reducing the load output from 48% to 46%.

[0051] Figure 4The diagram illustrates the relationship between the phased reduction in load output and the gradual decline in actual torque after the aforementioned load reduction demand is generated. Before the first load reduction, the actual torque is 202.56 N·m, and the load output is 48%. After the first load reduction, the load output decreases from 48% to 46%, but the actual torque does not immediately jump to the target torque allowable range. Instead, it gradually declines to 202.42 N·m, 202.30 N·m, and 202.23 N·m. This change indicates that there is still a dynamic transmission process between the reduction in load output and the actual torque response. Therefore, maintaining a load output of 46% after the first load reduction can avoid continuous load reduction before the full effect of the first load reduction has been observed. When the actual torque decreases from 202.56 N·m to 202.42 N·m, adjacent sampling intervals form a torque increment opposite to the original loading direction. Based on this, the controller determines that the first load reduction has begun to have an effect of causing the actual torque to fall back to the target torque allowable range.

[0052] When the actual torque reaches 202.23 N·m, it is still higher than the upper limit of the target torque allowable range, and the new out-of-range torque is 0.23 N·m. This out-of-range torque corresponds to a 1% reduction in the rated controllable output range. Therefore, the controller determines this 1% reduction as the subsequent load reduction, further reducing the load output from 46% to 45%. Figure 4 As shown, after subsequent load reduction, the actual torque continued to decrease from 202.23 N·m to 202.12 N·m, 202.04 N·m, and 201.97 N·m. When the actual torque reached 201.97 N·m, it had returned to the target torque range of 198 N·m to 202 N·m. At this point, the controller stopped further increasing the load reduction and maintained a 45% load output. Figure 4 The correspondence between the two loading output step changes and the actual torque continuous decline curve shows that the load reduction is not applied all at once, but rather the subsequent load reduction degree is gradually determined based on the actual torque response formed by the previous load reduction operation.

[0053] Once the actual torque returns to the target torque allowable range, the controller continues to collect the actual torque without immediately reloading. While the actual torque continues to change in the direction of the load reduction, the controller maintains the current load output and continues to monitor the changes in the absolute value of the torque increment in each sampling interval. After the absolute value of the torque increment obtained from continuous sampling decreases sequentially, and the absolute value of the last torque increment does not exceed the set threshold of 0.15 N·m, the remaining torque difference is recalculated based on the actual torque obtained from the last sampling. Then, based on the positional relationship between the actual torque and the target torque allowable range at this point, it is determined whether further load adjustments are needed. Figure 2 The dynamic attenuation judgment shown Figure 3The accumulated results shown are compared with the boundary torque margin, and Figure 4 The phased load reduction process shown can continuously correlate the dynamic loading effect after entering the target torque allowable range, the actual degree of exceeding the limit, and the subsequent load reduction response. This allows the controller to determine the next control action only after each loading effect is fully reflected, thereby reducing the actual torque overshoot and repeated adjustments caused by continuous load increase or continuous load reduction.

[0054] Example 2:

[0055] In this embodiment, the explosion-proof integrated torque testing system includes a torque sensor, a controller, a loading mechanism, and the object under test. The controller acquires the target test torque and determines the allowable range of the target torque according to the test requirements. The actual torque is continuously acquired by the torque sensor according to a predetermined sampling period. The controller determines the loading direction based on the torque difference between the target test torque and the actual torque, and determines the first loading command based on the torque difference. After the first loading command is executed, the current loading output is maintained. Loading commands in the same direction as the first loading command are not added. Instead, the actual torque is continuously acquired and the torque increment of adjacent sampling intervals is determined. When the absolute value of the continuously acquired torque increment decreases sequentially and the absolute value of the last torque increment does not exceed a set threshold, the remaining torque difference is recalculated based on the actual torque obtained from the last sampling, and this state is used as the basis for determining the next loading command.

[0056] In this embodiment, the loading output and the single-time loading output change are represented by a percentage of the rated controllable output range of the loading mechanism. The loading output change represents the magnitude of a single output adjustment implemented by the controller relative to the rated controllable output range of the loading mechanism, not the actual change in torque itself. The loading output of the loading mechanism is allowed to be adjusted within the range of 0% to 100%, and the single-time loading output change is pre-limited to the range of 1% to 10%. When the calculated loading output change is less than 1%, it is executed as 1%; when it exceeds 10%, it is executed as 10%. The target test torque is set to 200 N·m, the allowable range of the target torque is set to 198 N·m to 202 N·m, the sampling period is set to 100 ms, and the threshold for torque increment is set to 0.15 N·m.

[0057] To determine the actual torque adjustment effect of each loading command under the current test state, the controller, starting from the moment the corresponding loading command begins, counts the effective change in actual torque along the direction of decreasing torque difference, and continues this counting until the torque increment of that round meets the condition for recalculating the remaining torque difference. The following mathematical symbols are only used in the loading output change adjustment process of this embodiment 2. The realized torque corresponding to the p-th loading action is determined according to the following formula:

[0058]

[0059] Where E represents the realized torque in N·m; p represents the loading round; q represents the sampling interval number during the p-th loading round; M represents the total number of sampling intervals from the start of the p-th loading round until the torque increment meets the condition for recalculating the remaining torque difference; e represents the effective actual torque change along the direction of decreasing torque difference within the corresponding sampling interval in N·m. When the actual torque change direction of a sampling interval is consistent with the direction of decreasing torque difference, the corresponding change is included in the realized torque; when the change direction is opposite to the direction of decreasing torque difference, the effective actual torque change of that sampling interval is recorded as 0, and the reverse change is not considered as a realized positive adjustment effect. The calculation result corresponding to the first loading command is determined as the first realized torque, and the calculation result corresponding to the next loading command is determined as the second realized torque.

[0060] At the start of the first loading cycle, the actual torque was 185 N·m. The controller determined that the load output change corresponding to the first loading command was 8% of the rated controllable output range. After the first loading command was executed, the load output was maintained, and the actual torque changed in a direction close to the target test torque of 200 N·m. The actual torque changes corresponding to multiple effective sampling intervals were 3.70 N·m, 2.10 N·m, 1.20 N·m, 0.60 N·m, 0.30 N·m, and 0.10 N·m, respectively. The sum of the above actual torque changes was 8 N·m. Therefore, the actual torque increased from 185 N·m to 193 N·m, and the first achieved torque was [amount not specified]. The initial torque increment was 8 N·m. The absolute value of the subsequent torque increment decreased sequentially from 1.20 N·m to 0.60 N·m, 0.30 N·m, and 0.10 N·m, with the final increment of 0.10 N·m not exceeding the set threshold of 0.15 N·m. Based on this, the controller recalculated the remaining torque difference between the target test torque and the current actual torque, which had an absolute value of 7 N·m. Since 7 N·m is less than the first achieved torque of 8 N·m, if the 8% load output change continues, the actual torque adjustment capability demonstrated in the previous round is already greater than the current remaining adjustment requirement. Therefore, the next load command needs to reduce the load output change.

[0061] like Figure 5As shown, during the first and second loading cycles, the actual torque continued to change towards the target test torque after the loading output adjustment was completed, while the absolute value of the torque increment in each sampling interval generally showed a gradual decreasing trend. In the first cycle, the actual torque increased from 185 N·m to 193 N·m, and the absolute value of the final torque increment decreased to 0.10 N·m; in the second cycle, the actual torque further increased from 193 N·m to 197.50 N·m, and the absolute value of the final torque increment decreased to 0.05 N·m. The absolute values ​​of the final torque increment in both cycles were below the set threshold of 0.15 N·m. This allows for the separation of the continuous dynamic response after each loading command begins from the adjustment in the next loading cycle, avoiding the immediate and continuous increase of the loading output based solely on the actual torque at a single sampling moment.

[0062] To ensure that the change in load output is adjusted according to the actual remaining adjustment demand and the actual adjustment effect of the previous round, this embodiment determines the change in load output for the next round based on the current change in load output, the recalculated remaining torque difference, and the currently realized torque:

[0063]

[0064] Where L represents the change in load output (%), p represents the current loading cycle, p+1 represents the next loading cycle, R represents the absolute value of the remaining torque difference obtained after the dynamic response of the current cycle meets the recalculation conditions (N·m), and E represents the realized torque of the current cycle (N·m). R and E have the same unit, therefore their ratio is dimensionless and is used to correct the change in load output for the next cycle. When the realized torque is less than the absolute value of the remaining torque difference, the ratio is greater than 1, and the change in load output for the next cycle is increased relative to the current cycle; when the two values ​​are the same, the ratio is 1, maintaining the current change in load output; when the realized torque is greater than the absolute value of the remaining torque difference, the ratio is less than 1, and the change in load output for the next cycle is decreased. The calculated change in load output is still limited to the aforementioned range of 1% to 10% for a single load output change.

[0065] Substituting the first round of data into the above calculation relationship, the current load output change is... The absolute value of the remaining torque difference is 8%, calculated again. The torque is 7 N·m, the first achieved torque. The torque is 8 N·m, therefore the load output change corresponding to the next load command is 7%. The controller accordingly makes the second round load output change lower than the first round and outputs the next load command. At the start of the second round, the actual torque is 193 N·m. After the 7% load output change, the current load output is maintained. Subsequent effective actual torque changes along the direction of decreasing the remaining torque difference are 2.00 N·m, 1.20 N·m, 0.70 N·m, 0.40 N·m, 0.15 N·m, and 0.05 N·m, respectively. The sum of these changes is 4.50 N·m, thus increasing the actual torque from 193 N·m to 197.50 N·m. The absolute value of the final torque increment decreases sequentially, and the final 0.05 N·m does not exceed the set threshold of 0.15 N·m. Therefore, the second round dynamic response meets the recalculation conditions, and the second realized torque amount... The value was determined to be 4.50 N·m, and the absolute value of the remaining torque difference between the target test torque and the current actual torque was recalculated. It is 2.50 N·m.

[0066] Since the second realized torque of 4.50 N·m is greater than the absolute value of the recalculated remaining torque difference of 2.50 N·m, the actual torque adjustment capability corresponding to the current 7% change in load output has exceeded the subsequent adjustment requirements. Substituting the second round of data into the calculation relationship for the change in load output, the change in load output in the third round is approximately 3.89%, which the controller determines to be 3.9% according to the output resolution allowed by the loading mechanism. Figure 6 The corresponding changes in realized torque, remaining torque difference, and load output change between the first, second, and third rounds are further illustrated. In the first round, the load output change is 8%, the first realized torque is 8 N·m, and the remaining torque difference is 7 N·m. In the second round, the load output change decreases to 7%, the second realized torque is 4.50 N·m, and the remaining torque difference decreases to 2.50 N·m. In the third round, the load output change further decreases to 3.9%. Figure 6 The 2.50 N·m shown in the third round indicates that the effective actual torque change accumulated in the third round along the direction of reducing the remaining torque difference has reached the remaining adjustment requirement determined before the start of this round. At this time, the controller stops increasing the load output instead of continuing to add new load commands in the same direction according to the adjustment range of 3.9%.

[0067] The third loading cycle begins at 197.50 N·m. When the cumulative effective actual torque change along the direction of decreasing residual torque difference reaches 2.50 N·m, the actual torque reaches 200 N·m. The controller then stops increasing the load output and maintains the load output at the stop point, allowing the applied load to continue. During the load output maintenance, the actual torque continues to be acquired. When the actual torque continues to change to 200.10 N·m due to dynamic response, subsequent torque increments gradually decay and meet the recalculation conditions. The absolute value of the residual torque difference between the target test torque and the current actual torque is then 0.10 N·m, and the direction represented by the residual torque difference has changed from increasing actual torque to decreasing actual torque. Since 200.10 N·m is still within the allowable range of the target torque of 198 N·m to 202 N·m, the controller maintains the current load output, stops increasing the load in the aforementioned direction, and continues to observe the dynamic response. Figure 6 The change in the remaining torque difference in the third round to 0.10 N·m corresponds to the re-judgment result after maintaining the load output, thus reflecting the continuous adjustment process of the load output change from 8% to 7% and further to 3.9%.

[0068] When the second realized torque is less than the absolute value of the recalculated remaining torque difference, it indicates that the actual adjustment effect of the current load output change is insufficient, and the controller allows an increase in the subsequent load output change. When the second realized torque is the same as the absolute value of the recalculated remaining torque difference, the controller maintains the current load output change. When the second realized torque exceeds the absolute value of the recalculated remaining torque difference, the controller reduces the subsequent load output change. This increase also needs to be combined with the relationship between the first and second realized torque to determine whether the current actual torque response capability has been enhanced, avoiding excessive subsequent load adjustments based solely on the current remaining torque difference.

[0069] In another continuous loading state, the load output change of the previous loading command is 6%, and the first realized torque is 5.40 N·m. Then the load output change of the next loading command is reduced to 4%, but the second realized torque reaches 5.70 N·m. Figure 7The diagram illustrates the limiting process under this enhanced response state. After the load output change decreases from 6% to 4%, the realized torque actually increases from 5.40 N·m to 5.70 N·m, indicating that although the load output change decreases, the actual torque adjustment effect does not decrease accordingly. At this point, the recalculated absolute value of the remaining torque difference is 6 N·m. Although the second realized torque of 5.70 N·m is less than 6 N·m, and according to the individual proportional adjustment relationship, there is a tendency to increase the subsequent load output change, the controller prohibits this increase action because the second realized torque has reached and exceeded the first realized torque. It maintains the current load output change state of 4%, allowing the actual torque to continue releasing the dynamic response formed by the current load action. After maintaining this state, the re-evaluated absolute value of the remaining torque difference further decreases to 4.80 N·m, which is less than the second realized torque of 5.70 N·m. Therefore, the controller then reduces the subsequent load output change. Figure 7 The limitation in the control phase corresponds to the control stage from the confirmation of enhanced torque response to the reassessment after holding, so that no new load is generated when the remaining torque difference has not yet fully reflected the dynamic response.

[0070] In this way, the controller uses the first and second realized torque values ​​actually generated by each round of loading commands as the basis for adjusting the load output change. After the effect of the previous round of loading is fully realized, the remaining torque difference is re-determined, and the subsequent load output change is reduced, maintained, or increased according to the relationship between the realized torque value and the remaining adjustment requirements. At the same time, when the load output change has been reduced but the actual torque response has not weakened accordingly, the subsequent load output change is prohibited from being increased. This makes the load output change match the dynamic response state of the loading mechanism and the tested object during the test, reducing the possibility of actual torque overshoot and repeated adjustments caused by continuous adjustment with a fixed load amplitude.

Claims

1. A dynamic loading control optimization method for torque testing of an explosion-proof integrated machine, characterized in that, The target test torque and the actual torque are obtained. Based on the torque difference between the target test torque and the actual torque, the first loading command is output to the loading mechanism. After the output is output, the loading output is maintained and the superposition of loading commands in the same direction as the first loading command is stopped. The actual torque is continuously collected and the torque increment of adjacent sampling intervals is calculated. The loading output is maintained during the period when the actual torque changes in the direction that reduces the torque difference. When the absolute value of the torque increment obtained by continuous sampling decreases sequentially and the absolute value of the last torque increment does not exceed the set threshold, the remaining torque difference is recalculated with the actual torque of the last sample. When the actual torque is outside the target torque allowable range, the next loading command is output based on the remaining torque difference; When the actual torque enters the target torque allowable range before the condition for recalculating the remaining torque difference is met, the load output is maintained, and after the condition for recalculating the remaining torque difference is met, the load is increased or decreased according to the remaining torque difference.

2. The dynamic loading control optimization method for the torque testing process of the explosion-proof integrated machine according to claim 1, characterized in that, After the absolute value of the torque increment decreases sequentially and the absolute value of the last torque increment does not exceed the set threshold, the loading output is maintained; after the next loading command is output, if the absolute value of the torque increment in the subsequent sampling interval exceeds the set threshold, the loading output is paused until the subsequent torque increment meets the condition of recalculating the remaining torque difference again.

3. The dynamic loading control optimization method for the torque testing process of the explosion-proof integrated machine according to claim 1, characterized in that, When the actual torque enters the target torque allowable range before the condition for recalculating the remaining torque difference is met, the loading output is maintained, and the torque increment generated along the loading direction of the first loading command after entering the target torque allowable range is accumulated. Determine the boundary torque margin between the actual torque entering the target torque allowable range and the allowable range boundary along the loading direction. After satisfying the condition of recalculating the remaining torque difference, determine the load reduction amount based on the portion of the accumulated result that exceeds the boundary torque margin.

4. The dynamic loading control optimization method for the torque testing process of the explosion-proof integrated machine according to claim 1, characterized in that, Before outputting the next loading command, the actual torque change formed along the direction of decreasing torque difference during the action of the previous loading command is determined as the first realized torque amount; when the remaining torque difference is less than the first realized torque amount, the loading output change of the next loading command is made lower than the loading output change of the previous loading command, and after the torque increment during the action of the next loading command satisfies the condition of recalculating the remaining torque difference, the subsequent loading output change is adjusted according to the remaining torque difference.

5. The dynamic loading control optimization method for the torque testing process of the explosion-proof integrated machine according to claim 3, characterized in that, The accumulation result is accumulated according to the sampling order, accumulating the torque increment that is consistent with the loading direction after entering the target torque allowable range; When sampling to obtain the reverse torque increment opposite to the loading direction, the absolute value of the reverse torque increment is subtracted from the accumulated result, so that the accumulated result represents the same-direction loading effect that has not dissipated during the loading output.

6. The dynamic loading control optimization method for the torque testing process of the explosion-proof integrated machine according to claim 3, characterized in that, When the accumulated result reaches the boundary torque margin, the loading output is maintained and the loading command consistent with the loading direction is stopped; when the subsequent torque increment causes the actual torque to exceed the target torque allowable range, the amount of actual torque exceeding the allowable range boundary is included in the load reduction.

7. The dynamic loading control optimization method for the torque testing process of the explosion-proof integrated machine according to claim 3, characterized in that, After determining the load reduction amount based on the portion of the accumulated result that exceeds the boundary torque margin, a first load reduction amount is determined based on the load reduction amount and the first load reduction amount is output, while maintaining the load output after load reduction. When the actual torque generates a torque increment opposite to the loading direction, the amount by which the actual torque exceeds the allowable range boundary is re-determined, and the subsequent load reduction amount is output based on the re-determined torque amount.

8. The dynamic loading control optimization method for the torque testing process of the explosion-proof integrated machine according to claim 4, characterized in that, After the next loading command is output, the actual torque change formed in the direction of reducing the remaining torque difference during the period when the next loading command is in effect is accumulated; when the accumulated actual torque change reaches the remaining torque difference, the loading output is stopped and the loading output at the stop time is maintained until the torque increment collected during the period when the next loading command is in effect meets the condition for recalculating the remaining torque difference, and then the remaining torque difference is recalculated.

9. The dynamic loading control optimization method for the torque testing process of the explosion-proof integrated machine according to claim 4, characterized in that, After the torque increment during the next loading command meets the condition for recalculating the remaining torque difference, the actual torque change amount formed by the next loading command along the direction of decreasing torque difference is determined as the second realized torque amount; when the second realized torque amount is less than the recalculated remaining torque difference, the subsequent loading output change amount is increased; when the two values ​​are the same, the subsequent loading output change amount is maintained; when the second realized torque amount exceeds the recalculated remaining torque difference, the subsequent loading output change amount is decreased.

10. The dynamic loading control optimization method for the torque testing process of the explosion-proof integrated machine according to claim 9, characterized in that, The second realized torque is compared with the first realized torque. When the load output change of the next load instruction is lower than the load output change of the previous load instruction, and the second realized torque reaches or exceeds the first realized torque, the subsequent load output change is prohibited from being increased and the load output after the next load instruction is completed is maintained. When the recalculated remaining torque difference is less than the second realized torque, the subsequent load output change is reduced.

Images