Hydraulic station with oil online monitoring function

Abstract

The utility model discloses a hydraulic station with an oil liquid on-line monitoring function. The hydraulic station is composed of an oil supplementing unit, an oil tank ventilation assembly, a nitrogen energy accumulator, an oil liquid on-line monitoring unit, an oil tank, a blow-down valve assembly, a system temperature control unit, a system pressure stabilizing and purifying unit, a system oil pump assembly, a digital liquid level meter, a digital thermometer, accessories and pipelines. The oil liquid online monitoring system is characterized by having an oil liquid online monitoring function, and an oil liquid online monitoring unit comprises a lower computer unit, an oil path circulating unit, a communication unit and an upper computer unit. The oil way circulation unit is mainly composed of an oil taking opening, an oil taking pipeline, an oil inlet, an internal oil way pipeline, an oil outlet, an oil return pipeline and an oil return opening. The communication unit is mainly composed of a power line and a signal line. The upper computer unit mainly comprises an industrial personal computer and a display; a moisture sensor, a viscosity sensor and a ferromagnetic sensor are arranged in the upper computer unit, and real-time monitoring of oil moisture, viscosity and metal particles is achieved.

Description

Technical Field

[0001] The utility model belongs to the technical field of hydraulic systems, and in particular relates to a hydraulic station with an oil online monitoring function. Background Art

[0002] The high-speed, heavy-load and continuous production process characteristics of metallurgical enterprises cause huge losses due to unplanned shutdowns of metallurgical equipment. In order to avoid unplanned shutdowns, the level of equipment maintenance must be improved. From industrial mass production to the present, equipment maintenance technology has roughly gone through three stages: post-maintenance → preventive maintenance → condition maintenance or predictive maintenance. The third method is based on the operating conditions of the equipment and the analysis of operating condition data. It determines the equipment status and formulates a maintenance plan through detection, comparison and analysis. Its feature is the use of advanced testing technology for equipment status monitoring and fault diagnosis. Therefore, carrying out equipment status detection is the only way to improve the level of metallurgical equipment maintenance in the future.

[0003] At present, equipment status monitoring has formed a pattern of mainly vibration, oil monitoring, current monitoring and temperature monitoring, supplemented by other technologies. Among them, oil monitoring is the most promising technology for research and application after vibration detection, but it also has the following problems.

[0004] (1) Existing technologies mainly use offline methods to monitor oil, which can easily cause secondary contamination during the oil sample collection process, as well as inaccurate and untimely monitoring results.

[0005] (2) The lack of online oil detection methods for the main equipment of the production line makes it impossible to detect the early signs of equipment failure, and small problems become major failures, affecting the safe and reliable operation of the production line equipment.

[0006] (3) The lubrication system of a modern continuous production line has a huge impact on the high-reliability operation of the equipment. Therefore, with the continuous improvement of automation and intelligence levels, it is objectively necessary to improve the maintenance level of the lubrication system. Utility Model Content

[0007] The utility model provides a hydraulic cylinder with an oil online monitoring function, aiming to solve the technical problem of oil online state monitoring in a hydraulic system.

[0008] To this end, the utility model adopts the following technical solutions:

[0009] A hydraulic station with an oil online monitoring function, characterized in that it comprises an oil tank, an oil replenishment unit, an oil online monitoring unit, a system temperature control unit, a system pressure stabilization and purification unit, and a system oil pump assembly;

[0010] The system oil pump assembly is a power element, and the oil replenishment unit is used to replenish oil into the oil tank;

[0011] The system pressure stabilizing and purification unit includes a purification unit and a pressure stabilizing unit connected in series. The purification unit includes a high-precision filter, a pressure relay and a one-way valve. The high-precision filter is used to filter impurities in the oil. The pressure relay sends an alarm signal according to the set value when the high-precision filter is blocked. The one-way valve performs a bypass function when the high-precision filter fails or is blocked. The pressure stabilizing unit includes a relief valve, a control valve and an external nitrogen energy storage device. The system pressure is regulated by overflowing the relief valve.

[0012] The system temperature control unit includes a circulating oil pump, a heater, a cooler, a filter, and a thermostat; the heater is used to heat the oil, and the cooler is used to reduce the oil temperature;

[0013] The oil online monitoring unit includes a lower computer unit, an oil circulation unit, a communication unit and a host computer unit; the oil circulation unit includes an oil intake port, an oil intake pipeline, an oil inlet, an internal oil pipeline, an oil outlet, an oil return pipeline and an oil return port; the communication unit includes a power cord and a signal cord; the host computer unit includes an industrial computer and a display, and the industrial computer performs real-time analysis on the collected data; the lower computer unit has built-in moisture sensors, viscosity sensors and ferromagnetic sensors to realize real-time monitoring of oil moisture, viscosity and metal particles.

[0014] Furthermore, a digital level meter and a digital thermometer are provided in the oil tank. The digital level meter is used to monitor the height of the oil in the oil tank, and the digital thermometer is used to monitor the temperature of the oil in the oil tank.

[0015] Furthermore, the bottom of the oil tank is a slope with a slope of 3%-5%. A drain valve assembly is provided at the lowest point of the slope, and the drain valve assembly is used to discharge oil stains at the bottom of the oil tank.

[0016] Furthermore, the system pressure stabilizing and purification unit also includes a nitrogen accumulator.

[0017] Furthermore, a ventilation component is provided on the top of the oil tank to balance the air pressure inside and outside the oil tank.

[0018] The beneficial effects of the present invention are:

[0019] ⑴ Compared with the prior art, the present invention realizes real-time detection of hydraulic system failures and hydraulic oil performance by online monitoring of the real-time status of the hydraulic station oil, thereby achieving the purpose of predicting hydraulic system failures and hydraulic oil service life. Its application in steel enterprises helps to improve the level of enterprise equipment maintenance and also lays the foundation for the transformation of equipment maintenance mode to predictive maintenance mode.

[0020] (2) The hydraulic system of key equipment in steel enterprises implements online oil monitoring. Since the detection system has fault alarm and degradation trend prediction functions, it can effectively avoid sudden equipment failures caused by the hydraulic system.

[0021] ⑶ By real-time monitoring of the operating status, oil cleanliness and deterioration trend of the hydraulic system, the equipment maintenance plan is targeted, redundant maintenance and oil waste are avoided, and equipment maintenance costs can be effectively reduced. Industry data shows that the investment-profit ratio of online monitoring and diagnostic technology is 1:5, which has a good economic prospect. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is the system principle diagram of the utility model;

[0023] Figure 2 This is the principle diagram of the oil online monitoring system of the utility model;

[0024] In the figure: 1—oil replenishing unit, 2—oil tank ventilation assembly, 3—nitrogen accumulator, 4—oil online monitoring unit, 5—oil tank, 6—drain valve assembly, 7—system temperature control unit, 8—system pressure stabilizing and purification unit, 9—system oil pump assembly, 10—digital liquid level gauge, 11—digital thermometer. DETAILED DESCRIPTION

[0025] The utility model is further described below in conjunction with the accompanying drawings and specific embodiments:

[0026] For the convenience of description, the hydraulic station described in the present invention is described in sub-items according to its functional components.

[0027] 1. System oil pump assembly 9

[0028] The core component of the oil pump assembly 9 of the system of the present invention is a hydraulic plunger pump, which is the power source of the hydraulic system. The selected hydraulic oil pump meets the pressure and flow requirements of the hydraulic system.

[0029] 2. System temperature control unit 7

[0030] The temperature control unit 7 of the system of the present invention is composed of a circulating oil pump, a heater, a cooler, a filter, a thermostat, and related valves and accessories. When the oil temperature of the oil tank 5 is lower than the set value, the circulating oil pump is started, and the thermostat opens the valve on the heater side and closes the valve on the cooler side to achieve oil circulation heating; when the oil temperature of the oil tank 5 is higher than the set value, the circulating oil pump is started, and the thermostat opens the valve on the cooler side and closes the valve on the heater side to achieve oil circulation cooling; the system is equipped with a filter, which also achieves purification during the oil circulation process.

[0031] 3. System pressure stabilization and purification unit 8

[0032] The system pressure stabilizing purification unit 8 of the present invention includes a purification unit and a pressure stabilizing unit connected in series. The purification unit is composed of a high-precision filter, a pressure relay and a one-way valve. The pressure relay sends an alarm signal according to a set value when the high-precision filter is blocked; the one-way valve performs a bypass function when the high-precision filter fails or is blocked; and the high-precision filter realizes oil purification and filtration. The pressure stabilizing unit is composed of an overflow valve, a control valve and an external nitrogen accumulator. The system adjusts the system pressure through the overflow valve. At the same time, in order to eliminate the decrease in system load capacity and dynamic response performance caused by system pressure fluctuations, the present invention designs a nitrogen accumulator 3 to achieve system pressure stability.

[0033] 4. Oil online monitoring unit 4

[0034] The oil online monitoring unit 4 of the present invention includes a lower computer unit, an oil circulation unit, a communication unit, and an upper computer unit. Among them, the lower computer unit is mainly composed of an oil online acquisition module, a power module, and a control panel module to complete the data acquisition of online monitoring; the oil circulation unit is mainly composed of an oil intake port, an oil intake pipeline, an oil inlet, an internal oil pipeline, an oil outlet, an oil return pipeline, and an oil return port to complete the circulation of oil and realize real-time acquisition of oil; the communication unit is mainly composed of a power line and a signal line to complete data transmission; the upper computer unit is mainly composed of an industrial computer and a display, and the industrial computer performs real-time analysis on the collected data, and intuitively displays the real-time data through the data client of the display.

[0035] The acquisition module has built-in moisture sensors, viscosity sensors and ferromagnetic sensors to realize real-time monitoring of oil moisture, viscosity and metal particles; the host industrial computer has built-in oil status analysis module and fault diagnosis module to realize real-time analysis of oil moisture, viscosity and metal particles and predict and judge system or equipment failures.

[0036] 5. System temperature measurement components

[0037] The temperature measuring component of the system of the present invention realizes real-time measurement of the oil temperature of the oil tank 5 , and the measured value is compared and interlocked with the set value of the system temperature control unit 7 to realize the control of the oil temperature in the oil tank 5 .

[0038] 6. Fuel tank 5

[0039] The bottom of the oil tank 5 of the present invention is designed with a slope of 3%-5%, which is conducive to the sedimentation of oil and dirt at the bottom of the oil tank 5. A drain valve assembly 66 is designed at the bottom of the oil tank 5 to achieve complete discharge of dirt at the bottom of the oil tank 5.

[0040] The present invention is designed with a fuel tank 5 ventilation component 2 on the top of the fuel tank 5, which is used to adjust the pressure fluctuation of the fuel tank 5 caused by temperature and liquid level changes in the fuel tank 5, so as to make the pressure in the fuel tank 5 consistent with the atmospheric pressure and prevent dirt from entering the fuel tank 5.

[0041] 7. Oil replenishment unit 1

[0042] The oil replenishment unit 1 of the present invention is composed of a refueling pump, a filter, and a one-way valve. When the digital liquid level meter detects the lowest liquid level, the refueling pump is started to replenish the oil. At the same time, the oil replenishment unit 1 is equipped with a filter to purify the oil in the refueling process. Specific embodiment:

[0044] A hydraulic station for a rolling mill in a steel mill. An oil replenishment unit 1 is configured, and its oil filling pump has a rated flow of 40L / sec, a rated pressure of 10bar, and a filter accuracy of 20um. In actual working conditions, when the digital liquid level meter 10 detects a low liquid level of 60%, the oil filling pump can be automatically or manually started to replenish the oil. At the same time, a filter with an accuracy of 20um is configured in the oil filling link to ensure the cleanliness of the oil in the oil filling link.

[0045] Its oil tank 5 has an effective volume of 4m 3 The gradient of the bottom of the oil tank 5 is 4%, and a 4-inch drain valve and pipeline are designed at the lowest point. A ventilation component is designed on the top of the oil tank 5 to ensure the breathing of the oil tank 5. A digital level gauge and a digital thermometer are provided on the oil tank 5 to participate in the control. The digital level gauge and the oil level control system are set with three warning levels: ultra-low level (30%), low level (60%) and high level (100%). When the ultra-low level occurs, the hydraulic system is triggered to shut down, and when the low level occurs, the oil replenishment unit 1 is started to replenish oil; the digital thermometer participates in the oil temperature control, and the system is set with five warning oil temperatures: ultra-low temperature (24°C), start heating oil temperature (35°C), stop heating oil temperature (43°C), alarm high oil temperature (58°C), trip high oil temperature (65°C). When the oil temperature is lower than 35°C, the temperature control unit is started to perform circulation heating in the oil station, and the heating is stopped when the oil temperature reaches 43°C; when the oil temperature reaches 58°C, the temperature control unit is started to perform circulation cooling in the oil station, and the cooling is stopped after the temperature drops to 50°C; at the same time, the system is set to trip when the oil temperature is higher than 65°C.

[0046] The system oil pump assembly 9 and the pressure stabilizing and purification unit constitute the core oil supply part of the present invention, wherein the oil pump selects a hydraulic plunger pump, which is coupled with the overflow valve and the nitrogen accumulator 3 for pressure stabilization to achieve the constant system pressure, and the system output oil pressure is stabilized at 29Mpa; at the same time, the system is equipped with an oil filter with an accuracy of 10um to ensure the cleanliness of the oil supply.

[0047] The lower computer unit has built-in moisture sensors, viscosity sensors and ferromagnetic sensors to achieve real-time monitoring of oil moisture, viscosity and metal particles; the upper computer industrial computer has built-in oil state analysis module and fault diagnosis module to achieve real-time analysis of oil moisture, viscosity and metal particles and predict and judge system or equipment failures.

Claims

1. A hydraulic station with oil online monitoring function, characterized in that: Including oil tank, oil replenishment unit, oil online monitoring unit, system temperature control unit, system pressure stabilization and purification unit, system oil pump assembly; The system oil pump assembly is a power element, and the oil replenishment unit is used to replenish oil into the oil tank; The system pressure stabilizing and purification unit includes a purification unit and a pressure stabilizing unit connected in series. The purification unit includes a high-precision filter, a pressure relay and a one-way valve. The high-precision filter is used to filter impurities in the oil. The pressure relay sends an alarm signal according to the set value when the high-precision filter is blocked. The one-way valve performs a bypass function when the high-precision filter fails or is blocked. The pressure stabilizing unit includes a relief valve, a control valve and an external nitrogen energy storage device. The system pressure is regulated by overflowing the relief valve. The system temperature control unit includes a circulating oil pump, a heater, a cooler, a filter, and a thermostat; the heater is used to heat the oil, and the cooler is used to reduce the oil temperature; The oil online monitoring unit includes a lower computer unit, an oil circulation unit, a communication unit and a host computer unit; the oil circulation unit includes an oil intake port, an oil intake pipeline, an oil inlet, an internal oil pipeline, an oil outlet, an oil return pipeline and an oil return port; the communication unit includes a power cord and a signal cord; the host computer unit includes an industrial computer and a display, and the industrial computer performs real-time analysis on the collected data; the lower computer unit has built-in moisture sensors, viscosity sensors and ferromagnetic sensors to realize real-time monitoring of oil moisture, viscosity and metal particles.

2. The hydraulic station with oil online monitoring function according to claim 1 is characterized in that: A digital level gauge and a digital thermometer are arranged in the oil tank. The digital level gauge is used to monitor the height of the oil in the oil tank, and the digital thermometer is used to monitor the temperature of the oil in the oil tank.

3. The hydraulic station with oil online monitoring function according to claim 1 is characterized in that: The bottom of the oil tank is a slope with a slope of 3%-5%. A drain valve assembly is provided at the lowest point of the slope, and the drain valve assembly is used to discharge oil dirt at the bottom of the oil tank.

4. The hydraulic station with oil online monitoring function according to claim 1 is characterized in that: The system pressure stabilizing and purifying unit also includes a nitrogen accumulator.

5. The hydraulic station with oil online monitoring function according to claim 1 is characterized in that: A ventilation component is provided on the top of the oil tank to balance the air pressure inside and outside the oil tank.

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