Full-automatic large machine pressure sensor verification system

Abstract

The utility model discloses a full-automatic large-scale machine pressure sensor verification system, and the system comprises a pressure generation assembly which is used for achieving the precise, stable and rapid pressure control, and carrying out the verification of a pressure gauge and a pressure transmitter; the pressure generating assembly comprises a pressure table, a high-pressure cylinder stress application system and a low-pressure cylinder stress application system are arranged in the pressure table, the high-pressure cylinder stress application system comprises a high-pressure cylinder and a high-power stepping motor which are connected through a ball screw, and the low-pressure cylinder stress application system comprises a low-pressure cylinder and a low-power stepping motor which are connected through a ball screw; the signal acquisition component is used for acquiring and processing the pressure signal, converting the pressure signal into a digital signal and transmitting the processed digital signal to the computer; the resistance conversion assembly is used for converting the resistance value of the resistance type pressure sensor into a current signal so as to realize verification of the resistance type pressure sensor; and the computer is used for receiving the pressure digital signal and comparing and analyzing the pressure digital signal with standard pressure data.

Description

Technical fields:

[0001] This utility model relates to a fully automatic pressure sensor calibration system for large machines. Background technology:

[0002] In the field of railway maintenance and repair, a large number of hydraulic equipment are needed. Among them, pressure parameters are an important test data of hydraulic equipment. Using pressure sensors to display, record, monitor and adjust the pressure signals during production or testing is a common testing method.

[0003] Since the performance of pressure sensors is directly related to the quality of railway maintenance, it is essential to ensure the accuracy and reliability of pressure sensors in order to guarantee the quality of railway maintenance. The accuracy of pressure sensors can change over time, so it is necessary to perform regular pressure calibration on the pressure sensors.

[0004] For large railway maintenance machinery, most of them use non-universal pressure sensors. Traditional pressure calibrators cannot perform accurate testing, have relatively simple functions, and have low data detection and analysis capabilities, which cannot meet the actual needs of industrial automation and intelligent testing. Utility model content:

[0005] This utility model provides a fully automatic pressure sensor calibration system for large-scale machinery. The system features a rational structural design, using a high-precision pressure gauge as the standard source and an intelligent calibrator to collect and process signals. A stepper motor and hydraulic cylinder work together to precisely adjust the generated pressure, achieving hydraulic control from 0-40MPa. The system captures, processes, and transmits the pressure signals from each calibration point to a computer for comparative analysis. This allows for accurate testing of the pressure sensors in large-scale track maintenance machinery, meeting the practical needs of automation and intelligent testing in the instrumentation industry and solving problems existing in the prior art.

[0006] The technical solution adopted by this utility model to solve the above-mentioned technical problems is as follows:

[0007] A fully automatic pressure sensor calibration system for large machinery, characterized in that the calibration system comprises:

[0008] A pressure generating assembly is used to achieve precise, stable, and rapid pressure control and to calibrate pressure gauges and pressure transmitters. The pressure generating assembly includes a pressure table, within which a high-pressure cylinder force-applying system and a low-pressure cylinder force-applying system are provided. The high-pressure cylinder force-applying system includes a high-pressure cylinder connected by a ball screw and a high-power stepper motor, and the low-pressure cylinder force-applying system includes a low-pressure cylinder connected by a ball screw and a low-power stepper motor.

[0009] A signal acquisition component is used to acquire and process pressure signals, convert the pressure signals into digital signals, and transmit the processed digital signals to a computer.

[0010] A resistance conversion component is used to convert the resistance value of a resistive pressure sensor into a current signal to achieve the verification of the resistive pressure sensor.

[0011] A computer, which receives pressure digital signals and compares and analyzes them with standard pressure data.

[0012] The low-power stepper motor is model 57CM6C, the high-power stepper motor is model 57CM26C, the low-pressure cylinder is model ROA32X50, and its working range is 0-14MPa; the high-pressure cylinder is model ROA32X60, and its working range is 0-60MPa.

[0013] The signal acquisition component includes a digital pressure gauge, an intelligent pressure calibrator, and a potential isolation transmitter. The digital pressure gauge and the potential isolation transmitter are installed on a pressure table. The digital pressure gauge is connected to a computer via an RS232 serial port, and the potential isolation transmitter is connected to the intelligent pressure calibrator. The intelligent pressure calibrator is connected to the computer via an RS232-to-USB serial port.

[0014] The high-pressure cylinder and the low-pressure cylinder are equipped with detection oil circuits, which include an oil pump, a high-pressure check valve, and a liquid circuit shut-off valve; the liquid circuit shut-off valve is a high-pressure shut-off valve, and the high-pressure cylinder and the low-pressure cylinder are configured and used with a digital pressure gauge and a potential isolation transmitter.

[0015] A bevel gear reducer is configured on the high-power stepper motor.

[0016] The intelligent pressure calibrator is equipped with an LCD screen and a 24-bit AD converter for real-time detection and calibration of pressure transmitters, differential pressure transmitters, pressure sensors, and pressure switches.

[0017] A printer is configured on the computer to print out the verification records in a timely manner.

[0018] This invention employs the aforementioned structure, achieving precise, stable, and rapid pressure control through a pressure-generating component to calibrate pressure gauges and pressure transmitters; acquiring and processing pressure signals through a signal acquisition component, converting the pressure signals into digital signals, and transmitting the processed digital signals to a computer; converting the resistance value of a resistive pressure sensor into a current signal through a resistance conversion component, thereby verifying the resistive pressure sensor; and receiving the digital pressure signals through a computer and comparing and analyzing them with standard pressure data, offering advantages of precision, efficiency, safety, and reliability. Attached image description:

[0019] Figure 1 This is a schematic diagram of the structure of this utility model.

[0020] Figure 2 This is a schematic diagram of the detection oil circuit of this utility model.

[0021] Figure 3 This is a schematic diagram of the internal structure of the pressure table of this utility model.

[0022] Figure 4 This is a system diagram of the pressure generating component of this utility model. Detailed implementation method:

[0023] To clearly illustrate the technical features of this solution, the present invention will be described in detail below through specific embodiments and in conjunction with the accompanying drawings.

[0024] like Figure 1-4 As shown, the fully automatic pressure sensor calibration system for large machinery is characterized in that the calibration system includes:

[0025] A pressure generating assembly is used to achieve precise, stable, and rapid pressure control and to calibrate pressure gauges and pressure transmitters. The pressure generating assembly includes a pressure table, within which a high-pressure cylinder force-applying system and a low-pressure cylinder force-applying system are provided. The high-pressure cylinder force-applying system includes a high-pressure cylinder connected by a ball screw and a high-power stepper motor, and the low-pressure cylinder force-applying system includes a low-pressure cylinder connected by a ball screw and a low-power stepper motor.

[0026] A signal acquisition component is used to acquire and process pressure signals, convert the pressure signals into digital signals, and transmit the processed digital signals to a computer.

[0027] A resistance conversion component is used to convert the resistance value of a resistive pressure sensor into a current signal to achieve the verification of the resistive pressure sensor.

[0028] A computer, which receives pressure digital signals and compares and analyzes them with standard pressure data.

[0029] The low-power stepper motor is model 57CM6C, the high-power stepper motor is model 57CM26C, the low-pressure cylinder is model ROA32X50, and its working range is 0-14MPa; the high-pressure cylinder is model ROA32X60, and its working range is 0-60MPa.

[0030] The signal acquisition component includes a digital pressure gauge, an intelligent pressure calibrator, and a potential isolation transmitter. The digital pressure gauge and the potential isolation transmitter are installed on a pressure table. The digital pressure gauge is connected to a computer via an RS232 serial port, and the potential isolation transmitter is connected to the intelligent pressure calibrator. The intelligent pressure calibrator is connected to the computer via an RS232-to-USB serial port.

[0031] The high-pressure cylinder and the low-pressure cylinder are equipped with detection oil circuits, which include an oil pump, a high-pressure check valve, and a liquid circuit shut-off valve; the liquid circuit shut-off valve is a high-pressure shut-off valve, and the high-pressure cylinder and the low-pressure cylinder are configured and used with a digital pressure gauge and a potential isolation transmitter.

[0032] A bevel gear reducer is configured on the high-power stepper motor to adjust the stepper motor speed to suit different application scenarios.

[0033] The intelligent pressure calibrator is equipped with an LCD screen and a 24-bit AD converter for real-time detection and calibration of pressure transmitters, differential pressure transmitters, pressure sensors, and pressure switches.

[0034] A printer is configured on the computer to print out the verification records in a timely manner.

[0035] The working principle of the fully automatic large-scale machine pressure sensor calibration system in this embodiment of the utility model is as follows: based on a high-precision pressure gauge as a standard source, an intelligent calibrator is used to collect and process signals, and a stepper motor and a hydraulic cylinder are used to precisely adjust the generated pressure to achieve 0-40MPa hydraulic control. The pressure signals of each calibration point are captured, processed, and transmitted to a computer for comparison and analysis. This allows for accurate detection of the pressure sensor of large-scale track maintenance machinery, meeting the actual needs of instrument industrial automation and intelligent detection.

[0036] The verification system described in this application is fully automated, easy to operate, shortens the verification cycle, and improves work efficiency. It reduces the uncertainty caused by human operation and improves the accuracy and reliability of verification. Automation lowers the requirements for professional skills, allowing non-professionals to operate it after simple training. At the same time, it can automatically generate verification reports without the need for manual data recording and analysis, thereby speeding up decision-making. The generated verification reports usually follow a unified format and standard, which facilitates subsequent data management and archiving. The electronic verification reports are easy to store and retrieve.

[0037] Furthermore, this application enables the calibration of most pressure transmitters within its measurement range, meeting the calibration requirements of different types and ranges of pressure transmitters, thus improving the versatility and flexibility of the equipment. It reduces the cost for enterprises to purchase multiple dedicated calibration devices, achieving optimized resource allocation. It avoids the inconvenience of frequently changing calibration equipment and improves overall calibration efficiency.

[0038] In the overall solution, the calibration system includes: a pressure generating component for achieving precise, stable, and rapid pressure control to calibrate pressure gauges and pressure transmitters; the pressure generating component includes a pressure table with a high-pressure cylinder force application system and a low-pressure cylinder force application system within it; the high-pressure cylinder force application system includes a high-pressure cylinder connected by a ball screw and a high-power stepper motor, and the low-pressure cylinder force application system includes a low-pressure cylinder connected by a ball screw and a low-power stepper motor; a signal acquisition component for acquiring and processing pressure signals, converting the pressure signals into digital signals, and transmitting the processed digital signals to a computer; a resistance conversion component for converting the resistance value of a resistive pressure sensor into a current signal to verify the resistive pressure sensor; and a computer for receiving the digital pressure signals and comparing and analyzing them with standard pressure data.

[0039] The pressure-generating assembly incorporates two systems: a high-pressure cylinder booster system and a low-pressure cylinder booster system, ensuring faster and more stable pressure control. The coordinated operation of these high and low-pressure systems significantly improves the speed and stability of pressure control, while also expanding the testing range, enabling the equipment to more comprehensively meet various complex testing requirements.

[0040] For the resistance conversion component in the calibration application, the resistance type pressure transmitter can be measured. Traditional pressure calibrators can only directly measure electrical signals and cannot directly calibrate and verify the output of the resistance type pressure transmitter. Therefore, this system integrates a resistance conversion component to measure the output resistance value of the resistance type pressure transmitter in real time, thereby realizing a comprehensive evaluation of the sensor performance.

[0041] Specifically, the low-power stepper motor is model 57CM6C, the high-power stepper motor is model 57CM26C, the low-pressure cylinder is model ROA32X50 with an operating range of 0-14MPa, and the high-pressure cylinder is model ROA32X60 with an operating range of 0-60MPa. When the equipment is building up low pressure, the low-power stepper motor drives the low-pressure cylinder, resulting in a slow rise in system pressure and high pressure control accuracy, which can be used to calibrate the low-pressure gauge. When the pressure rises, the low-power stepper motor stops, and the high-power stepper motor drives the high-pressure cylinder to build up pressure, resulting in a faster rise in pressure, which can be used to calibrate the high-pressure gauge.

[0042] The signal acquisition components include a digital pressure gauge, an intelligent pressure calibrator, and a potential isolation transmitter. The digital pressure gauge and the potential isolation transmitter are installed on a pressure table. The digital pressure gauge is connected to a computer via an RS232 serial port, and the potential isolation transmitter is connected to the intelligent pressure calibrator. The intelligent pressure calibrator is connected to the computer via an RS232-to-USB serial port.

[0043] When the pressure value reaches the calibration point or calibration range, the intelligent pressure calibrator collects and processes the transmitter's output signal, and transmits the processed signal to the computer. At the same time, the computer records the standard table value and compares the two data. Finally, it summarizes and analyzes the data from each calibration point and generates a calibration report.

[0044] The pressure test bench is computer-controlled, allowing the calibration pressure to be set to any preset pressure point and automatically generating a pressure range. This enables precise, stable, and rapid pressure control, calibrating most pressure gauges and pressure transmitters within the range.

[0045] The collected data allows for the creation of a complete database of calibration instruments. Each pressure point has a precise automatic pressure build-up time of 5-30 seconds and a stability of <0.05%. The system incorporates two built-in filters to effectively prevent clogging, and both the standard interface and the two interfaces for the instruments under test utilize quick-connect couplings.

[0046] It should be noted that the calibration system of this application is used to test the performance and stability of various pressure sensors on large railway maintenance machinery. The system developed by the research group has achieved its research and development goals through field testing, reducing measurement errors caused by manual operation, improving the efficiency and effectiveness of calibration operations, and enhancing the level of operational safety.

[0047] In summary, the fully automatic large-scale machine pressure sensor calibration system in this embodiment of the utility model uses a high-precision pressure gauge as the standard source, employs an intelligent calibrator to collect and process signals, and uses a stepper motor and hydraulic cylinder to precisely adjust the generated pressure to achieve hydraulic control from 0-40MPa. The system captures, processes, and transmits the pressure signals from each calibration point to a computer for comparative analysis, thereby accurately detecting the pressure sensors of large-scale track maintenance machinery and meeting the actual needs of instrument industrial automation and intelligent detection.

[0048] The above specific embodiments should not be construed as limiting the scope of protection of this utility model. For those skilled in the art, any alternative improvements or modifications made to the embodiments of this utility model shall fall within the scope of protection of this utility model.

[0049] Any aspects of this utility model not described in detail are known to those skilled in the art.

Claims

1. A fully automatic pressure sensor calibration system for large machinery, characterized in that, The verification system includes: A pressure generating assembly is used to achieve precise, stable, and rapid pressure control and to calibrate pressure gauges and pressure transmitters. The pressure generating assembly includes a pressure table, within which a high-pressure cylinder force-applying system and a low-pressure cylinder force-applying system are provided. The high-pressure cylinder force-applying system includes a high-pressure cylinder connected by a ball screw and a high-power stepper motor, and the low-pressure cylinder force-applying system includes a low-pressure cylinder connected by a ball screw and a low-power stepper motor. A signal acquisition component is used to acquire and process pressure signals, convert the pressure signals into digital signals, and transmit the processed digital signals to a computer. A resistance conversion component is used to convert the resistance value of a resistive pressure sensor into a current signal to achieve the verification of the resistive pressure sensor. A computer, which receives pressure digital signals and compares and analyzes them with standard pressure data.

2. The fully automatic large-scale machine pressure sensor calibration system according to claim 1, characterized in that: The low-power stepper motor is model 57CM6C, the high-power stepper motor is model 57CM26C, the low-pressure cylinder is model ROA32X50, and its working range is 0-14MPa; the high-pressure cylinder is model ROA32X60, and its working range is 0-60MPa.

3. The fully automatic large-scale machine pressure sensor calibration system according to claim 1, characterized in that: The signal acquisition component includes a digital pressure gauge, an intelligent pressure calibrator, and a potential isolation transmitter. The digital pressure gauge and the potential isolation transmitter are installed on a pressure table. The digital pressure gauge is connected to a computer via an RS232 serial port, and the potential isolation transmitter is connected to the intelligent pressure calibrator. The intelligent pressure calibrator is connected to the computer via an RS232-to-USB serial port.

4. The fully automatic large-scale machine pressure sensor calibration system according to claim 1, characterized in that: The high-pressure cylinder and the low-pressure cylinder are equipped with detection oil circuits, which include an oil pump, a high-pressure check valve, and a liquid circuit shut-off valve; the liquid circuit shut-off valve is a high-pressure shut-off valve, and the high-pressure cylinder and the low-pressure cylinder are configured and used with a digital pressure gauge and a potential isolation transmitter.

5. The fully automatic large-scale machine pressure sensor calibration system according to claim 1, characterized in that: A bevel gear reducer is configured on the high-power stepper motor.

6. The fully automatic large-scale machine pressure sensor calibration system according to claim 3, characterized in that: The intelligent pressure calibrator is equipped with an LCD screen and a 24-bit AD converter for real-time detection and calibration of pressure transmitters, differential pressure transmitters, pressure sensors, and pressure switches.

7. The fully automatic large-scale machine pressure sensor calibration system according to claim 1, characterized in that: A printer is configured on the computer to print out the verification records in a timely manner.

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