Ultra-large and ultra-long digital hydraulic cylinder based on key components

Abstract

An ultra-large and ultra-long digital hydraulic cylinder based on key components, comprising a hydraulic cylinder body structure, a hydraulic cylinder V-packing sealing component, a spherical plain bearing, a piston rod laser-cladded coating, a hydraulic cylinder state monitoring and adjusting unit, a hydraulic cylinder bearing monitoring and evaluating unit, a piston rod coating monitoring and evaluating unit, an industrial personal computer, a display screen, and an audible and visual alarm device, wherein the hydraulic cylinder state monitoring and adjusting unit comprises position sensors, laser distance measurement sensors (6), a laser distance measurement target, and pressure sensors; a 1# position sensor (1) is arranged at the rear side of a cylinder body (4) of the hydraulic cylinder body structure, a 2# position sensor (2) is arranged at the front side of the cylinder body, and a 3# position sensor (3) is arranged at the front side of a piston rod; the industrial personal computer calculates the equivalent deflection of the hydraulic cylinder on the basis of the relative position distances between the position sensors; a certain number of laser distance measurement sensors are uniformly mounted on the outside of the piston rod side of the cylinder body end of the hydraulic cylinder body structure; the laser distance measurement target is correspondingly mounted at the end of the piston rod (5), and is used for measuring a displacement value of the hydraulic cylinder; the laser distance measurement sensors measure displacement of the hydraulic cylinder body structure in all directions, and transmit signals to the industrial personal computer; the hydraulic cylinder bearing monitoring and evaluating unit is used for detecting a bearing state of the hydraulic cylinder body structure; the piston rod coating monitoring and evaluating unit is used for detecting a coating state of the surface of the piston rod of the hydraulic cylinder. The hydraulic cylinder achieves online performance evaluation and real-time state detection of the spherical plain bearing of the hydraulic cylinder, thereby ensuring the long-term safe use of the hydraulic cylinder.

Description

Ultra-large and ultra-long digital oil cylinder based on key components TECHNICAL FIELD

[0001] The present application relates to the technical field of oil cylinders. More specifically, the present application relates to an ultra-large and ultra-long digital oil cylinder based on key components. BACKGROUND

[0002] With the development of science and technology, the application of ultra-large and ultra-long oil cylinders in the fields of metallurgical forging equipment, maritime engineering ships, large-scale engineering construction, etc. is also increasing. The design difficulty, reliability requirement, raw material manufacturing difficulty, processing difficulty, and surface technology difficulty of ultra-large and ultra-long oil cylinders are far higher than those of ordinary oil cylinders. The current design and manufacturing level of ultra-large and ultra-long oil cylinders still lags behind the world-leading enterprises. The oil cylinder complete machine mainly uses foreign brands, and the key components such as oil cylinder V group seal, joint bearing fabric liner, and piston rod laser cladding coating material are completely dependent on imports, which has the risk of "neck blocking".

[0003] The pile frame main oil cylinder of a pile driving ship is a typical representative of an ultra-large and ultra-long oil cylinder, which is a core component of a large pile driving ship. It is mainly used for the luffing action of the pile frame and mainly includes key components such as oil cylinder seal, joint bearing, and piston rod surface coating. The domestic key components have problems such as fast aging, poor batch stability, and short fatigue life, which leads to serious performance degradation and low reliability of the oil cylinder complete machine during operation, and cannot meet the requirements of extreme service conditions of large pile driving ships. With the continuous extension of ocean engineering construction to the outer deep water area, the number of major engineering projects such as cross-sea channels and deep-sea wind power construction is increasing, and the specifications of large pile driving ships are also increasing. The world's largest 150m pile driving ship being built by the Second Institute of Naval Architecture has a diameter of more than 1.6m and a stroke of more than 21m.

[0004] The ultra-large pile driving ship realizes the variable amplitude operation of the pile frame weighing thousands of tons through a single oil cylinder. Due to the weight of the pile frame of thousands of tons and the inconvenience of maintenance, when the main oil cylinder and key components fail, it may lead to the inability to use the pile driving ship, requiring a long maintenance period and high maintenance cost, or even cause the arm frame to collapse suddenly, resulting in serious safety accidents. Therefore, the pile frame main oil cylinder of the pile driving ship needs to meet the requirements of high performance and high reliability.

[0005] The pile driving operation conditions of the pile driving ship mainly include resting, luffing down, luffing up, straight driving, and reeling, etc. The stress characteristics and use requirements of the oil cylinder are different under different conditions. The current pile frame main oil cylinder of the pile driving ship is used in a relatively extensive manner, without controlling the stress of the oil cylinder at different strokes or distinguishing the use requirements of the oil cylinder under different conditions. It only monitors the key parameters such as the working pressure and stroke of the oil cylinder, without online evaluation of the state of the key components of the oil cylinder, which has certain safety risks. SUMMARY

[0006] The application aims to provide a super-large and super-long digital oil cylinder based on key components, so as to realize fine control of a pile driver main oil cylinder of a pile driver under different working conditions and significantly improve the use safety of the pile driver main oil cylinder.

[0007] The application adopts the technical scheme that a super-large and super-long digital oil cylinder based on key components comprises an oil cylinder body structure, oil cylinder V group sealing, joint bearing and other key components, a piston rod laser cladding coating, an oil cylinder state monitoring and adjusting unit, an oil cylinder bearing monitoring and evaluating unit, a piston rod coating monitoring and evaluating unit, an industrial computer, a display screen and an audible and visual alarm.

[0008] The oil cylinder V group sealing is a domestic sealing mainly composed of a pressing ring, a sealing ring and a supporting ring.

[0009] Preferably, the domestic V group sealing material adopts cloth rubber, selects FKM as a basic rubber, selects N990 in combination with special mineral carbon black as a filler, and selects TAIC / double 2.5 combination as a vulcanization system, supplemented by ZnO, HT-290 and WS-280, so as to solve the problems of poor pressure resistance, poor impact resistance and short service life of the domestic V group sealing, and break through the preparation technology of the domestic V group sealing of the large specification oil cylinder.

[0010] The joint bearing is a domestic self-lubricating joint bearing mainly composed of an inner ring, an outer ring and a self-lubricating liner.

[0011] Preferably, the self-lubricating liner is prepared by using domestic yarn, and through a special pretreatment process, the yarn is soaked in a slurry and twisted, so as to enhance the strength of the yarn. The domestic yarn after special treatment can be continuously knitted, so as to solve the characteristics of the domestic yarn, such as easy fluffing, low strength and inability to continuously knit, and break through the technology that the domestic yarn cannot be prepared into a self-lubricating liner.

[0012] The piston rod laser cladding coating is an ultrahigh-speed laser cladding coating prepared by using a domestic self-developed iron-based alloy powder.

[0013] Preferably, the coating preparation material adopts the domestic self-developed iron-based alloy powder, and an ultrahigh-speed laser cladding technology suitable for large-diameter long-stroke rods is developed to perform surface protection treatment on the oil cylinder piston rod base material, so as to form a high corrosion and corrosion resistant coating combined with the base material in a metallurgical way, and the powder utilization rate reaches 92%. The self-developed powder eliminates the dependence on imported products for laser cladding metal powder, and the ultrahigh-speed laser cladding technology solves the problems of easy coating falling, low construction efficiency, low powder utilization rate and poor coating performance.

[0014] The oil cylinder state monitoring and adjusting unit comprises a position sensor, a laser ranging sensor, a laser ranging target and a pressure sensor.

[0015] The 1# position sensor is arranged at the rear side of the cylinder body of the oil cylinder body structure, the 2# position sensor is arranged at the front side of the cylinder body, and the 3# position sensor is arranged at the front side of the piston rod; the industrial computer calculates the equivalent deflection of the oil cylinder according to the relative position distance between the position sensors;

[0016] A plurality of laser ranging sensors are evenly arranged on the outside of the cylinder end and the piston rod side of the oil cylinder body structure, and a laser ranging target is correspondingly arranged at the end of the piston rod, which is used for measuring the displacement value of the oil cylinder; the laser ranging sensors measure the displacement of the oil cylinder body structure in each direction and transmit the signals to the industrial computer;

[0017] At least two pressure sensors are used to detect the large cavity pressure P1 of the oil cylinder body structure and the small cavity pressure P2 of the oil cylinder body structure;

[0018] The oil cylinder bearing monitoring and evaluation unit is used for detecting the bearing state of the oil cylinder body structure.

[0019] Preferably, the number of laser ranging sensors is 2, which are arranged at 180 degrees along the circumference of the cylinder end of the oil cylinder body structure; the laser ranging target is correspondingly arranged at the circumferential position of the end of the piston rod, which can measure the real-time displacement X1 and X2 of the oil cylinder;

[0020] The number of pressure sensors is 2, which are installed on the valve group to detect the large and small cavity pressures of the oil cylinder body structure; the valve group is attached to the oil cylinder body structure and communicates with the oil cylinder body structure through a pipeline.

[0021] Preferably, the industrial computer calculates the displacement of the oil cylinder according to the displacement value of the oil cylinder and according to the following formula: X=(X1+X2) / 2, and the maximum displacement X0 of the oil cylinder.

[0022] The industrial computer includes an oil cylinder body structure deflection monitoring unit, which divides the stroke of the oil cylinder body structure into a plurality of continuous first stroke ranges, and sets an equivalent deflection limit value for each first stroke range;

[0023] The industrial computer calculates the current equivalent deflection D of the oil cylinder;

[0024] The oil cylinder body structure deflection monitoring unit compares the current equivalent deflection D of the oil cylinder with the equivalent deflection limit value in the corresponding first stroke range; if the current equivalent deflection D of the oil cylinder reaches 90% of the equivalent deflection limit value, the audible and visual alarm is started; if the current equivalent deflection D of the oil cylinder reaches 100% of the equivalent deflection limit value, the audible and visual alarm is started, and the industrial computer controls the valve group to stop working;

[0025] Preferably, the industrial computer includes an oil cylinder body structure pressure monitoring unit, which divides the stroke of the oil cylinder body structure into a plurality of continuous second stroke ranges, and sets a large cavity pressure limit value for each second stroke range;

[0026] The oil cylinder body structure pressure monitoring unit compares the detected current oil cylinder body structure large cavity pressure P1 with the oil cylinder body structure large cavity pressure limit value corresponding to the second stroke range, and if the large cavity pressure value reaches 100% of the oil cylinder body structure large cavity pressure limit value, the audible and visual alarm is started, and the industrial computer control valve group is temporarily stopped.

[0027] Preferably, the industrial computer includes an oil cylinder body structure working condition detection unit, which is provided with a reversed frame resting working condition and a vertical standing working condition.

[0028] When the oil cylinder body structure displacement position is in the range of 0-X0*c1, the displacement change is less than 5%, and the oil cylinder body structure large cavity pressure P1 changes less than 10%, the oil cylinder body structure working condition detection unit determines that the oil cylinder body structure is in the reversed frame resting working condition.

[0029] When the oil cylinder body structure displacement position is in the range of X0*c2-X0*c3, the displacement change is less than 5%, and the oil cylinder body structure large cavity pressure P1 changes less than 10%, and the oil cylinder body structure small cavity pressure P2 changes less than 10%, the oil cylinder body structure working condition detection unit determines that the oil cylinder body structure is in the vertical standing working condition.

[0030] When the oil cylinder body structure working condition detection unit monitors that the oil cylinder body structure is in the reversed frame resting working condition for more than H1, the audible and visual alarm is started.

[0031] When the oil cylinder body structure working condition detection unit monitors that the oil cylinder body structure is in the vertical standing working condition for more than H2, the audible and visual alarm is started.

[0032] Preferably, the piston rod coating monitoring and evaluation unit includes a line array industrial camera, a data transfer computer and a display system computer.

[0033] Preferably, the line array industrial camera selects a color CMOS global industrial camera, the number of which is X (X≥3), and the customized support frame is fixed to the outer edge part of the oil cylinder body at the extension end of the piston rod. The line array industrial camera is arranged equidistantly on the customized support frame in a ring shape, and the surface topography and cleanliness of the piston rod are monitored in real time, and the damaged areas such as corrosion, scratches and peeling of the coating surface are detected.

[0034] The data transfer computer processes the picture information taken by the line array industrial camera, and classifies and analyzes the data. The data analysis system divides the surface of the oil cylinder piston rod into multiple areas from bottom to top for monitoring, and the area of each area is Y square meters. Through the obtained picture information, the number of rust spots in a single area, the area of a single rust spot, or the rubbing and impact area of a single area are calculated and analyzed, and the result data is fed back to the display system computer.

[0035] The display system computer displays the surface morphology of the coating of each region (Y square meters) of the piston rod, and according to the calculation and analysis results, a warning is given. When the piston rod is scratched or hit, the local position morphology of the surface of a single region is severely damaged; or the number of rust spots in a single region of the coating surface exceeds Z, and the area of each rust spot is not more than D mm 2 (D is appropriate data selected according to the specification); or a rust spot with an area exceeding D mm 2 appears in a single region; the display system issues a red light warning signal, prompting that the region needs to be repaired; for various types of pollution falling on the surface of each region of the piston rod, the display system issues a yellow light warning signal, prompting that the coating of the region needs to be cleaned.

[0036] Preferably, the oil cylinder bearing monitoring and evaluation unit comprises a pin shaft sensor, a noise sensor, a vibration sensor, a red-hot external imager, an acceleration sensor, a high-definition camera and a high-precision displacement sensor.

[0037] The pin shaft sensor is installed at the pin shaft of the joint bearing instead of the original pin shaft, and monitors the load of the joint bearing during service.

[0038] The noise sensor is installed at the joint bearing seat to collect sound information of the joint bearing during service in real time.

[0039] The vibration sensor is installed at the joint bearing seat to measure the vibration of the joint bearing in real time.

[0040] The red-hot external imager is installed at the end of the piston rod to detect the temperature of the friction between the gasket and the inner ring of the joint bearing in real time. When the temperature rise rate reaches or exceeds 0.5℃ / h and the temperature exceeds 100℃, the industrial computer controls the audible and visual alarm to issue an alarm signal.

[0041] The acceleration sensor is installed at the joint bearing seat to detect the acceleration of the joint bearing.

[0042] The high-definition camera has multiple cameras, some of which are installed at the end of the piston rod to cover the entire monitoring range of the joint bearing and monitor the appearance of the joint bearing, and some of which are installed at the joint bearing seat to take pictures of the joint bearing fitting.

[0043] The high-precision displacement sensor is installed on the side of the joint bearing. When the joint bearing gasket is worn, displacement will occur, which will drive the displacement sensor to move.

[0044] Preferably, the industrial computer comprises a bearing monitoring unit.

[0045] The bearing monitoring unit initializes the parameters of the pin shaft sensor, noise sensor, vibration sensor, red-hot external imager, acceleration sensor, high-definition camera, and high-precision displacement sensor;

[0046] The bearing monitoring unit has a large amount of joint bearing service process data and life test data in the database through machine learning;

[0047] The bearing monitoring unit collects the load data F of the joint bearing monitored by the pin shaft sensor. If the load data F reaches 95% of the rated load [F], the industrial computer judges that it is abnormal and reminds to stop and overhaul. If the load data F is greater than [F], the industrial computer judges that the joint bearing is crushed and fails, and reminds to replace the joint bearing;

[0048] The bearing monitoring unit collects real-time sound data S monitored by the noise sensor. If the sound data S exceeds the preset value and the time duration is greater than or equal to 2s, the industrial computer judges that it is abnormal and reminds to stop and overhaul;

[0049] The bearing monitoring unit collects the real-time frequency data ω of the joint bearing measured by the vibration sensor. If the frequency data ω exceeds the preset value and the time duration is greater than or equal to 2s, the industrial computer judges that it is abnormal and reminds to stop and overhaul;

[0050] The bearing monitoring unit collects the real-time temperature data T of the joint bearing friction measured by the red-hot external imager. If the temperature data T rises at a speed of 0.5℃ / h or the temperature exceeds 100℃, the industrial computer judges that it is abnormal and reminds to stop and overhaul. If the temperature data T is greater than or equal to 150℃, the industrial computer judges that the joint bearing is overheated and fails, and reminds to replace the joint bearing;

[0051] The bearing monitoring unit collects the acceleration value A of the output vibration and the joint bearing state parameters monitored by the acceleration sensor in real time. If the acceleration value A exceeds the limit value [A], the industrial computer judges that it is abnormal and reminds to stop and overhaul;

[0052] The bearing monitoring unit collects the wear amount L of the joint bearing liner monitored by the high-precision displacement sensor in real time. If the wear amount L is less than the liner thickness, but its increasing speed is greater than or equal to 1mm / min, the industrial computer judges that it is abnormal and reminds to stop and overhaul. If the wear amount L is equal to the liner thickness, the industrial computer judges that the joint bearing is failed, and reminds to replace the joint bearing;

[0053] The bearing monitoring unit collects the appearance of the joint bearing monitored by the high-definition camera in real time, and compares it with the content in the database to determine whether the appearance of the joint bearing appears pitting, surface peeling, or not. If the liner is extruded and the joint bearing fails, the industrial computer reminds to replace the joint bearing.

[0054] Preferably, the sensor monitoring sound, vibration, acceleration data collected by the bearing monitoring unit is filtered to remove invalid data.

[0055] Preferably, the bearing monitoring unit predicts the remaining life of the joint bearing, specifically:

[0056] Theoretically, the remaining life of the joint bearing is:

[0057] The remaining life of the joint bearing is:

[0058] A decline coefficient α is obtained through experiments and actual service data and calculations of the joint bearing. Therefore, combined with the weight of the joint bearing online monitoring temperature and wear data, the remaining life of the joint bearing is:

[0059] Preferably, the oil cylinder body structure includes a cylinder body and a piston arranged inside the cylinder body, the piston divides the inside of the cylinder body into a rod cavity and a rodless cavity, the rod cavity is a small cavity, the rodless cavity is a large cavity, the side of the piston towards the rod cavity is fixedly connected with a piston rod, a sealing element is arranged between the piston rod and the cylinder body, and the rod cavity and the rodless cavity are respectively connected with oil pipes.

[0060] It also includes an oil cylinder sealing monitoring device, which includes a piston rod outer peripheral surface detection device, an oil detection device, and a piston rod speed detection device.

[0061] The piston rod outer peripheral surface detection device is arranged at the end of the cylinder body to detect whether there is hydraulic oil on the outer peripheral surface of the piston rod extending out of the oil cylinder body structure, judge the piston rod coating defect state, and evaluate the sealing damage risk.

[0062] The oil detection device is arranged on the two oil pipes to detect the oil quality of the hydraulic oil in the oil pipes.

[0063] The piston rod speed detection device is arranged on the oil cylinder body structure to detect the actual moving speed and the theoretical moving speed of the piston rod.

[0064] The industrial computer includes an oil cylinder sealing control unit, which is connected with each detection device, the display screen and the alarm, respectively, obtains the data detected by each detection device, judges whether there is leakage in the oil cylinder body structure, and displays prompt information through the display screen; when there is leakage in the oil cylinder body structure, the industrial computer controls the alarm to issue an alarm information.

[0065] Preferably, the oil cylinder sealing control unit detects the external leakage working condition and the internal leakage working condition of the oil cylinder body structure, respectively.

[0066] The outer leakage working condition detection of the oil cylinder body structure specifically includes the following steps:

[0067] SA1, detecting whether there is hydraulic oil leakage on the outer peripheral surface of the piston rod extending out of the oil cylinder body structure through the piston rod outer peripheral surface detection device, and transmitting to the industrial computer oil cylinder sealing control unit; if there is, proceed to step SA2, otherwise proceed to step SA3;

[0068] SA2, detecting the oil quality of the hydraulic oil in the two oil pipes through the oil detection device, obtaining the moisture and particle content of the hydraulic oil in the two oil pipes, and transmitting to the industrial computer oil cylinder sealing control unit; when the moisture and particle content of the hydraulic oil in any of the oil pipes exceeds the set oil quality threshold, the industrial computer oil cylinder sealing control unit determines that the oil cylinder body structure has an outer leakage condition, displays prompt information through the display screen, and sends alarm information through the alarm; when the moisture and particle content of the hydraulic oil in the two oil pipes does not exceed the set oil quality threshold, the industrial computer determines that the oil cylinder body structure has the possibility of outer leakage, and displays prompt information through the display screen;

[0069] SA3, detecting the oil quality of the hydraulic oil in the two oil pipes through the oil detection device, obtaining the moisture and particle content of the hydraulic oil in the two oil pipes, and transmitting to the industrial computer oil cylinder sealing control unit; when the moisture and particle content of the hydraulic oil in the two oil pipes does not exceed the set oil quality threshold, the industrial computer oil cylinder sealing control unit determines that the oil cylinder body structure does not have an outer leakage condition; when the moisture and particle content of the hydraulic oil in any of the oil pipes exceeds the set oil quality threshold, the industrial computer oil cylinder sealing control unit determines that the oil cylinder body structure has the possibility of outer leakage, and displays prompt information through the display screen;

[0070] The inner leakage working condition detection of the oil cylinder body structure specifically includes the following steps: SB1, detecting the oil pressure of the rod cavity and the rodless cavity of the oil cylinder body structure through two pressure sensors, and transmitting to the industrial computer oil cylinder sealing control unit; the industrial computer oil cylinder sealing control unit compares the pressure difference of the two chambers with the set pressure difference threshold, if the pressure difference of the two oil pipes reaches the set pressure difference threshold, proceed to step SB2, otherwise proceed to step SB3;

[0071] SB2, detecting the actual moving speed and the theoretical moving speed of the piston rod by the piston rod speed detecting device and transmitting to the industrial computer oil cylinder sealing control unit; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold value, the industrial computer judges that the oil cylinder body structure has internal leakage, displays prompt information through the display screen and sends alarm information through the alarm; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold value, the industrial computer judges that the oil cylinder body structure has the possibility of internal leakage, displays prompt information through the display screen;

[0072] SB3, detecting the actual moving speed and the theoretical moving speed of the piston rod by the piston rod speed detecting device and transmitting to the industrial computer oil cylinder sealing control unit; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold value, the industrial computer judges that the oil cylinder body structure has no internal leakage; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold value, the industrial computer judges that the oil cylinder body structure has the possibility of internal leakage, displays prompt information through the display screen.

[0073] Preferably, the oil cylinder sealing control unit estimates the remaining life of the sealing element, and the remaining life of the sealing element is calculated by the following formula:

[0074] In the formula, T y is the remaining life of the sealing element, T s is the designed life of the sealing element, T i is the equivalent used life of the sealing element, Q f is the non-metallic particle content of the hydraulic oil in any of the oil pipes; β is the non-metallic particle content threshold of the hydraulic oil; is the variance of the periodic detection value of the pressure difference between the two oil pipes; Q is the threshold of the variance of the pressure difference between the two oil pipes.

[0075] Taking the pile frame main oil cylinder of a pile driving ship as an example, the present application at least has the following beneficial effects:

[0076] 1. Real-time detection of the state of key components such as cylinder seal, joint bearing, and piston rod coating, and the whole machine can be realized, and the design-application accumulation of large pile driver pile frame cylinder based on domestic key components can be formed, which can guarantee the reliable application and continuous iteration and upgrading of key components and the whole machine of the cylinder, improve the technical level of the core key components and the whole machine of the main cylinder of the large pile driver, promote the high-quality development of the industry, and help the localization of the main cylinder and key components, which can effectively guarantee the construction of national major projects such as cross-sea bridges and deep-sea wind power projects, and maintain the stability of the industry chain and the safety of the supply chain.

[0077] 2. Realize the fine control of the pile driver pile frame main cylinder under different working conditions, and significantly improve the safety of the pile driver pile frame main cylinder. Through the position detection of different parts of the cylinder body structure, the deflection value of the cylinder body structure under long stroke is calculated by combining certain algorithm, the overload protection of long stroke cylinder is realized; combined with the pressure and stroke detection of the cylinder body structure, the stress of super large and super long cylinder under different strokes is constrained to ensure the safe operation of the cylinder; for the idle condition of the cylinder body structure, the idle condition is managed by using pressure and displacement to prevent abnormal damage caused by long-term idling of the cylinder body structure.

[0078] 3. Realize the online performance evaluation of the joint bearing of the cylinder body structure, and promote the application and promotion of key technologies such as domestic glue and domestic yarn of joint bearing. Real-time state detection is performed on the joint bearing to timely discover abnormal conditions of the joint bearing, and maintenance is performed on the joint bearing to ensure long-term safe use of the cylinder; the remaining life of the joint bearing in service is predicted to avoid various losses caused by sudden failure of the bearing, and the joint bearing failure time is predicted in advance to plan the replacement of the joint bearing in advance to avoid delay of the construction period.

[0079] 4. Realize the online performance evaluation of the seal of the cylinder body structure, and promote the domestic substitution of the key seal of the cylinder body structure. The seal state of the cylinder body structure is detected online, and the existence of external leakage and seal damage risk of the cylinder body structure is judged by double evaluation of the surface state of the piston rod, leakage condition, and oil quality of the hydraulic oil in the oil pipe; the existence of internal leakage of the cylinder seal is judged by double evaluation of the difference between the actual moving speed and the theoretical moving speed of the piston rod combined with the pressure of the two cavities of the cylinder body structure; the seal state of the cylinder body structure can be detected in real time and accurately to provide safety protection for the use of the pile driver.

[0080] 5. Realize the online performance evaluation of the laser cladding coating surface state of the piston rod of the cylinder body structure, and promote the application and promotion of key technologies such as domestic powder for laser cladding and ultra-high-speed laser cladding. Real-time state detection is performed on the cladding coating to timely discover surface defects of the coating, which is convenient for timely maintenance of the cladding coating to ensure long-term safe use of the cylinder.

[0081] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0082] Figure 1 is a structural assembly diagram of the hydraulic cylinder body of the piling vessel of the present invention.

[0083] Figure 2 is a flowchart illustrating the working principle of the main hydraulic cylinder monitoring system for the piling vessel of the present invention.

[0084] Figure 3 is a schematic diagram of the joint bearing in this invention;

[0085] Figure 4 is a schematic diagram of the installation position of the monitoring sensor in the joint bearing in a technical solution of the present invention;

[0086] Figure 5 is a schematic diagram of the installation position of the monitoring sensor in the spherical bearing in another technical solution of the present invention;

[0087] Figure 6 is a flowchart of the joint bearing monitoring process in this invention;

[0088] Figure 7 is a system structure diagram of the cylinder sealing monitoring device, industrial control computer, display screen and alarm of the present invention;

[0089] Figure 8 is a schematic diagram of the main oil cylinder according to one embodiment of the present invention;

[0090] Figure 9 is a schematic diagram of the internal structure of the hydraulic cylinder body when the cylinder body and the piston are eccentric.

[0091] Figure 10 is a flowchart of the detection of external leakage conditions of the main oil cylinder of the present invention;

[0092] Figure 11 is a flowchart of the detection process for internal leakage of the main cylinder of the present invention.

[0093] Explanation of reference numerals in the attached drawings: 1-1# position sensor, 2-2# position sensor, 3-3# position sensor, 4-cylinder block, 5-piston rod, 6-laser rangefinder sensor, 7-valve assembly, 8-first pressure sensor, 9-second pressure sensor, 10-spherical bearing, 11-spherical bearing housing, 11-1-inner ring, 11-2-outer ring, 11-3 gasket, 12-pin sensor, 13-noise sensor, 14-vibration sensor, 15-infrared thermal imager, 16-accelerometer, 17-high-definition camera, 18-high-precision displacement sensor, 19-seal, 20-speed sensor, 21-linear scanning camera, 22-oil sensor, 23-oil pipe connected to the rod chamber, 24-flow sensor, 25-oil pipe connected to the rodless chamber. Detailed Implementation

[0094] The present application will be described in detail below with reference to the accompanying drawings. Those skilled in the art will be able to implement the present application based on these descriptions. Before the present application is described in detail with reference to the accompanying drawings, it should be pointed out that the technical solutions and technical features provided in each part of the following description, including the description below, can be combined with each other without conflict.

[0095] In addition, the embodiments of the present application involved in the following description are generally only embodiments of a part of the present application, not all embodiments. Therefore, all other embodiments obtained by those skilled in the art based on the embodiments in the present application without creative labor should be within the scope of protection of the present application.

[0096] The present application will be described in detail below with reference to the accompanying drawings. Those skilled in the art will be able to implement the present application based on these descriptions. Before the present application is described in detail with reference to the accompanying drawings, it should be pointed out that the technical solutions and technical features provided in each part of the following description, including the description below, can be combined with each other without conflict.

[0097] As shown in FIGS. 1-6, a preferred embodiment of the present application provides a super-long digital oil cylinder based on key components, including: an oil cylinder body structure, an oil cylinder V group seal, a joint bearing, a piston rod laser cladding coating, an oil cylinder state monitoring and adjusting unit, an oil cylinder bearing monitoring and evaluation unit, a piston rod coating monitoring and evaluation unit, an industrial computer, a display screen and an audible and visual alarm;

[0098] The oil cylinder state monitoring and adjusting unit includes a position sensor, a laser distance measuring sensor 6 (preferably a line laser distance measuring sensor 6), a laser distance measuring target and a pressure sensor;

[0099] A 1# position sensor 1 is arranged at the rear side of the cylinder body 4 of the oil cylinder body structure, a 2# position sensor 2 is arranged at the front side of the cylinder body 4, and a 3# position sensor 3 is arranged at the front side of the piston rod 5. The industrial computer calculates the equivalent deflection of the oil cylinder based on the relative position distance between each position sensor;

[0100] A certain number of laser distance measuring sensors 6 are evenly installed on the outside of the cylinder body 4 end piston rod 5 side of the oil cylinder body structure, and a laser distance measuring target is correspondingly installed at the end of the piston rod 5 for measuring the oil cylinder displacement value. The laser distance measuring sensor 6 measures the displacement of each direction of the oil cylinder body structure and transmits the signal to the industrial computer;

[0101] At least two pressure sensors, a first pressure sensor 8 for detecting the large cavity pressure P1 of the oil cylinder body structure, and a second pressure sensor 9 for detecting the small cavity pressure P2 of the oil cylinder body structure;

[0102] The oil cylinder bearing monitoring and evaluation unit is used for oil cylinder body structure bearing state detection.

[0103] The technical scheme can further include the following technical details to better achieve the technical effects: the number of the laser ranging sensors 6 is 2, which are arranged at 180 degrees along the circumference of the end of the cylinder body structure cylinder 4; the laser ranging targets are correspondingly installed at the circumferential position of the end of the piston rod 5, and can measure the displacement value of the oil cylinder;

[0104] The number of the pressure sensors is 2, which are installed on the valve group 7 to detect the pressure of the large and small cavities of the oil cylinder body structure, the valve group 7 is attached to the oil cylinder body structure and communicates with the oil cylinder body structure through a pipeline, and can realize the functions of oil supply pressure detection, oil cylinder pressure maintaining, extension and retraction, and reversing.

[0105] The technical scheme can further include the following technical details to better achieve the technical effects: the industrial computer calculates the maximum displacement value X0 of the oil cylinder body structure according to the laser ranging sensor 6;

[0106] The industrial computer includes an oil cylinder body structure deflection monitoring unit, which divides the stroke of the oil cylinder body structure into a plurality of continuous first stroke ranges, and sets an equivalent deflection limit value for each first stroke range;

[0107] The industrial computer calculates the current equivalent deflection D of the oil cylinder, specifically: the distances D1 between the 1st position sensor 1 and the 3rd position sensor 3 and the distances D2 between the 2nd position sensor 2 and the 3rd position sensor 3 are measured respectively, and the fixed distance D3 between the 1st position sensor 1 and the 2nd position sensor 2 is combined, and the equivalent deflection D is calculated according to the following formula: D=D3*tan(arccos((D3 2 +D1 2 -D2 2 ) / 2*D3*D1)).

[0108] Table 1 Note: n1, n2, n3 represent the percentage of the stroke of the oil cylinder, the value range is 0-100%, the value is taken according to the deflection limit value of different oil cylinder strokes, and according to the control requirements, it can be further subdivided, and theoretically the deflection limit value of the oil cylinder in the whole stroke range can be one-to-one constrained, wherein 0

[0109] The oil cylinder body structure deflection monitoring unit compares the current equivalent deflection D of the oil cylinder with the equivalent deflection limit value in the corresponding first stroke range, if the current equivalent deflection D of the oil cylinder reaches 90% of the equivalent deflection limit value, the audible and visual alarm is started, if the current equivalent deflection D of the oil cylinder reaches 100% of the equivalent deflection limit value, the audible and visual alarm is started, and the industrial computer controls the valve group 7 to stop working (lose power) to protect the oil cylinder;

[0110] The technical scheme can further include the following technical details to better achieve the technical effects: the industrial computer includes a cylinder body structure pressure monitoring unit, the cylinder body structure pressure monitoring unit divides the cylinder body structure stroke into a plurality of continuous second stroke ranges, and each second stroke range is provided with a cylinder body structure large cavity pressure limit value. The cylinder body structure design pressure P0 is measured by the large cavity pressure sensor and the small cavity pressure sensor. According to the cylinder bearing capacity, the cylinder large cavity pressure limit value under different strokes is formulated, as shown in the following table 2.

[0111] Table 2 Note: a, a1, a2, a3 represent the percentage of the cylinder stroke, the value range is 0-100%, the value is taken according to the allowable load of different cylinder strokes, and according to the control requirement, it can be further subdivided, and theoretically, the cylinder pressure limit value in the whole stroke range can be one-to-one constrained, wherein 0

[0112] The cylinder body structure pressure monitoring unit compares the detected current cylinder body structure large cavity pressure P1 with the cylinder body structure large cavity pressure limit value corresponding to the second stroke range. If the large cavity pressure value reaches 100% of the cylinder body structure large cavity pressure limit value, the audible and visual alarm is started, and the industrial computer controls the valve group 7 to stop working to protect the cylinder.

[0113] The technical scheme can further include the following technical details to better achieve the technical effects: the industrial computer includes a cylinder body structure working condition detection unit, the cylinder body structure working condition detection unit is provided with a reversed frame resting working condition and a vertical working condition, and the two working conditions are judged according to the following table 3.

[0114] Table 3 Note: c1, c2, c3 represent the percentage of the cylinder stroke, the value range is 0-100%, the value is taken according to the design characteristics of different pile driving barges, and 0

[0115] When the displacement position of the cylinder body structure is in the range of 0-X0*c1, the displacement change is less than 5% during the range, and the cylinder body structure large cavity pressure P1 changes less than 10%, the cylinder body structure working condition detection unit determines that the cylinder body structure is in the reversed frame resting working condition.

[0116] When the displacement position of the cylinder body structure is in the range of X0*c2-X0*c3, the displacement change is less than 5% during the range, and the cylinder body structure large cavity pressure P1 changes less than 10%, the cylinder body structure small cavity pressure P2 changes less than 10%, the cylinder body structure working condition detection unit determines that the cylinder body structure is in the vertical working condition.

[0117] When the oil cylinder body structure working condition detection unit monitors that the oil cylinder body structure is in the upside-down resting working condition for more than H1, a sound-light alarm is started to remind the operator to perform oil cylinder maintenance operation.

[0118] When the oil cylinder body structure working condition detection unit monitors that the oil cylinder body structure is in the upright waiting working condition for more than H2, a sound-light alarm is started to remind the operator to perform oil cylinder maintenance operation.

[0119] The technical scheme can further include the following technical details to better achieve the technical effects: the piston rod coating monitoring and evaluation unit includes a line array industrial camera, a data relay computer and a display system computer;

[0120] The line array industrial camera is a color CMOS global industrial camera, and there are six of them. A customized support frame is fixed to the outer edge part of the oil cylinder body at the extending end of the piston rod. The line array industrial cameras are arranged in a ring shape at equal intervals on the customized support frame. The camera lens is aligned with the surface of the piston rod coating, and the surface morphology and cleanliness of the coating are monitored in real time. The image information of the coating surface obtained by the industrial camera has a direct impact on the accuracy of subsequent data processing and maintenance warning. Preferably, a high-resolution line array industrial camera scans the surface of the piston rod, and the wear condition of the surface of the piston rod is determined through visual processing and comparative analysis.

[0121] The data relay computer processes the picture information taken by the line array industrial camera, classifies and analyzes the data, and the data analysis system divides the surface of the oil cylinder piston rod into multiple areas for monitoring from bottom to top. Each area has an area of 1 square meter. Through the obtained picture information, the number of rust spots in a single area and the area of a single rust spot, or the area of rubbing, impact, cracks, corrosion, crystallization, peeling, oxidation and other piston rod surface coating failure forms in a single area are calculated and analyzed. The collected images are subjected to preprocessing operations such as cropping, scaling and rotating to maintain the consistency and quality of the images. Finally, the images are divided into training set: validation set at a ratio of 5:1, and the result data is fed back to the display system computer;

[0122] The display system computer displays the surface morphology of the coating of each area (1 square meter per area) of the piston rod, and performs early warning according to the calculation and analysis results. When the piston rod is rubbed, impacted, and the local position morphology of the surface of a single area is severely damaged; or the number of rust spots on the surface of a single area exceeds 10, and the area of each rust spot is not more than 19.63mm 2 ; or a single area has an area exceeding 19.63mm 2Rust spots; the display system sends a red light warning signal, prompting the area to be repaired; for various types of pollution falling on the surface of the piston rod in each area, the display system sends a yellow light warning signal, prompting the coating in the area to be cleaned. In this way, the intelligent maintenance warning function of the oil cylinder is realized.

[0123] The technical solution can also include the following technical details to better achieve the technical effect: the oil cylinder bearing monitoring and evaluation unit includes a pin shaft sensor 12, a noise sensor 13, a vibration sensor 14, a red-hot external imager 15, an acceleration sensor 16, a high-definition camera 17, and a high-precision displacement sensor 18.

[0124] The pin shaft sensor 12 is installed on the pin shaft of the joint bearing 10 instead of the original pin shaft, and monitors the load of the joint bearing 10 during service. The pin shaft sensor 12 is connected to the industrial computer, and when the load exceeds the specified load value, the industrial computer controls the audible and visual alarm to issue an alarm signal.

[0125] The noise sensor 13 is installed on the joint bearing seat 11 and collects sound information in real time during the service of the joint bearing 10. The sound processing module eliminates interference sound data from the sound information and uploads it to the industrial computer for data processing. When the sound data is abnormal, the industrial computer controls the audible and visual alarm to issue an alarm signal.

[0126] The vibration sensor 14 is installed on the joint bearing seat 11 and measures the real-time vibration of the joint bearing 10. The industrial computer processes the received frequency data, and if abnormal frequency data is detected, the industrial computer controls the audible and visual alarm to issue an alarm signal.

[0127] The red-hot external imager 15 is installed at the end of the piston rod 5 and detects the real-time temperature of the friction between the gasket 11-3 and the inner ring 11-1 of the joint bearing 10. When the temperature rise rate reaches or exceeds 0.5℃ / h and the temperature exceeds 100℃, the industrial computer controls the audible and visual alarm to issue an alarm signal.

[0128] The acceleration sensor 16 is installed on the joint bearing seat 11 to detect the acceleration of the joint bearing 10.

[0129] The high-definition camera 17 has multiple units, some of which are installed at the end of the piston rod 5 to cover the entire monitoring range of the joint bearing 10 and monitor the appearance of the joint bearing 10. Some high-definition cameras 17 are installed on the joint bearing seat 11 to capture the joint bearing 10 fitting place and input the video into the trained model. The model is equipped with visual recognition, and the model provides real-time feedback on whether the joint bearing 10 fitting place gap and gasket 11-3 are falling off or being extruded.

[0130] High-precision displacement sensor 18 is installed on the side of joint bearing 10, and displacement will occur when gasket 11-3 of joint bearing 10 is worn out, and the displacement of joint bearing 10 is driven by the displacement of displacement sensor, and the wear of gasket 11-3 of joint bearing 10 is calculated by the difference between the measured value of displacement sensor and the initial value.

[0131] In the embodiment, joint bearing 10 of the oil cylinder body structure is installed on joint bearing seat 11, one end of piston rod 5 is movably arranged in the oil cylinder body, and the other end of piston rod 5 is connected with joint bearing 10, joint bearing 10 includes inner ring 11-1 and outer ring 11-2, and gasket 11-3 is attached to the inner wall of outer ring 11-2.

[0132] The technical scheme can further include the following technical details to better achieve the technical effects: the industrial computer includes a bearing monitoring unit;

[0133] The bearing monitoring unit initializes the parameters of pin shaft sensor 12, noise sensor 13, vibration sensor 14, red-hot external imager 15, acceleration sensor 16, high-definition camera 17 and high-precision displacement sensor 18;

[0134] The bearing monitoring unit has a large amount of service data and life test data of joint bearing 10 in the bearing monitoring unit, and a database is obtained through machine learning;

[0135] The bearing monitoring unit collects load data F of joint bearing 10 monitored by pin shaft sensor 12, if the load data F reaches 95% of the rated load [F], the industrial computer judges that it is abnormal and reminds to stop and overhaul, if the load data F is greater than [F], the industrial computer judges that joint bearing 10 is crushed and fails, and reminds to replace joint bearing 10;

[0136] The bearing monitoring unit collects real-time sound data S monitored by noise sensor 13, if the sound data S exceeds the preset value and the time duration is greater than or equal to 2s, the industrial computer judges that it is abnormal and reminds to stop and overhaul;

[0137] The bearing monitoring unit collects real-time frequency data ω of joint bearing 10 measured by vibration sensor 14, if the frequency data ω exceeds the preset value and the time duration is greater than or equal to 2s, the industrial computer judges that it is abnormal and reminds to stop and overhaul;

[0138] The bearing monitoring unit collects real-time temperature data T of the friction part of joint bearing 10 by red-hot external imager 15, if the temperature data T has a heating speed of 0.5℃ / h or the temperature exceeds 100℃, the industrial computer judges that it is abnormal and reminds to stop and overhaul, if the temperature data T is greater than or equal to 150℃, the industrial computer judges that joint bearing 10 is overheated and fails, and reminds to replace joint bearing 10;

[0139] The bearing monitoring unit collects the acceleration value A of the output vibration monitored by the acceleration sensor 16 in real time and the state parameters of the knuckle bearing 10, and if the acceleration value A exceeds the limit value [A], the industrial computer judges that it is abnormal and reminds to stop and overhaul;

[0140] The bearing monitoring unit collects the wear amount L of the knuckle bearing 10 gasket 11-3 monitored by the high-precision displacement sensor 18 in real time, and if the wear amount L is less than the thickness of the gasket 11-3 but its increasing speed is greater than or equal to 1mm / min, the industrial computer judges that it is abnormal and reminds to stop and overhaul; if the wear amount L is equal to the thickness of the gasket 11-3, the industrial computer judges that the knuckle bearing 10 is invalid and reminds to replace the knuckle bearing 10;

[0141] The bearing monitoring unit collects the appearance of the knuckle bearing 10 monitored by the high-definition camera 17 in real time, and compares it with the content in the database to determine whether the appearance of the knuckle bearing 10 has pitting and surface peeling, and if the gasket 11-3 is identified to be extruded and the knuckle bearing 10 is invalid, the knuckle bearing 10 is replaced.

[0142] The technical solution can also include the following technical details to better achieve the technical effect: the sound, vibration and acceleration data monitored by the sensor collected by the bearing monitoring unit are filtered to remove invalid data.

[0143] The technical solution can also include the following technical details to better achieve the technical effect: the bearing monitoring unit performs remaining life prediction of the knuckle bearing 10, specifically:

[0144] Theoretically, the remaining life of the knuckle bearing 10 is:

[0145] The remaining life of the knuckle bearing 10 is equal to the designed service life minus the equivalent service life;

[0146] A descending coefficient alpha is obtained through experiments and actual service data and calculation of the knuckle bearing 10, so the remaining life of the knuckle bearing 10 is combined with the weight of the online monitoring temperature and wear amount data of the knuckle bearing 10:

[0147] The technical solution can also include the following technical details to better achieve the technical effect: as shown in Figures 7-11, the oil cylinder body structure includes a cylinder body and a piston arranged inside the cylinder body, the piston divides the inside of the cylinder body into a rod cavity and a rodless cavity, the rod cavity is a small cavity, the rodless cavity is a large cavity, one side of the piston towards the rod cavity is fixedly connected with a piston rod, a sealing element 19 is arranged between the piston rod and the cylinder body, and the rod cavity and the rodless cavity are respectively connected with oil pipes (23, 25);

[0148] Also included is an oil cylinder sealing monitoring device, which includes a piston rod outer peripheral surface detection device, an oil detection device, and a piston rod speed detection device;

[0149] The piston rod outer peripheral surface detection device is arranged at the end of the cylinder body and is used to detect whether hydraulic oil exists on the outer peripheral surface of the piston rod extending out of the oil cylinder body structure. The piston rod outer peripheral surface detection device includes two linear scanning cameras, and the two linear scanning cameras 21 are symmetrically arranged at one end of the cylinder body close to the rod cavity. The scanning ranges of the two linear scanning cameras 21 together cover the entire outer peripheral surface of the piston rod. The linear scanning camera 21 transmits the captured outer peripheral surface state data of the piston rod to the industrial computer, and the industrial computer can analyze the data based on the YOLOv8 model to determine whether there is oil leakage on the surface of the piston rod and to determine the defect state of the piston rod coating and assess the risk of sealing damage. YOLOv8 is an SOTA model that supports all-around visual AI tasks, including detection, segmentation, pose estimation, tracking, and classification. First, a number of oil cylinder hydraulic oil leakage pictures and piston rod coating defect pictures need to be taken to create a certain amount of data set, which includes pictures, labels, training set, validation set, and test set. Then, the data set format is converted into yolo_txt format, and then the required training model is selected, providing s, m, l, and x versions, which gradually increase (as the architecture increases, the training time also gradually increases). Next, training, validation, and prediction can be performed. For the detection of oil cylinder body structure leakage and piston rod coating defects, the linear scanning camera 21 is arranged at one end of the cylinder body close to the rod cavity to capture the easy-to-leak position and the surface of the piston rod coating. The video is then transmitted in real time to the trained model, and after processing, if there is an external leakage condition and a piston rod coating surface defect in the output video result, it will be labeled in real time.

[0150] The oil detection device is arranged on the two oil pipes to detect the oil quality of the hydraulic oil in the oil pipes. The oil detection device includes two oil quality sensors 22, and the two oil quality sensors 227 are used to detect the moisture and particle content of the hydraulic oil in the two oil pipes. The oil quality sensor 22 communicates with the industrial computer using RS485. By comparing the detected moisture and particle (including metal particles and non-metal particles) content of the hydraulic oil with the set oil quality threshold, it can be determined whether there is an external leakage. The oil quality threshold can be determined by measuring the oil quality under different degrees of external leakage through experiments.

[0151] The two pressure sensors in the oil cylinder state monitoring and adjusting unit communicate with the industrial computer using RS485. Generally, in the actual operation of the oil cylinder, there is a pressure difference between the two sides of the liquid flowing inside the flat plate, and there is relative motion between the flat plates, and the internal leakage formula is:

[0152] In formula (1), b is the gap width; l is the gap length; h is the gap height; μ is the dynamic viscosity of the fluid; U is the relative velocity; △p is the pressure difference between the rod cavity and the rodless cavity; in the actual internal leakage of the oil cylinder body structure, the gap width b causing the internal leakage corresponds to the circumference of the inner diameter of the hydraulic cylinder, that is, πd; in addition, the eccentricity of the cylinder body and the piston needs to be considered, as shown in FIG. 9, an eccentricity coefficient needs to be added to the internal leakage calculation formula, so that the internal leakage calculation formula of the oil cylinder body structure is:

[0153] In formula (2), b is the gap width; l is the gap length; h is the gap height; μ is the dynamic viscosity of the fluid; U is the relative velocity; △p is the pressure difference between the rod cavity and the rodless cavity; in the actual internal leakage of the oil cylinder body structure, the gap width b causing the internal leakage corresponds to the circumference of the inner diameter of the hydraulic cylinder, that is, πd; in addition, the eccentricity of the cylinder body and the piston needs to be considered, as shown in FIG. 9, an eccentricity coefficient needs to be added to the internal leakage calculation formula, so that the internal leakage calculation formula of the oil cylinder body structure is: is the eccentricity rate;

[0154] Therefore, the pressure difference between the rod cavity and the rodless cavity can effectively reflect the internal leakage of the oil cylinder body structure.

[0155] A piston rod speed detection device is arranged on the oil cylinder body structure to detect the actual moving speed and the theoretical moving speed of the piston rod; the piston rod speed detection device includes a flow sensor 24 and a speed sensor 20; the flow sensor 24 is arranged on the oil pipe connected with the rodless cavity to detect the flow of the hydraulic oil in the oil pipe; the speed sensor 20 is arranged at the end of the piston rod to detect the actual moving speed of the piston rod. The actual moving speed of the piston rod obtained by the industrial computer through the speed sensor 20 is V1, and the flow in the oil pipe detected by the flow sensor 24 is Q1, at this time the corresponding cross-sectional area of the piston is S1, Q1 / S1 is the theoretical moving speed of the piston rod, then the industrial computer compares |Q1 / S1-V1| with the set speed error threshold to determine whether there is internal leakage. The speed error threshold can be determined by measuring the difference between the theoretical moving speed and the actual moving speed of the piston rod under different degrees of internal leakage through experiments.

[0156] The industrial computer includes an oil cylinder sealing control unit, which is connected with each detection device, the display screen and the alarm respectively, obtains the data detected by each detection device, judges whether the oil cylinder body structure has leakage, and displays prompt information through the display screen; when the oil cylinder body structure has leakage, the industrial computer controls the alarm to issue an alarm information.

[0157] ​The technical scheme can further include the following technical details to better achieve the technical effects: the oil cylinder sealing control unit detects the external leakage working condition and the internal leakage working condition of the oil cylinder body structure respectively;

[0158] In this technical scheme, when the sealing element 19 of the oil cylinder body structure fails in different forms, the oil cylinder body structure will have different degrees of internal and external leakage. The detection system detects a plurality of use data of the oil cylinder body structure through the detection devices respectively, and then processes the data through the industrial computer to determine whether the oil cylinder body structure has external leakage and internal leakage, and whether there is a possibility of external leakage and internal leakage, displays prompt information on the display screen, and controls the alarm to issue alarm information. The external leakage is that the hydraulic oil leaks to the outside of the cylinder body through the connection between the piston rod and the cylinder body. At this time, when the piston rod extends out of the cylinder body, a certain amount of hydraulic oil will be brought out of the outer periphery of the piston rod, and with the extension and retraction of the piston rod, the oil quality of the hydraulic oil will inevitably be affected. Therefore, whether there is external leakage is determined by detecting whether there is hydraulic oil on the outer periphery of the piston rod extending out of the cylinder body and the oil quality of the hydraulic oil in the two oil pipes. The internal leakage is the leakage between the rod cavity and the rodless cavity. At this time, the oil pressure in the rod cavity and the rodless cavity will change, thereby affecting the moving speed of the piston rod. Therefore, whether there is internal leakage is determined by detecting the oil pressure of the hydraulic oil in the two oil pipes and the theoretical moving speed and actual moving speed of the piston rod.

[0159] As shown in FIG. 10, the external leakage working condition detection of the main oil cylinder specifically includes the following steps:

[0160] SA1, detecting whether there is hydraulic oil leakage on the outer periphery of the piston rod extending out of the oil cylinder body structure by the piston rod outer periphery detection device, and transmitting to the industrial computer oil cylinder sealing control unit; if there is, proceed to step SA2, otherwise proceed to step SA3;

[0161] SA2, detecting the oil quality of the hydraulic oil in the two oil pipes by the oil quality detection device, obtaining the moisture and particle content of the hydraulic oil in the two oil pipes, and transmitting to the industrial computer oil cylinder sealing control unit; when the moisture and particle content of the hydraulic oil in any of the oil pipes exceeds the set oil quality threshold, the industrial computer oil cylinder sealing control unit determines that the oil cylinder body structure has external leakage, displays prompt information "Please note that there is external leakage" on the display screen, and issues alarm information through the alarm; when the moisture and particle content of the hydraulic oil in the two oil pipes does not exceed the set oil quality threshold, the industrial computer determines that the oil cylinder body structure has the possibility of external leakage, and displays prompt information "Please note that there is a possibility of external leakage" on the display screen.

[0162] SA3, detecting the oil quality of the hydraulic oil in the two oil pipes by the oil quality detection device, obtaining the water content and particle content of the hydraulic oil in the two oil pipes, and transmitting to the industrial computer oil cylinder sealing control unit; when the water content and particle content of the hydraulic oil in the two oil pipes do not exceed the set oil quality threshold, the industrial computer oil cylinder sealing control unit judges that the oil cylinder body structure does not exist external leakage, at this time, the display screen can also display the prompt information "no external leakage"; when the water content and particle content of the hydraulic oil in any of the oil pipes exceed the set oil quality threshold, the industrial computer oil cylinder sealing control unit judges that the oil cylinder body structure has the possibility of external leakage, and displays the prompt information "please note, there is a possibility of external leakage" through the display screen;

[0163] As shown in FIG. 11, the internal leakage condition detection of the oil cylinder body structure specifically includes the following steps: SB1, detecting the oil pressure of the rod cavity and the rodless cavity of the oil cylinder body structure by two pressure sensors, and transmitting to the industrial computer oil cylinder sealing control unit; the industrial computer oil cylinder sealing control unit compares the pressure difference of the two chambers with the set pressure difference threshold, if the pressure difference of the two oil pipes reaches the set pressure difference threshold, step SB2 is performed, otherwise step SB3 is performed;

[0164] SB2, detecting the actual moving speed and the theoretical moving speed of the piston rod by the piston rod speed detection device, and transmitting to the industrial computer oil cylinder sealing control unit; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold, the industrial computer judges that the oil cylinder body structure has internal leakage, displays the prompt information through the display screen, and sends the alarm information through the alarm; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold, the industrial computer judges that the oil cylinder body structure has the possibility of internal leakage, and displays the prompt information through the display screen;

[0165] SB3, detecting the actual moving speed and the theoretical moving speed of the piston rod by the piston rod speed detection device, and transmitting to the industrial computer oil cylinder sealing control unit; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold, the industrial computer judges that the oil cylinder body structure does not exist internal leakage; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold, the industrial computer judges that the oil cylinder body structure has the possibility of internal leakage, and displays the prompt information through the display screen.

[0166] The technical scheme can further include the following technical details to better achieve the technical effects: the detection method further includes estimating the remaining life of the seal 19, and when the seal 19 does not fail, the particle content in the hydraulic oil, the pressure of the rod cavity and the rodless cavity can be periodically monitored to determine the current health condition of the seal 19. After the industrial computer obtains the particle content of the hydraulic oil in the oil pipe and the pressure of the two oil pipes, the change of the particle content and the pressure difference of the two oil pipes is taken as an evaluation parameter of the seal life of the oil cylinder, and the remaining life of the seal 19 is estimated by the following formula, and the calculated remaining life is displayed on the display screen;

[0167] In formula (3), T y is the remaining life of the seal 19, T s is the design life of the seal 19, T i is the equivalent of the used life of the seal 19, Q f is the non-metallic particle content of the hydraulic oil in any of the oil pipes; and β is the threshold value of the non-metallic particle content of the hydraulic oil. is the variance of the periodic detection value of the pressure difference between the two oil pipes; and Q is the threshold value of the variance of the pressure difference between the two oil pipes. The threshold value β of the non-metallic particle content can be determined by experiment, and the current non-metallic particle content Q f After comparison, the health degree of the seal 19 is evaluated. On the other hand, the construction of the piling ship has repeatability and periodicity, and during the stable pressure work of the oil cylinder, the pressure of the rod cavity and the rodless cavity is periodically monitored to obtain the variance of the pressure difference between the two cavities and the variance value of the pressure difference between the rod cavity and the rodless cavity under different leakage degrees in the test environment is taken as the threshold value Q.

[0168] Although the embodiments of the present application have been disclosed as above, they are not limited to the application listed in the specification and the embodiments, and can be fully applied to various fields suitable for the present application, and additional modifications can be easily realized by those skilled in the art, and therefore the present application is not limited to specific details and the embodiments shown and described herein, without departing from the general concept defined by the claims and the equivalent scope.

Claims

1. A super-huge and super-long digital oil cylinder based on key components, characterized in that, Comprise: Oil cylinder body structure, oil cylinder V group seal, joint bearing, piston rod laser cladding coating, oil cylinder state monitoring adjustment unit, oil cylinder bearing monitoring evaluation unit, piston rod coating monitoring evaluation unit, industrial computer, display screen and audible and visual alarm; The oil cylinder state monitoring adjustment unit comprises a position sensor, a laser ranging sensor, a laser ranging target and a pressure sensor; A 1# position sensor is arranged at the rear side of the cylinder body of the oil cylinder body structure, a 2# position sensor is arranged at the front side of the cylinder body, and a 3# position sensor is arranged at the front side of the piston rod; the industrial computer calculates the equivalent deflection of the oil cylinder according to the relative position distance between the position sensors; A certain number of laser ranging sensors are evenly installed on the outside of the cylinder end piston rod side of the oil cylinder body structure, and a laser ranging target is correspondingly installed at the end of the piston rod for measuring the displacement value of the oil cylinder; the laser ranging sensor measures the displacement of the oil cylinder body structure in each direction and transmits the signal to the industrial computer; At least two pressure sensors are used to detect the large cavity pressure P1 of the oil cylinder body structure and the small cavity pressure P2 of the oil cylinder body structure; The oil cylinder bearing monitoring evaluation unit is used for bearing state detection of the oil cylinder body structure; The piston rod coating monitoring evaluation unit is used for surface coating state detection of the oil cylinder piston rod.

2. The key component based super large and super long digital oil cylinder according to claim 1, wherein, The number of laser ranging sensors is 2, which are arranged at 180 degrees along the circumference of the cylinder end of the oil cylinder body structure; the laser ranging target is correspondingly installed at the circumferential position of the end of the piston rod, which can measure the displacement value of the oil cylinder; The number of pressure sensors is 2, which are installed on the valve group to detect the large and small cavity pressures of the oil cylinder body structure; the valve group is attached to the oil cylinder body structure and communicates with the oil cylinder body structure through a pipeline.

3. The key component based hyper large and hyper long digital oil cylinder according to claim 1 or 2, characterized in that, The industrial computer calculates the maximum displacement value X0 of the oil cylinder body structure according to the laser ranging sensor; The industrial computer comprises an oil cylinder body structure deflection monitoring unit, which divides the stroke of the oil cylinder body structure into a plurality of continuous first stroke ranges, and sets an equivalent deflection limit value for each first stroke range; The industrial computer calculates the current equivalent deflection D of the oil cylinder; The oil cylinder body structure deflection monitoring unit compares the current equivalent deflection D of the oil cylinder with the equivalent deflection limit value in the corresponding first stroke range; if the current equivalent deflection D of the oil cylinder reaches 90% of the equivalent deflection limit value, the audible and visual alarm is started; if the current equivalent deflection D of the oil cylinder reaches 100% of the equivalent deflection limit value, the audible and visual alarm is started, and the industrial computer controls the valve group to stop working.

4. The key component based hyper large and hyper long digital oil cylinder as claimed in claim 3, wherein, The industrial computer comprises an oil cylinder body structure pressure monitoring unit, which divides the stroke of the oil cylinder body structure into a plurality of continuous second stroke ranges, and sets an oil cylinder body structure large cavity pressure limit value for each second stroke range; The oil cylinder body structure pressure monitoring unit compares the detected current oil cylinder body structure large cavity pressure P1 with the oil cylinder body structure large cavity pressure limit value of the corresponding second stroke range; if the large cavity pressure value reaches 100% of the oil cylinder body structure large cavity pressure limit value, the audible and visual alarm is started, and the industrial computer controls the valve group to stop working.

5. The key component based hyper large and hyper long digital oil cylinder as claimed in claim 4, wherein, The industrial computer comprises an oil cylinder body structure working condition detection unit, which is provided with a reversed frame resting working condition and a vertical standing working condition; When the displacement position of the oil cylinder body structure is in the range of 0-X0*c1, the displacement change is less than 5%, and the large cavity pressure P1 of the oil cylinder body structure changes less than 10%, the oil cylinder body structure working condition detection unit determines that the oil cylinder body structure is in the inverted standing working condition; When the displacement position of the oil cylinder body structure is in the range of X0*c2-X0*c3, the displacement change is less than 5%, the large cavity pressure P1 of the oil cylinder body structure changes less than 10%, and the small cavity pressure P2 of the oil cylinder body structure changes less than 10%, the oil cylinder body structure working condition detection unit determines that the oil cylinder body structure is in the vertical standing working condition; wherein 0 When the oil cylinder body structure working condition detection unit monitors that the oil cylinder body structure is in the inverted standing working condition for more than H1, the audible and visual alarm is started; When the oil cylinder body structure working condition detection unit monitors that the oil cylinder body structure is in the vertical standing working condition for more than H2, the audible and visual alarm is started.

6. The key component based super-huge and super-long digital oil cylinder according to claim 1, wherein, The piston rod coating monitoring and evaluation unit comprises a linear array industrial camera, an optical fiber, a data relay computer and a display system computer; The linear array industrial camera is arranged on the outer edge of the cylinder body at the extension end of the piston rod in a ring shape at equal intervals, and is used to monitor the surface state of the coating when the oil cylinder piston rod is extended and retracted. The optical fiber is arranged between the linear array industrial camera, the data relay computer and the display system computer, and is used for signal transmission. The data relay computer is installed in the control room, collects the picture information taken by the linear array industrial camera, and analyzes and processes the data. The display system computer is installed in the control room, and is used to display the coating monitoring picture, the data analysis interface and the analyzed data information.

7. The key component based hyper large and hyper long digital hydraulic cylinder as claimed in claim 1, wherein, The oil cylinder bearing monitoring and evaluation unit comprises a pin shaft sensor, a noise sensor, a vibration sensor, a red-hot external imager, an acceleration sensor, a high-definition camera and a high-precision displacement sensor. The pin shaft sensor is installed on the pin shaft of the joint bearing instead of the original pin shaft, and monitors the load of the joint bearing during service. The noise sensor is installed on the joint bearing seat to collect sound information in real time during the service of the joint bearing. The vibration sensor is installed on the joint bearing seat to measure the vibration of the joint bearing in real time. The red-hot external imager is installed at the end of the piston rod to detect the temperature of the friction between the gasket and the inner ring of the joint bearing in real time. When the temperature rise rate reaches or exceeds 0.5℃ / h and the temperature exceeds 100℃, the industrial computer controls the audible and visual alarm to send an alarm signal. The acceleration sensor is installed on the joint bearing seat to detect the acceleration of the joint bearing. The high-definition camera has multiple cameras, some of which are installed at the end of the piston rod to cover the entire monitoring range of the joint bearing and monitor the appearance of the joint bearing, and some of which are installed on the joint bearing seat to take pictures of the joint bearing fitting. The high-precision displacement sensor is installed on the side of the joint bearing. When the joint bearing gasket is worn, displacement will occur, which will drive the displacement sensor to move.

8. The key component based hyper large and hyper long digital oil cylinder as claimed in claim 7, wherein, The industrial computer comprises a bearing monitoring unit. The bearing monitoring unit initializes parameters of the pin shaft sensor, the noise sensor, the vibration sensor, the red-hot external imager, the acceleration sensor, the high-definition camera and the high-precision displacement sensor; The bearing monitoring unit has a large amount of joint bearing service process data and life test data to obtain a database through machine learning; The bearing monitoring unit collects load data F of the joint bearing monitored by the pin shaft sensor, and if the load data F reaches 95% of the rated load [F], the industrial computer judges that an abnormality occurs and reminds to stop and overhaul; if the load data F is greater than [F], the industrial computer judges that the joint bearing is crushed and fails, and reminds to replace the joint bearing; The bearing monitoring unit collects real-time sound data S monitored by the noise sensor, and if the real-time sound data S exceeds a preset value and the time duration is greater than or equal to 2s, the industrial computer judges that an abnormality occurs and reminds to stop and overhaul; The bearing monitoring unit collects real-time frequency data ω of the joint bearing measured by the vibration sensor, and if the frequency data ω exceeds a preset value and the time duration is greater than or equal to 2s, the industrial computer judges that an abnormality occurs and reminds to stop and overhaul; The bearing monitoring unit collects real-time temperature data T of the joint bearing friction part collected by the red-hot external imager, and if the temperature data T has a heating speed of 0.5℃ / h or the temperature exceeds 100℃, the industrial computer judges that an abnormality occurs and reminds to stop and overhaul; if the temperature data T is greater than or equal to 150℃, the industrial computer judges that the joint bearing has a high temperature and fails, and reminds to replace the joint bearing; The bearing monitoring unit collects acceleration value A of output vibration and joint bearing state parameters monitored by the acceleration sensor in real time, and if the acceleration value A exceeds a limit value [A], the industrial computer judges that an abnormality occurs and reminds to stop and overhaul; The bearing monitoring unit collects wear amount L of the joint bearing liner monitored by the high-precision displacement sensor in real time, and if the wear amount L is less than the thickness of the liner but the increasing speed is greater than or equal to 1mm / min, the industrial computer judges that an abnormality occurs and reminds to stop and overhaul; If the wear amount L is equal to the thickness of the liner, the industrial computer judges that the joint bearing fails, and reminds to replace the joint bearing; The bearing monitoring unit collects the appearance and morphology of the joint bearing monitored by the high-definition camera in real time, and compares the appearance and morphology with the content in the database to judge whether pitting and surface peeling occur on the appearance and morphology of the joint bearing, and if the liner is identified to be extruded and the joint bearing fails, the industrial computer reminds to replace the joint bearing.

9. The key component based hyper large and hyper long digital hydraulic cylinder as claimed in claim 8, wherein, The bearing monitoring unit predicts the remaining life of the joint bearing, and specifically: Theoretically, the remaining life of the joint bearing is: Remaining life of joint bearing = designed service life - equivalent service life; A decline coefficient a is obtained through test and data and calculation of actual service of the joint bearing, so that the remaining life of the joint bearing is:

10. The key component based hyper large and hyper long digital hydraulic cylinder as claimed in claim 1, wherein, The oil cylinder body structure comprises a cylinder body and a piston arranged in the cylinder body, the piston divides the inside of the cylinder body into a rod cavity and a rodless cavity, the rod cavity is a small cavity, the rodless cavity is a large cavity, one side of the piston towards the rod cavity is fixedly connected with a piston rod, an oil cylinder V group seal is arranged between the piston rod and the cylinder body, and the rod cavity and the rodless cavity are respectively connected with oil pipes; Further comprising an oil cylinder sealing monitoring device, which comprises a piston rod outer peripheral surface detection device, an oil product detection device and a piston rod speed detection device. The piston rod outer peripheral surface detection device is arranged at the end of the cylinder body and is used to detect whether hydraulic oil exists on the outer peripheral surface of the piston rod extending out of the oil cylinder body structure; The oil quality detection device is arranged on the two oil pipes and is used to detect the oil quality of the hydraulic oil in the oil pipes; The piston rod speed detection device is arranged on the oil cylinder body structure and is used to detect the actual moving speed and the theoretical moving speed of the piston rod; The industrial computer includes an oil cylinder sealing control unit, which is connected with each detection device, the display screen and the alarm respectively, acquires the data detected by each detection device, judges whether the oil cylinder body structure has leakage, and displays prompt information through the display screen; when the oil cylinder body structure has leakage, the industrial computer controls the alarm to send alarm information.

11. The key component based hyper large and hyper long digital hydraulic cylinder of claim 10, wherein, The oil cylinder sealing control unit respectively detects the external leakage working condition and the internal leakage working condition of the oil cylinder body structure; The external leakage working condition detection of the oil cylinder body structure specifically includes the following steps: SA1, the piston rod outer peripheral surface detection device is arranged at the end of the cylinder body and is used to detect whether hydraulic oil exists on the outer peripheral surface of the piston rod extending out of the oil cylinder body structure, and is transmitted to the industrial computer oil cylinder sealing control unit; if there is, step SA2 is performed, otherwise step SA3 is performed; SA2, the oil quality detection device is arranged on the two oil pipes and is used to detect the oil quality of the hydraulic oil in the oil pipes, acquire the moisture content and the particle content of the hydraulic oil in the two oil pipes, and transmit them to the industrial computer oil cylinder sealing control unit; when the moisture content and the particle content of the hydraulic oil in any of the oil pipes exceed the set oil quality threshold, the industrial computer oil cylinder sealing control unit judges that the oil cylinder body structure has external leakage, displays prompt information through the display screen, and sends alarm information through the alarm; when the moisture content and the particle content of the hydraulic oil in the two oil pipes do not exceed the set oil quality threshold, the industrial computer judges that the oil cylinder body structure has the possibility of external leakage, and displays prompt information through the display screen; SA3, the oil quality detection device is arranged on the two oil pipes and is used to detect the oil quality of the hydraulic oil in the oil pipes, acquire the moisture content and the particle content of the hydraulic oil in the two oil pipes, and transmit them to the industrial computer oil cylinder sealing control unit; when the moisture content and the particle content of the hydraulic oil in the two oil pipes do not exceed the set oil quality threshold, the industrial computer oil cylinder sealing control unit judges that the oil cylinder body structure has no external leakage; when the moisture content and the particle content of the hydraulic oil in any of the oil pipes exceed the set oil quality threshold, the industrial computer oil cylinder sealing control unit judges that the oil cylinder body structure has the possibility of external leakage, and displays prompt information through the display screen; The inner leakage working condition detection of the oil cylinder body structure specifically comprises the following steps: SB1, detecting the oil pressures of the rod cavity and the rodless cavity of the oil cylinder body structure through two pressure sensors and transmitting to the industrial computer oil cylinder sealing control unit; the industrial computer oil cylinder sealing control unit compares the pressure difference of the two cavities with a set pressure difference threshold value, if the pressure difference of the two oil pipes reaches the set pressure difference threshold value, step SB2 is performed, otherwise step SB3 is performed; SB2, detecting the actual moving speed and the theoretical moving speed of the piston rod through the piston rod speed detection device and transmitting to the industrial computer oil cylinder sealing control unit; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than a set speed error threshold value, the industrial computer judges that the oil cylinder body structure has an inner leakage condition, displays prompt information through the display screen and sends alarm information through the alarm; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold value, the industrial computer judges that the oil cylinder body structure has a possible inner leakage, and displays prompt information through the display screen; SB3, detecting the actual moving speed and the theoretical moving speed of the piston rod through the piston rod speed detection device and transmitting to the industrial computer oil cylinder sealing control unit; when the difference between the theoretical moving speed and the actual moving speed of the piston rod does not exceed the set speed error threshold value, the industrial computer judges that the oil cylinder body structure does not have an inner leakage condition; when the difference between the theoretical moving speed and the actual moving speed of the piston rod is greater than the set speed error threshold value, the industrial computer judges that the oil cylinder body structure has a possible inner leakage, and displays prompt information through the display screen.

12. The key component based hyper large and hyper long digital hydraulic cylinder as claimed in claim 11, wherein, The oil cylinder seal control unit estimates the remaining life of the seal, and the remaining life estimate of the seal is calculated by the following formula: where T y is the remaining life of the seal, T s is the design life of the seal, T i is the equivalent used life of the seal, Q f is the non-metallic particulate content of the hydraulic fluid in any of the oil lines; β is the non-metallic particulate content threshold of the hydraulic fluid; The variance of the periodic detection value of the pressure difference of the two oil pipes; Q is the threshold value of the variance of the pressure difference of the two oil pipes.

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