The present disclosure belongs to the technical field of hydraulic control, and relates to a velocity and position compound control system for a pump-valve dual-source driven hydraulic cylinder used in engineering machinery.
In engineering machinery, a hydraulic system is generally used to drive the action of working devices, and a driver operates a handle to control the operation of hydraulic actuators through open-loop control. Due to the harsh working conditions of engineering machinery, the external load force changes drastically in a wide range. Therefore, under the impact of system leakage and oil compressibility, it is difficult for hydraulic actuators to operate at a desired velocity and displacement. An external velocity-displacement sensor is usually mounted on the hydraulic cylinder, which can achieve high-precision control of the hydraulic cylinder through a closed loop of velocity and position. In the published invention patent CN201611252976.3, a high-precision displacement control hydraulic cylinder system and control method thereof is proposed, in which two external displacement sensors are used to improve displacement control precision. However, the external displacement sensors are easily contaminated by oil stains, solutions, and dust and exhibit poor reliability, increasing the complexity of system maintenance. The integrated displacement sensor inside the hydraulic cylinder can effectively avoid the impact of harsh environments, but processing difficulty and costs of the hydraulic cylinder are significantly increased. In addition, the use of sensors that continuously collect the velocity and displacement of the hydraulic cylinder results in high costs, which is not suitable for the engineering machinery field with low control precision requirements and strict cost limitations.
In addition, the existing engineering machinery hydraulic system features a low degree of intelligence, without a self-learning and adaptive capability to respond to variable load, environment, and changes in the system. Moreover, fault diagnosis and service life prediction cannot be performed, and all repairs are performed after accidents, resulting in safety accidents and economic losses. Furthermore, historical fusion data cannot be used for analysis, calculation, comparison, and decision-making, causing a serious waste of energy.
To further improve the prior art, the present disclosure proposes a velocity and displacement detection and control method suitable for hydraulic cylinders in engineering machinery. Additionally, the operation data of the system in a full life cycle can be grasped.
The present disclosure proposes a velocity and position integrated control system and method for a pump-valve dual-source driven hydraulic cylinder, which can achieve velocity and displacement detection and control, and further feature a fault diagnosis function.
To achieve the foregoing objective, the present disclosure adopts the following technical solutions:
A velocity and position compound control system for a pump-valve dual-source driven hydraulic cylinder includes: a first power source, a first hydraulic pump, a second power source, a second hydraulic pump, a safety valve, a proportional directional valve, a pilot operated check valve, a single-rod hydraulic cylinder, a handle, a tank, a velocity sensor, a first pressure sensor, a second pressure sensor, a third pressure sensor, a temperature sensor, a position transmitting unit, magnetic induction marks, a count correction module, an integrator module, a calculation control module, a signal acquisition module, a data storage module, a cloud memory, a communication protocol module, a fault diagnosis module, and a process monitoring module, where
In the velocity and position compound control system for a pump-valve dual-source driven hydraulic cylinder, magnetic induction marks with known spacing are processed in an axial direction of a piston rod of the single-rod hydraulic cylinder as position monitoring points, where the magnetic induction marks are equidistantly arranged.
In the velocity and position compound control system for a pump-valve dual-source driven hydraulic cylinder, the position transmitting unit is mounted on the end portion of the single-rod hydraulic cylinder, and the position transmitting unit is a magnetoresistive sensor, a hall sensor, or an eddy current sensor.
In the velocity and position compound control system for a pump-valve dual-source driven hydraulic cylinder, the calculation control module outputs the following parameters according to the signal processing module:
In the velocity and position compound control system for a pump-valve dual-source driven hydraulic cylinder, the integrator module outputs the following parameters: a theoretical position of the hydraulic cylinder:
total input energy:
useful energy:
throttling loss:
and system efficiency:
η=ECY/ES;
In the velocity and position compound control system for a pump-valve dual-source driven hydraulic cylinder, one pulse is sent to the count correction module each time the magnetic induction mark passes through the position transmitting unit; and if a total number of passes is k, an actual position xa of the hydraulic cylinder is determined according to a formula xa=kλ+x0, a position deviation is calculated as Δx=xt−xa, a distance between two position detection points is λ, a velocity correction coefficient γ is calculated according to a formula γ=Δx/λ+1, and γ is transmitted to the calculation control module.
In the velocity and position compound control system for a pump-valve dual-source driven hydraulic cylinder, the data storage module is configured to store operation data of a hydraulic cylinder drive system in a full life cycle;
Compared with the prior art, the present disclosure has the following beneficial effects:
1. In the present disclosure patent, the second power source drives the second hydraulic pump to control the operating velocity and displacement of the hydraulic cylinder, and a valve group unit is used to compensate for an asymmetric flow of the single-rod hydraulic cylinder. The system pressures and the oil temperature are collected to compensate for the leakage of a theoretical output flow and oil compressibility of the second hydraulic pump, and the flow can be detected and controlled with high precision without a flow sensor. This present disclosure resolves the problem that the existing flow sensor cannot control a flow in a closed-loop, is high in costs and complex to mount, and has large pressure losses.
2. In the present disclosure, the operating velocity and displacement of the hydraulic cylinder are estimated from the flow of the second hydraulic pump. After correction through the integrator module and the correction step, the velocity and position of the hydraulic cylinder can be controlled at low costs and with high reliability without the need for an expensive high-precision displacement sensor.
3. In the present disclosure, the pressure, flow, power, energy, and other information during the operation of the system are collected in real time. Through an intelligent algorithm, the operating and health statuses of a key component can be analyzed and controlled in a full life cycle, and fault prediction can be achieved, making the entire hydraulic system intelligent. This is a function that the conventional hydraulic system does not have.
To describe the technical solutions in embodiments of the present disclosure or in the prior art more clearly, the accompanying drawings required in the embodiments are briefly described below. Apparently, the accompanying drawings in the following description show merely some embodiments of the present disclosure, and other drawings can be derived from these accompanying drawings by those of ordinary skill in the art without creative efforts.
In the figures: 1—first power source, 2—first hydraulic pump, 3—relief valve, 4—first pressure sensor, 5—temperature sensor, 6—pilot operated check valve, 7—proportional directional valve, 8—second power source, 9—second pressure sensor, 10—second hydraulic pump, 11—third pressure sensor, 12—single-rod hydraulic cylinder, 13—count correction module, 14—integrator module, 15—calculation control module, 16—signal acquisition module, 17—data storage module, 18—communication protocol module, 19—fault diagnosis module, 20—process monitoring module, 21—handle, 22—cloud memory, 23—rotating speed sensor; 12-1—position transmitting unit, 12-2—magnetic induction mark, 12-3—zero position reference point, 12-4—piston rod.
The technical solutions of the embodiments of the present disclosure are clearly and completely described below with reference to the accompanying drawings. Apparently, the described embodiments are merely a part rather than all of the embodiments of the present disclosure. All other embodiments obtained by those skilled in the art based on the embodiments of the present disclosure without creative efforts shall fall within the protection scope of the present disclosure.
Meanings of the parameters in this specification are as follows:
AA-rodloss-chamber area of hydraulic cylinder, AB-rod-chamber area of hydraulic cylinder, QA-rodloss-chamber flow of hydraulic cylinder, QB-rod-chamber flow of hydraulic cylinder, v-velocity of hydraulic cylinder, α-ratio of areas of two chambers of hydraulic cylinder, ps-outlet pressure of first hydraulic pump, pA-rodloss-chamber pressure of hydraulic cylinder, pB—rod-chamber pressure of hydraulic cylinder, xt—theoretical position of hydraulic cylinder, x0—initial position of hydraulic cylinder, λ—distance between two adjacent magnetic induction marks, xa—actual position of hydraulic cylinder, k—number of pulses, Δx—position deviation, Ps—input power, PCY—useful power, PLS—power loss, Es—input energy, ECY—useful energy, ELS—throttling loss, η—system efficiency, γ—correction coefficient, V1—displacement of first hydraulic pump, n1-rotating speed of first power source, V2—displacement of second hydraulic pump, n2—rotating speed of second power source, T—oil temperature, Cd—flow coefficient of proportional directional valve, w—area gradient of proportional directional valve, xv—control signal of proportional directional valve, Qv—flow of proportional directional valve, ρ—hydraulic oil density, Δpv—pressure difference of proportional directional valve.
In order to make the above objective, features and advantages of the present disclosure clearer and more comprehensible, the present disclosure will be further described in detail below in combination with accompanying drawings and particular implementations.
As shown in
This system is further provided with a first pressure sensor 4, a second pressure sensor 9, a third pressure sensor 11, a temperature sensor 5, a position transmitting unit 12-1, a count correction module 13, an integrator module 14, a calculation control module 15, a signal acquisition module 16, a data storage module 17, a cloud memory 22, a communication protocol module 18, a fault diagnosis module 19, and a process monitoring module 20.
A P port of the proportional directional valve 7 is connected to the first pressure sensor 4 and an outlet port of the first hydraulic pump 2. An A port of the proportional directional valve 7 is connected to a rodless chamber of the single-rod hydraulic cylinder 12 and the second pressure sensor 9. A B port of the proportional directional valve 7 is connected to a rod chamber of the single-rod hydraulic cylinder 12 and the third pressure sensor 11. The oil and outlet ports of the pilot operated check valve 6 are connected to an outlet portT of the proportional directional valve 7 and the tank, respectively. The inlet and outlet ports of the second hydraulic pump 10 are connected to the rodless chamber and the rod chamber of the single-rod hydraulic cylinder 12, respectively. The signal acquisition module 16 receives a rotating speed n2 of the second power source 8, a temperature signal T of the temperature sensor 5, an outlet pressure ps of the first hydraulic pump 2, a rodless-chamber pressure pA of the single-rod hydraulic cylinder 12, a rod-chamber pressure pB of the single-rod hydraulic cylinder 12, and an output signal u of a handle 21, and an output port of the signal acquisition module 16 is connected to the calculation control module 15 and the data storage module 17. An output port of the calculation control module 15 is connected to the integrator module 14 and the data storage module 17, and transmits a control signal to the second power source 8, the proportional directional valve 7, the pilot operated check valve 6, and the first hydraulic pump 2. An output port of the integrator module 14 is connected to the count correction module 13 and the data storage module 17. The count correction module 13 receives an output signal of the position transmitting unit 12-1, and an output signal of the count correction module 13 is connected to the calculation control module 15. The data storage module 17 is connected to the communication protocol module 18, the fault diagnosis module 19, and the process monitoring module 20. The communication protocol module 18 is connected to the cloud memory 22.
As shown in
In this embodiment, the working principle of the velocity and position compound control system for the hydraulic cylinder is shown in
In step 1, the system is powered and initialized, and the calculation control module 15 reads a position of the single-rod hydraulic cylinder 12 at the end of the last operation from the data storage module 17, as an initial position x0 of the current operation of the single-rod hydraulic cylinder 12.
In step 2, the output signal of the handle 21 is received by the signal acquisition module 16, and processed by the calculation control module 15 and converted into a set velocity vt of the single-rod hydraulic cylinder 12, to obtain a rotating speed control signal n20 of the second power source 8, where n20=vt·AB/V2. When the single-rod hydraulic cylinder 12 extends, the proportional directional valve 7 works in the left position, a displacement setting signal xv0 of the proportional directional valve 7 is determined according to
and the proportional directional valve 7 compensates for an asymmetric flow of the single-rod hydraulic cylinder 12 and controls the pilot operated check valve 6 to be turned off to prevent oil in the rod chamber from returning to the tank. When the single-rod hydraulic cylinder 12 retracts, the proportional directional valve 7 works in the left position, the control valve displacement setting signal xv0 is determined according to
and the pilot operated check valve 6 is controlled to be opened, to cause excess oil from the rodless chamber of the single-rod hydraulic cylinder 12 to return to the tank.
In step 3, the set velocity vt of the single-rod hydraulic cylinder 12 is input into the integrator module for integral calculation according to the operating time, and summation is performed on a result of the integral calculation and the initial position x0, to obtain a theoretical position of the hydraulic cylinder, that is,
In addition, during the operation of the single-rod hydraulic cylinder 12, one pulse is sent to the count correction module 13 each time the magnetic induction mark 12-2 passes through the position transmitting unit 12-1. The count correction module 13 counts the number k of pulses. In combination with the spacing λ of the magnetic induction marks 12-2, the actual position of the hydraulic cylinder can be determined, that is, xa=k·λ+x0.
In step 4, the theoretical position xt of the single-rod hydraulic cylinder 12 is compared with the actual position xa transmitted by the position transmitting unit, and specifically, one pulse is sent to the count correction module each time the magnetic induction mark passes through the position transmitting unit. If the total number of passes is k, the actual position xa of the hydraulic cylinder is determined according to the formula x=kλ+x0, and the position deviation is calculated as Δx=xt−xa and the correction coefficient is calculated as γ=Δx/λ+1. In addition, a rotating speed control signal n20 of the second power source 8 is corrected based on the correction coefficient γ. Calculation is performed to obtain a corrected rotating speed control signal n21=γ·n20 and a set signal of the proportional directional valve 7 being xv1. Then, an actual operating velocity va of the single-rod hydraulic cylinder 12 is corrected.
In step 5, The velocity and displacement of the single-rod hydraulic cylinder 12 are corrected according to step 2 to step 4 each time the magnetic induction mark 12-2 passes through the position transmitting unit 12-1. After multiple iterations and corrections, the actual operating velocity va and the position xa of the hydraulic cylinder reach an allowable error range with the set velocity vt and the position xt, respectively. In addition, during the operation of the system, the pressures ps, pA, and pB and the temperature T are input into the calculation control module 15, to compensate for leakage of an output flow and oil compressibility of the second hydraulic pump. In this way, flow rates of the two chambers of the hydraulic cylinder can be obtained through calculation. Finally, position information of the single-rod hydraulic cylinder 12 is stored in the data storage module for the next initialization.
The calculation control module 15 calculates total input power, useful power, and power loss by using the following formulas:
P
s
=Q
B(pA−pB)+QvPs
P
CY
=p
A
Q
A
—p
B
Q
B
P
LS
=Q
v
Δp
v
The integrator module 14 calculates total input energy, useful energy, and throttling loss by using the following formulas:
η=ECY/ES.
The data storage module 17 stores a rotating speed n1 of the first power source 1, a displacement V1 of the first hydraulic pump 2, a rotating speed n2 of the second power source 8, a displacement V2 of the second hydraulic pump 10, an opening xv of the proportional directional valve 7, a temperature signal T of the temperature sensor 5, an outlet pressure ps of the first hydraulic pump 2, a rodless-chamber pressure pA of the single-rod hydraulic cylinder 12, a rod-chamber pressure pB of the single-rod hydraulic cylinder 12, a rodless-chamber flow QA of the hydraulic cylinder 12, a rod-chamber flow QB of the hydraulic cylinder 12, the total input power Ps, useful power P2, a velocity v of the single-rod hydraulic cylinder 12, the initial position x0 of the single-rod hydraulic cylinder 12, the total input energy ES, the useful energy ECY, the throttling loss ELS, and the system efficiency η.
The fault diagnosis module 19 can detect and preprocess a fault signal of the hydraulic system by using the system pressure, flow, power, energy consumption, system efficiency, and other information recorded by the data storage module 17. It is assumed that a system efficiency threshold is λη and an energy consumption threshold is λE. If the system efficiency n is less than λη, the hydraulic system will be shut down, and the pressure, flow, and power information are compared with curves in a healthy state to find out fault features. Based on an expert library, a fault can be accurately located after completing the identification of the fault features and fault reasons. If accumulated energy E2 of the hydraulic cylinder driving system working is greater than λE, it can be theoretically considered that the hydraulic system has reached a fatigue state, and the system is to perform active shutdown for maintenance.
The process monitoring module 20 can display in real time data curves of the pressure, flow, position, system power, and system energy consumption in the data storage module 14, achieving visualization of hydraulic system parameters.
The communication protocol module 18 can upload the data in the data storage module 17 to the cloud memory 22. The cloud memory 22 has a complete automatic data backup mechanism, and can store operation data of the system in a full life cycle, laying the foundation for proactive operation and maintenance as well as optimization of system energy efficiency.
Number | Date | Country | Kind |
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202211567275.4 | Dec 2022 | CN | national |