液压有源测试在锻造机液压故障诊断中的应用
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摘要
随着液压技术的快速发展,大型锻造机液压系统越来越复杂,由于液压系统内泄漏引发的故障停机造成的经济损失越来越巨大,急需一种快速、准确的在线内泄漏的检测方法,本文提出了基于液压有源测试技术锻造机故障诊断方法研究。建立了开式液压系统泄漏模型和开式液压系统的液压有源在线测试泄漏模型,对开式液压系统的总泄漏进行了分析,得到总泄漏为主油路所有控制元件的泄漏量和某一支路元件的泄漏之和,并对主油路控制元件、支路元件泄漏的测试方法进行了分析。通过某1 250 t锻造机液压系统压力不足的故障进行了应用研究,验证了所提方法对于检测复杂液压系统的内泄故障的有效性。
With the rapid development of hydraulic technology,the hydraulic system of a large forging machine is becoming increasingly complex. A fast and accurate approach for online detection is urgently needed to address large economic losses caused by continuous internal leakage of the hydraulic system. This study proposes a method of fault diagnosis for the forging machine based on hydraulic active test technology. A leakage model and an online detection model of an open hydraulic system are built. The total leakage of this hydraulic system is theoretically analyzed to derive the total sum of leakage of all control components of the main oil route and the leakage of a branch component.Furthermore,the detection method for the leakage of the main oil route control component and that of the branch component is theoretically analyzed. By conducting applied research on the deficiency in pressure of the hydraulic system of a 1 250 t forging machine,the researchers verified the effectiveness of the proposed method in detecting the internal leakage failure of the complex hydraulic system.
With the rapid development of hydraulic technology,the hydraulic system of a large forging machine is becoming increasingly complex. A fast and accurate approach for online detection is urgently needed to address large economic losses caused by continuous internal leakage of the hydraulic system. This study proposes a method of fault diagnosis for the forging machine based on hydraulic active test technology. A leakage model and an online detection model of an open hydraulic system are built. The total leakage of this hydraulic system is theoretically analyzed to derive the total sum of leakage of all control components of the main oil route and the leakage of a branch component.Furthermore,the detection method for the leakage of the main oil route control component and that of the branch component is theoretically analyzed. By conducting applied research on the deficiency in pressure of the hydraulic system of a 1 250 t forging machine,the researchers verified the effectiveness of the proposed method in detecting the internal leakage failure of the complex hydraulic system.
引文
[1]GOHARRIZI A Y,SEPEHRI N. A wavelet-based approach for external leakage detection and isolation from internal leakage in valve-controlled hydraulic actuators[J]. IEEE Transactions on industrial electronics,2011,58(9):4374-4384.
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[11]张玉存,马睿,付献斌,等.基于拓扑传递的耦合机械故障特征提取方法[J].中国机械工程,2012,23(4):435-438.ZHANG Yucun,MA Rui,FU Xianbin,et al. A method of feature extraction in coupling machinery faults based on topological transitivity[J]. China mechanical engineering,2012,23(4):435-438.
[12]苏欣平,聂广坤,郭爱东,等.基于二级模糊综合评判的液压系统故障诊断研究[J].中国工程机械学报,2011,9(4):482-486.SU Xinping,NIE Guangkun,GUO Aidong,et al. Hydraulic system fault diagnosis based on two-phase synthesized fuzzy evaluation[J]. Chinese journal of construction machinery,2011,9(4):482-486.
[13]MURALIDHARAN V,SUGUMARAN V. Rough set based rule learning and fuzzy classification of wavelet features for fault diagnosis of monoblock centrifugal pump[J]. Measurement,2013,46(9):3057-3063.
[14]谷立臣,刘沛津,陈江城.基于电参量信息融合的液压系统状态识别技术[J].机械工程学报,2011,47(24):141-150.GU Lichen,LIU Peijin,CHEN Jiangcheng. State recognition technique of hydraulic system based on electrical parameters information fusion[J]. Journal of mechanical engineering,2011,47(24):141-150.
[15]NURMI J,MATTILA J. Detection and isolation of leakage and valve faults in hydraulic systems in varying loading conditions,part 2:fault detection and isolation scheme[J].International journal of fluid power,2012,13(1):17-27.
[16]许庆华.山东液压测试仪[EB/OL].(2018-09-16)[2018-09-23]. https://liuqianhl1988. cn. gongchang.com/product/t2845721. html.
[17]STAUFF. PPC-04-plus of the STAUFF[EB/OL].(2018-09-16)[2018-09-23]. https://www. stauff.com/index. php? id=5492.
[18]蒋玲玲,张莉.某液压缸活塞杆连续抖动故障分析与排除[J].机床与液压,2017,45(2):163-164.JIANG Lingling,ZHANG Li. Fault analysis and elimination on continuous jitter of the piston rod of a hydraulic cylinder[J]. Machine tool&hydraulics,2017,45(2):163-164.
[19]杨成刚,赵静一.便携式有源液压测试仪及测试方法:中国,200910148231. 6[P]. 2011-06-15.YANG Chenggang,ZHAO Jingyi. Portable active hydraulic tester and test method:CN,200910148231. 6[P].2011-06-15.
[20]周梓荣,彭浩舸,曾曙林.环形间隙中泄漏流量的影响因素研究[J].润滑与密封,2005(1):7-9,19.ZHOU Zirong,PENG Haoge,ZENG Shulin. Research on the Influence factors of leakage in annular clearance seals[J]. Lubrication engineering,2005(1):7-9,19.
[2]GOHARRIZI A Y,SEPEHRI N,WU Yan. Internal leakage diagnosis in hydraulic actuators using wavelet transforms[C]//ASME 2009 Dynamic Systems and Control Conference. Hollywood,California,USA:ASME,2009:17-23.
[3]AN L,SEPEHRI N. Leakage fault identification in a hydraulic positioning system using extended kalman filter[C]//Proceedings of 2004 American Control Conference.Boston,MA,USA:IEEE,2004:3088-3093.
[4]MAHULKAR V,ADAMS D E,DERRISO M. Derivative free filtering in hydraulic systems for fault identification[J].Control engineering practice,2011,19(7):649-657.
[5]KALYONCU M,HAYDIM M. Mathematical modelling and fuzzy logic based position control of an electrohydraulic servosystem with internal leakage[J]. Mechatronics,2009,19(6):847-858.
[6]FU Xianbin,LIU Bin,ZHANG Yucun,et al. Fault diagnosis of hydraulic system in large forging hydraulic press[J]. Measurement,2014,49:390-396.
[7]TAN Hongzhou,SEPEHRI N. Parametric fault diagnosis for electrohydraulic cylinder drive units[J]. IEEE transactions on industrial electronics,2002,49(1):96-106.
[8]AN Liang,SEPEHRI N. Hydraulic actuator leakage fault detection using extended Kalman filter[J]. International journal of fluid power,2005,6(1):41-51.
[9]WU Zhiyong,XU Zengbing,GAO Ming. Trend prediction of hydraulic liquid leakage based on ES-LSSVM[J]. Applied mechanics and materials,2012,137:440-444.
[10]YAO Jianyong,YANG Guichao, MA Dawei. Internal leakage fault detection and tolerant control of single-rod hydraulic actuators[J]. Mathematical problems in engineering,2014,2014:345345.
[11]张玉存,马睿,付献斌,等.基于拓扑传递的耦合机械故障特征提取方法[J].中国机械工程,2012,23(4):435-438.ZHANG Yucun,MA Rui,FU Xianbin,et al. A method of feature extraction in coupling machinery faults based on topological transitivity[J]. China mechanical engineering,2012,23(4):435-438.
[12]苏欣平,聂广坤,郭爱东,等.基于二级模糊综合评判的液压系统故障诊断研究[J].中国工程机械学报,2011,9(4):482-486.SU Xinping,NIE Guangkun,GUO Aidong,et al. Hydraulic system fault diagnosis based on two-phase synthesized fuzzy evaluation[J]. Chinese journal of construction machinery,2011,9(4):482-486.
[13]MURALIDHARAN V,SUGUMARAN V. Rough set based rule learning and fuzzy classification of wavelet features for fault diagnosis of monoblock centrifugal pump[J]. Measurement,2013,46(9):3057-3063.
[14]谷立臣,刘沛津,陈江城.基于电参量信息融合的液压系统状态识别技术[J].机械工程学报,2011,47(24):141-150.GU Lichen,LIU Peijin,CHEN Jiangcheng. State recognition technique of hydraulic system based on electrical parameters information fusion[J]. Journal of mechanical engineering,2011,47(24):141-150.
[15]NURMI J,MATTILA J. Detection and isolation of leakage and valve faults in hydraulic systems in varying loading conditions,part 2:fault detection and isolation scheme[J].International journal of fluid power,2012,13(1):17-27.
[16]许庆华.山东液压测试仪[EB/OL].(2018-09-16)[2018-09-23]. https://liuqianhl1988. cn. gongchang.com/product/t2845721. html.
[17]STAUFF. PPC-04-plus of the STAUFF[EB/OL].(2018-09-16)[2018-09-23]. https://www. stauff.com/index. php? id=5492.
[18]蒋玲玲,张莉.某液压缸活塞杆连续抖动故障分析与排除[J].机床与液压,2017,45(2):163-164.JIANG Lingling,ZHANG Li. Fault analysis and elimination on continuous jitter of the piston rod of a hydraulic cylinder[J]. Machine tool&hydraulics,2017,45(2):163-164.
[19]杨成刚,赵静一.便携式有源液压测试仪及测试方法:中国,200910148231. 6[P]. 2011-06-15.YANG Chenggang,ZHAO Jingyi. Portable active hydraulic tester and test method:CN,200910148231. 6[P].2011-06-15.
[20]周梓荣,彭浩舸,曾曙林.环形间隙中泄漏流量的影响因素研究[J].润滑与密封,2005(1):7-9,19.ZHOU Zirong,PENG Haoge,ZENG Shulin. Research on the Influence factors of leakage in annular clearance seals[J]. Lubrication engineering,2005(1):7-9,19.