阅读说明：本技术 一种自移机尾液压系统状态监测及故障诊断系统和方法 (Self-moving tail hydraulic system state monitoring and fault diagnosis system and method ) 是由 王奋雄 杨子君 李林林 于 2021-09-08 设计创作，主要内容包括：本发明提供一种自移机尾液压系统状态监测及故障诊断系统和方法,监测及故障诊断系统包括多个被监测机构、传感器模块、监测分站、交换机和监测诊断计算机,所述传感器模块安装在被监测机构的各个待监测设备上,监测被监测机构的运行状态,将监测到的物理信号传输给监测分站,所述监测分站经过交换机采用局域网将物理信号传输给监测诊断计算机,在监测诊断计算机上进行可视化的数据监测、故障诊断；本发明的监测诊断计算机将传感器模块检测到的输入的物理信号由信号处理模块、特征提取模块进行特征值提取,与故障档案库的数值进行对比,最终显示相应的状态提醒和报警灯指示,有效提升了系统的工作效率,提高了工作安全系数,提高了监测诊断效率。(The invention provides a state monitoring and fault diagnosis system and method for a self-moving tail hydraulic system, wherein the monitoring and fault diagnosis system comprises a plurality of monitored mechanisms, sensor modules, monitoring substations, an exchanger and a monitoring diagnosis computer, the sensor modules are arranged on each device to be monitored of the monitored mechanisms, the running state of the monitored mechanisms is monitored, monitored physical signals are transmitted to the monitoring substations, the monitoring substations transmit the physical signals to the monitoring diagnosis computer through the exchanger by adopting a local area network, and visual data monitoring and fault diagnosis are carried out on the monitoring diagnosis computer; the monitoring and diagnosing computer provided by the invention extracts the characteristic value of the input physical signal detected by the sensor module through the signal processing module and the characteristic extraction module, compares the extracted characteristic value with the numerical value of the fault archive, and finally displays corresponding state reminding and alarm lamp indication, so that the working efficiency of the system is effectively improved, the working safety coefficient is improved, and the monitoring and diagnosing efficiency is improved.)

1. A state monitoring and fault diagnosis system of a self-moving tail hydraulic system is characterized by comprising a plurality of monitored mechanisms, sensor modules, monitoring substations, an exchanger and a monitoring diagnosis computer, wherein the sensor modules are installed on each device to be monitored of the monitored mechanisms, monitor the running state of the monitored mechanisms and transmit monitored physical signals to the monitoring substations;

the monitored mechanism comprises a material rack deviation adjusting mechanism, a belt deviation adjusting mechanism, a supporting leg mechanism, a traveling mechanism and a main loop, and the equipment to be monitored comprises an oil supply cylinder, a hydraulic valve block, a variable plunger pump, a hydraulic cylinder and a hydraulic motor;

the sensor module comprises a plurality of pressure sensors, temperature sensors and vibration displacement sensors, wherein the pressure sensors comprise an SP1 pressure sensor and an SP2 pressure sensor, the SP1 pressure sensor is installed on the oil outlet side of the No. 1 hydraulic valve block, and the SP2 pressure sensor is installed on the oil inlet side of the No. 2 hydraulic valve block and is used for measuring and collecting pressure signal values of the pressure sensors; the temperature sensor is arranged in the oil supply oil cylinder and used for measuring and collecting the temperature of the oil supply oil cylinder; the vibration displacement sensor is used for measuring and collecting vibration data of the shell of the hydraulic oil cylinder;

the monitoring substation is arranged in an underground centralized control room, is used for realizing an underground communication function and is used for receiving physical signals monitored by the sensor module;

the monitoring and diagnosing computer comprises a display interface, a fault archive, a signal processing module, a feature extraction module and a fault judgment module, wherein the display interface comprises an equipment display area, an alarm lamp indicating area, an equipment state monitoring and diagnosing area, a main switch and a time button, detected physical signals are subjected to feature value extraction through the signal processing module and the feature extraction module and are compared with a numerical value of the fault archive, the fault judgment module diagnoses and displays corresponding prompt, and meanwhile, the alarm lamp indicating area displays corresponding indication.

2. The system for monitoring the state and diagnosing the fault of the self-moving tail hydraulic system according to claim 1, wherein the equipment display area comprises a receiving frame deviation adjusting mechanism monitoring and diagnosing area, a belt deviation adjusting mechanism monitoring and diagnosing area, a supporting leg mechanism monitoring and diagnosing area, a traveling mechanism monitoring and diagnosing area and a main loop monitoring and diagnosing area, so that modular real-time monitoring and diagnosis are performed, and the monitoring and diagnosing efficiency is improved.

3. The system for monitoring the state and diagnosing the fault of the self-propelled tail hydraulic system according to claim 2, wherein the system comprises a normal operation indication, a fault operation indication and a stop state indication, and the three indication states respectively correspond to green, red and black of a warning lamp.

4. The self-propelled tail hydraulic system state monitoring and fault diagnosis system according to claim 3, wherein the equipment state monitoring areas comprise a pressure monitoring diagnosis area, a vibration displacement diagnosis area and a temperature monitoring diagnosis area.

5. The system of claim 4, wherein the warning light indicator area indicates if and only if a color is displayed, i.e., if and only if there is one of the following operating conditions: normal operation, fault operation and shutdown.

6. The method for monitoring the state and diagnosing the fault of the self-propelled tail hydraulic system by using the monitoring and fault diagnosing system as claimed in claim 5, is characterized by comprising the following steps of:

(1) turning ON a monitoring and diagnosing computer to press a main switch to enable the switch to be in an ON position, and monitoring the running condition of each monitored mechanism in real time by a sensor module;

(2) the sensor module transmits the acquired signal to a monitoring substation, the monitoring substation transmits a physical signal to a signal processing module of a monitoring and diagnosing computer by adopting a local area network through a switch, the physical signal is processed and then extracted by a characteristic extraction module and compared with the numerical value of a fault archive library, according to the comparison result, an alarm lamp indicating area displays the current running state according to alarm lamps with different colors, when the input physical signal exceeds a set value, the alarm lamp turns red, and when the input physical signal is in the set value range, the alarm lamp turns green;

(3) the operation state of the monitored mechanism can be visually checked by clicking corresponding determination buttons below a receiving frame deviation adjusting mechanism monitoring and diagnosing area, a belt deviation adjusting mechanism monitoring and diagnosing area, a supporting leg mechanism monitoring and diagnosing area, a walking mechanism monitoring and diagnosing area and a main loop monitoring and diagnosing area in a display area of the selected equipment, entering a corresponding display interface of the monitored mechanism, and arranging an action displacement curve graph and a temperature distribution curve graph in the interface.

7. The method for monitoring the state and diagnosing the fault of the self-moving tail hydraulic system according to claim 6, wherein the device state monitoring areas including the pressure monitoring diagnosis area, the vibration displacement diagnosis area and the temperature monitoring diagnosis area are selected by clicking, and a corresponding device state monitoring area sub-interface of the monitored mechanism is entered, so that threshold setting and error range setting calibration can be performed in the sub-interface.

Technical Field

The invention relates to the technical field of hydraulic systems, in particular to a system and a method for monitoring the state and diagnosing faults of a self-moving tail hydraulic system.

Background

The self-moving machine tail is a moving device of a fully-mechanized coal mining and fully-mechanized excavation working surface of a coal mine, and is mainly matched with a belt conveyor and a transfer machine for use. Research finds that at present, research on the self-moving tail mainly focuses on four aspects of structural design, dynamic analysis, hydraulic control and simulation modeling, the state monitoring and fault diagnosis research on the self-moving tail is less, and further the intelligent monitoring and diagnosis on a hydraulic system of the self-moving tail are less. At the present stage, the state monitoring and fault diagnosis of the self-moving tail hydraulic system mainly depends on manual experience, and the identification and positioning of fault equipment are carried out by combining parameters of various on-site test equipment and depending on an existing fault mode through professional engineering technicians.

Currently, many researchers are dedicated to the study of self-moving tails. A Chinese patent entitled "a visual intelligent self-moving tail and an operation method thereof" granted 5/7/2021 (application number 202110113411.1), which realizes pose adjustment by image acquisition, storage and uploading to a fault diagnosis system, and does not analyze and identify faults; a Chinese patent entitled complete set of scraper conveying equipment remote fault analysis and evaluation system (application number 201810706462.3) granted by 10, month and 8 in 2019, which designs a self-moving tail monitoring system, diagnoses the running condition of equipment by comparing data models and analyzes fault occurrence points. However, the above two patents are only explained for the aspect of fault diagnosis, and do not organically integrate online monitoring and fault diagnosis.

The coal mine fully-mechanized mining and fully-mechanized excavating work is developed towards intellectualization, in order to improve the production efficiency and the product quality to the maximum extent, the equipment must be ensured to operate under the healthy and normal working condition, once the equipment breaks down, the fault of the hydraulic system must be known at the first time, particularly, the fault of the hydraulic system has diversity and burstiness, and the cause is complex, the damage is serious, and the like, so that the hydraulic system is difficult to complete the fault judgment work smoothly in time only by manual diagnosis. Therefore, the design of the self-moving tail hydraulic system for state monitoring and fault diagnosis is very important.

Disclosure of Invention

Aiming at the defects in the prior art, the invention provides a system and a method for monitoring the state and diagnosing the fault of a self-moving tail hydraulic system, which can solve the problems in the existing design.

The technical scheme of the invention is as follows: a self-moving tail hydraulic system state monitoring and fault diagnosis system comprises a plurality of monitored mechanisms, sensor modules, monitoring substations, an exchanger and a monitoring diagnosis computer, wherein the sensor modules are installed on each device to be monitored of the monitored mechanisms, monitor the running state of the monitored mechanisms and transmit monitored physical signals to the monitoring substations;

the monitored mechanism comprises a material rack deviation adjusting mechanism, a belt deviation adjusting mechanism, a supporting leg mechanism, a traveling mechanism and a main loop, and the equipment to be monitored comprises an oil supply cylinder, a hydraulic valve block, a variable plunger pump, a hydraulic cylinder and a hydraulic motor;

the sensor module comprises a plurality of pressure sensors, temperature sensors and vibration displacement sensors, wherein the pressure sensors comprise an SP1 pressure sensor and an SP2 pressure sensor, the SP1 pressure sensor is installed on the oil outlet side of the No. 1 hydraulic valve block, and the SP2 pressure sensor is installed on the oil inlet side of the No. 2 hydraulic valve block and is used for measuring and collecting pressure signal values of the pressure sensors; the temperature sensor is arranged in the oil supply oil cylinder and used for measuring and collecting the temperature of the oil supply oil cylinder; the vibration displacement sensor is used for measuring and collecting vibration data of the shell of the hydraulic oil cylinder;

the monitoring substation is arranged in an underground centralized control room, is used for realizing an underground communication function and is used for receiving physical signals monitored by the sensor module;

the monitoring and diagnosing computer comprises a display interface, a fault archive, a signal processing module, a feature extraction module and a fault judgment module, wherein the display interface comprises an equipment display area, an alarm lamp indicating area, an equipment state monitoring and diagnosing area, a main switch and a time button, detected physical signals are subjected to feature value extraction through the signal processing module and the feature extraction module and are compared with a numerical value of the fault archive, the fault judgment module diagnoses and displays corresponding prompt, and meanwhile, the alarm lamp indicating area displays corresponding indication.

Preferably, the equipment display area comprises a receiving frame deviation adjusting mechanism monitoring diagnosis area, a belt deviation adjusting mechanism monitoring diagnosis area, a supporting leg mechanism monitoring diagnosis area, a walking mechanism monitoring diagnosis area and a main loop monitoring diagnosis area, so that modular real-time monitoring diagnosis is carried out, and monitoring diagnosis efficiency is improved.

Preferably, the indication device comprises a normal operation indication, a fault operation indication and a shutdown state indication, and the three indication states respectively correspond to green, red and black of the alarm lamp.

Preferably, the equipment state monitoring area comprises a pressure monitoring diagnosis area, a vibration displacement diagnosis area and a temperature monitoring diagnosis area.

Preferably, the warning light indicator area is if and only if one color is displayed, i.e. if and only if there is one of the following operating states: normal operation, fault operation and shutdown.

The invention also provides a method for monitoring the state and diagnosing the fault of the self-moving tail hydraulic system, which comprises the following steps:

(1) turning ON a monitoring and diagnosing computer to press a main switch to enable the switch to be in an ON position, and monitoring the running condition of each monitored mechanism in real time by a sensor module;

(2) the sensor module transmits the acquired signal to a monitoring substation, the monitoring substation transmits a physical signal to a signal processing module of a monitoring and diagnosing computer by adopting a local area network through a switch, the physical signal is processed and then extracted by a characteristic extraction module and compared with the numerical value of a fault archive library, according to the comparison result, an alarm lamp indicating area displays the current running state according to alarm lamps with different colors, when the input physical signal exceeds a set value, the alarm lamp turns red, and when the input physical signal is in the set value range, the alarm lamp turns green;

(3) the operation state of the monitored mechanism can be visually checked by clicking corresponding determination buttons below a receiving frame deviation adjusting mechanism monitoring and diagnosing area, a belt deviation adjusting mechanism monitoring and diagnosing area, a supporting leg mechanism monitoring and diagnosing area, a walking mechanism monitoring and diagnosing area and a main loop monitoring and diagnosing area in a display area of the selected equipment, entering a corresponding display interface of the monitored mechanism, and arranging an action displacement curve graph and a temperature distribution curve graph in the interface.

Further, the equipment state monitoring area including the pressure monitoring diagnosis area, the vibration displacement diagnosis area and the temperature monitoring diagnosis area is selected by clicking, a corresponding sub-interface of the equipment state monitoring area of the monitored mechanism is entered, and threshold setting and error range setting calibration can be carried out in the sub-interface.

The invention has the advantages that:

(1) the online monitoring and fault diagnosis of the self-moving tail are organically integrated, and the physical signals of the hydraulic systems of all mechanisms are monitored and diagnosed in a software system of a monitoring computer, so that the times of unexpected shutdown and emergency shutdown are reduced, and the working efficiency of the system is effectively improved;

(2) the state monitoring and fault diagnosis system of the self-moving tail hydraulic system can perform visual monitoring and intelligent diagnosis on a monitoring computer, so that the intervention of personnel is reduced, and the working safety coefficient is improved;

(3) the state monitoring and fault diagnosis software system of the self-moving tail hydraulic system is provided with five module areas, so that modularized real-time monitoring and diagnosis are carried out, and the monitoring and diagnosis efficiency is improved.

Drawings

FIG. 1 is a hydraulic system diagram of a self-propelled tail hydraulic system state monitoring and fault diagnosis system of the present invention;

FIG. 2 is a flow chart of a state monitoring and fault diagnosis system of a self-propelled tail hydraulic system of the present invention;

wherein: 1. the system comprises an ST temperature sensor, an oil supply cylinder 2, a hydraulic valve block 3, a hydraulic valve block 1# 4, an SP1 pressure sensor, a hydraulic valve block 5, a hydraulic valve block 2# 6, a variable plunger pump, a pressure sensor 7, an SP2 pressure sensor 8, a hydraulic oil cylinder, a vibration displacement sensor 9, an SX vibration displacement sensor 10 and a hydraulic motor.

Detailed Description

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which a person skilled in the art can, without any creative effort, fully implement the present invention.

The specific implementation mode of the invention is as follows: as shown in fig. 1-2, a state monitoring and fault diagnosis system for a self-moving tail hydraulic system includes a plurality of monitored mechanisms, sensor modules, monitoring substations, switches and monitoring and diagnosis computers, wherein the sensor modules are installed on each device to be monitored of the monitored mechanisms, monitor the operating states of the monitored mechanisms, and transmit the monitored physical signals to the monitoring substations, and the monitoring substations transmit the physical signals to the monitoring and diagnosis computers through the switches by using a local area network, and perform visual data monitoring and fault diagnosis on the monitoring and diagnosis computers;

the monitored mechanism comprises a material rack deviation adjusting mechanism, a belt deviation adjusting mechanism, a supporting leg mechanism, a traveling mechanism and a main loop, and the equipment to be monitored comprises an oil supply cylinder 2, a hydraulic valve block, a variable plunger pump 6, a hydraulic cylinder 8 and a hydraulic motor 10;

the sensor module comprises a plurality of pressure sensors, ST temperature sensors 1 and SX vibration displacement sensors 9, wherein the pressure sensors comprise SP1 pressure sensors 4 and SP2 pressure sensors 7, the SP1 pressure sensors 4 are installed on the oil outlet side of a No. 1 hydraulic valve block 3, and the SP2 pressure sensors 7 are installed on the oil inlet side of a No. 2 hydraulic valve block 5 and are used for measuring and collecting pressure signal values of the pressure sensors; the ST temperature sensor 1 is arranged in the oil supply oil cylinder 2 and used for measuring and collecting the temperature of the oil supply oil cylinder 2; the SX vibration displacement sensor 9 is used for measuring and collecting shell vibration data of a material frame deviation adjusting mechanism 1# -2 #, a belt deviation adjusting mechanism 3# -6 #, and a supporting leg mechanism 7# -10 # hydraulic oil cylinder 8;

the monitoring substation is a mining intrinsic safety type monitoring substation, is arranged in an underground centralized control room, is used for realizing an underground communication function, and is used for receiving a physical signal monitored by the sensor module;

the monitoring and diagnosing computer comprises a display interface, a fault archive, a signal processing module, a feature extraction module and a fault judgment module, wherein the display interface comprises an equipment display area, an alarm lamp indicating area, an equipment state monitoring and diagnosing area, a main switch and a time button, detected physical signals are subjected to feature value extraction through the signal processing module and the feature extraction module and are compared with a numerical value of the fault archive, the fault judgment module diagnoses and displays corresponding prompt, and meanwhile, the alarm lamp indicating area displays corresponding indication.

Preferably, the equipment display area comprises a receiving frame deviation adjusting mechanism monitoring diagnosis area, a belt deviation adjusting mechanism monitoring diagnosis area, a supporting leg mechanism monitoring diagnosis area, a walking mechanism monitoring diagnosis area and a main loop monitoring diagnosis area, so that modular real-time monitoring diagnosis is carried out, and monitoring diagnosis efficiency is improved.

Preferably, the indication device comprises a normal operation indication, a fault operation indication and a shutdown state indication, and the three indication states respectively correspond to green, red and black of the alarm lamp.

Preferably, the equipment state monitoring area comprises a pressure monitoring diagnosis area, a vibration displacement diagnosis area and a temperature monitoring diagnosis area.

Preferably, the warning light indicator area is if and only if one color is displayed, i.e. if and only if there is one of the following operating states: normal operation, fault operation and shutdown.

The invention also provides a method for monitoring the state and diagnosing the fault of the self-moving tail hydraulic system, which comprises the following steps:

(1) turning ON a monitoring and diagnosing computer to press a main switch to enable the switch to be in an ON position, and monitoring the running condition of each monitored mechanism in real time by a sensor module;

(2) the sensor module transmits the acquired signal to a monitoring substation, the monitoring substation transmits a physical signal to a signal processing module of a monitoring and diagnosing computer by adopting a local area network through a switch, the physical signal is processed and then extracted by a characteristic extraction module and compared with the numerical value of a fault archive library, according to the comparison result, an alarm lamp indicating area displays the current running state according to alarm lamps with different colors, when the input physical signal exceeds a set value, the alarm lamp turns red, and when the input physical signal is in the set value range, the alarm lamp turns green;

(3) the operation state of the monitored mechanism can be visually checked by clicking corresponding determination buttons below a receiving frame deviation adjusting mechanism monitoring and diagnosing area, a belt deviation adjusting mechanism monitoring and diagnosing area, a supporting leg mechanism monitoring and diagnosing area, a walking mechanism monitoring and diagnosing area and a main loop monitoring and diagnosing area in a display area of the selected equipment, entering a corresponding display interface of the monitored mechanism, and arranging an action displacement curve graph and a temperature distribution curve graph in the interface.

The operation explanation is carried out by taking the running state of the receiving frame deviation adjusting mechanism and the fault diagnosis thereof as an example, the main switch is pressed to enable the switch to be in the ON position, the alarm lamp indicating area can display the running state of each mechanism at present, the mouse clicks the determining button below the receiving frame deviation adjusting mechanism, the equipment state monitoring area can display the action displacement curve chart of the receiving frame deviation adjusting mechanism in a default mode, the monitoring area is provided with a set curve and a real-time curve, and when an input physical signal exceeds a set value, the alarm lamp turns red.

Further, the equipment state monitoring area including the pressure monitoring diagnosis area, the vibration displacement diagnosis area and the temperature monitoring diagnosis area is selected by clicking, a corresponding sub-interface of the equipment state monitoring area of the monitored mechanism is entered, and threshold setting and error range setting calibration can be carried out in the sub-interface.

The operation of the sub-interface is explained by taking the operation state of the receiving frame deviation adjusting mechanism and the fault diagnosis thereof as an example, the software can enter the sub-interface of the receiving frame deviation adjusting mechanism by double-clicking a monitoring area, a threshold value and an error range can be set in the interface, when real-time data exceeds the threshold value range, an alarm lamp turns red, physical quantity and detection points to be monitored and diagnosed can be selected on a left panel of the subsystem, and when the physical quantity and the detection points are selected, the corresponding button color becomes dark.

Specifically, when the detected pressure signal is subjected to characteristic value extraction through the signal processing module and the characteristic extraction module and compared with a numerical value of a fault archive, when the characteristic value of the pressure signal is in a set interval of P1-P2, the main loop valve block device displays normal, and the alarm lamp is green; otherwise, the alarm lamp turns red, and the popup window displays that the pressure of the valve block is abnormal; when the characteristic value of the temperature signal is smaller than T, the oil supply cylinder 2 of the main loop displays normal, the alarm lamp is green, otherwise, the alarm lamp turns red, and the popup window displays 'oil temperature is abnormal'; when the displacement characteristic values of a No. 1 hydraulic oil cylinder and a No. 2 hydraulic oil cylinder of the receiving frame deviation adjusting mechanism are in an X1-X2 range, the receiving frame deviation adjusting mechanism displays normal, the alarm lamp is green, otherwise, the alarm lamp turns red, and the popup window displays that the hydraulic oil cylinder of the receiving frame deviation adjusting mechanism is abnormal (the reason is abrasion and corrosion of a piston rod, piston abrasion or sealing damage of a guide sleeve); when the displacement characteristic value of the No. 3-6 hydraulic oil cylinder 2 is within an interval of X3-X4, the belt deviation adjusting mechanism displays normal, the alarm lamp is green, otherwise, the alarm lamp turns red; when the displacement characteristic value of the 7# -10 # hydraulic oil cylinder is within an interval of X5-X6, the belt deviation adjusting mechanism displays normal, the alarm lamp is green, and otherwise, the alarm lamp turns red.

While the preferred embodiments of the invention have been described, it is to be understood that the invention is not limited to the precise embodiments described, and that equipment and structures not described in detail are understood to be practiced as commonly known in the art; any simple modification, equivalent change and modification of the above embodiments according to the technical essence of the present invention by those skilled in the art can be made without departing from the technical scope of the present invention, and still fall within the protection scope of the technical solution of the present invention.